boiler life assessment.pdf
TRANSCRIPT
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Oleh:
PURNAWAN SAPTA WARDHANACertified CSWIP3.1 #81201
9 Agustus 2014
BOILER LIFE ASSESSMENT
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SUHU YANG SANGAT TINGGI PADA BOILER (KETEL UAP) LEBIH DARI 15000F ATAU 8000C
DAPAT MENYEBABKAN TERBENTUKNYA BRITTLE IRON OXSIDE ATAU DISEBUT
MAGNETIT DIDALAM DAN DILUAR PERMUKAAN DRUM PLATE.
PADA SUHU YANG TINGGI, UAP AIR AKAN BEREAKSI DENGAN BESI BAJA UNTUK
MEMBENTUK MAGNETIT DAN HYDROGEN.
KECEPATAN REAKSI INI MENINGKAT SEIRINGAN DENGAN SUHU YANG MENINGKATSEHINGGA MENYEBABKAN ATOM OKSIGEN AKAN BERDIFUSI KE DALAM MELALUILAPISAN MAGNETIT , DAN ATOM BESI AKAN MENYEBAR KE LUAR , SEHINGGASCALE/KERAK TERUS TUMBUH BAHKAN SETELAH PERMUKAAN TABUNG BENAR-BENARTERTUTUP OLEH SCALE. DINDING TABUNG YANG TERTUTUP SCALE AKAN PANASHINGGA SUHU DI LUAR JANGKAUAN OPERASI YANG DIINGINKAN. AKIBAT KONTAKJANGKA PANJANG DENGAN SUHU YANG TERLALU TINGGI DAN DIKOMBINASIKANDENGAN TEKANAN YANG SANGAT TINGGI DI DALAM TABUNG, AKAN MENYEBABKANINTERGRANULAR MIKRO ATAU RETAK PADA LOGAM DAN CREEP DEFORMASI (PEMBENGKAKAN LAMBAT ATAU MENGGEMBUNG LOGAM ) DIMANA MELEBIHI YIELDSTRENGTH MATERIAL, YANG PADA AKHIRNYA MENYEBABKAN KEGAGALAN TABUNGDENGAN MENYEBABKAN MELEDAK .
MASALAH SEKUNDER ADALAH, DI MANA POTONGAN OKSIDA SCALE BREAK ( BIASANYAKARENA TEGANGAN TEROKSIDA OXFOLIATIONMAL SELAMA BOILER STARTUP ATAUSHUTDOWN) YANG MASUK KE TURBIN DAN MENYEBABKAN KOROSI PADA TURBIN
UNTUK ITU BOILER HARUS DILAKUKAN INSPECTION
KENAPA BOILER HARUS DI INSPECTION SECARA
BERKALA??????????
