{"id":624,"date":"2019-01-13T19:57:27","date_gmt":"2019-01-13T19:57:27","guid":{"rendered":"http:\/\/johnbrear-plantintegrity.com\/?page_id=624"},"modified":"2019-01-14T09:53:35","modified_gmt":"2019-01-14T09:53:35","slug":"on-line-life-monitoring-of-headers-and-tubes","status":"publish","type":"page","link":"https:\/\/johnbrear-plantintegrity.com\/?page_id=624","title":{"rendered":"On-line life monitoring of headers and tubes"},"content":{"rendered":"<figure id=\"attachment_626\" aria-describedby=\"caption-attachment-626\" style=\"width: 350px\" class=\"wp-caption alignright\"><img fetchpriority=\"high\" decoding=\"async\" src=\"http:\/\/johnbrear-plantintegrity.com\/wp-content\/uploads\/2019\/01\/stub-boxes.jpg\" alt=\"\" width=\"350\" height=\"300\" class=\"size-full wp-image-626\" \/><figcaption id=\"caption-attachment-626\" class=\"wp-caption-text\">Superheater headers and stub boxes<\/figcaption><\/figure>\r\n<p><strong>Plant:<\/strong><\/p>\r\n<ul>\r\n    <li>4 x 350 and 4 x 650 MW coal-fired units in the far east<\/li>\r\n<\/ul>\r\n<p><strong>Objective:<\/strong><\/p>\r\n<ul>\r\n    <li>To develop, install and commission an on-line life monitoring system using thermocouples and steam pressure and temperature sensors only<\/li>\r\n<\/ul>\r\n<p><strong>Scope: <\/strong><\/p>\r\n<ul>\r\n    <li>Superheater and reheater headers, manifolds and tubes on two boiler designs<\/li>\r\n    <li>Fatigue, creep and creep-fatigue damage for headers and manifolds<\/li>\r\n    <li>Creep, fireside and steamside corrosion mechanisms for boiler tubes<\/li>\r\n<\/ul>\r\n<p><strong>Approach:<\/strong><\/p>\r\n<ul>\r\n    <li>Review design, operating conditions, materials and prioritise boiler components for on-line monitoring<\/li>\r\n    <li>Provide instrumentation plan for sensors<\/li>\r\n    <li>Install sensors and monitor operation for several months, covering various start-ups, shut-downs, mill changes etc<\/li>\r\n    <li>Develop finite element models of all components<\/li>\r\n    <li>Model actual operation from monitoring and \u2018map\u2019 temperatures from thermocouples to the finite element analysis<\/li>\r\n    <li>Develop \u2018stress functions\u2019 which correlate temperatures from monitoring to the stresses at the critical locations on each component.  This method utilises both temperature and temperature change to capture transient behaviour<\/li>\r\n    <li>Develop software to capture and validate sensor data, and then for each component, calculate life consumed by creep, fatigue and creep-fatigue<\/li>\r\n    <li>Allow validation and revision of life calculations on the basis of inspection data<\/li>\r\n<\/ul>\r\n<p><strong>Benefits:<\/strong><\/p>\r\n<ul>\r\n    <li>Boiler components prioritised in terms of severity and nature of damage<\/li>\r\n    <li>Focussed inspection and maintenance plan developed<\/li>\r\n    <li>Real-time stress display for all monitored components<\/li>\r\n    <li>On-demand remaining life calculation<\/li>\r\n    <li>Life extension options, through changes in operation, identified<\/li>\r\n    <li>Effect of market\u2013driven changes in operation on component life quantified<\/li>\r\n<\/ul>\r\n<p><strong>Published:<\/strong><\/p>\r\n<p>Brear, J.M., Jones, G.T., Jarvis, P. and Sanders, J, \u201cOn-line monitoring of power plant components\u201d, ERA Conf \u2018Engineering Asset Management for Utilities, Industry and Commerce\u2019, London, 7-8 October 1997.  Paper 3.7<\/p>\r\n<p>Annis, V.A., Jeffery, C. and Brear, J.M., \u201cOn-line creep-fatigue monitoring of steam headers\u201d, IMechE Seminar `Load Cycling, Plant Transients and Off-design Operation.\u2019,  London, April 1991<\/p>","protected":false},"excerpt":{"rendered":"<p>Plant: 4 x 350 and 4 x 650 MW coal-fired units in the far east Objective: To develop, install and commission an on-line life monitoring system using thermocouples and steam pressure and temperature sensors only Scope: Superheater and reheater headers, manifolds and tubes on two boiler designs Fatigue, creep and creep-fatigue damage for headers and &hellip; <a href=\"https:\/\/johnbrear-plantintegrity.com\/?page_id=624\" class=\"more-link\">Continue reading <span class=\"screen-reader-text\">On-line life monitoring of headers and tubes<\/span> <span class=\"meta-nav\">&rarr;<\/span><\/a><\/p>\n","protected":false},"author":1,"featured_media":0,"parent":114,"menu_order":2,"comment_status":"closed","ping_status":"closed","template":"","meta":{"footnotes":""},"class_list":["post-624","page","type-page","status-publish","hentry"],"_links":{"self":[{"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=\/wp\/v2\/pages\/624","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=624"}],"version-history":[{"count":4,"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=\/wp\/v2\/pages\/624\/revisions"}],"predecessor-version":[{"id":629,"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=\/wp\/v2\/pages\/624\/revisions\/629"}],"up":[{"embeddable":true,"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=\/wp\/v2\/pages\/114"}],"wp:attachment":[{"href":"https:\/\/johnbrear-plantintegrity.com\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=624"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}