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Weld Jointing Influence on Boiler Tube Sheet Integrity

Picture for Weld Jointing Influence on Boiler Tube Sheet Integrity
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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.

Product Number: MPWT19-14366
Author: Sameer Ayyar, Mahmood Al-Ridy, Farhat Choudhary, Adi Alammari, Itoro Akrasi
Publication Date: 2019
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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.
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