Kshirod Mohan Bose

Assistant Chief Engineer

Ghorashal Power Station
Mobile No. 01711076856
E-mail: kshirod124@yahoo.com
 Presentation Outline
• Fundamentals of Boiler
• Boiler Operation
• Boiler Maintenance
• Tips for Maintenance.
Steam Power Plant
– Steam Generator
• Steam Pressure is Pre-set
• Steam Temperature is Pre-set
– Definition of Boiler
• A boiler is a closed vessel in which water or other fluid
is heated. The fluid does not necessarily boil.
 Power required to be generated
 Operating Pressure
 Fuel-quality and type
 Water availibility and its quality
 Probable load factoe
 Location of the power house or process plants
 Cost of operations and maintenance
 Cost of installations and erection
 Availibility of floor space
5
 It should be capable of quick start-up
 Should meet large load fluctuations
 Occupy less floor space
 Should afford easy maintenance and inspection
 Should essentially posses the capacity of producing maximum steam with
minimum fuel consumption
 Light and simple in construction
 Various joints should be accessible for inspection and should be away from
direct flame impact
 Tubes should be sufficiently strong to resist wear and corrosion
 Mud and other deposits should not collect on heated plates
 The velocity of water and that of flue gas should be a minimum.
Emerging Market Requirements For
Thermal Power Generation

 High Reliability & Availability

 Highest Plant efficiency
 Suitable for differing modes of operation
 Suitable for varying fuel quality
 Minimum emission of Pollutants
 Lowest cost
 Classification of Boiler
• On the basis of Use:
• Stationary Boiler
–For power Plant
–For Utility Power Plant
–For Plant Process
• Mobile boiler
–Locomotive
–Marine
• On the basis of Tube of Boiler:
– Water Tube
– Fire Tube
• On the basis of furnace
Position of Boiler:
– Externally Fired
– Internally Fired
• On the basis of Heat Source/Fuel:
– Solid/Liquid/Gaseous Fuel (Conventional Boiler)
• Coal Fired Boiler
• Oil Fired Boiler
• Gas Fired Boiler
• Gas & Oil/Duel Fuel Boiler
– Hot Waste Gases as By-product of other Chemical
Process
• Heat Recovery Steam Generator (HRSG)
– HRSG without Burner
– HRSG with Burner/duct Firing System
– Electrical Energy
– Nuclear Energy
 • On the basis of
• On the basis of Steam Draught:
Circulation:
• Natural Draught
– Natural Circulation Boiler
Boiler
• Forced Draught
– Forced Circulation Boiler
Boiler
• Induced Draught
Boiler
• Balanced
Draught Boiler
 Type of boilers

 Drum type
- for sub-critical parameters

 Once-through type
- for sub/super Critical Parameters
• Low Pressure boiler (P<1.275 MPa)
• Medium Pressure boiler (P<3.82 MPa)
• High Pressure boiler (P<9.8 MPa)
• Super High Pressure boiler (P<13.73 MPa)
• Sub Critical Pressure boiler (P<16.67 MPa)
• Super Critical Pressure boiler (P<22.13 MPa)
STEAM

