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Risk-Based Inspection – Flyash Erosion on Boiler Tube at Coal-Fired Power Plant by

Mohamad Hasrul Hilmi b. Khairul Aman

Dissertation submitted in partial fulfillment of the requirements for the

Bachelor of Engineering (Hons) (Mechanical Engineering)

JUNE 2010

Universiti Teknologi PETRONAS Bandar Seri Iskandar

31750 Tronoh Perak Darul Ridzuan

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Table of Contents

CERTIFICATION OF APPROVAL ... i

CERTIFICATE OF ORIGINALITY ... ii

ABSTRACT ... iii

ABSTRACT ... iv

CHAPTER 1: INTRODUCTION ... 1

1.1 Background ... 1

1.2 Problem Statement... 2

1.3 Objective and Scope of Study ... 2

CHAPTER 2: LITERATURE REVIEW AND THEORY... 3

2.1 Coal-Fired Thermal Power Plant ... 3

2.2 Brief Analysis on Erosion Rate ... 6

2.3 Flyash Erosion ... 8

2.3.1 Features of Failure ... 8

2.3.2 Locations of Failures ... 9

2.4 Boiler Tube Material ... 10

2.5 Risk-Based Inspection (RBI) ... 10

2.5.1 Qualitative Analysis ... 10

2.5.2 Semi-Quantitative Analysis ... 10

2.5.3 Qauntitative Analysis ... 11

2.6 Consequence Analysis for Steam ... 12

2.6.1 Estimation of Maintenance Cost ... 12

2.6.2 Estimation of Production Loss Cost ... 14

2.6.3 Down Time ... 14

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CHAPTER 3: METHODOLOGY/PROJECT WORK ... 13

3.1 Project Implementation Approach ... 15

3.1.1 Obtaining Boiler Database ... 16

3.1.2 Damage Mechanism Study & Release Event Tree ... 16

3.1.3 Semi-Quantitative Analysis ... 17

3.1.4 Risk Ranking ... 25

3.1.5 Risk Result Comparison ... 25

CHAPTER 4: RESULT AND DISCUSSION ... 26

4.1 Release Event Tree ... 26

4.2 Downtime Analysis ... 27

4.3 API 581 Probability of Failure Analysis ... 28

4.4 API 581 Consequence of Failure Analysis ... 28

4.5 Proposed Consequence of Failure Analysis ... 31

CHAPTER 5: CONCLUSION AND RECOMMENDATION ... 35

5.1 Conclusion ... 35

5.2 Recommendation ... 36

REFERENCES ... 37

APPENDICES ... 39

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List of Figures

Figure 1: Typical Diagram of a Coal-Fired Thermal Power Plant Figure 2: Simplified Steam Generator Schematic

Figure 3: Dependence of Erosion on Particle and Velocity and Flyash Loading Figure 4: Typical Boiler Locations Where Flyash Erosion Can Occur

Figure 5: Risk Evaluation Process of Qualitative, Semi-quantitative and Quantitative RBI Approaches based on API Code

Figure 6: Analysis of Downtime

Figure 7: Project Implementation Stages

Figure 8A: Determination of Technical Module Subfactors for Thinning Figure 8B: Determination of Technical Module Subfactors for Thinning Figure 9: Determination of Business of Interruption Cost

Figure 10: RBI Release Event Tree Figure 11: Shortest Downtime Period Figure 12: Longest Downtime Period

Figure 13: API 581 Semi-Quantitative Approach Risk Matrix for A-213 T22 Figure 14: API 581 Semi-Quantitative Approach Risk Matrix for A-213 T91 Figure 15: Proposed Semi-Quantitative Approach Risk Matrix for A-213 T22

(Longest Downtime)

Figure 16: Proposed Semi-Quantitative Approach Risk Matrix for A-213 T91 (Longest Downtime)

Figure 17: Proposed Semi-Quantitative Approach Risk Matrix for A-213 T22 (Shortest Downtime)

List of Tables

Table 1: Classification of Coals by Abrasion Propensity Table 2: Labour Rates

Table 3: Equipment Damage Cost for Carbon Steel Table 4: Material Cost Factor

Table 5: Classification of Boiler Tube Data Table 6: TMSF Conversion

Table 7: Consequence Category

Referensi

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