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DAFTAR ISI
1. TUJUAN BOILER LIFE ASSESSMENT
2. EVALUASI SELAMA OPERASI DENGAN INSPECTION
3. PERSIAPAN UNTUK INSPECTION
4. DATA REQUIREMENT
5. INSPECTION PADA HIGH PRESSURE PARTS.
6. SAMPLE TUBE INSPECTION *)
7. VISUAL INSPECTION PADA PART-PART BOILER .
8. SURVEY KUALITAS AIR
9. VISUAL INSPECTION UNTUK AUX EQUIPMENT
10. HIGH PRESSURE PARTS INSPECTION DETAILS
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1. Mengevaluasi keadaan sekarang dan kondisi komponen boiler dalam rangka Untuk
melanjutkan operasi boiler stabil dan handal
2. Evaluasi sisa umur untuk Superheater dan alat pemanas dengan pemeriksaan UT
scale thickness
3. Evaluasi creep dan skema inspeksi masa depan dengan pemeriksaan metalurgi
untuk water wall, economizer, Superheater dan Reheater tube
4. Evaluasi tingkat kerusakan creep Superheater dan reheater dengan uji kekerasan
(Hardness Test)
5. Evaluasi sisa umur berdasarkan Pengukuran ketebalan untuk water wall,
6. Evaluasi sisa umur berdasarkan penipisan ketebalan untuk economizer karena
Korosi Suhu rendah,
7. Evaluasi sisa umur berdasarkan penipisan ketebalan untuk Superheater dan
reheater tube karena Korosi Suhu tinggi
8. Konfirmasi penyebab inner scale generation
9. Evaluasi sisa umur berdasarkan cek struktur logam ,inner scale , dll untuk tabung
sample (Destructive test)
1- TUJUAN DARI BOILER LIFE ASSESSMENT
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2. EVALUASI SELAMA OPERASI DENGANINSPECTION
FAILURE PENYEBAB KEGAGALAN
FENOMENA LIFE EVALUATION INSPECTION ITEM
CREEP Penyumbatanoleh material asing
Penambahan danpertumbuhan dariscale pada inner surface
Long-term stress
Swelling (Deformasimengelembung)
Perubahanstruktur Metal
Outside diameter danpengukuran thickness
Metallurgical inspection *)
Metallurgical inspection for SH, RH header, *)
Metallurgical inspection *) dan NDT (UT) untuk main steam pipe line danhigh temperature RH pipe
FATIGUE (Kelelahan)
siklus thermal stress
Pertumbuhancrack
Stress analysis
Surface crack inspection (PT,MT)
NDE (PT) pada area welding untukSuperHeater dan ReHeater Tube
CORROSION FATIGUE
siklus thermal stress disebabkankorosi lingkungan
interaksicorrosion danfatigue
Ultrasonic test
Sample tube inspection *)
Sample tube inspection pada SH, RH dan water wall *)
Check Burner Nozzle dan Wind Box Damper
CORROSION
EROSION
High temp corrosion
Low temp corrosion
Ash erosion
Penipisanketebalan
Pengukuran thickness tahunan
Pengukuran tube thickness pada SH ,RH, Water Wall and Eco dengan UT
Steam drum
Boiler aux
Eco Hanger tube dengan borescope, etc
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3-PERSIAPAN UNTUK INSPECTION BEFORE INSPECTION
PEMBERSIHAN SUPERHEATER, REHEATER, ECONOMIZER DAN WATER WALL
AIR HEATER WASHING
SCAFFOLDING
REMOVAL OF INSULATION
OPEN MAN HOLES, INSPECTION HOLES, FLANGES DLL
DURING INSPECTION SURFACE PREPARATION OF INSPECTION PARTS
SURFACE FINISHING (GRINDING) OF INSPECTION PARTS
PERALATAN INSPECTION
CUTTING TUBES *)
WELDING TUBES *)
MATERIAL REQUIREMENT NEW TUBES *)
MAN HOLE PACKING
INSULATION
PERIOD OF INSPECTION
ONE WEEKS
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4- DATA REQUIREMENT
BOILER REFERENCE DATA STEAM TEMPERATURE 0C
MAXIMUM STEAM FLOW TON/HR BOILER DESIGN PRESSURE KGM/CM2
FEED WATER TEMP 0C
REHEATED INLET STEAM TEMPERATURE 0C REHEATED OUTLET STEAM TEMPERATURE 0C
REHEATER DESIGN PRESSURE KGM/CM2
KIND OF FUEL (BAHAN BAKAR) GAS, OIL, SAWIT
FUNCTIONAL INSPECTION WITH BOILER IN OPERATION MENGUMPULKAN DRAWINGS DAN TECHNICAL DATA
RECORDING DARI ACTUAL OPERASI DAN DATA PERBEDAANLOADS DAN KONDISI PADA LOG SHEET BOILER DAN VERIFIKASIDARI DATA BOILER SAAT OPERASI
MENGUMPULKAN DATA THERMAL HISTORY PADA SAAT OPERASI
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PERALATAN YANG DIPUNYA INDOMARINE
1. UT THICKNESS
2. PORTABLE HARDNESS TEST
3. BORESCOPE
4. LAPTOP UNTUK PENGOPERASIAN BORESCOPE
5. UT SCALE THICKNESS ATAU BISA MENGGUNAKAN UT PHASED ARRAY
6. PORTABLE SCANER (JIKA BUKAN BOILER IM UNTUK SCAN DRAWING)
PERALATAN YANG DIBUTUHKAN
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5-INSPECTION PADA HIGH PRESSURE PARTS
NON DESTRUCTIVE TEST MENGIKUTI ITEM SEBAGAIBERIKUT:
1. ECONOMIZER HEADERS, COILS, PIPING FROM ECONOMIZER TO STEAM DRUM,.2. STEAM DRUM.3. FURNACE WATER WALLS, (SCREEN TUBE/REAR WALL SISI LUAR ATAS, ROOF WALL,
FRONT WALL, SIDE WALL L & R, BANK TUBE, UPPER CONNECTION PIPE/RISER ,WATER WALLS HEADERS.
