• Journal of the Korean Solar Energy Society
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• v.28 no.6
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• pp.33-39
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• 2008

The purpose of this study is not only to evaluate the stress behavior of tubes in superheater in HRSG during the load change operation but also to find root causes of failure from stress behavior. Firstly, temperature during operation was collected to perform stress analysis from actual HRSG. Part load and full load stress analysis which can be represented as the whole load change operations were performed using commercial finite element software. The possibility that can lead to tubes failure is found by stress analysis and its results is compared with metallurgical mircrostructure of failed tube which was taken from actual HRSG.

• Proceedings of the KSME Conference
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• 2008.11b
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• pp.3053-3058
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• 2008

We develop a heat exchanger modules for a multi-burner boiler. The heat exchanger module is kind of a heat recovery steam generator (HRSG). This heat recovery system has 4 heat exchanger modules. The 1st module consists of 27 bare tubes due to high temperature exhaust gas and the others consist of 27 finned tubes. The maximum steam pressure of each module is 1 MPa and tested steam pressure is 0.7 MPa. In order to test these heat exchanger modules, we make a 0.5t/h flue tube boiler (LNG, $40\;Nm^3/h$). We tested the heat exchanger module with changing the position of each heat exchanger module. We measured the inlet and outlet temperature of each heat exchanger module and calculated the heat exchange rate. The results show that if module C is placed at second stage (the 1st stage is always module O, bare tube module), there is no need to attach an additional heat exchanger module. In this case the exit temperature of module C is low enough to enter an economizer which is more effective in heat recovery than a heat exchanger module.

• 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.

• Proceedings of the KWS Conference
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• 2009.11a
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• pp.62-62
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• 2009

석탄화력발전소의 CO2배출량 감소와 고효율, 대용량화로 인해 초초임계압(USC:Ultra Super Critical) 화력발전소의 건설이 증가하고 있다. USC 발전소는 효율향상을 위한 증기온도와 압력의 상승 때문에 보일러 고온고압부에 기존의 소재에 비해 고온강도와 내산화성의 재료물성이 향상된 신소재 적용이 불가피하다. 특히 사용된 신소재 중에서 보일러 본체를 구성하는 수냉벽관(Water wall), 과열기와, 재열기용 튜브 및 후육부인 헤더와 배관재로 기존의 2.25Cr-1Mo강을 개량한 2.25Cr-1.6W계 내열강이 적용되고 있다. 2.25Cr-1.6W강은 SMI와 MHI가 공동개발한 소재로 1995년 튜브제품이, 1999년에 단조, 파이프재, 플레이트제품이 ASME code case로 등재되었고, 2009년 ASME code case 2199-4로 개정되어 사용 중이다. 이 소재는 2.25Cr-1Mo강에 고온강도 개선을 위해 석출강화효과가 있는 V과 Nb을 첨가하였고, 탄화물의 열적안정성과 고용강화효과 증대를 위해 W을 첨가하였다. 그리고 제작성과 용접성 및 재료의 인성 향상을 위해 B첨가와 C함량을 낮추었다. 합금성분의 첨가와 조정에 의해 고온강도는 개선되었지만, 보일러 설치 및 보수를 위한 용접과정에서 용접금속과 CGHAZ(Coarse Grain HAZ)에서 용접균열이 발생하였다. 대부분의 용접균열은 용접결함이나 고온 혹은 저온균열이 아닌 2.25Cr-1.6W계강의 강도 개선을 위해 첨가한 V과 Nb이 용접후열처리 도중 입내에 MX형태의 미세석출로 입내를 강화시킴으로서 발생한 재열균열 민감성 증대에 기인된 것으로 판단된다. 이에 본 연구에서 용접 및 후열처리 과정에서 용접금속과 HAZ에서 발생하는 용접금속의 응력분포를 전산해석을 통해 확인하고 실제 후육파이프 용접부에서 잔류응력을 측정해 비교하였다. 용접부 응력분포는 SYSWELD 프로그램을 사용해 해석을 수행하였고, 발전소 실배관재의 용접부 응력측정은 수평부 측정이 용이하도록 지그를 부착한 Potable 잔류응력측정기를 사용해 Hole Drilling Method(HDM)를 적용하여 잔류응력을 측정하였다. 해석 결과 CGHAZ부위의 잔류응력이 용접금속과 기타 부위에 비해 높은 응력분포를 나타냈으며, 이는 CGHAZ와 용접용융선 부근에서 균열이 발생하는 실제값과 일치하는 결과를 보였다. 실제 배관재 용접부에서 측정한 잔류응력값은 항복응력의 약 50% 이하 응력값을 나타냈다. 배관 구조에 기인한 시스템응력의 영향을 제거하기 위해 배관재 용접부를 중심으로 양끝단을 절단 후 용접부에서 측정한 응력은 항복응력 대비 25%수준의 낮은값을 보였다. 그러나 배관재가 장기간 고온환경에 노출되었고 용접금속 내부의 균열이 발생한 상태에서 측정하였기 때문에 용접잔류응력은 상당부분 해소되어 상대적으로 낮은 응력값이 얻어진 것으로 판단된다.

