CAUSE ANALYSIS AND IMPROVEMENT MEASURES FOR SUPERHEATED PLATEN TUBES FAILURE OF A 580 t/h CFB BOILER.

One of the most frequent causes of coal fired power plant shutdown is boiler tube leak. Superheaters are crucial components of boilers operating under high temperatures and pressures. Understanding the superheater potential damages is essential to define the rectification action needed to keep and elevate overall power plant productivity. This paper highlights the analysis of platen superheater tube failure in a 2x150 MW coal-fired power plant in South Sumatera. Various test including chemical composition, hardness, tensile, metallography, SEM fracture surface examination, and XRD compound analysis were conducted for investigation purposed. The failure was initiated by the plugging of the tube elbow due to deposits and ashes adhering to the tube's interior. This obstruction prevented saturated steam flow inside the tube, leading to overheating and a subsequent drop in mechanical strength. Overheating was confirmed by the presence of spheroid particles in the ferrite matrix. Prolonged overheating resulted in the formation of microvoids, leading to creep failure and crack formation in the tube. The improvements made by adding refractory material give positive results. The platen superheater tubes which previously exceeded temperature limits, currently operate within normal range temperatures, reduced spray water consumption 6-10 tons/day, and significantly increased boiler efficiency from 83.19% to 83.54%. [ABSTRACT FROM AUTHOR]