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HowLongTermOverheatingTubeFailuresHappenin
Leaveacomment
Boilers
writtenby:DrVTSathyanathaneditedby:LamarStonecypherupdated:3/8/2011
Longtermoverheatingtubefailuresareduetooperatingmetaltemperatureoftheboilertubesgoingabovethe
allowablelimit.Thesetypesoffailureareseeninsteamcooledtubeslikesuperheatersandreheatersandinwater
cooledtubesofwaterwalls.
Boilersusedforindustrialsteamgenerationandpower
generationhavekilometersoftubesthatcarrywaterand
steamincirculationsystemandsuperheaters,respectively.
Thesetubesareofvarioussizesandthicknesses
dependinguponthepressureandthemidwallmetal
temperature.Thetubesselectedareboilerqualitytubes
manufacturedundervariousstandardslikeASME,BS,DIN,
JIS,etc.Whileselectingthetubethereisarequirementto
selectthecorrectmaterialforwithstandingthemetal
temperature.Thiswilldependuponthelocationwherethe
heattransfersurfaceislocated.Normallythewatercooled
areaslikeeconomizerandwaterwallsaremadeofcarbon
steelofboilerquality.Superheatersandreheaterswill
havecombinationoflowalloytubestostainlesssteeltubes
selectedtowithstandthemetaltemperature.
Midwallmetaltemperature
Whenheatistransferredfromtheburningfuelorhotgasesbyradiationorconvection,theoutsidetubetemperatureis
veryhightheheatisthentransferredtothemediuminsidethetubewhichiswaterorsteam.Thereisatemperature
gradientthatexitsfromtheoutermostlayerofthetubetotheinnermostlayerofthetube.Thetemperatureatthemiddle
ofthetubethicknessiscalledthemidwallmetaltemperature.Thewaterwallsintheboilerfurnacefacethehighest
temperature,namelytheflametemperature,andsincethewaterflowingthoughthetubeissodesignedtocarrytheheat
awayandthecoolthetubebypropercirculation,themidwalltemperatureismaintainedwithinallowablelimitofthe
material.Themidwallmetaltemperaturecanbeaccuratelydetermined,howevertherearemanyrulesofthumbusedby
theoperatingengineers.Inthewaterwallareathemetaltemperaturewillbesaturationtemperatureofwateratthedrum
operatingpressureplus30degreecentigrade.Inthesuperheaterareaitissteamtemperatureinsidethetubeatthe
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HighPressureBoilersLongTermOverheatingTubeFailures
locationplus50degreecentigradeforradiantheattransfer
surfaceand40degreeforconvectiveheattransferarea.
LongtermoverheatedtubesFailed&internaldepositblockingtubeflowarea
RelatedReading
UnderstandingTubeFailuresinHighPressureBoilersBoilertubefailuresareinevitable.Therearetwentytwoprimary
reasonsfortubefailuresinaboiler.Itistruethatbeingforewarnedisbeingforearmed.Knowledgeandgoodoperating
andmaintenancepracticereducetubefailures.
MechanismsofSteamSootBlowerErosionTherearemanymechanismsthatcancausesteamsootblowererosionof
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boilertubesatvariousheattransfersections.Knowingthewaythesemechanismscontributetoerosionwillhelpto
preventlossofavailabilityofboiler.
CausesofHighTemperatureCorrosioninBoilersHightemperaturecorrosionoccurinboilersoccursmainlyintwo
areaswaterwallsandsuperheaters.Theinorganicimpuritiesinfuellikevanadium,sodium,sulphur,etc.,are
responsible.Readontolearnmoreabouthowthishappens.
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