Root Cause Failure Investigation Of Boiler Super-Heater Tube In Coal Power Plant At Kapar, Klang

Mohad Khalil, Mohad Khazin (2015) Root Cause Failure Investigation Of Boiler Super-Heater Tube In Coal Power Plant At Kapar, Klang. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Failure analysis of structures has gained a considerable interest in many engineering areas. The aim of this research is to determine the root cause of the structural failures which can reduce the failure risks and prevent similar failures in the future. This thesis presents experimental investigations for the failure of a super-heater tube of a coal-fired power plant using several failure analysis procedures. The failure analysis comprised of visual inspection, optical microscopic, ultrasonic thickness measurement test and hardness test. A sample of a total-fractured super-heater tube obtained from an industry was used in this investigation. Initial visual investigations found that the super-heater tube had a longitudinal crack. This fracture appearance is called fish mouth stress rupture. The ultrasonic thickness test is to detect a significant oxide layer that occurs in the steam side surface. The optical microscopy were used to identify intergranular cracks, voids, elongated grain and deposit layers. The hardness test is to determine the resistance of material to penetration after being heated. The results for the hardness test and ultra-thickness test used to determine the rupture temperature and estimate the life period of the fail tube using Larson Miller Parameter.

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