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    Boiler Tube Failure

    Uploaded by

    Bhupendra Gobade
    The document outlines general measures to minimize boiler tube failure, including: 1) Conducting visual inspections and thickness surveys to identify tube damage or erosion. 2) Shielding or providing baffles in erosion-prone areas to reduce gas velocity. 3) Ensuring quality welding and inspections of welds on pressure parts. 4) Giving emphasis to prevent flue gas and ash erosion through inspections and protections.

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    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd

    Boiler Tube Failure

    Uploaded by

    Bhupendra Gobade
    143 views7 pages
    The document outlines general measures to minimize boiler tube failure, including: 1) Conducting visual inspections and thickness surveys to identify tube damage or erosion. 2) Shielding or providing baffles in erosion-prone areas to reduce gas velocity. 3) Ensuring quality welding and inspections of welds on pressure parts. 4) Giving emphasis to prevent flue gas and ash erosion through inspections and protections.

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    Boiler Tube Failure.pptx

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    The document outlines general measures to minimize boiler tube failure, including: 1) Conducting visual inspections and thickness surveys to identify tube damage or erosion. 2) Shielding or providing baffles in erosion-prone areas to reduce gas velocity. 3) Ensuring quality welding and inspections of welds on pressure parts. 4) Giving emphasis to prevent flue gas and ash erosion through inspections and protections.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    143 views7 pages

    Boiler Tube Failure

    Uploaded by

    Bhupendra Gobade
    The document outlines general measures to minimize boiler tube failure, including: 1) Conducting visual inspections and thickness surveys to identify tube damage or erosion. 2) Shielding or providing baffles in erosion-prone areas to reduce gas velocity. 3) Ensuring quality welding and inspections of welds on pressure parts. 4) Giving emphasis to prevent flue gas and ash erosion through inspections and protections.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 7

    General Measures To Minimize Boiler Tube Failure

    • Visual inspection of heating surface to be carried out to


    identify type of failure viz. eroded tube, deformation, swelling,
    bulging of tube etc.
    • Shielding of tubes / bends in identified highly erosion prone
    areas to be done to reduce erosion due to gas velocity in
    second pass.
    • Tube thickness survey and thickness mapping in all identified
    areas to be carried out.
    • 100% welding inspection to be carried out to ensure quality
    weld joints. Involvement of experience IBR welders to be
    ensured for pressure parts welding works.
    • Emphasis to be given to prevent flue gas / ash erosion. Erosion
    prone areas are to be extensively inspected and protected by
    providing shield / baffles, refractory etc
    Preventive techniques to minimize tube failures:
    • Extensive Inspection of Pressure Parts as below-
    * During annual overhaul, inspection of LTSH/
    Economiser banks on left and right sides to be carried
    out after removing skin casing and cutting fins at places
    based on experience.
    * Economiser coils to be lifted on both sides for
    inspection and to assess healthiness of tubes.
    * Annual inspection of Platen super heaters and Re-
    heater bank bends to be done by arranging sky climber
    and platforms.
    * Inspection of Roof tubes: Final super heater tubes
    and Super heater terminal tubes to be carried out by
    arranging multi tier platforms.
    • Shielding the Tubes at Critical Zones
    • To avoid ash erosion failures, shrouding /
    sacrificial shields to be provided for water wall
    screen/ extended water wall, Super heater screen
    tubes, extended steam cooled wall, LRSB’s opening
    bends, LTSH terminal tubes/ ECO hanger tubes,
    LTSH straight tube, ECO coil straight tubes and rear
    side straight tubes. LTSH supply tube 90 deg.
    bends/ offset bends etc.
    • Cassette baffles to be provided for bends of LTSH
    and ECO coil assembly to reduce erosion.
    Importance of Boiler Tube Stoppers
    • The alignment of all coil assemblies and tubes in the
    horizontal pass and second pass to be thoroughly checked.
    • Stoppers (locking arrangement) to prevent movement of
    steam-cooled spacers to be provided for Platen and Re-
    heater coil assemblies.
    • Tubes that come out of connectors / distorted attachment
    can cause failure and hence to be corrected during boiler
    overhaul.
    • Vibration arrestors/ clamps get deformed and make dent
    on tubes. They are to be repaired as and when noticed.
    Quality Welding:
    • Welding electrodes to be procured as per the
    recommendation of manufacturer and preserved as per
    standards.
    • 100% Radiography of weld joints to be carried out
    Maintenance of Flue Gas Path:
    • Through inspection of refractory to be made to avoid
    flue gas diversion and impingement on bends and
    headers.
    • Refractory linings to be provided in areas of high ash
    erosion where shielding of tubes is difficult.
    Expert Analysis of Tube Failure:
    • Failure analysis to be carried out through manufacture’s
    experts and metallurgical laboratories to identify root
    cause of tube failure as and when required.
    Post Operational Chemical Cleaning:
    • With continued operation over a period of time the
    magnetite layer grows in thickness due to slow
    corrosion of boiler steel tubes. Also carryovers from
    condensers and pre-boiler systems deposited on the
    inner surface of boiler tubes where the heat transfer is
    high.
    • This growth of oxides and carryovers result in loss of
    heat transfer and accelerated corrosion of boiler
    tubes. This makes the boiler less efficient and more
    prone to localized heating. At times it may lead to tube
    failure. Therefore, importance to be given for chemical
    cleaning of boilers.

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