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The unavailability of coal fired electrical generating capacity is often attributable to corrosion in steam generators. Electricity demand grows faster than new plants come online, forcing greater use of old plants. Identifying such problems requires proper inspection tools and techniques to take the guesswork out of whether boiler tubes should be repaired or replaced.
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Stress assisted corrosion (SAC) is a major concern for kraft recovery boilers in the pulp and paper industry. A water leak can cause a smelt-water explosion in the boiler. A number of carbon steel tubes showed a deep decarburized layer on the inner surface (water-touched) and also an unusually large grain size at the inner tube surface.
Failure analysis methodology is applied to the principal mechanisms by which boiler tubes fail during service. sThe failure analysis procedure, or methodology for evaluation, is provided in a step by step approach. Among the case histories discussed are: fatigue, erosion, short-term overheating, and hydrogen damage.
Pertinent mechanisms of scale and deposition control processes as well as the sources of contaminants are discussed. Methods of prevention and control parameters are demonstrated with laboratory and field results.
Deposit weight density(DWD). Removing and measuring the deposits in boiler tubes. Data collected by several laboratories on boiler tube samples are compared and analyzed.
Water wall tubes from boiler operating for 14 years were subject to repeated failures ranging from pinholes to cracks and ruptures. A failure analysis on a received tube was carried out including destructive and non-destructive testing.
Determining the deposit weight density (DWD) on a boiler tube surface, via the glass-bead-blasting technique. Removes most boiler deposits. Useful when other methods fail.
This standard describes a simple test method that employs GBB equipment to remove boiler waterside deposits on a piece of tubing removed from a representative area of a boiler. Historical Document 1999
Boiler system is one of the most critical systems for a utility plant. A utility plant had experienced high percentages of boiler downtime owing to boiler tube sheet cracking failures. Investigations carried out revealed high stress at the tube-to-tube sheet joint in the boiler fire-side entrance. Tube-to-tube sheet joints at the boiler fire-side entrance had been fabricated by strength welding and without any expansion. The strength welded joint had created undue stress leading to cracking of the weld joint by thermal expansion. A higher quality expanded joint consisting of expanding, flaring and seal welding the fire-side entrance was implemented during the re-tube process. The utility plant has now zero downtime due to boiler tube failure. This article summarizes the description and history of failures with the boiler at the utility plant; investigations and corrective actions carried out; and the present improved condition of the boilers.