Periodic overheating of superheaters, caused by insufficient control of firebox temperatures during start-up and shutdown periods, usually results in thick-lipped fissures and blistering with all the evidence of creep failure. As in the case of water tubes, a superheater tube will fail rapidly (often violently) when flow is blocked for a short period of time and tube temperature escalates rapidly to plastic flow temperatures.
Fire side wastage is another common cause of creep failure of boiler tubes in addition to the scale formation problem on the inner side of boiler tubes (steam-side).When boiler tubes are experiencing wastage, the hoop stress is going to increase respectively especially when severe oxide cracking and exfoliation occur.
D type water tube boiler. In the water tube boiler, the water and steam flow inside the tubes and the hot gases flow over the outside surfaces. Where as in fire tube boilers hot gases from combustion travels through the tubes. flue gases produced from furnace where fuel is burnt. Water tube boiler design and working. In a typical Water tube boiler design as shown in the figure, it consists of two drums the steam drum and the water or mud drum.
In water tube boilers thermal fatigue can occur when there is frequent wetting of a hot surface such as is caused by an ill placed and leaking valve dripping internally into a hot steam line. Such failure
A water tube boiler is such kind of boiler where the water is heated inside tubes and the hot gasses surround them. This is the basic definition of water tube boiler. Actually this boiler is just opposite of fire tube boiler where hot gasses are passed through tubes which are surrounded by water. 18.104.22.168. Advantages of Water Tube Boiler There
Feb 14, 2011 · 32 years in the trade has taught me a thing or two.This is another possibility why your relief valve has popped on your hot water boiler.Very first thing to do is turn off the power to the furnace
tube metal leading to accelerated creep damage and premature failure of the tube. Inferior quality of de-superheated spray water used to control the steam temperature was identified as
The water tube boilers ( where water to steam flow is within tubes and combustion of fuel is out side, in a furnace), are top supported units, suspended from a self supporting steel structure , arranged to provide total freedom of expansion for all parts of the boiler in down ward direction.
creep cracks on tube surfaces and puncturing. Tube failure in the super heater is hazardous enough to shut down the whole plant hence it is important to take remedial actions to avoid technical as well as economic losses. Prolonged localized heating which is reported as a root cause of tube failures is a result of improper
have been determined through creep tests made over periods of up to 200,000 hours. The hot strength properties of our boiler tubing materials make them suitable for use in pressure-bearing plants having operating temperatures of up to 1,000°C. They also have excellent fabrication characteristics necessary for tube materials
Boilers. Boilers suffer from many forms of degradation while in service. Water Wall tubes can suffer from Hydrogen Damage, pitting, ash and soot-blower erosion, graphitization, under-deposit corrosion, thermal fatigue cracking and creep damage. The VertiScan System is used to rapidly scan the water walls of a boiler during an outage
Jan 26, 2014 · I have major water pressure creep all the time. New water heater installed with expansion tank and the pressure is being relieved by the pressure release valve. I have tested the lines with a pressure gauge and the flow is regulated at 40-50 psi when running. The gauge registers a high of 150 psi over night which triggers the release valve.
Sep 10, 2015 · new expansion tank,high vent,water feeder/backflow preventer,relief valve ,boiler gauge,nozzle and filter at tank,all parts needed replacing hydronic boiler with major issues fixed steven
Oct 30, 2018 · For high-temperature steel boiler system, additional alloying elements such as Cr and Ni to improve tensile strength and creep resistance at high temperatures. Most of the seamless boiler tubes are made of carbon steel and alloy steel.
For boilers creep and creep rupture data have been used as part of the criteria for establishing maximum allowable working pressures. The values are listed in ASME Boiler and Pressure Vessel Code, “Section I, Power Boilers.” Designing to, or below, these maximum values is required by law in most states and Canadian provinces.
In general, 30% of all tube failures in boilers and reformers are caused by creep. This paper gives details of four case studies in which internally pressurised tubes failed by creep bulging and
water tubes and cause tube failure. Re-tubing of the boilers is a very expensive upgrade and thus it makes feed water treatment an essential step in boiler operation. Phosphates, chelates, and polymers are commonly used for water treatment in boiler plant. By properly treating the water the life of the boiler tubes will be extended.
Typically, for boiler tube samples one option to have isostress creep testing performed on test specimens removed from boiler tube samples. Because of the wall thickness used in standard reheater and superheater boiler tubing, you are faced with having to remove sub-size tensile specimens from the longitudinal (along the length of the tube) direction and have them creep tested in an inert
Boiler tubes can be categorised into water tube and fire tube. A water tube refers to the flow of water inside the tube with combustion gasses flow externally. On the other hand, a fire tube refers to combustion gasses that flow inside the tube with the tube being surrounded by water on its exterior.
more significant role than stress does in determining the creep life of a boiler tube. In order to avoid the tube failure, detection of tube temperature distribution is necessary to take proper action. Therefore, temperature distribution in the tubes in water tube boiler needs to be analyzed numerically.
