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Steam Digest 2002 Steam 1 Component Damage Mechanism P iping [ 6 to 8] Drums and Headers [ 6 to 8] 4. A “Safety Expert System”—a software package, which could be customized for each steam cycle, should be developed. 5. ASME Boiler and Pressure Vessel Code sections dealing with boiler and piping inspections and defect evaluations need to be updated and more specific guidance for NDT and fitness for service evaluations should be provided. 2 Safety Issues in Fossil Utility and Industrial Steam Systems Table 3: Critical steam components, their damage mechanisms, and influences 3 Major Influences Destructive 4 Failures CreepWelds, temperature, time Yes LCF, LCCF Temperatur e changes Carbon steel graphitization LCF, SCC LCCF, BoilerTubes[ 10] LCCF ( 20 others) Feedwater and Wet Steam Piping [ 9, 14 to 16] Deaerator, Flash Tank, Hot Water and Steam Vessels - Welds [ 9, 17] LP Turbine Roters and Disks [ 9, 11 to 13] LP Turbine to 13] HP/ IP Turbine 11 to 13] Blades [ 9, 11 Rotors [ 8, TemperatureandtimeYes $ Impact Temperaturecycling, design, water chemistry No 0 107 Waterchemistry, cycling, heat flux, etc. Yes 0 FACDesign, water chemistry Yes CavitationDesign, operation Yes SCCResidualstress, chemistry No CF, LCCF Weld quality, water chemistry, temperature changes CF, SCC Design ( water piston) , residual welding stress, operation, water chemistry n SCCDesignstresses, temperature , high-strength steel, steam chemistry CFSteamchemistry, design, vibration No CF SCC Turbine[ 11 to 13] Destructive Overspeed Steam chemistry, design vibration, erosion, high-strength steel p itting, No 1 7 1 6 107 Yes107 Yes 107 No106 LCFCycling, inclusions, fatigue design Yes 0 Steam chemistry valves ( boiler carryover) , sticking Turbine[ 11 to 13] R ubbing Steam chemistry, deposits, thrust bearing, expansion 1 7 Yes10710 - 8 Yes107 1. Numbers in [ ] are References 2. CF - Corrosion Fatigue, LCF - Low Cycle Fatigue, LCCF - Low Cycle Corrosion Fatigue, SCC - Stress Corrosion Cracking, FAC - Flow-Accelerated Corrosion 3. Age influences the degree of damage for all issues except the last two 4. At least one destructive failure during the last 30 years 5. Lost production and repairs per one event. The cost of lost production is typically much higher than the loss from repairs with a ratio up to 10:1 REFERENCES 1. 2001 National Board Incident Report. U.S. National Board of Boiler and Pressure Vessel Inspectors. 2. “The Numbers are in … Ten Years of Incident Reports Underscore Human Error as Primary Cause of Accidents.” National Board Bulletin. Summer 2002. 3. G. Celedonia, et al. “Make Safety Performance Part of ‘Business as Usual’.” Power, January/February 2001. 4. Fitness for Service. API Recommended Practice 579, January 2000. 5 41
Safety Issues in Fossil Utility and Industrial Steam Systems 42 5. Handbook of Loss Prevention. Allianz Versicherungs-AG, Berlin/Munchen 1978. 6. Corrosion in Power Generating Equipment. Editors Markus O. Speidel and Andrejs Atrens. Plenum Press, New York, 1984. 7. Fatigue and Fracture, Volume 19. ASM Handbook, ASM International, Materials Park, OH, 1996. 8. R. Viswanathan. Damage Mechanisms and Life Assessment of High-Temperature Components. ASM International, Metals Park, OH, 1989. 9. Low Temperature Corrosion Problems in Fossil Power Plants – State of Knowledge. EPRI, Palo Alto, CA. To be published. 10. B. Dooley and W. McNaughton. Boiler Tube Failures: Theory and Practice, Vol. 2: Water-Touched Tubes. Electric Power Research Institute, Palo Alto, CA, 1996. 