Preventing Failures in Steam Systems

<body topmargin=0 leftmargin=0 marginheight=0 marginwidth=0> <table cellpadding=0 cellspacing=0 border=0><tr> <td valign="top" colspan=2 height=100 BGCOLOR="#CCCCFF" TEXT="#080000" bgproperties="fixed" background="0d200640egdysm.jpg"> <div> <FONT SIZE="6" COLOR="#000066" FACE="Arial" ><B>Jonas, Inc.</B></FONT><FONT SIZE="5" COLOR="#000099" FACE="Arial" ><B> </B></FONT><FONT SIZE="1" COLOR="#000099" FACE="Arial" ><B>   </B></FONT><FONT SIZE="3" COLOR="#000099" FACE="Arial" ><B> |</B></FONT><B>     </B><A HREF="index.htm" TARGET="_top" TITLE="Jonas, Inc."><U><B>Home</B></U></A><B> </B><B> </B><B>   </B><B> |    </B><A HREF="contact.htm" TARGET="_top" TITLE="Contact Us"><U><B>Contact Us</B></U></A><B>                                           </B></div> <div> back to<B>  </B><A HREF="training_courses.htm" TARGET="_top" TITLE="Training"><U><B>Training</B></U></A><FONT SIZE="3" COLOR="#000099" FACE="Arial" ><B>                                                                                         </B></FONT></div> <div> </div> </td> </tr><tr> <td valign="top" width=155 BGCOLOR="#0000BF" TEXT="#F7F7FF"> <div> <A HREF="training.htm" TARGET="_top" TITLE="Water Chemistry and Corrosion Control in"><U>Water Chemistry and Corrosion Control in Steam Systems</U></A></div> <div> <B><IMG BORDER="0" SRC="Symb075c00b700c8ffcccc00.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Preventing Failures in Steam Systems</B></div> <div> <A HREF="turbines.htm" TARGET="_top" TITLE="Steam Turbines and Auxiliaries "><U>Steam Turbines and Auxiliaries </U></A></div> <div> <A HREF="trregister.htm" TARGET="_top" TITLE="Training Course Notification"><U>Training Course Notification</U></A></div> <bR> </td> <td valign="top" height=380 BGCOLOR="#FFFFFF" TEXT="#080000"> <div> <B>Preventing Failures in Steam Systems</B><FONT SIZE="3" COLOR="#0000BF" FACE="Arial" ><B> </B></FONT></div> <div> <A HREF="trregister.htm" TARGET="_top" TITLE="Training Course Notification"><U><B>Click Here</B></U></A><B> to be notified when next training course dates are announced.</B></div> <bR> <div> Two-day workshop on analysis and prevention of equipment corrosion, fatigue, creep, and other failures.  Aimed at steam cycle and cycle component designers, engineers, operators, maintenance and inspection personnel, water chemists, engineers, metallurgists, and safety and quality assurance personnel; utility and industrial steam generation. </div> <div> The workshop participants will learn about the industry experience and the basics of design, operation, and material behavior, and about the engineering solutions to the typical problems.  They will be able to achieve significant improvements in the failure and damage control through a better understanding of steam cycle operation, by timely inspections, diagnostic monitoring, preventive maintenance, and by knowledge of relevant  properties of the materials used.  They will better understand how cooperation of operators, water chemists, mechanical and thermodynamic designers, chemical, material, and engineering, and management helps in achieving these improvements. </div> <div> <B>Background </B></div> <div> With the increase of unit sizes, stresses, and heat fluxes, equipment aging, unit cycling, and the high cost of replacement power and steam, the prevention of failures and corrosion of the steam cycle components is of critical importance. </div> <div> The cost of corrosion, creep and fatigue, erosion, and scale and deposit buildup in the U.S. utility systems is over  $3 billion/year.  It is even higher for the industrial systems. As much as 50% of the outage time has been attributed to problems with the boiler tubes, condensers, turbines, feedwater heaters, carbon steel piping, PWR steam generators, and BWR pipe welds.  Industrial application problems are at least as frequent.  The cost of replacement power can be as high as $100/MWh or over one million dollars a day for a large utility unit ($7000/MWh - summer 1998).  The cost of reduced or lost production in an industrial plant can be equally high (~$1 million/day). </div> <div> Main problems include: </div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Erosion-corrosion and cavitation of carbon steel piping and other components</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Boiler, heater, and condenser tube failures</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Deaerator weld cracking</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Stress corrosion cracking of LP turbine blade attachments</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Fatigue of blades</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Creep and low cycle fatigue of high temperature components</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Deposition on turbine blades and loss of MW</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Solid particle erosion of turbines and