Boiler # 2 ( 150-B-02 ) Trip Inspection Findings

Boilers Tubes The tube failures were found at the rear wall ( west Side ) of the fire box tubes in front of the burners. Out of total 75 tubes of the rear wall tubes, 8 tubes were found affected. Counting from north ( man-way side ) to south, the affected tubes are from tube # 32 to tube # 39 ( center of rear wall tubes ) Tube # 33 was found ruptured (fish mouth type) at elevation 10 M. Thickness of the lip is 1.3 mm out of 4 mm. Tube # 35 was found with small rupture at the outside diameter of the top elbow ( 2 long opening ). The opening lip was found 2mm out of 4 mm nominal. Tube # 39 was found with a small crack opening at 6 M elevation. Tubes # 35, #36, #37 and # 38 showed corrosion holes at 6 M elevation . Tubes # 32 and # 34 were found with corrosion gouges / metal loss and hard layer of oxidization (No holes) at the same elevation. The internal surfaces of the failed tubes showed uniform thick scale covering the whole internal surface. In some sections, the scale was heavy and irregular. Ball test was conducted and revealed no blockage through these failed tubes.

Burners Condition The burners tips were found heavily fouled.

Corrosion Mechanism External high temperature oxidation resulted in corrosion holes and creep cracks ( at elevation 6 M ). High temperature creep resulted tube rupture ( at elevation 10 M )

Completed Repairs Affected tubes ( 8 total ) were plugged from steam drum and Mud drum sides and sealed welded. The plugged tubes were drilled to avoid internal pressure build up. Ceramic fiber were installed on top of the plugged tubes to insulate them from the heat. Burners tips were cleaned and cleared.

Tube # 33

Tube # 35

Tube # 39

Tubes at Elevation 6 M

Corrosion Holes