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e come
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resen a on rrangemen
. n ro uc on
2. Module of a typical RLA Study3. BHEL contribution in the area of RLA4. ni T t F iliti t BHE
5. Current developments in BHEL in the
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LEP
N on-pres su re Part s Pres s ure Part s
RLAPETCondit ion As sessm en t
R&M Pro osal
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Bharat Heavy Electricals Limited, Tiruchirapalli
RESIDUAL LIFE ASSESSMENT STUDY
s u y con uc e as ca y o n ou :
pressure parts and piping
To determine the remaining left out life of thepressure parts
Enable to take Run, Re air and Re lacement decisionsProvide technically sound and viable input for R&M
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Why RLA Study
pera on o o er a e eva e
temperatures more than design limit Variations in coal quality
ev a ons n a er em s ry
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Bharat Heavy Electricals Limited, Tiruchirapalli
Why RLA Study
ros on on on e ou er sur ace o e rum ue o
steam leakage
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Bharat Heavy Electricals Limited, Tiruchirapalli
Why RLA Study
Sagged Header
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Bharat Heavy Electricals Limited, Tiruchirapalli
Why RLA Study
Foreign Body inside RH Inlet Header
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Bharat Heavy Electricals Limited, Tiruchirapalli
y u ySeawater Corrosion in S-Panel
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Bharat Heavy Electricals Limited, Tiruchirapalli
RLA Study Aims At
Evaluation of present condition of pressure
par s p p ng
Avoiding premature pressure parts failuresand associated unforeseen outages
Identification of problem areas
Analysis of root cause of problems
Providing technically sound and viable
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Bharat Heavy Electricals Limited, Tiruchirapalli
RLA of What?
Pressure parts
Highly varying duty
Varying Load, Cyclic Load
Fuel Quality Variations
Carried out extensively
Structural parts Limited study
Need based
Visual examination gives good clue Non pressure parts
Mostly maintenance oriented
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an e assesse eas y
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Bharat Heavy Electricals Limited, Tiruchirapalli
RLA STUDY
Pre-Site Study Phase Site Study Post-Site Study Phase
Tender Review/
Review of requirements based
on available information
Review of Operational History Laboratory Analysis
-
Replica Evaluation
Discussions with Utility Scheduling of Activities Review & Finalisation
Scope Finalisation Preparatory Works Report Preparation &
o ecommen a ons
Submission of Offer Study & Preliminary proposals for improvement
Submission
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Report Submission
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Steam Generating Unit
PRESSURE PARTS
HIGH TEMP (>400 C) HIGH THICKNESSSH HEADERS, DeSH
MS HRH & PRDS PIPINGS
LOW TEMP (
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Bharat Heavy Electricals Limited, Tiruchirapalli
erv ce ours enera on ecor s a n enance ecor s
o. o ar -ups va a y ep acemen ecor s
Transient Conditions PLF Design Changes
Steady State Conditions
Excursions
Failure History Inspection Records
RLA/CA/PET
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Bharat Heavy Electricals Limited, Tiruchirapalli
Stages of Residual Life Assessment
Re ie of ast o erational &
maintenance data of the plant including
water chemistry variations
Field testing
Laboratory testing
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Bharat Heavy Electricals Limited, Tiruchirapalli
Review Of Past Data
Plant operation
Number of start-ups & shut downs
O eratin conditions
Operating practice
a n enance an repa rFailures and repairs
Review of root cause analysis
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sua nspec on
Erosion, corrosionSwelling, scaling
,
Supports, pipe hangers etc
Dimensional checks
ThicknessOutside diameter
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Bharat Heavy Electricals Limited, Tiruchirapalli
Field Testin
Non destructive examination
Penetrant testing including fluorescent type
Ma netic article ins ection Wetfluorescent & Dry)
Ultrasonic
In-situ hardness checks
Tube sampling - WW internal deposits
WW H2 embr ttlement
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Bharat Heavy Electricals Limited, Tiruchirapalli
