s72018 “Tube Fallures in High Pressure Boilers ‘essenical zon pwatce SlucalEooen + SechenlEpetng * Chctel Emineiog 1 Comme Aslesoos + pn betacaos 1 Rae Daur ene + Marne Enonescna * UsiceEoseteo + sans She Stine tendarneefsheoy on Understanding Tube Failures in High Pressure Boilers Boiler tbe ures ae inevitable, There are twensy-wo primary reasons for cube ules in a oiler ‘Knowledge and good operating end mamtcaance prachice recuce te flues. Reducing tbe alae i boilers inerenses the availability of boiler Whatever the ype of fel being ire, all hgh pressure boilers are bound to have a tube flue during he course oftheir working lif Did you kaow thata single tube flue in 2500 MW bolle: ‘requinng four days of repair wor can result na loss of more than S1,000,000 apart fom the seteration las? “There are sx major group into which al tube flares cam be clasifed, These six group canbe fuer divided ino total of tweniy-two primary tyes. All igh pressure boilers commissioned and put into operation go through a stabilization period, during which some tething problems oceut, Including few tbe fires Classification of tube failures “Tube failures are classified as in-service failures in boilers. These flues canbe grouped unde si major cases 1 Stes raprae 2 Fatigue 3, Was side comosion 4 Erosion 5. Fireside corrosion (Caled sho as High temperature Coronion) 6. Lack of quality contol These lad to twenty-two primary causes hat an cause a tube failure ina high pressure bole: Short erm overeating failure [Long tem overheating litte (elle aso as eeep files) Dissinala tal weld fare Fatigue eased by vibration “Thermal fgue duet tempers Hacuation Corrosion aig fies (Caustic corrosion nse the tbe [ydeogen damage in water wal ners] surface “Tbe internal iting Ely ask eosion ting slag erosion Soot blower ero Coal particle erosion Low fempeatre fs gas corrosion Fire side watewallcorsion Con ash corrosion Oil ash corsion Damage during mainenance cleaning CChemcalexeusion damage hips:w.brighthubengineering.com/powerplanis’34265-understanding-tube-ailures-in-high-pressure-bolers! 18si72018 “Tube Fallures in High Pressure Boilers (© Matai defect and weld defects ‘Tube faire during stabilization period “The ube failures in a boiler during intl phase of operation ate different fom the types that occur ate prolonged operation. During the iia period a operation of boiler the typeof tube furs ‘seen ac sor era overeating, weld failures, materi defects, chemical excursion flue, and Somesmes fatigue failures. Te short erm overbeaing flue i mainly due to blockage inthe Quid ‘ath by some foreign mater which ge ilo the tbe surfice ring fabrication o ding erection Fhe unit. The blockage can also happen when debi after acid cleaning ofthe bolle snot. removed completely. This flue ear be visually iene by it characteristic appeacance ofa fish tmouth-lke opening ands is also calle as fish mouth fale. ‘Tube failure during aormal operation period Any ofthese twenty-two mechanisms an be the ease ofa tube file ding normal operation, However few ike water sid coresion, caustic corsion, hydrogen damage in the water wal, oot bower erosion, damage caring maintenance cleaning, nd ube itera piting can be totaly tliminatd ins boiler if good operating and maintenance practixs at told bythe boiler designers ae lw Ths res ag em orig ye ene carom falling slag damage, ete ca sl happen ia a bole due ofl quality variation, operating tempers, star od shutdown te te Hence ti fly posible o avoid bef ina Nigh pressure boiler, but tha umber of them can be misinzed by aayeing all les and taking coetive and preventive acon ‘Tobe lure in high pressure boil follow a nena buh tub curve, with higher rte during initial pertion period, sabilring toa tower rate during the normal operating period and agin inreasing {8 the boilers age and ess tonto fiten years of operation. During this etiod the bole pressure parts are eveluated for her reining ie and corestive ation taken few photos of tube faire te shuor below. ‘Short erm overeating, Long erm overheating Thermal Fatigue are Related Articles on this Site soababinbengmct soe Sento on Custom Saarch hips:w.brighthubengineering.com/powerplanis’34265-understanding-tube-ailures-in-high-pressure-bolers! 218si72018 “Tube Fallures in High Pressure Boilers SUBSCRIBE & FOLLOW: RELATED TOPICS: : rag Pere Fuaecrane yer anutcairgTshroay Tweets oy ge “ew Pn Engrg asin Tus ae nsoee by eres wt eincngnsna toroneers on "me Most Popular Engineering sre in BH Engineering {DEH Eraeerng ip dolls: STEM vs. Spars. Winer ae we fvestng? ‘oulyiniad0nGUGe eolge Recholarenps aston SIGNUP FOR EMAILS Choc sup ra sar» Atos BHEngnowng Tomer conse ue ry Paley éseine With Us Cony hips:w.brighthubengineering.com/powerplanis’34265-understanding-tube-ailures-in-high-pressure-bolers! 38