FIRETUBES

• Application: hotel, heater, small

BURNE industrial process
R
• Fuel: Oil, Gas
• Steam capacity up to 5 Ton/h
• Saturated temperature
• Design pressure up to 2.5 Bar
• Fully shop assembly
• Application: Auxiliary
boiler, industrial
process
• Fuel: Oil and Gas only
• Steam Capacity up to
220 Ton/hr
• Design Pressure up to
110 Bar
• Design Temperature up
to 500o C
• Mainly shop assembly,
very minimum site
works
• Application: Industrial process,
Steam turbine drive (< 50 MW)
• Multi Fuels: Oil, Gas and Solid
• Steam Capacity up to 200 Ton/hr
• Design Pressure up to 120 Bar
• Design Temperature up to 500o C
• Site assembly
Consideration of Industrial Boiler:
– Multi-fuel Burning capability
– Waste Fuel Utilization
(biomass, waste acid, sludge,
etc.)
– Cogeneration Potential to
maximize heat from their fuel
• Application: Electric Utility
(more than 50 MWe)
• Main Fuel: Coal
• Steam Capacity up to 1,850
Ton/hr (600 MW)
• Design Pressure up to 173 Bar
• Design Temperature up to
538o C
• Site assembly
• Application: Industrial process,
Steam Turbine drive
• Fuel: Flexible Solid fuels
• Emission: Low, environmental
friendly
• Steam Capacity up to 800 Ton/hr
• Design Pressure up to 120 Bar
• Design Temperature up to 500o C
• Site assembly
• Application: Industrial
process, Steam Turbine
drive
• Fuel: Flexible Solid fuels
• Emission: Low,
environmental friendly
• Steam Capacity up to 265
Ton/hr
• Design Pressure up to 100
Bar
• Design Temperature up to
500o C
• Modularized concept
• Application: Electric Utility
• Fuels: Pulverized Coal
• Steam Capacity up to 2,500
Ton/hr (800 MW)
• Design Pressure up to 253
Bar
• Design Temperature up to
538o C
• Higher efficiency (no steam
drum, no blow-down
system)
• Feed water quality is major
concern
• Site assembly
 Introduction to Supercritical
Technology
What is Supercritical Pressure ?

Critical point in water vapour cycle is a

thermodynamic state where there is no clear
distinction between liquid and gaseous state of
water.
Water reaches to this state at a critical pressure
above 22.1 MPa and 374 oC.

21
PV Diagram of Water
Rankine Cycle Subcritical Unit
• 1 - 2 > CEP work
• 2 - 3 > LP Heating
• 3 - 4 > BFP work
• 4 - 5 > HP Heating
• 5 – 6 > Eco, WW
• 6 – 7 > Superheating
• 7 – 8 > HPT Work
• 8 – 9 > Reheating
• 9 – 10 > IPT Work
• 10–11 > LPT Work
• 11 – 1 > Condensing

23
 Rankine Cycle Supercritical Unit
• 1 - 2 > CEP work

• 2 – 2s > Regeneration

• 2s - 3 > Boiler Superheating

• 3 – 4 > HPT expansion

• 4 – 5 > Reheating

• 5 – 6 > IPT & LPT Expansion

• 6 – 1 > Condenser Heat rejection

24
VARIATION OF LATENT HEAT
WITH PRESSURE
Absolute Pressure Saturation Latent Heat
(Bar) Temperature (K J/Kg.)
(oC)

50 264 1640
150 342 1004
200 366 592
221 374 0

25
 Departure from Nucleate Boiling
Nucleate boiling is a type of boiling that takes place when the surface temp is hotter than
the saturated fluid temp by a certain amount but where heat flux is below the critical heat
flux. Nucleate boiling occurs when the surface temperature is higher than the saturation
temperature by between 40C to 300C.

WATER
DENSITY

STEAM

175 224

PRESSURE(ksc)

26
Supercritical Boiler Water Wall
Rifle Tube And Smooth Tube

27
 Efficiency and CO2 Emission
Steam Steam CO2
Plant type Efficiency
Pressure Temperature Emissions
with power rating (%)
(kg/cm2) (C) (g/kW-hr)

Sub Critical
170 540 35 900
(500 MW)

# Super Critical 247 565 40 830

Ultra Super Critical 250 600 42 784

Advanced Ultra
300 700 45 740
Super Critical

# The improvements are with respect to the best units under construction in
India
• Extension of coal reserves by 11%
• Competitive in electricity cost on deployment
28
 Furnace Wall Designs