,
Metallography In situ metallographic examination
roscop c nspec on S ot chemical check when needed
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Bharat Heavy Electricals Limited, Tiruchirapalli
T ical Tests Done for RLA
Hi h tem erature headers & i in
Ultrasonic, dye-penetrant tests
roscopy, rep cas
Other inspections like
Dimensions, Internal inspection
In-situ hardness
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uper ea er e ea er u es
Tube samples, ultrasonic test OD & Thickness
Deposit Analysis
Steam side oxide scale thickness Life prediction
Attemperators
Ultrasonic, dye penetrant tests Replication, hardness
Fibroscopy
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Bharat Heavy Electricals Limited, Tiruchirapalli
rums owncomers
Ultrasonic d e- enetrant tests
MPI (Wet fluorescent & Dry)
Fibroscopy
Tube samples, ultrasonic testDeposit analysis (Internal & External)
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Bharat Heavy Electricals Limited, Tiruchirapalli
Visual Inspection
ep ca on, n-s u ar ness
OD & thickness angers uppor s nspec on
Stress analysis to identify the most stressed points
enera gu e nes or se ect ng nspect on po nts High turbulence or velocity zones
on ensa on po n s
Dead ends & high stressed points
points
All su orts
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Bh H El l L d h ll
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Bharat Heavy Electricals Limited, Tiruchirapalli
Tubes samples from high heat flux zone
Detailed dimensional measurements
Presence of internal deposits covering
epos con en
Constituents of deposit
o ven se ec on c ean ng s necessary
Presence of external and internal corrosion
Micro structure analysis (hydrogen damage)
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Bh t H El t i l Li it d Ti hi lli
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Bharat Heavy Electricals Limited, Tiruchirapalli
Microscopy & SEM)
Deposit analysis ( Internal & External)
cce erate creep rupture test ng
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Bh t H El t i l Li it d Ti hi lli
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Bharat Heavy Electricals Limited, Tiruchirapalli
Scope of RLA as per IBR 391 A
Component Visual
Ultrasonic
testing
particel
testing
penetrant
inspection Replication Sampling
Deposit
Analysis
Drum (Steam) Yes Yes No * Yes Yes No Yes
Water Drum Yes Yes No * Yes Yes No Yes
*
Attemperator Header Yes Yes No * Yes Yes No No
High Temp Header Yes No No * No No Yes No
Low temp eco tubes Yes No No * No No Yes No
Convection SH coils Yes No No * No No Yes Yes
Primary SH coils Yes No No * No No Yes No
Prefinal SH coils Yes No No * No No Yes No
Final SH Coils Yes No No * No No Yes No
Reheater coils Yes No No * No No Yes NoHigh temp header Yes Yes No * Yes Yes No No
Final SH header 'Yes Yes No * Yes Yes No No
Reheater Header Yes Yes No * Yes Yes No No
a n s eam p p ng es o o o es o o
Platen SH header Yes Yes No * Yes Yes No No
Primary SH header Yes Yes No * Yes Yes No No
Economizer header Yes No No * Yes No No No
Auxiliaries Yes No No * No No No No
Boiler bank tubes Yes No No * No No No NoWater wall Yes No No * No No Yes No
Furnace water walls Yes No No * No No Yes No
* MPI will be done on case to case basis
** Oxide scale based life prediction will be done based on operational history and failures
*** UT for checkin inte rit of butt welds
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$ Header internal inspection by fiberscope
Bharat Heavy Electricals Limited Tiruchirapalli
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Bharat Heavy Electricals Limited, Tiruchirapalli
Microstructural Evaluation By Replication
Sampling Thick Walled Components Is
Non-destructive Technique Adopted
or va ua on s ep ca on. To examine s heroidisation and
cavitation level
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Bharat Heavy Electricals Limited, Tiruchirapalli
Re lica Techni ue
The material surface preparation by
grinding, polishing and etching
e p as c se rep ca s app e rm y
to the surface
After curing, the replica can be removed
an go spu ere e opograp ca
image of the micro structure is examined
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Bharat Heavy Electricals Limited, Tiruchirapalli
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Bharat Heavy Electricals Limited, Tiruchirapalli
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Bharat Heavy Electricals Limited, Tiruchirapalli