The strength of a boiler tube depends on the level of stress as well as on temperature when the tube metal tem-peratures are in the creep range. Because an increase in ei-ther stress or temperature can reduce the time to rupture, attention must be given to both factors during investigation of a failure by a stress-rupture mechanism, which can be
CBCW Series. The CBCW is the newest member of the Cleaver-Brooks Industrial Watertube Boiler family. Design with a 100% membrane water-cooled furnace, this boiler system includes high-efficiency boiler and burner, heat recovery economizer, and advanced control system. All available at shortened lead times and includes comprehensive technical documentation.
Boiler tube failures, especially in coal-fired power plants, continue to be the major cause of boiler forced outages. However, if a tube leak is detected early more severe damage to surrounding
Higher stresses due to significant wall loss at the failure contributed to intergranular creep cracks. The tube wall was thinned down to approximately 0.075 inch at the edge of the failure.
heat in some instances (CleaverBrooks, 2013), the water in the boiler is sometimes used not in the super heat phase but it will be hot still. Apart from creep other boiler failures occurs due to corrosion, graphitization, oxide scale formation, slagging and foaming of tubes and caustic embrittlement. The normal failure type for water tube
Boiler tubes in service operate under high temperatures and iso stress conditions. A material operating at high temperature and constant stress is subjected to creep deformation. Boiler tube failure due to corrosion, scale formation, and material degradations, are measure problems
Boiler is a closed vessel in which the water is heated up to convert it from the liquid phase to superheat steam at specified pressure by addition of heat. The tubes are operated continuously at high temperature due to the formation of scale which has lower conductivity than that of steel.
During normal operation, alloy superheater tubes will experience increasing temperature and strain over the life of the tube until the creep life is expended. Furnace water wall tubes can also fail from long-term overheat. In the case of water wall tubes, the tube temperature increases abnormally, most commonly from waterside problems such as deposits, scale, or restricted flow. In the case of either superheater or water wall tubes, eventual failure is by creep rupture.
These differed from locomotive boilers, also known as "fire tube boilers", in that, whereas the fire tube boiler consisted of a cylinder filled with water, which was heated by tubes passing through it carrying exhaust gases from a furnace, in the water tube boiler the situation was reversed, with water passing through steam-generating tubes mounted directly above the furnace. Advantages of the water tube boiler included comparative lightness and the ability to run at higher pressures.
Basically, the cause of sagging or warpage in SH tube elements can be from either higher than normal tube metal temperatures that allows the elements to permanently deform or creep at elevated temperature, or failed assembly supports or fouled assemblies that increase bending forces on the assemblies resulting in creep of the material.
In low-temperature regions of the boiler, load cycling also causes thermal fatigue cracking in economizer inlet headers or tubes, lower furnace wall tubes or headers, and steam drum internals. This fatigue cracking primarily occurs from the ingress of relatively colder water into hot boiler components or vice versa.
Creep rupture can be avoided in tubing by selecting a grade of steel whose creep rupture strength is sufficient to withstand the specific operating conditions. For boilers creep and creep rupture data have been used as part of the criteria for establishing maximum allowable working pressures.
Tube failure during normal operation period. Tube failure in high pressure boilers follow a normal bath tub curve, with higher rate during initial operation period, stabilizing to a lower rate during the normal operating period and again increasing as the boilers age and cross ten to fifteen years of operation.
The demand of remaining life assessment of the boilers arises from technical, economic, and legal reasons. Creep is major damage mechanism of primary superheat tube boiler during prolong operation at high temperature and pressure in a water tube boiler.
increasing temperature and strain over the life of the tube until the creep life is expended. Furnace water wall tubes also can fail from long-term overheat.
Failure of boiler water-wall tubes in a thermal power station is a very common phenomenon. ‘High-temperature creep’ is one of the main reasons behind these failures. A systematic study of the failures may lead to minimization of the failure occurrences preventing disruption of power generation and associated monetary losses.
Boilers are used to heat water to generate steam for power generation. The main components of boiler include water-wall tube, superheaters and economizer. The failure of boiler is a common phenomena and the causes of the failure might include pitting, erosion, fatigue, creep and stress corrosion cracking.
Long term overheating of the tube happens over a period of time, as the tubes are subjected to temperatures which are not so high to cause instantaneous bulging of the tube to a failure point. During this period of long term overheating the tube outer surface develops bulging, creeping elongate fissures along the axis of the tube.
Aug 22, 2018 · A water tube boiler is such kind of boiler where the water is heated inside tubes and the hot gasses surround them. This is the basic definition of water tube boiler. Actually this boiler is just opposite of fire tube boiler where hot gasses are passed through tubes which are surrounded by water. Advantages of Water Tube Boiler
1 Most common boiler tube failure modes. Current work was dedicated to identification of healthy thickness of water wall in the boiler. Every occurrence of ruptured tubes leads to emergency shutdown of the entire plant. As boiler ages, corrosion and erosion causes the tube wall to become thinner until it cannot sustain the internal pressure.