Spiral Wall Configuration Vertical Wall Configuration

Spiral Water wall Tubing

Lateral Heat Flux Profile

Configuration of Furnace
Furnace Corner at Transition
 Steam Water Cycle Chemistry Controls
Sl Parameter Sub Critical Super Critical
No.
Type of Boiler  LP and HP dosing. Or  No HP dosing
1 water  All Volatile Treatment  Combined water treatment (CWT).
treatment (Hydrazine + Ammonia)
Silica < 20 ppb in feed water and steam, Standard value <15 ppb in the cycle
2
< 250 ppb in boiler drum Expected value <10 ppb in the cycle
pH 9.0 - 9.5 for feed, steam & 9.0 – 9.6 for AVT(All volatile treatment)
3 condensate, 8.0 – 9.0 for CWT(Combine water
9.0 – 10.0 for Boiler drum treatment)
Dissolved < 7 ppb for feed. < 7 ppb for feed in case of AVT
4
Oxygen (DO) 30 – 150 ppb for feed in case of CWT
Cation (H+) <0.20 µS/cm in the feed & steam Standard value <0.15 µS /cm in the cycle
5 Conductivity cycle Expected value- <0.10 µS /cm in the cycle

Condensate None, Chemical Dosing provided CPU is essential for 100% flow. No dosing.
6 Polishing Unit
(CPU)
Silica and TDS By maintaining feed water quality Blow down possible till separators are
7
control and By operating CBD functioning (upto 30% load).

34
 Advantages of SC Technology
I ) Higher cycle efficiency means
Primarily
– less fuel consumption
– less per MW infrastructure investments
– less emission
– less auxiliary power consumption
– less water consumption
II ) Operational flexibility
– Better temp. control and load change flexibility
– Shorter start-up time
– More suitable for widely variable pressure operation

35
 ECONOMY
Higher Efficiency (η%)
•Less fuel input.
•Low capacity fuel handling system.
•Low capacity ash handling system.
•Less Emissions.

 Approximate improvement in Cycle

Efficiency
Pressure increase : 0.005 % per bar
Temp increase : 0.011 % per deg K

36
• Application: Cogeneration, Combined Cycle
• Type: Horizontal (Natural Circulation), Vertical
(Forced Circ.)
• Steam Capacity up to 400 Ton/hr (GT 9 FE size)
depend on GT type
• Single, Dual or Triple Pressures up to 120 Bar
• Design Temperature up to 450o C
• Site assembly
• Application: Steam turbine drive
(turbine propulsion) in the
shipboard
• Multi Fuels: Oil, Gas and Solid
• Steam Capacity up to 70 Ton/hr
• Design Pressure up to 58 Bar
• Design Temperature up to 500o C
• Limited spaces, compact
arrangement
• Dynamic behavior
• Steam results from adding sufficient heat to
water to cause it to vaporize.
• This vaporization occurs in 2 steps:
– by adding heat to the water to raise it to the
boiling temperature (sensible heat)
– by continuing the addition of heat to change the
state from water to steam (latent heat)
• Saturated steam:
– steam at which boiling occurs at a constant
pressure
– same temperature with the boiling water (mixed
steam + water)
• Superheated steam:
– steam with temperature higher then saturated
steam at the same pressure
– close to the properties of a perfect gas
 Stack &
Fuel SH Steam
Un-burnt

Radiation &
Air RH Steam
Unaccounted
• Circulation is the movement of water, steam, or a
mixture of the two, through heated tubes
• Adequate circulation will result:
– The cooling fluid absorbing heat from the tube metal
at a rate which maintains the tube temperature at or
below design condition
– Keep the tube within the other physical and
chemical limitations required by the inside and
outside environment
• Two type of Circulation:
– Natural Circulation or Thermo Symphonic
– Forced Circulation or Controlled Circulation
  The water/steam circulates naturally by the density
different between the higher temperature fluid and the
STEAM
(Ms)
lower temperature fluid