valves</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Failures of bearings</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Cavitation and malfunction of pumps and valves. </div> <div> <B>Objectives of the Workshop </B></div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">To improve knowledge of the equipment damage mechanisms, related design, operation, and maintenance, NDT, corrosion prevention, and monitoring. </div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">To improve communication and cooperation between engineering, operators, maintenance, chemists, management, and vendors. </div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">To jointly analyze the current operating and design practices and problems and to make recommendations where improvements can be made. </div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">An update on the state-of-knowledge and on where to find it. </div> <div> <B>Agenda </B></div> <div> <TABLE BORDER="2" CELLPADDING="2" CELLSPACING="1" WIDTH="562" BORDERCOLORLIGHT="#C0C0C0" BORDERCOLORDARK="#808080" FRAME="BOX" RULES="ALL" ALIGN="BOTTOM" HSPACE="0" VSPACE="0" > <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="470"><div> <B>Day 1</B></div> </tD> <tD VALIGN=TOP WIDTH="73"><div> <B>Hours</B></div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="470"><div> 1.  Introduction: Cost of Outages and Repairs </div> </tD> <tD VALIGN=TOP WIDTH="73"><div> 1</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 ><NOBR><div> 2.  Equipment Damage Problems (lecture w. examples) </div> </NOBR></tD> <tD VALIGN=TOP WIDTH="73"><div> 2</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 33 WIDTH="470"><div> 3.  Material Properties  including mechanical, fracture, fatigue,     creep, and erosion (lecture, metal samples) </div> </tD> <tD VALIGN=TOP WIDTH="73"><div> 3</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 ><NOBR><div> 4.  Modern Design Practices (lecture with examples, rules, example software) </div> </NOBR></tD> <tD VALIGN=TOP WIDTH="73"><div> 1</div> </tD> </tR> </TABLE></div> <bR> <div> <TABLE BORDER="2" CELLPADDING="2" CELLSPACING="1" WIDTH="566" BORDERCOLORLIGHT="#C0C0C0" BORDERCOLORDARK="#808080" FRAME="BOX" RULES="ALL" ALIGN="BOTTOM" HSPACE="0" VSPACE="0" > <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="472"><div> <B>Day 2</B></div> </tD> <tD VALIGN=TOP WIDTH="75"><div> <B>Hours</B></div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 64 ><NOBR><div> 5.  Cycle Chemistry vs. Corrosion </div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Feedwater, Boiler Water, and Steam Chemistry </div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Chemical Transport, Local Impurity Concentration vs. Corrosion              </div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Basics and Examples </div> </NOBR></tD> <tD VALIGN=TOP WIDTH="75"><div> 2</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="472"><div> 6.   NDT and Fracture Mechanics (lecture, video) </div> </tD> <tD VALIGN=TOP WIDTH="75"><div> 1</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="472"><div> 7.   Life Extension (lecture and examples) </div> </tD> <tD VALIGN=TOP WIDTH="75"><div> 1</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="472"><div> 8.   Diagnostic Monitoring (lecture) </div> </tD> <tD VALIGN=TOP WIDTH="75"><div> 1/2</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 33 WIDTH="472"><div> 9.  Troubleshooting, Failure Analysis, Root Cause Analysis       (lecture, examples, samples) </div> </tD> <tD VALIGN=TOP WIDTH="75"><div> 1</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 33 WIDTH="472"><div> 10.  Safety Issues, Applications, and Case Histories (joint        analysis of case histories) </div> </tD> <tD VALIGN=TOP WIDTH="75"><div> 1</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 ><NOBR><div> 11.  Conclusions and Recommendations (includes answering       questions)</div> </NOBR></tD> <tD VALIGN=TOP WIDTH="75"><div> 1/2</div> </tD> </tR> <tR> <tD VALIGN=TOP HEIGHT= 16 WIDTH="472"><div> 12.  Information and Selected References</div> </tD> <tD VALIGN=TOP WIDTH="75"><IMG BORDER="0" SRC="1x1.gif" HEIGHT="16" ALIGN="bottom" WIDTH="75" HSPACE="0" VSPACE="0"></tD> </tR> </TABLE></div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Up-to-date literature is displayed </div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Actual pieces of damaged cycle components and test specimens are displayed, circulated, and discussed </div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">All major safety issues are covered </div> <div> <B>NOTES: </B><FONT SIZE="2" COLOR="#000000" FACE="Arial" >Participants should prepare case histories and questions and bring samples of damaged components for demonstrations and discussion. </FONT></div> <bR> <DIV ALIGN="LEFT"></DIV> <div> <IMG SRC="1e266430.gif" border=0 width="358" height="67" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <div>     </div> </td> </tr></table></body>