• Plant Journal
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• v.11 no.2
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• pp.32-38
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• 2015

This study was conducted on combined cycle power plant consisting of HRSG with integral deaerator type to avoid tube failures of low pressure evaporator tubes. Based on the observation of pH variation at the discharge of boiler feed water pump by continuous pH measurement for a period of time, it was identified that pH of feed water is getting reduced as ammonia is distributed into vapor and liquid depending on the distribution ratio of ammonia in the LP drum after the deaerator. To solve this problem, the counterplan was prepared by reexamination of ammonia injection point and quantity. In conclusion, it was accomplished that 9.2~9.6 is the optimized pH range for boiler feed water by arranging additional piping for ammonia to inject directly to LP drum.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.40 no.7
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• pp.679-683
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• 2016

Boilers of large-sized coal-fired power plants are being operated under very poor conditions such as continuous operation or repeating of start-up and shutdown for a stable supply of electricity. Thus periodic inspection and maintenance are required to ensure reliability of operation. The loads of existing scaffolding systems for the maintenance of boilers are concentrated in the lower parts structurally, which may cause a serial collapse of the overall scaffolding system when there are problems in some members. Therefore, in this study, a safe furnace scaffolding system is developed by dispersing the loads in the upper part, as well as minimizing the hazards of serial collapsing. In addition, for cases where the direct installation of furnace scaffolding is challenging owing to the structure of the boiler tube, a lifting system for the installation of furnace scaffolding is developed so that furnace scaffolding can be supported to secure the integrity of the power generating facility.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.25 no.12
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• pp.1995-2001
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• 2001

In this study, a small punch creep(SP-Creep) test using miniaturized specimen(10${\times}$10${\times}$0.5mm) is described to develop the new creep test method for high temperature structural materials. The SP-Creep test is applied to 2.25Cr-lMo(STBA24) steel which is widely used as boiler tube material. The test temperatures applied for the creep deformation of miniaturized specimens are between 550∼600$^{\circ}C$. The SP-Creep curves depend definitely on applied load and creep temperature, and show the three stages of creep behavior like in conventional uniaxial tensile creep curves. The load exponent of miniaturized specimen decreases with increasing test temperature, and its behavior is similar to stress exponent behavior of uniaxial creep test. The creep activation energy obtained from the relationship between SP-Creep rate and test temperature decreases as the applied load increases. A predicting equation or SP-Creep rate for 2.25Cr-lMo steel is suggested. and a good agreement between experimental and calculated data has been found.

• Korean Chemical Engineering Research
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• v.61 no.3
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• pp.419-425
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• 2023

This paper presents the research results of analyzing the high-temperature corrosion characteristics of three currently commercialized heat exchanger tube materials under actual operating conditions of a biomass power plant. In order to precisely analyze the high-temperature corrosion characteristics of these materials, a high-temperature corrosion evaluation device was installed in the power plant equipment, which allows for adjusting the surface temperature of the heat exchanger tubes. Experiments were conducted for approximately 300 hours under various temperature and operating conditions. In this study, the commercialized heat exchanger tube materials used were SA213T12, SA213T22, and SA213T91 alloys. In order to objectively analyze the high-temperature corrosion characteristics of each material, an international standard-based process to remove corrosion products was applied to obtain the weight change of the specimens, and the average thickness loss and corrosion rate were derived. Thus, the high-temperature corrosion results for each condition were quantitatively compared and analyzed. In addition, in order to increase the reliability of the high-temperature corrosion evaluation method introduced in this study, the surface and cross-sectional corrosion of the specimens were confirmed by using scanning electron microscopy and energy-dispersive X-ray analysis. Based on these analysis results, it was found that the corrosion resistance of the commercial heat exchanger materials increases as the content of chrome and nickel in the composition increases. Additionally, it was found that the corrosion phenomenon is rapidly accelerated as the surface temperature increases. Finally, the replacement period (lifetime) of the heat exchanger tubes under each condition could be inferred through this study.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2012.04a
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• pp.150-154
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• 2012

A flow induced mechanical vibration and acoustic resonance should be considered at design stage because they are mainly occurred in the tube bank of boiler. Acoustic resonance is occurred when the vortex shedding frequency of tube bank coincides with the acoustic natural frequency of the cavity. Effective solution to avoid acoustic resonance is installing acoustic baffles in the tube banks parallelly inside of the flow cavity. Thus, location and number of acoustic baffles should be exactly calculated to eliminate the acoustic resonance. This paper presents case study of acoustic resonance due to inappropriate number and location of acoustic baffles. Measured frequency and mode in the study is verified by FEM acoustic modal analysis. The number and location of acoustic baffles to avoid acoustic resonance are calculated by using FEM acoustic modal analysis.

• Proceedings of the KSME Conference
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• 2003.11a
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• pp.373-378
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• 2003

It is important that overheat protection of super heated tube in boiler operation and maintenance. The overheat of super heat tube can make damage and rupture of tube material, which causes accidental shutdown of boiler. The super heated tube overheat is almost due to the lack of uniformity of gas temperature distribution. There are two ways to protect overheat of super heated tube. The one is to control hot gas operation pattern which is temperature or flow distribution. the other is to control super heated steam flow distribution. The former is difficult than the later, because of control device design. In this paper steam flow control method which uses orifices is proposed to protect overheat of super heat tube.