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ME476
Composite Boiler Damage
Technical committee

Ship type PCC

Date of build 1992
Navigation route Japan ~ The Red Sea
Trouble machinery
Category Boiler
Name Water tube
Type Gadelius GCS
Maker
Date of trouble September 2003

1. Process of damage discovery

During inspection of the composite boiler main engine exhaust gas-side, a boiler water leak was dis-
covered at the bottom of the water tubes.

2. Damage condition

The boiler water leak was occurring at the bottom of the main engine exhaust gas outlet. Discovery
was early and damage was limited to corrosion of the water tube.
If corrosion discovery was late, there are case reports of corrosion to the water tube and the tube plate.

3. Repair

Corrosion of only the water tube was confirmed and plug-up was implemented. After this, the plug
was welded to the water tube.
The water tube is scheduled to be replaced at next docking.

4. Presumed causes

With regard to composite boilers, there have recently been many reports of similar leakage cases hav-
ing the following points in common:
• Many reports of corrosion to the water tube and tube plate are situated at the bottom of the
main engine exhaust gas outlet.
• Drainage of the cleaning water after carrying out exhaust-side washing is difficult, and it is easy
for water to accumulate in this region.
• During anchorage, there is rain water intrusion from the funnel.
• As EGE capacity is small, boiler stoking hours is long.
From these facts, it is surmised that removal of cleaning water after washing, as well as soot removal
was insufficient, and due to the intrusion of rain water during anchorage, corrosion of the water tube
due to low temperature corrosion is considered to be a cause.
Furthermore, as boiler reheating time becomes longer, it is also surmised that damage was caused due
to longer exposure to sulfur dioxide.

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Similar cases: On a bulk carrier built in December 1993, water tube damage occurred in May 2001.
Corrosion progressed on this vessel during voyage due to the entry of steam during exhaust econo-
mizer soot blowing, resulting in broken hole. The areas of low temperature corrosion were in the vi-
cinity of the soot blower, and when the steam valve was inspected, it was found to be corroded and
leaking.
The soot blower steam valve was replaced from a ordinary copper material valve to one in which the
valve body and valve seat are of SUS material.

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