4. SATURATION STEAM PIPE.5. PRIMARY, SECONDARY SUPER HEATER (IF ANY)6. CONNECTING PIPE BETWEEN PRIMARY SUPERHEATER AND SECONDARY
SUPERHEATER. (IF ANY)7. REHEATER / AIR PREHEATER.8. MAIN SUPERHEATER STEAM PIPES
**INSPECTION 7 ITEM
1. EXTERNAL VISUAL INSPECTION2. INTERNAL VISUAL INSPECTION WITH BORESCOPE3. UT FOR THICKNESS MEASUREMENTS BY UT 4. PT AND UT ON CIRCUMFERENTIAL WELDS (R)5. PT ON PIPING ATTACHMENTS (R)6. PT ON NOZZLES WELDS OF THE COIL TUBES (R)7. PT ON NOZZLES WELDS TO THE SHELL OF THE
INLET/OUTLET PIPE
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THE MINIMUM REQUIRED THICKNESS
t = minimum required thickness.
D = outside diameter of cylinder.
e = thickness factor for expanded tube ends.
P = maximum allowable working pressure.
S = maximum allowable stress value at the design temperature of the metal.
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DESIGN / OPERATING INFORMATIONUNTUK PERHITUNGAN WAKTU YANG TERSISA BERDASARKAN THICKNESS
DESIGN INFORMATION MATERIAL TYPE / GRADE NOMINAL OUTSIDE DIAMETER DESIGN PRESSURE DESIGN THICKNESS DESIGN TEMPERATURE ORIGINAL NOMINAL
THICKNESS LAMA BOILER BEROPERASI
OPERATING INFORMATION MAXIMUM DESIGN METAL
TEMPERATURE TUBE NORMAL OPERATING
PRESSURE ORIGINAL MEASURED
MINIMUM THICKNESS RATA-RATA THICKNESS
METAL
Thickness
measurements
of water wall
tubes furnace
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PERHITUNGAN BOILER LIFE ASSESSMENT
MENCARI LAJU KOROSI
= ( )
PENENTUAN BOILER LIFE ASSESSMENT
=( )MIN
DENGAN SYARAT KUALITAS AIR, CARA MENGOPERASIKAN
BOILER SAMA SELAMA BEROPERASI SELAMA INI.
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6-SAMPLE TUBE - *)
DESTRUCTIVE TEST PADA SAMPLE TUBE DI AREA WATER WALL ,SUPERHEATER DAN REHEATER TUBES
DIAGNOSA SELAMA OPERASI BERDASARKAN CHECK STRUCTURE METAL, THICKNESS, INNER SCALE, DLL *)
SAMPLE TUBE YANG DIAMBIL SESUAI DENGAN HASIL PENGUKURAN HARDNESS TEST
INVESTIGATION ITEMS VISUAL INSPECTION NON DESTRUCTIVE TEST CHEMICAL ANALYSIS *) MEASUREMENT OF THE TUBE DIMENSION HARDNESS MEASUREMENT
CROSS SECTIONAL MICROSTRUCTURE OBSERVATION *) STEAM OXIDATION OBSERVATION CREEP RUPTURE TEST *) PENGUKURAN THICKNESS PADA INNER SCALE
INFORMATION MATERIAL SAMPLE TUBE TUBE DIMENSION
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SAMPLE TUBES UNTUK MICRO TEST
THINNING OF BULGED ZONE INTERNAL SURFACE SCALE EXTERNAL SURFACE SCALE
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7-VISUAL INSPECTION UNTUK PART-PART DARI BOILER
BURNER
WIND BOX
HANGER FOR RISER PIPE
OUTER CASING
BUCKSTAY
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8- SURVEY KUALITAS AIR
INSPECTION INI UNTUK MENGKONFIRMASI
PENYEBAB DARI SCALE/KERAK
INSPECTION ITEMS
CHECK OF LABORATORY ANALYSIS METHOD FOR
QUALITY ITEMS
KONFIRMASI HASIL KUALITAS AIR SEBELUM
DIOPERASIKAN
CHECK INSTRUMENT CONDITION ON SAMPLING RACK
USED FOR WATER QUALITY CONTROL
CONFIRMATION OF PH VALUE AND IRON/COPPER
BALANCE IN THE CYCLE
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9-VISUAL INSPECTION PADA AUX EQUIPMENT
INSPECTION INI UNTUK MENGETAHUI PENYEBAB SCALE
GENERATION
CONDENSER HOT WELL. CONDENSER TUBE SIDE DEAERATOR. LOW PRESSURE-FEED
WATER HEATER. FEED WATER TANK. HIGH PRESSURE-FEED
WATER HEATER.