Characteristic of Natural Circulation

 Circulation Ratio = Mw/Ms is low
WATER
(Mw)  The water wall tubes normally have
DOWNTAKE or DOWNCOMER

Steam +
Water larger diameter to reduce the pressure
drop of steam/water inside the tubes
 Friction factors that oppose circulation:
– friction between water and metal
HOT SIDE
COLD SIDE

tube (+ any scale deposit inside the

tube)
– friction in tube bent
– friction in lower drum and header
– friction around upper drum internal
 The water/steam circulates forced by circulating pump
 The circulating pump provide addition head to the existing thermal head

Characteristic of Forced Circulation

Ms
 Circulation Ratio = Mw/Ms is high

Mw  The steam produced is higher then

Natural Circulation Boiler for the same
COLD SIDE

running time
 Furnished with Orifice located at the
inlet of Furnace Wall tubes to assist in
HOT SIDE

obtaining an adequate water flow of

varying length and heat absorbtion.
The other functions:
– create pressure drop
– measure the water flow
CIRCULATING
PUMP ORIFICE – regulate the flow balance
• Water/Steam Velocity
– The velocity relates to the force. The force is depend on the
density different and the height of boiler circuit
• Pressure
– The higher pressure of boiler will cause the water/steam
density smaller
• Heat Supply
– The higher heat supply to the combustion will increase
produced steam. It will reduce the water/steam density
hence the Circulation ratio will increase
• Area
– Natural circulation must have tubes with larger diameter to
reduce the water/steam resistance within the tube
  Furnace
– radiation mode
Spaced SH
Radiant SH

Evap.
 Radiant (Platen) Super heater
– luminous radiation mode
– non-luminous radiation mode
Econ.
– convection mode
 Convective (Spaced) Super
heater
– non-luminous radiation mode
– convection mode
 Evaporator (Boiler Bank)
Furnace

– convection mode
 Economizer
– convection mode
• Furnace heat release rate
– maximized local absorbsion rate and avoid “hot spot”
– prevent excessive slag accumulation
– influences completeness of combustion process
• Flue gas velocities through tube banks
– limit the draft loss to control flue-gas velocity
• Tube spacing
– prevent slaging especially for residual oil, coal with low
ash-fushion temperature

BOILER DESIGN IS TAILORED TO THE FUELS & FIRING SYSTEM

• Pressure Components (Mainly Water Circuit)
– Economizer
– Furnace and convection pass
– Water Circuits, including drums and steam
separators and re-heater.
– Attemparators
– Connection Piping and Headers
Non- pressure Boiler Components
(Mainly Air & Fuel Component)
Fuel preparation Equipments
Burners
Air Heaters
Duct works and supports.
• Balance of Plant Equipments
– Fans
– Feed Pumps
– Pollution Control Equipments
– Controls
 Economizer
• Used for Feed
Water Heating.
• For adding heat
at higher
temperature
• Use waste Heat
• Increases
Efficiency.
 STEAM
Steiner OUTLET
FEED WATER
SECONDARY INLET
SEPARATOR

RISER
TUBES

BAFFLE
PRIMARYY
PLATES
SEPARATOR
DOWNCOMER
 To HPC To
From
IPC
HPC
Stack

Con. SH 1

Con. SH 2

RH 2

RH 1
Platen SH

Econ.

FW RAH
Radiant SH

FD ID

Furnace
Boiler of 210 MW Ghorashal Power Station
Sub- critical, Super High Pressure, Water Tube, Balanced
Draft with Condensing Turbine
Boiler Auxiliaries: the devices
incorporated in the boiler circuit to boost
up the efficiency and performance of the
steam generation plant and assist in the
systematic and adequate operation of the
boiler unit for prolonged periods safely

61
The function of Boiler Auxiliaries:

• Auxiliaries allow more heat to be produced.

• Minimizing heat loss is key to maximizing output.
• Efficiency is the key to generation.
• Combustion needs oxygen so airflow is key to heat
production.
• Fuel type and size is key to combustion rate.
• Sizing of Auxiliaries is critical.

