water tube boiler tube failure

On Board Marine Boiler Repairs - Bright Hub Engineering

Repairs In Water Tube Boiler: Instruction for Plugging / Repair of Water Tube Boiler & Economizer: In case of tube failure, steam pressure has to be removed and the oil burner dismantled. If the leakage is readily visible from the burner hole, the boiler can be emptied and repairs commence.

Avoiding Boiler Problems

is distu:rbed, theresulting unstable flame To eliminate a low water inicident, all boiler instead of deposiling on tube stir-caD lead to flame failure. if fteloilF is installations should 1hae low I water cut- faces. Proper boiler feedwater treatment sprayed into the furnace during sueces- outs.

Boiler Tubes Failure: Causes and Remedies a Case Study of a

ABSTRACT: The boiler tube failure is occurring frequently in fertilizer plants, power plants, sugar manufacturing plants, paper manufacturing plants and all industries using boilers. The present study is related to the boiler tube failure analysis of three Boilers which are under operation at National Fertilizers Limited Naya Nangal.


Boiler is a two drum, bent-tube, "D" type Boiler. The line consists of three Models; "D", "DL" and "DLD" which vary only in size, dimensions, and capacity. All models are covered by this manual. The Boiler has a six-wall water cooled furnace. The inside and outside furnace walls, as well as the floor and roof, are constructed of tangent tubes.

Water Tube Boilers

Water-tube boiler sections. The energy from the heat source may be extracted as either radiant or convection and conduction. The furnace or radiant section. This is an open area accommodating the flame(s) from the burner(s). If the flames were allowed to come into contact with the boiler tubes, serious erosion and finally tube failure would occur.

Boiler Tube Failure Analysis - Jonas Inc

Boiler Tube Failure Analysis The service environment of fossil-fired boilers and HRSGs, along with human errors during engineering, fabrication, construction, operation, and maintenance will always result in occasional boiler tube failures (BTF).

Water Tube Boilers - P C McKenzie Company

The boiler carries a manufacturer’s 20 year warranty due to failure from thermal shock. The Unilux Water Tube Boiler is available as steam hot water, high temperature hot water ( HTHW) and steam in capacities from 31 to 1500 HP firing natural gas or No 2 oil. >>

Corrosion fatigue failure of tubes in water tube boilers

Corrosion fatigue failure of tubes in water tube boilers Introduction. Chemicals Industries Division of HSE is aware of three relatively recent failures associated with water tube boilers. Each of

Water boiler tube burst - Corrosion and Failure Analysis

Some days ago we have had a water boiler tube burst. Burst location was in a radiant rear water tube at the top convection zone on an almost horizontal part of the tube, about 1,5 m from the top water tubes header. First visual inspection of damaged tube was a typical failure of a "thin-lipped" burst of the boiler tube.

Water Tube Boiler Parts and Functions - Boilersinfo

In a water tube boiler fuel is fired into a water cooled furnace. Sheet metal and refractory enclosing the boiler called casing. At the end of the furnace, the flue gas turns into the convection section and travels towards the stack.

Chapter 14 - Boiler System Failures | SUEZ

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.

Boiler tube failures: Case histories of steam blanketing and

The boiler tubes, made of ASTM A 178 GrC, failed by precipitation of the phosphates used for the chemical treatment of the boiler water, coupled withmore » Precipitation was caused by inadequate heat flow inducing a departure from nucleate boiling (DNB), steam blanketing, and deposits. « less

Problems in Boilers - Marine StudyMarine Study

May 22, 2015 · Sometimes, due to tube failure in an economiser if the individual tube cannot be isolated, or if the failures are of a multiple nature, it becomes necessary to make an emergency bypass of the economiser on the water side.

Cause of Boiler Tube Failures - Chicago Tube & Iron

During periodic shutdowns of the boiler unit, tube failures can occur. Quite often they are related to dew point corrosion, an insidious condition that can penetrate up to 0.50” of steel per year. Thin walled tubes that normally last 10 years can become badly pitted during shutdown, and replacement tubing becomes an unanticipated expense.

Boiler Tube Failures - eecpowerindia.com

boiler tubes. Fly ash erosion, is a significant boiler tube failure concern, occurs in the regions with high local flue gas velocities, with high ash loading, and with abrasive particles such as quartz


Failure Analysis of Cracked Boiler Tube Page 4 of 10 Figure 1: Photographs displaying (a) the site of failure (replacement tube welded in) and (b) submitted portions of the failed tube. The failure had been cut up into pieces prior to submission. The adjacent, mirrored tube had leaked and been replaced several years before.

Thermal Considerations in Boiler Tube Failures

with boiler feed-water chemicals. The effect of these internal scales and deposits is to impede heat transfer and raise the tube metal temperatures. A thermal analysis is presented that permits calculation of the tube metal temperature as a function of Q/ Ao and internal scale thickness for both water and steam cooled tubes.

Water tube boilers Flashcards | Quizlet

The total heating surface of a boiler includes all parts of the boiler which are exposed on one side of the gases of combustion and on the other side to the water and steam being heated The heating surface incudes: generating surface, generating tubes, screen tubes, waterwall tubes, support tubes, superheater surface, and economizer surface

Failure Analysis and Prevention of Furnace Water wall Tube

with known leaks. In the boiler tube water wall tube, primary & final super heater, re heater, condensers are failed due to various reason but the water wall tube failures are in more number because it is directly affected by furnace draft condition, operation control, coal quality.. etc.

