Creep life prediction of super heater coils used in coal based thermal power plants subjected to fly ash erosion and oxide scale formation

Super heater coils of the coal based thermal power plants and subjected to severe operating conditions from both steam side and gas side. Formation of oxide scale due to prolonged service lead to temperature raise of the tube and erosion due to fly ash present in the combusted gases leads to tube thinning. Both these factors lead to creep rupture of the coils much before the designed service life. Failure of super heater coils during service of the boiler leads to power loss and huge monitory loss to the power plants. An attempt is made to model the creep damage caused to the super heater coils using heat transfer analysis tube thinning due to erosive wear of the tubes. Combined effects of these parameters are taken into consideration to predict the life of the super heater coils. This model may be used to estimate the life of the coils operating under the severe operating conditions to prevent the unexpected failure of the coils.