62
Main role of Boiler Auxiliaries:

Power Output MW Steam Flow Temperature and

Turbine Pressure

Boiler Capacity Auxiliaries

Under Capacity Over Capacity

< Desired MW Wasted Costs

Maximum Operation Wasted Energy

63
 Usually a boiler is fitted with the
following auxiliaries (accessories):
• Air Pre-heater • Chemical Dosing system
• Economizer • Soot blowers and wall
• Super Heater blowers
• De-super heater • Pressure reduction valves
(Attemparator) • Pulverizes and fuel firing
• Boiler Feed Pumps system
• Forced and Induced Draft • Ash handling system.
Fans
• Equipment Tanks
– Feed Water Tank/ deaerator
– Deaerator
– Continuous Blow-down
Expander
– Drainage expander

64
65
Burner

• Fuel
• Natural
Gas
• Oil
• Coal Dust
• Quantity
• Boiler
Size

66
Mechanism of combustion

Design of Combuster / Burner

Energy/Heat
FUEL + Air +
Flue Gas
Main Components:
C , H, S, O, N
(Asphaltenes) – Fuel Oil
Some Problems :
+ 1. High Emission
2. Low Availability
Impurities: 3. Low Reliability
Sulfur, Vanadium, 4. High Corrosion
H2O, Organic material, 5. High Maintenance
etc.

67
Air Heaters

68
RELIEF VALVE
 CL

NWL
O

 DEPENDING UPON THE DESIGN OF THE UNIT, GENERALLY NORMAL

OPERATING WATER LEVEL IS ( 4 to 6 ‘ ) BELOW THE CENTER LINE OF ST. DRUM
 TOTAL RANGE OF WATER FLUCTUATION (13 - 15 “ ). THE CENTER OF THE
GAUGE IS TERMED ZERO. ZERO POINT IS SLIGHTLY BELOW THE NWL TO
CORRECT FOR SUBCOOLING EFFECTS DURING OPERATION.
CHAIN WHEEL ISOLATING VALVE
 THE LEVEL IN THE WATER GAUGE WILL BE LOWER THAN THE ACTUAL
BECAUSE THE DENSITY IN THE GAUGE GLASS ASSY. IS GREATER THAN THAT
OF THE STEAM DRUM
 GREEN LIGHT INDICATE WATER IN THE LOWER PORTION DEPENDING UPON
WATEER LEVEL. RED LIGHT
INDICATES STEAM IN THE TOP PORTION OF THE GAUGE GLASS DEPENDING
UPON WATEER LEVEL.

YARWAY WATER GAUGE

70
COMBUSTION AIR and FLUE GAS CIRCUITS

72
 POWER Energy Systems Indonesia

INDUCED DRAFT SYSTEM

- 0.125
KPa

PRECIPITATOR

FORCED DRAFT FAN INDUCED DRAFT FAN

 TO KEEP THE BALANCE OF FIRING WITH FURNACE DRAFT OR WITHOUT FORCED DRAFT FAN.
 TO MOVE THE GASEOUS PRODUCT OF COMBUSTION OUT TO THE STACK.

