Remaining life assessment of service exposed reheater and superheater tubes in a boiler of a thermal power plant

Abstract

This paper presents the high temperature tensile and the stress rupture properties of 150,000 hours service-exposed superheater and reheater tubes made of 2.25Cr-1 Mo steels in a 120 MW boiler of a thermal power plant. These were used to estimate the remaining life for safety. Experimentally determined yield strength and ultimate tensile strength as well as estimated 10,000 hours - 100000 hours rupture strength as obtained from experimental data in the temperature range of 793 to 853K exhibit a decreasing trend with increasing temperature. Microstructural study did not reveal any significant degradation in terms of creep cavities, cracks, graphitization etc. In general, analysis of tensile and stress rupture data reveal that the service exposed superheater and reheater tubes can remain in service for a length of more than ten years at the operating hoop stress level 40 MPa / 813K, provided no localised damage in the form of cracks or dents has been developed. It is recommended that a similar health check should be carried out after 50,000 hours of service exposure at 813K.