Special Focus: Wear Protection
Increasing power plant efficiency while decreasing environmental impact
Si es posible mejorar la vida útil de una pieza reparada por encima de una pieza nueva, también es posible mejorar el rendimiento y la disponibilidad de la planta, lo que permite importantes ahorros de energía y generación de carbono. Informa Dr Gary Heath.
Wenn die Lebensdauer eines reparierten Teils über die eines neuen Teils erhöht werden kann, wird damit auch die Leistung und Verfügbarkeit der Anlage verbessert und führt zu erheblichen Energieeinsparungen. Bericht von Dr. Gary Heath.
If the lifetime of a repaired part can be increased over that of a new part, plant performance and availability can also be improved, leading to significant energy savings and carbon generation. Dr Gary Heath reports.
F
or many years energy demand has been strongly growing and will continue. Te installation of new plant capacity can take years so there is an enormous pressure on power
plants to improve operational output, efficiency and availability. Further, there is the constant requirement to reduce operating costs and the environmental impact of achieving these targets. Te maintenance department can play a critical role by selecting longer-lasting key components to extend outage intervals and also reduce unplanned down-time and inventory. Component repair rather than replacement
produces immediate costs savings and also reduces the use of materials, energy and transport in producing these new components. After years of research, field tests and
involvement of power plant engineers, many innovative products have been developed to support the maintenance departments in their daily fight against wear and corrosion. From welding and brazing through to thermal spraying
and wear protection parts, many solutions have been developed to extend the life of critical power plant components (by as much as five times). A selection of these wear resistant technologies and their related applications are highlighted.
Wear resistant plate solutions Weld overlay wear plates are becoming popular for the protection of large surfaces against wear in coal/alternative fuel and ash handling. However, their usefulness in a power plant can be restricted in some applications by the minimum plate thickness, surface roughness, lack of abrasion and erosion resistance. One of the most comprehensive and successful ranges of plate products are called CastoDur Diamond Plate (CDP) which include specific plates and alloys to resist abrasion, erosion, impact and corrosion. Te latest development are the unique CDP
Powder wear plates. Te use of super hard Tungsten Carbides particles offer high abrasion and erosion resistance in combination with light weight, minimal thickness (as low as 3mm) and smooth surface. A new variation which uses a Stainless Steel base metal allows these plates to provide optimal wear resistance in aggressive corrosion environments. Typical applications include fans, cyclones, chutes, liners, etc.
Fig. 4. Arc spraying of a large boiler tubes panel in workshop.
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Nano structural engineering Te world’s first NanoAlloy formulation was developed to provide outstanding abrasion and erosion resistance using an innovative nano structural engineering approach to alloy development based on a low cost ferrous base. Tis science was translated into a welding wire which could be used with normal welding equipment in the power plant but producing a protective overlay with a bulk hardness over 71HRC. Applications have been proven in the power industry in coal, ask and alternative fuel transport and grinding systems. Use in coal grinding systems have shown a 5 times improvement in wear life in key components.
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