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10-HIGH PRESSURE PARTS INSPECTION DETAILS
1. ECONOMIZER HEADERS ,COILS, PIPING FROM ECONOMIZER TO
STEAM DRUM ,
2. STEAM DRUM
3. FURNACE WATER WALLS, (SCREEN TUBE/REAR WALL, ROOF WALL
SISI LUAR ATAS, FRONT WALL, SIDE WALL L & R, BANK TUBE, UPPER
CONNECTION PIPE/RISER ,WATER WALLS HEADERS)
4. SATURATION STEAM PIPE
5. PRIMARY, SECONDARY SUPERHEATER
6. CONNECTING PIPE ANTARA PRIMARY SUPER HEATER DAN
SECONDARY SUPERHEATER
7. REHEATER/ AIR PREHEATER
8. MAIN SUPERHEATER STEAM PIPES
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10-1 ECONOMIZER
NDE FOR HEADERS EXTERNAL VISUAL INSPECTION INTERNAL VISUAL INSPECTION WITH BORESCOPE MEASUREMENT OF THICKNESS BY UT PT ON NOZZLES WELDS OF THE COIL TUBES AND HEADERS
ATTACHMENTS PT AND UT ON CIRCUMFERENTIAL WELDS BETWEEN HEADER AND
CONICAL PIECES
NDE FOR TUBE EXTERNAL VISUAL INSPECTION MEASUREMENT OF ECONOMIZER TUBE AND HANGER TUBE THICKNESS
WITH BORESCOPE UT FOR THICKNESS MEASUREMENTS
NDE FOR PIPING FROM ECONOMIZER TO STEAM DRUM EXTERNAL VISUAL INSPECTION FOR PIPING, HANGERS AND SUPPORTS UT FOR THICKNESS MEASUREMENTS PT AND UT ON CIRCUMFERENTIAL WELDS (RANDOM) PT ON PIPING ATTACHMENTS PT ON THE ELBOWS
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10-2 STEAM DRUM
BEFORE THE NDT INSPECTIONS, THE INTERNAL PARTS OF THE DRUM SHALL BE DISMANTLED
NDE FOR STEAM DRUM EXTERNAL VISUAL INSPECTION INTERNAL VISUAL INSPECTION UT FOR SHELL THICKNESS MEASUREMENTS UT FOR HEAD THICKNESS MEASUREMENTS PT AND UT ON CIRCUMFERENTIAL AND LONGITUDINAL
WELDS (R) PT ON STEAM DRUM ATTACHMENTS (SADDLES AND
ACCESSORIES) PT ON NOZZLES WELDS
NDE FOR DOWNCOMERS & FEEDERS (FEED WATER PIPE)
EXTERNAL VISUAL INSPECTION FOR PIPING, HANGERS AND SUPPORTS
UT FOR THICKNESS MEASUREMENTS PT AND UT ON CIRCUMFERENTIAL WELDS PT ON PIPING ATTACHMENTS
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10-3 FURNACE WATER WALLS, (SCREEN TUBE/REAR WALL, ROOF WALL SISI LUAR ATAS, FRONT WALL, SIDE WALL L & R, BANK TUBE, UPPER CONNECTION PIPE/RISER ,WATER WALLS
HEADERS
NDE FOR FURNACE WATER WALLS, SCREEN, ROOF WALL EXTERNAL VISUAL INSPECTION
UT FOR THICKNESS MEASUREMENTS METALLOGRAPHIC EXAMINATION BY PLASTIC REPLICAS *)
SAMPLES FOR DESTRUCTIVE TEST *)
NDE FOR RISER EXTERNAL VISUAL INSPECTION
UT FOR THICKNESS MEASUREMENTS
NDE FOR HEADERS EXTERNAL VISUAL INSPECTION
INTERNAL VISUAL INSPECTION WITH BORESCOPE
UT UNTUK THICKNESS MEASUREMENTS PT PADA NOZZLES WELDS DARI COIL TUBES
PT PADA CABANG (T) WELDS DAN HEADERS ATTACHMENTS, TERMASUK DRAINS TUBES