 TO AVOID EXPLOSIVE BURST OUT OF THE BOILER

74
 ELECTROSTATIC
PRECIPITATOR
Negative FABRICs with
Charged Positive
Charged (+)
AIR
HEATER

ASH
HOPER

ASH HOPERS

ID FAN
AIR INLET

FD FAN

75
 Boiler Operation
• Firstly Starting Up the boiler
– Make sure all drain of feed line and periodical blow
down valves are closed.
– Drum fill up with water
– Start ID Fan (if any)
– Start FD Fan
– Ensure Furnace Pressure (as per design) and air flow
– Chemical test of Air of boiler (ensure there is no CH4)
– Start Fire (according to Instruction manual)
– Operate temperature & pressure of steam according
to Instruction manual
• Loading after synchronization of unit
• Air supply increase & Fuel Increase.
• Start burners accordingly as per instruction
manual
• Load the boiler fully at Rated Temperature and
Pressure.
• Normally Gas/ oil fired burner fuel is same but
incase of coal fired boiler 30% of rated load is
achieved by liquid fuel then fuel changed to
heavy fuel.
Operation & Maintenance at Running
Condition
• Keep the plant clean
• Inspect Boiler Drum Level.
• Inspect Fans, Air-heaters periodically.
• Ensure water quality (for Hardness, pH etc.)
• Keep dozing of Hydrazine and Ammonium
Phosphate.
• Maintain Constant pressure & Temperature of
steam.
• Type of Maintenance:
– Preventive Maintenance
– Corrective / Break Down Maintenance
 Duty
Design Cycle Cost of
Feature Downtime
Manufact
urer’s Type of
Recomm Fuel
endation
Replace
Diagnosti
ment
cs & Maintenance
Parts
Expert Planning
availabilit
System
y
Reserve
Reliability
Requirem
Needed
ent
Onside
Maintena Environm
nce Utilization ent
Capability Need
 MAINTENANCE PLANNING

• For Maximization of Running Hours

• To avoid forced outage
• To run reliably
• To minimize Maintenance time
 Daily Maintenance
 To ensure water level
 To ensure water quality
 To ensure steam Temperature & Pressure
 To Ensure Flue gas Temperature
 To Ensure Oxygen and Carbon dioxide quantity
of water
 To Inspect for Water or air leakage and
maintenance if Possible
 To Ensure quantity of blow down
 To ensure the working environment clean.
 Monthly Maintenance
 To ensure function ability of all safety
valves
 To ensure the openings of drain valves
 Quarterly Maintenance
 To inspect exterior of boiler
 To inspect Internal Part of boiler
(mainly furnace) if shutdown is
available.
Half yearly Maintenance
 To inspect Steam or Water leakage.
 To ensure correctness of Pressure Gauge.
 To ensure correctness of level meter
 To check feed water regulator
 To ensure the correctness of pressure
control devices like, safety valve, Feed
Pump & Dozing Pumps.
 To ensure freeness of suspension
 To Review Boiler Log book, Maintenance
Registers & Water quality log book.
 Yearly Maintenance
To inspect & Repair Interior and Exterior of Boiler

 To inspect boiler tube inside for Scale, Corrosion,

Grooving or wrack.
 To inspect & Tightening bolts
 To Inspect and Repair of all Manhole, Connection
points and headers for crack, corrosion or erosion
 Inspect water wall tube thickness through ultrasonic
thickness gauge.
 To perform Hydraulic Test for Pressure parts.
 To ensure the correctness of pressure control
devices like, safety valve, Feed Pump & Dozing
Pumps.
 To ensure freeness of suspension
 To Review Boiler Log book, Maintenance Registers
& Water quality log book.
 Purpose of Water Treatment
• Reduce Corrosion
• Reduce Scale
• To reduce force trip & outage
• To increase efficiency of Boiler
• To reduce Deposition in Turbine &
Super heater.
 Dozing

• Hydrazine Dozing for reducing

Oxygen
• Ammonium Phosphate Dozing
for Maintaining pH through
neutralization of acid
 Causes of Boiler Tube Failure
Long Term Overheating Creep
Short Term Overheating Thermal Fatigue
Mechanical Overload Corrosion Fatigue

