RECOVERY BOILER

SUPERHEATER BOX CRACKING

During a shut down at the end of 2010, cracks have been determined in the
secondary superheater boxes, located in the penthouse in one of the latest Mesto
Power Oy recovery boilers in Chile.
The cracks were of a typical fatigue pattern and protruded along the tube to box
weld.

Most of the cracks were orientated towards the primary superheater II, but few
cracks orientated towards the secondary superheater were also detected.

NONE of the cracks penetrated into the superheater tubes.

All cracks have been removed by grinding and weld repaired accordingly.
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Earlier during 2010, we have had a primary superheater I tube leakage in a

Brazilian mill with similar superheater design.
The tube cracks occurred just below and inside the box and were also of fatigue
type.

Typical fatigue failure.

RECOMMENDATIONS:

1.

Make sure that the two (2) lowest sootblowers do not operate at higher
pressure than 14 bar.

2.

Remove insulation above the primary superheater I and II and perform

visual inspection and liquid penetrant examination of the tube to box welds.

3.

Do not cover with insulation after the inspection, leave without insulation.

4.

Examine secondary and tertiary superheaters in similar way.

Consider recovering at least the tertiary superheater with insulation after the
examinations.

5.

Make sure that all clamps and ties are maintained in good shape, not allowing
any excessive tube movement.