11. T. McCloskey, R. Dooley, and W. McNaughton. Turbine Steam Path Damage: Theory and Practice, Vol. 2: Damage Mechanisms. Electric Power Research Institute, Palo Alto, CA, 1999. 12. O. Jonas. “Corrosion and Deposition Problems in Steam Cycle.” Power Station Chemistry 2000 Conference. May 15-16, Queensland, Australia. 13. O. Jonas and B. Dooley. “Major Turbine Problems Related to Steam Chemistry: R&D, Root Causes, and Solutions.” Paper presented at 5th International Conference on Cycle Chemistry in Fossil Plants, EPRI, Charlotte, NC, June 10-12, 1997. 14. B. Chexal, et al. Flow-Accelerated Corrosion in Power Plants. Electric Power Research Institute, Palo Alto, CA, 1996. TR-106611. 15. O. Jonas. “Alert: Erosion-Corrosion of Feedwater and Wet Steam Piping.” Power, February 1996. 16. O. Jonas. “Erosion-Corrosion of PWR Feedwater Piping - Survey of Experience, Design, Water Chemistry, and Materials.” Report for U.S. Nuclear Regulatory Commission, NUREG/CR-5149, ANL-88-23, March 1988. 17. O. Jonas. “Deaerators: An Overview of Design, Operation, Experience, and R&D.” Proc. of the American Power Conference, Vol. 49, A. 979, Ill. Institute of Technology, 1987. 18. Cost of Corrosion in the Electric Power Industry. EPRI. Palo Alto, CA. October 2001. Report 1004662. 19. B. Syrett, et al. “Cost of Corrosion in the Electric Power Industry.” Materials Performance. Vol. 41, No. 3. March 2002. Steam Digest 2002
Page 1 and 2: A compendium of articles on the tec
Page 4 and 5: TABLE OF CONTENTS INTRODUCTION Chri
Page 6: CLOSED-LOOP ENERGY MANAGEMENT CONTR
Page 10 and 11: Steam Digest 2002 Energy Efficiency
Page 12 and 13: Steam Digest 2002 Crude oil is refi
Page 14 and 15: Steam Digest 2002 to be newer and h
Page 16 and 17: Steam Digest 2002 Condensing steam
Page 18 and 19: Steam Digest 2002 this case, it is
Page 20 and 21: Steam Digest 2002 Appendix Appendix
Page 22 and 23: Steam Digest 2002 Decision Climate
Page 24 and 25: Steam Digest 2002 as summer approac
Page 26: Steam Digest 2002 late quick and ea
Page 29 and 30: An Analysis of Steam Process Heater
Page 31 and 32: An Analysis of Steam Process Heater
Page 34 and 35: Steam Digest 2002 Combustion Contro
Page 36 and 37: Steam Digest 2002 mal efficiency by
Page 38 and 39: Steam Digest 2002 Figure 5: Cross L
Page 40 and 41: Steam Digest 2002 Insulation Improv
Page 42 and 43: Steam Digest 2002 Reduce Fuel Costs
Page 44 and 45: Steam Digest 2002 Safety Issues in
Page 48 and 49: Steam Digest 2002 The Human Side of
Page 50 and 51: Steam Digest 2002 Preliminary Resul
Page 52 and 53: Steam Digest 2002 Table 2: Estimate
Page 54 and 55: Steam Digest 2002 Table 5: Energy U
Page 56: Steam Digest 2002 Fuel savings, P
Page 59 and 60: Results from the Industrial Assessm
Page 61 and 62: Steam Digest 2002 Results from the
Page 64 and 65: Steam Digest 2002 ProSteam - A Stru
Page 66 and 67: Steam Digest 2002 Figure 1: Typical
Page 68 and 69: Steam Digest 2002 The value of the
Page 70 and 71: Steam Digest 2002 value shown in Fi
Page 72: Steam Digest 2002 Trbn_A3 Three-Sta
Page 75 and 76: Steam System Improvements at Dupont
Page 77 and 78: Steam System Improvements at Dupont
Page 80 and 81: Steam Digest 2002 Closed-Loop Energ
Page 82 and 83: Steam Digest 2002 Figure 3: Advice
Page 84 and 85: Steam Digest 2002 gions. Constraint
Page 86 and 87: Steam Digest 2002 4. Provide overri
Page 88: Steam Digest 2002 Operations can id
Page 91 and 92: An Introduction to Steam Outsourcin

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