An Analysis of a Reheater Failure and a Proposal to Upgrade the Device Design

Piotr Duda, Łukasz Felkowski, Adam Zieliński and Andrzej Duda
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Piotr Duda: Institute of Thermal and Process Engineering, Cracow University of Technology, Al. Jana Pawła II 37, 31-864 Kraków, Poland
Łukasz Felkowski: Institute of Thermal and Process Engineering, Cracow University of Technology, Al. Jana Pawła II 37, 31-864 Kraków, Poland
Adam Zieliński: Institute for Ferrous Metallurgy, ul. K. Miarki 12-14, 44-100 Gliwice, Poland
Andrzej Duda: Institute of Thermal and Process Engineering, Cracow University of Technology, Al. Jana Pawła II 37, 31-864 Kraków, Poland

Energies, 2019, vol. 12, issue 12, 1-10

Abstract: The aim of this paper is to present an example of damage to the reheater tubes and conduct the material and numerical analyses to establish the cause of the device failure. Cracks were observed on the first, second, and third tube row. Close to the damaged area, a ferritic structure could be observed with highly degraded bainite areas, characterized by coagulation and coalescence of precipitates. The cause of the damage was analysed using the finite element method (FEM). The big yield of the tube cross-section confirmed that the tube may get damaged during subsequent cycles of the boiler operation, which was also proved by the microstructure testing results. For the reheater under analysis, the tubes have to be lengthened to achieve a reduction in stresses, arising due to thermal loads to values lower than allowable stresses according to Standard EN 13480-3. The modelling results confirmed the correct operation for the upgraded system.

Keywords: reheater; rupture; microstructural degradation; failure analysis (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2019
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