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Bharat Heavy Electricals Limited, Tiruchirapalli
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o pu ere ep ca
Bharat Heavy Electricals Limited, Tiruchirapalli
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Bharat Heavy Electricals Limited, Tiruchirapalli
Cree Cavit Level Classification S stem Pro osed
by Wedel & Neubauer
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y , p
Indian Boiler Re ulationsASME
ANSI
DIN
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y p
Organisation for RLA in BHEL
R&M department Supporting Depts Service After Sales
Scope of Work
Technical ,Report Preparation
FES, WRI
Central LabNDTL
Offer Submission
Order ReceiptReport to Customer &
ar ca on , orp o er nspec ora e
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y p
Supporting Depts
For
NDE TUBE FAILURE ANALYSIS WATER CHEMISTRY &OXIDE SCALE THICKNESS
INSITU METALLOGRAPHY
Specialised Work
NDTL,SAS CENTRAL LAB Corp. R&D
ACCELERATED
CREEP RUPTURE TEST
CENTRAL LAB,
WRI
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Expert PanelFor RLA
Engineering& R&D Metallurgical
Analysis
NDE
Doctorates : 5Post Graduates : 50
Doctorates : 6Post Graduates : 10
Level I : 43Level II : 136
Graduates : 250 Graduates : 10 Level III : 6
eve , as per -
Techniques UT, RT, MT, PT, Eddy Current(ET), & Leak Test (LT)
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National NDT Award from ISNT 4 times
Two Registered Assessors Qualified from
ns u e o eg s ere er e
Assessors (IRCA, UK)
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spec a con r u on n e area o
Personnel, Boiler Inspectorate Personnel and
Customers Personnel HRD Training Program on RLA Being
Conducted for Education of BHEL En ineers
Customer Engineers & Boiler Inspectors WRI & BHEL Indo-German Pro ram
Encompasses RLA also
Boilers Including Piping & Industrial Boilers &
other Com onents
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(cont.)
Training of BHEL executives in the field of RLA at
,
Field Training at Chandrapura TPS by EPRI, USA
o er ea er o ca on w
Material Based on Assessment by RLA Techniques
Being Met When Called for
SAIL, Bokaro in Full Agreement Technically
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Special NDT techniques developed by BHEL
Detection of hydrogen damage by UT Measurement of oxide scale thickness by
.
Microstructural evaluation by replication
A new technique called VAPINE'.
by UT.
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Post Ex osture Uni-Axial Accelerated cree testin
In-Situ Hardness Tester
-
Digital Strain Measurement Gauge
Portable Microscope for Insitu MetallurgicalExamination
Portable Alloy Analyser
with microprocessor
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Unique Test Facilities at BHEL (Cont)
Impact test facility up to minus 196 deg C
Scanning Electron Micro Scope
Atomic Absorption Spectrometer Portable Stress Anal ser
Video Fibrescope
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Scannin Electron Micro Sco e
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-
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Li ament Crack Detection b UT
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ecommen at ons ormat yp ca
Residual life ins ection intervals of components
ar s nee ng rep acemen s
Parts needin re airs
Chemical cleaning advice & procedure
o cat ons requ re or e extens on
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Advice on water regimes Improvements in operational methods
Retrofits / improvements in control &
instrumentation
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stu es arr e out y
Total Number of studies carried out : 208Power Boilers : 138
Process/Industrial Boilers : 70
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Run Repair Replace
RLA
Evaluates For All Phases
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Bharat Heavy Electricals Limited, Tiruchirapalli
Currentworking ofBHELin the RLA Field
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Current working of BHEL in the RLA Field
Working on a comprehensive Advanced RLA software to evaluate pressure part creep and Fatique life
assessment called ALIAS.
and accurate. Planning to use in site with data
.
Strain measurement to Evaluate the safety factor of
Drum as per ASME code Section 8UG L101.
Drum with the ASME design safety margin for the
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.
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Committed to making a better world