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10-4 SATURATION STEAM PIPE
NDE FOR EACH PIPE
EXTERNAL VISUAL INSPECTION
UT FOR THICKNESS MEASUREMENTS
PT AND UT ON CIRCUMFERENTIAL WELDS (R)
PT ON PIPING ATTACHMENTS
PT ON THE ELBOWS EXTRADOS
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10-5 PRIMARY,SECONDARY SUPERHEATER
NDE FOR THE HEADERS (TYPE PENDAND : 1 PCS ; TYPE U ON TOP : 2PCS) EXTERNAL VISUAL INSPECTION INTERNAL VISUAL INSPECTION WITH BORESCOPE UT FOR THICKNESS MEASUREMENTS UT FOR HEADER THICKNESS MEASUREMENTS PT ON NOZZLES WELDS OF THE COIL TUBES (R) PT ON NOZZLES WELDS TO THE SHELL OF THE INLET/OUTLET
PIPE PT AND UT ON CIRCUMFERENTIAL WELDS BETWEEN HEADER
AND HEADS/ PIPING PT ON HEADERS ATTACHMENTS METALLOGRAPHIC EXAMINATION BY PLASTIC REPLICAS *)
NDE FOR COILS EXTERNAL VISUAL INSPECTION UT FOR THICKNESS MEASUREMENTS INTERNAL VISUAL INSPECTION WITH BORESCOPE HARDNESS MEASUREMENTS SAMPLES FOR DESTRUCTIVE EXAMINATIONS *)
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10-6 CONNECTING PIPE ANTARA PRIMARY DAN SECONDARY SUPERHEATER,
DESUPERHEATER NDE FOR CONNECTING PIPE
EXTERNAL VISUAL INSPECTION UT FOR THICKNESS MEASUREMENTS PT AND UT ON CIRCUMFERENTIAL WELDS (R) PT ON PIPING ATTACHMENTS PT ON THE ELBOWS EXTRADOS METALLOGRAPHIC EXAMINATION BY PLASTIC REPLICAS
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NDE FOR DESUPERHEATER EXTERNAL VISUAL INSPECTION INTERNAL VISUAL INSPECTION WITH BORESCOPE UT FOR THICKNESS MEASUREMENTS PT ON CIRCUMFERENTIAL WELDS (R) METALLOGRAPHIC EXAMINATION BY PLASTIC REPLICAS
*)
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10-7 REHEATER / AIR PREHEATER
NDE FOR EACH ONE OF THE HEADERS
EXTERNAL VISUAL INSPECTION INTERNAL VISUAL INSPECTION WITH BORESCOPE UT FOR THICKNESS MEASUREMENTS PT ON NOZZLES WELDS OF TUBES PT ON NOZZLES WELDS TO THE SHELL OF THE
INLET/OUTLET PIPE PT AND UT ON CIRCUMFERENTIAL WELDS (R) PT ON HEADERS ATTACHMENTS (R) METALLOGRAPHIC EXAMINATION BY PLASTIC REPLICAS *)
NDE FOR COILS
EXTERNAL VISUAL INSPECTION UT FOR THICKNESS MEASUREMENTS INTERNAL VISUAL INSPECTION WITH BORESCOPE HARDNESS MEASUREMENTS SAMPLES FOR DESTRUCTIVE EXAMINATIONS *)
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10-8 MAIN SUPERHEATER STEAM PIPES
NDE FOR EACH PIPE
EXTERNAL VISUAL INSPECTION
UT FOR THICKNESS MEASUREMENTS
PT AND UT ON CIRCUMFERENTIAL WELDS (R)
PT ON PIPING ATTACHMENTS (R)
PT ON THE ELBOWS EXTRADOS
PT ON NOZZLES WELDS TO THE PIPE
METALLOGRAPHIC EXAMINATION BY PLASTIC REPLICAS *)