Boiler Tube Failures - YouTube

May 09, 2009 · Part 2 •Flow Accelerated Corrosion (FAC). •Stress Corrosion Cracking (SCC) •Hydrogen Damage •Sulphur corrosion •Graphitization •Thermal Fatigue •Waterside Corrosion Fatigue •Soot

Firetube vs Watertube Boilers: a Comparison

The firetube boiler passes combustion gas inside a series of tubes surrounded by water in a vessel to produce steam, while a watertube instead sends water through a series of tubes surrounded by combustion gas used to transfer heat energy and produce steam. Here are a few key differences between the two:

Boiler Tube Failure Research Papers - Academia.edu

Impact of Boiler Water Chemistry on Waterside Tube Failures This paper emphasis on the study of typical premature failure of water wall tubes of two thermal power plant boiler of same capacity (250 MW) and same operational parameter but with different boiler water chemistry.

Boiler Maintenance and Upgrades — Attacking Tube Failures

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

Boiler Tube Failures | Boiler | Corrosion

Super heater tubes, re heater tubes & furnace water wall tubes always experienced high temperature ductile failures such as stress-rupture failure, initiated by creep process or sudden overheating due to steam starvation or flue gas disruption.

How to Destroy a Boiler -- Part 3

This action could potentially result in water wall tube overheat damage due to the interruption of the boiler’s natural circulation. The lower water wall headers should be routinely blown down every time the unit is brought out of service after fuel firing has been halted and the unit is still under pressure.

(PDF) Failure analysis of the boiler water-wall tube

The failure mechanism is identified as a result of the significant localized wall thinning of the boiler water-wall tube due to oxidation.


Failure of tubes in boiler of the power plants may occur due to various reasons. These include failures due to creep, corrosion, erosion, overheating and a host of other reasons.

Anatomy of a Boiler Failure—A Different Perspective

The report concluded that the tube explosion that blew out the outer wall of the furnace was caused by ash and water from boiler washing, coming into contact with tubes. That mixture caused

Tube Failures in High Pressure Boilers

This failure can be visually identified by it characteristic appearance of a fish-mouth-like opening and so is also called as fish mouth failure. Tube failure during normal operation period. Any of these twenty-two mechanisms can be the cause of a tube failure during normal operation.

Update: Benchmarking Boiler Tube Failures

In addition to preventing boiler tube failures, tight control of water chemistry parameters can improve heat transfer and, therefore, unit heat rate. Even with good control, however, boiler tube

Water Tube Boilers - P C McKenzie Company

The boiler carries a manufacturer’s 20 year warranty due to failure from thermal shock The Unilux Water Tube Boiler is available as steam hot water, high temperature hot water ( HTHW) and steam in capacities from 31 to 1500 HP firing natural gas or No 2 oil.

A Review of the Common Causes of Boiler Failure in the Sugar

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

Water Tube Boiler | Operation and Types of Water Tube Boiler

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 b

Steam Boiler Tube Failure by Caustic Gouging | Chardon

Many boilers have a limiting factor of alkalinity caused by the amount of carbonate in the make up water used by the boiler. Carbonates will break down in a boiler to form both caustic and carbon dioxide. Caustic is desirable in a steam boiler but excessive levels should be prevented. Slow warm-ups of boilers should be used to prevent local hot spots causing caustic gouging also. All boilers should be started on low fire to prevent eventual tube failure. Share:

Boiler Tube Failure Handbook - M&M Engineering Associates

Boiler Tube Assessment; Water Treatment Technologies Services; Publications. Boiler Tube Failure Handbook; the Conduit; Publications by Author; Resources

Condenser Tube Failure Mechanisms - POWER Magazine

The operating environment within a condenser is extremely harsh, and in spite of the designer’s best intentions, sometimes tubes made of the best materials fail. The most important tube failure

Boiler Tube Failure Handbook - M&M Engineering Associates

Holes, pits and gouges are three examples of corrosion and may occur on the fire/gas side or on the water/steam side of the tube. Deformation includes thinning from the water or fireside and bulging or blistering. Often more than one of these characteristics can appear in a failure.

How to Destroy a Boiler -- Part 1

Boiler feedwater is treated to protect it from two basic problems: the buildup of solid deposits on the interior or water side of the tubes, and corrosion. Prevention of scaling or buildup - The need for proper feedwater treatment is obvious if you will consider the comparison of a boiler and a pot of boiling water on the stove.

Best Practices For Expanding Water-Tube Boiler Tubes

Additionally, when expanding boiler tubes it is critical that you follow the step rolling process and use both a flare roll and a straight roll expander. If you force the expander to flare and expand in one operation, it can result in tube leaks and premature failure of the vessel.

Impact of Boiler Water Chemistry on Waterside Tube Failures

This paper emphasis on the study of typical premature failure of water wall tubes of two thermal power plant boiler of same capacity (250 MW) and same operational parameter but with different boiler water chemistry. The investigation concludes on the waterside corrosion in both of the case.