• Korean Journal of Air-Conditioning and Refrigeration Engineering
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• v.20 no.7
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• pp.478-485
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• 2008

The extreme steam temperature deviation experienced in the superheater of a tangentially fired boiler can seriously affect its economic and safe operation. This temperature deviation is one of the main causes of boiler tube failures. The steam temperature deviation is mainly due to the thermal load deviation in the lateral direction of the superheater. The thermal load deviation consists of several causes. One of the causes is the non-uniform heat flow distribution of burnt gas on the superheater tube system. This distribution is very difficult to measure in situ using direct experimental techniques. So, we need thermal load model to estimate the tube temperature. In this paper, we propose a thermal load distribution model by using CFD analysis and plant data. We successfully predict the tube temperature and the steam flow rate in a final superheater system from the thermal load model and one dimensional heat-flow system analysis. The proposed model and analysis method would be valuable in preventing the frequent tube failure of the final superheater tubes.

• Korean Journal of Air-Conditioning and Refrigeration Engineering
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• v.20 no.6
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• pp.416-426
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• 2008

The boiler tube failure often experienced in the superheater of a utility boiler can seriously affect the economic and safe operation of the power plant. It has been known that this failure is mainly caused by the thermal load deviation in the superheater tube system, and deeply intensified by the non-uniform distribution of steam flow rates. The nonuniform steam flow is distinctively prominent at low power load rather than at full power load. In this paper, we analyze the steam flow distribution in the superheater tube system by using one dimensional flow network model. At 30% power load, the deviation of steam flow rate is predicted to be within 0.8% of the averaged flow rate. This deviation can be reduced to 0.1% and 0.07% by assuming two cases, that is, the removal of 13th tube at each tube rows and the installation of intermediate header, respectively. The assumed two cases would be effective for the uniform steam flow distribution across 85 superheater tube rows.

• Corrosion Science and Technology
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• v.21 no.2
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• pp.130-137
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• 2022

In this work, the degradation of high-pressure superheater tubes exposed to the flame of a duct burner in a heat recovery steam generator of a district heating system was evaluated. To assess the deterioration of the used superheater tube, the microstructure, microhardness, and tensile properties were investigated by comparison to an unused tube. The study found that a fin bound at the outer surface of the used tube became fragile only in the location facing the flame. This indicates that the tube was directly exposed to the flame from the duct burner or underwent abnormal overheating. While the unused tube showed a uniform value in hardness and equiaxial grain structure, the used tube revealed a decrease in hardness up to 105 HV and an increase in grain size with a plate-like morphology in the location facing the flame. The coarsening of the grain structure by the flame weakened the mechanical properties of yield strength, tensile strength, and elongation.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.22 no.1
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• pp.177-189
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• 1998

The contents of this paper include a non-destructive technique for evaluating the degradation of the boiler superheater tube in a fossil power plant through an electrochemical polarization test. Correlation between Ip of polarization parameter and SP-DBTT for the superheater tubes in long-term use was obtained. 1.0Cr-0.5Mo steel was degraded by softening, and the degree of degradation was dependent upon carbides with Cr and Mo elements. Since brittle fracture at low temperature and ductile fracture mode at high temperature were shown, similarity between standard Charpy and small punch tests could be found. In addition, SP-DBTT showing the degree of degradation was higher, as the time-in use of the materials got longer. Electrolyte including picric acid of 1.3 g in distilled water of 100ml at 25.deg. C temperature and sodium tridecylbenzene sulfonate with 1g could be applied to evaluate the degradation of 1.0Cr-0.5Mo steel by means of the electrochemical polarization test. Ip and Ipa values measured through the electrochemical test are the appropriate parameters for representing the degradation of the superheater tube(1.0Cr-0.5Mo steel) for the fossil power plant. It is poassible to evaluate the degradation of materials with different time histories electrochemically, by Ip value only, at field test.

• Korean Journal of Air-Conditioning and Refrigeration Engineering
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• v.24 no.3
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• pp.281-287
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• 2012

The internal oxide scale of twelve superheater and reheater tubes were tested which were serviced for 30,000~120,000 hours in thermal power plants. The oxide scale was formed in three layers. The Cr-rich area was observed beneath the original metal surface. The hematite ($Fe_2O_3$) phase was formed on the outer surface. The intermediate layer was magnetite ($Fe_3O_4$). The thickness of Cr-rich layer was about half of the total scale. All layers grew during the operation hour of the plant. The thickness of thickest scale was 0.2mm in superheater tubes. This can increase the tube metal temperature about $7^{\circ}C$ more than initial state. $7^{\circ}C$ tube metal temperature can reduce tube life about 30%, but the boiler tube's design margin is big enough therefore it has been analyzed that it would not effect on the life span.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.36 no.5
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• pp.563-569
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• 2012

