THERMAL SPRAY COATINGS ON Bilal Hussain

VIBRATING GRATE TUBES

 PROBLEM STATEMENT
T H I N N I N G O F V I B R AT I N G G R AT E T U B E S

Client (BSP) experience thinning of Vibrating Grate tubes which leads to

the tubes failure.
Substrate Material:
Working Temp:
Degradation Mechanism:
Average Thinning Rate:
Maximum Thinning Rate:
SA210 Gr. A1
850-900 C
High Temp Wear (Initial analysis by customer)
0.61mm in 14 months
more than 3mm in 14 months
 APPLICATION OF HIGH VELOCITY THERMAL SPRAY
COATINGS FOR WEAR RESISTANCE
High Performance Wear Resistant Coatings were applied with Thermal
Spray process on VG Tubes on 20th to 26th of Mar 2023.
Substrate Material: SA210 Gr. A1
Coatings Alloys: 78E and 103T
Service Temp of Coatings: 1000C
APPLICATION OF HIGH VELOCITY THERMAL SPRAY
COATINGS FOR WEAR RESISTANCE
 INSPECTION FINDINGS – APRIL 2023
Client conducted inspection in the month of April 23 and anticipated that
the coatings has been washed out.
 INSPECTION FINDINGS – APRIL 2023
Coatings were fully intact with some spot defects.
 INSPECTION FINDINGS – 15 JUNE 2023
On 15th june 2023, SETL and client’s team inspected the coated surface
and found some defects on coatings.
 INSPECTION FINDINGS – 15 JUNE 2023
On 15th june 2023, SETL and client’s team inspected the coated surface
and found some defects on coatings.
 INSPECTION FINDINGS – 15 JUNE 2023
On 15th june 2023, SETL and client’s team inspected the coated surface
and found some defects on coatings.
 INSPECTION FINDINGS – 15 JUNE 2023
On 15th june 2023, SETL and client’s team inspected the coated surface
and found some defects on coatings.
 INSPECTION FINDINGS – 08 TH JULY 2023
On 08th July 2023, SETL and client’s team inspected the coated surface
and corrosion products were observed on coated surface.
 INSPECTION FINDINGS – 08 TH JULY 2023
On 08th July 2023, SETL and client’s team inspected the coated surface
and corrosion products were observed on coated surface.
 INSPECTION FINDINGS – 08 TH JULY 2023
On 08th July 2023, SETL and client’s team inspected the coated surface
and corrosion products were observed on coated surface.
 INSPECTION FINDINGS – 08 TH JULY 2023
On 08th July 2023, SETL and client’s team inspected the coated surface
and corrosion products were observed on coated surface.
 INSPECTION FINDINGS – 08 TH JULY 2023
On 08th July 2023, SETL and client’s team inspected the coated surface
and corrosion products were observed on coated surface.
 INSPECTION FINDINGS – 08 TH JULY 2023
SETL requested for operational parameters from June till July and
performed patch work on areas identified during 15th June inspection
and reinforced high thinning rate area.
 INSPECTION FINDINGS – 08 TH JULY 2023
SETL requested for operational parameters from June till July and
performed patch work on areas identified during 15th June inspection
and reinforced high thinning rate area.
 INSPECTION FINDINGS – 08 TH JULY 2023
SETL requested for operational parameters from June till July and
performed patch work on areas identified during 15th June inspection
and reinforced high thinning rate area.
 INSPECTION FINDINGS – 08 TH JULY 2023
SETL requested for operational parameters from June till July and
performed patch work on areas identified during 15th June inspection
and reinforced high thinning rate area.
 INSPECTION FINDINGS – 08 TH JULY 2023
SETL requested for operational parameters from June till July and
performed patch work on areas identified during 15th June inspection
and reinforced high thinning rate area.
 ACTIONS TAKEN BASED ON INSPECTION 08 TH JULY 2023
Evaluating corrosion products on coated surface; SETL requested
operational parameters from BSP team and evaluated degraded surface.
Findings:
- Chemical Decomposition is the dominant degradation mechanism.
- Coatings, Substrate interface gets unstable due to corrosion of substrate
material and causes delamination.
- Washing of tubes accelerate the degradation mechanism.
- Sliding of fuel over the surface assists to remove corrosion products and expose
fresh substrate material.
- A Corrosion resistant coatings required to protect VG tubes which can have no
impact due to moisture during off-loading time and provides sliding properties.
 APPLICATION OF CORROSION RESISTANT ALLOY ON
GRATE2&3
Based on evaluation and compatibility, corrosion resistant alloy was
applied on grate2&3 during 9-11 Nov 23 shutdown and was kept under
observation.
 THINNING RATE OF CORROSION RESISTANT COATINGS
APPLIED ON GRATE2&3
The corrosion resistant coatings applied on Grate2&3 in Nov 23 were
inspected during April shutdown and the thinning rate observed was 13-
15 microns a month.
Anticipated thinning rate per annum is 156-180 microns.
 APPLICATION OF CORROSION RESISTANT COATINGS
Upon the availability of boiler during April 24 shutdown, corrosion
resistant coatings were applied on VG tubes in Zone1&2 areas and
sealed with high temperature sealer to assist resistance against
moisture.
 APPLICATION OF CORROSION RESISTANT COATINGS
Upon the availability of boiler during April 24 shutdown, corrosion
resistant coatings were applied on VG tubes in Zone1&2 areas and
sealed with high temperature sealer to assist resistance against
moisture.
 APPLICATION OF CORROSION RESISTANT COATINGS
Upon the availability of boiler during April 24 shutdown, corrosion
resistant coatings were applied on VG tubes in Zone1&2 areas and
sealed with high temperature sealer to assist resistance against
moisture.
 APPLICATION OF CORROSION RESISTANT COATINGS
Upon the availability of boiler during April 24 shutdown, corrosion
resistant coatings were applied on VG tubes in Zone1&2 areas and
sealed with high temperature sealer to assist resistance against
moisture.
 APPLICATION OF CORROSION RESISTANT COATINGS
Upon the availability of boiler during April 24 shutdown, corrosion
resistant coatings were applied on VG tubes in Zone1&2 areas and
sealed with high temperature sealer to assist resistance against
moisture.
 APPLICATION OF CORROSION RESISTANT COATINGS
Upon the availability of boiler during April 24 shutdown, corrosion
resistant coatings were applied on VG tubes in Zone1&2 areas and
sealed with high temperature sealer to assist resistance against
moisture.
 INSPECTION FINDINGS DURING MAY 24 SHUTDOWN
Client experienced tube leakage on grate-4 and had to take forced
shutdown.
Following were the inspection findings:
- Tube leakage was observed on three tubes of grate-4.
- Coatings applied during April shutdown were in good condition.
- High temp Sealer was intact on coated surface.
- High temp sealer was observed intact which was applied on bare
tubes as well.
INSPECTION FINDINGS DURING MAY 24 SHUTDOWN
INSPECTION FINDINGS DURING MAY 24 SHUTDOWN
INSPECTION FINDINGS DURING MAY 24 SHUTDOWN
INSPECTION FINDINGS DURING MAY 24 SHUTDOWN