2%
24%
24%

9%
11%
6%
4% 20%
89
 Boiler Tube Preventive Maintenance
• Inspection
– Non destructive evaluation
– Feed water & fuel quality
– Other part that may affect tube, e.g. blower
position
• Feed water treatment
• Chemical/mechanical cleaning
• Often already included in boiler maintenance
 Boiler Tube Preventive Maintenance
• Reference
– Assessment result
– Maintenance history
– Manual book, design calculation, or reference book
– Best practices
– Third party recommendation
• Periodic time
– May vary, depends on the part and failure mode
– Planned
 Boiler Tube Preventive Maintenance
• Inspection methods
– Visual check
– NDT technique:
• Ultrasonic (flaw & thickness)
• Bore scope inspection
• Eddy current
• PT/MT
– Lab examination
• Water quality
• Replica test (microstructure)
Six Most Common NDT
Methods
1. Visual Testing (VT)
2. Dye Penetrant Testing (DPT)
3. Magnetic Particle Testing (MPT)
4. Ultrasonic Testing (UT)
5. Eddy Current Testing (ECT)
6. Radiography Testing (RT)- X-ray

93
 Visual Testing Equipment

Fig: Video scope

Fig: Advanced Video scope Fig: Bore scopes

Fig. Microscope Fig: Magnifying glass

94
 Dye Penetrant Testing of a Boiler

At first the surface of the material that is to be tested is

cleaned by a liquid. The liquid is called cleaner.
95
 Dye Penetrant Testing of a Boiler

Then a liquid with high surface wetting characteristics is applied to the

surface of the part and allowed time to seep into surface breaking
defects. This liquid is called penetrant. After five or ten minutes the
excess penetrant is removed from the surface.
96
 Dye Penetrant Testing of a Boiler

Then another liquid is applied to pull the trapped penetrant out the
defect and spread it on the surface where it can be seen. This liquid
is called developer.
97
 Findings

After Dye Penetrant

Testing
there are two surface
cracks are Detected.

Two surface cracks

98
 Basic Principle of MPT
Magnetic Flux Leakage Crack
Magnetic Flux Line

S N
N S N S

Fig.1: Magnetized Metal with no crack Fig.2: Magnetized Metal with crack

In the first figure the magnetized metal has no crack and there only two
poles that is north pole and south pole. And in second figure the
magnetized metal has a crack and at the crack point there creates
another north and south pole for the magnetic flux leakage.
 Magnetic Particle Testing Process
The first step in a magnetic
particle testing is to magnetize the
test component by a MPT
equipment. If there any defects on
the surface or near to the surface
are present, the defects will create
a leakage field.
Then finely milled iron particles coated with a dye pigment are
applied to the specimen. These particles are attracted to magnetic
flux leakage fields and will cluster to form an indication directly
over the defects. This indication can be visually detected under
proper lighting conditions.

100
 Magnetic Particle Testing in Super heater
Pipe Welding

First the welding joint is magnetized by MPT equipment. Then finely

milled iron particles are applied to the magnetized weld joint.

101
 Magnetic Particle Testing in Gas
Pipe Welding
Iron particles make a
cluster at the welding
joint for magnetic
flux leakage because
of welding defects.

Cluster

102
 Ultrasonic Testing
• This technique is used for the
detection of internal surface
(particularly distant surface) defects in
sound conducting materials. In this
method high frequency sound waves
are introduced into a material and they
are reflected back from surface and
flaws. Reflected sound energy is
displayed versus time, and inspector
can visualize a cross section of the
specimen showing the depth of
features.

103
 Eddy-current Test
Crack detection is one of the primary uses of eddy current
inspection. Cracks cause a disruption in the circular flow patterns
of the eddy currents and weaken their strength. This change in
strength at the crack location can be detected.