The superheater and reheater tubes of a heavy-load fossil power plant boiler can be damaged by overheating, and therefore, the degree of overheating is assessed by measuring the oxide scale thickness inside the tube during outages. The tube temperature prediction from the oxide scale thickness measurement is necessarily accompanied by destructive tube sampling, and the result of tube temperature prediction cannot be expected to be accurate unless the selection of the overheated point is precise and the initial-operation tube temperature has been obtained. In contrast, if the tube temperature is to be predicted analytically, considerable effort (to carry out the analysis of combustion, radiation, convection heat transfer, and turbulence fluid dynamics of the gas outside the tube) is required. In addition, in the case of analytical tube temperature prediction, load changes, variations in the fuel composition, and operation mode changes are hardly considered, thus impeding the continuous monitoring of the tube temperature. This paper proposes a method for the short-term prediction of tube temperature; the method involves the use of boiler operation information and flow-network-analysis-based tube heat flux. This method can help in high-temperaturedamage monitoring when it is integrated with a practical tube-damage-assessment method such as the Larson-Miller Parameter.

• 제어로봇시스템학회:학술대회논문집
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• 2004.08a
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• pp.1201-1204
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• 2004

This paper suggests a DCS (Distributed Control System) model for steam temperature system of the thermal power plant. The model calculated within sectional range is linear. In order to calculate mathematical models, the system is partitioned into two or three sectors according to its thermal conditions, that is, saturated water/steam and superheating state. It is divided into three sections; water supply, steam generation and steam heating loop. The steam heating loop is called 'superheater' or steam temperature system. Water spray supply is the control input. A first order linear model is extracted. For linear approach, sectional linearization is achieved. Modeling methodology is a decomposition-synthetic technique. Superheater is composed of several tube-blocks. For this block, linear input-output model is to be calculated. Each tiny model has its transfer function. By expanding these block models to total system, synthetic DCS linear models are derived. Control instrument include/exclude models are also considered. The resultant models include thermal combustion conditions, and applicable to practical plant engineering field.

• Korean Journal of Air-Conditioning and Refrigeration Engineering
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• v.21 no.3
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• pp.157-166
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• 2009

The pulverized coal combustion behavior in the coal fired utility boiler has been investigated with the CFD and process analysis techniques. The used commercial software were CFX and PROATES, and these were coupled each other to get more reliable boundary condition set-up, resulting in more reliable solution. For two cases which were the actual operation condition of A power plant, the calculated values from the coupled CFD and process analysis for thermal energy system were compared with the plant data, and the good agreements were obtained for Case 1 and 2. The calculated temperature distributions on the surface of heat exchangers were compared with the plant data for the steam temperatures across heat exchangers, and these explained the actual operating situation very well. The temperature deviation across the final superheater tube, which was believed to be the main cause of the frequent tube failure, were also explained very well with the calculated distributions of gas temperature and radiation on the plane of the final superheater.

• Journal of Korea Society of Waste Management
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• v.35 no.8
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• pp.754-761
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• 2018

There is growing concern over the effects of global warning. In response, the power generation sector must consider a wider range of systems and fuels to generate power. One of the classes of solid fuels that is being increasingly developed is biomass. However, one of the most serious problems that biomass plants face is severe corrosion. To mitigate the problem, various approaches have been proposed in terms of additive utilization. This study is based on the results obtained during the co-combustion of wood chip and waste wood in a circulating fluidized bed boiler (CFBC boiler). The KCl concentration was reduced from 59.9 ppm to 3.9 ppm during the injection of ammonium sulfate, and NOx was reduced by 25.5 ppm from 30.6 ppm to 5.1 ppm. However, SOx increased by 110.2 ppm from 33.2 ppm to 143.4 ppm, and HCl increased by 71.5 ppm from 340.5 ppm to 412.0 ppm. Thus, we confirmed that the attitude of the superheater tube was reduced by 87 ~ 93%, and the injection of ammonium sulfate was effective in preventing high-temperature corrosion.

• Transactions of the Korean Society of Pressure Vessels and Piping
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• v.16 no.1
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• pp.65-73
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• 2020

Integrity evaluations on a platen superheater were conducted as per ASME Section VIII Division 2(hereafter 'ASME VIII(2)') which was originally used for design with implicit consideration of creep effects. A platen superheater subjected to severe loading conditions of high pressure and high temperature at creep regime in a supercritical thermal plant in Korea was chosen for present study. Additional evaluations were conducted as per nuclear-grade high-temperature design rule of RCC-MRx that takes creep effects into account explicitly. Comparisons of the two results from ASME VIII(2) and RCC-MRx were conducted to quantify the conservatism of ASME VIII(2). From present analyses, it was shown that the design evaluation results exceeded allowable limits of RCC-MRx for the plant design conditions although limits of ASME VIII(2) were satisfied regardless of operation time, which means that design as per ASME VIII(2) might be potentially non-conservative in case of operation in creep range. A high-temperature design evaluation program as per RCC-MRx, called 'HITEP_RCC-MRx' has been used and it was shown that pressure boundary components can be designed reliably with the program especially for the loading conditions of long-term creep conditions.