Magnetic Field
From Test Coil

Magnetic Field
From
Eddy Currents

Crack
Eddy Currents

104
Eddy Current Testing
Equipments

105
 Radiography Testing Process
Radioactive Source

Electrons
+ -
X-ray Generator or
Radioactive Source
Creates Radiation

X-ray film
Radiation
Penetrate
the Sample

Top view of developed film

106
Boiler Tube Preventive Maintenance
• Boiler feed water treatment &
quality check
– Prevent deposit, hard particle, or
other impurity that may cause
damage the tube
– Periodic
• Chemical/mechanical cleaning
– External & internal surface of
tube
– Reduce deposits/scales
– Should be done efficiently &
carefully  other failure mode
may active such as caustic
corrosion, acid corrosion, etc.
 Boiler Tube Preventive Maintenance
Other efforts:
• Review operation parameters
• Software supports
 Boiler Tube Corrective Action
General Strategies for Damaged Tubes:
• Pre-repair inspection
• Removal of the failed tube section
• Repair/Replacement of the failed tube
• Post-repair inspection and tests
• Future preventive/control actions
 Boiler Tube Corrective Action
• The following historical information should be
considered in making the decision about repair
– Was the original material selection in the design
appropriate?
– Did all the original materials meet specified requirement?
– Did the operating conditions contribute to the failure in
anyway : creep, fatigue, erosion, shock or thermal loading?
– Are there any unusual metallurgical characteristics in the
defective or suspect area?
– Has the problem occurred in any other units at the same
site or within the industry?
 Boiler Tube Corrective Action
Guidelines for tube repair/replacement:
Locations Actual wall thickness Course of Action

Furnace support Tubes Tubes equal to or Monitor thickness

Economizer stringer greater than 85% t
support Tubes Tubes less than 85% t Restore tube wall thickness
or replace tube
Economizer, Furnace Tubes equal to or Monitor thickness
Wall and other water greater than 85% t
cooled Tubes Tubes less than 85% t Restore tube wall thickness
or replace tube
Super-heater, Re heater Tubes equal to or Monitor thickness
and other steam cooled greater than 85% t
Tubes Tubes less than 85% t Restore tube wall thickness
or replace tube
 Boiler Tube Corrective Action
Pre-Repair : Confirm materials to be repaired
• It is critical to confirm the materials to be
replaced prior to developing an optimized
procedure.
• The specific grade of material is required as
well as the specification number : For example
ASME SA-213 T22
• Upgrading materials is, for several key BTF
mechanisms, the optimal strategy.
 Boiler Tube Corrective Action
Specific Repair Procedures
• Every utility should use a qualified welder for all repairs.
• Use gas tungsten arc welding for root passes
• Do not use backing rings for tubing in the water touched
• circuits.
• Some semi-automatic welding processes have been used in
limited applications.
• Slag removal is required prior to performing maintenance
work.
• Access is critical.
 Boiler Tube Corrective Action
Method Applicability
• The preferred
Tube section
Some repair techniquesrepair method
and their application
replacement• Consists of replacing tube section with one of same material and
dimensions.
Grind out and • Applicable for small defects such as pin-hole leaks.
re-weld • Vee-preparation and re weld.
Pad welding • Should only be used in an emergency as repeat failures are nearly
always guaranteed. Should be replaced at next major outage.
• Involves mechanically closing the rupture to original contour,
veeing a weld groove and rewelding.

Window May be required if access all around the tube is limited. Should be
welding used only as a temporary measure with full replacement at next
outage.
Boiler tube For restoring thinned tubes to original thickness
build-up
 Boiler Tube Corrective Action
Example of window welding
Check Tube Thickness Regularly/
Periodically

Change Tube if the thickness

reduces to 80% of original thickness

Weld all root passes with Argon

Welding
Name of Place Type of Problem Remark/ Cause

Scale, Corrosion or Pitting Water Quality Problem

Water Wall Over Heating Operational/ Burner
Problem
Drum Scale, Corrosion or Water Quality Problem
Block Water Quality Problem
Super Heater & Re-
heater Over Heating Operational/ Burner
Problem
Economizer Leakage/ Corrosion/ Pitting Fatigue
Feed line Leakage/ Corrosion/ Pitting Fatigue
Steiner of Stop Metal Deposition Water Quality Problem
Valves
Headers Corrosion Fatigue
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