Boiler maintenance And inspection

Pre-Boiler water treatment

The quality of the water used within
the boiler cycle is very important . Higher pressure boilers require higher quality water . Maintaining the recommended feed water and boiler water quality limits will insure more reliable and increase unit availability.

Typical arrangement of the pre-boiler water treatment equipment:

1.pre-boiler water treatment:-used to

remove the contaminates in the raw feed water. 2.clarification:-the addition of chemicals to assist in the setting out of suspended solids. 3.filtration:-used to kill the organics in the water and to remove the finer suspended material. 4.demineralization:-used to remove the dissolved solids (various cations and anions) in the feed water.

 5.dearation:-to remove the bulk of free

oxygen in the feed water. 6.addition of hydrazine:-an oxygen scavenger used for additional free oxygen removal. 7.addition of ammonia:-to increase the PH of the feed water between 8.5 and 9.5. 8.condensate treatment:-to purify the condensate returns for boiler feed water usage. 9.condensate polishing:-to remove the bulk of the contaminates such as metal oxides which have been entrained in the condensate.

Chemical cleaning: The purpose of chemical cleaning is

to remove any internal deposits within the boiler and therefore reduce the possibility of down time due to tube failures. Periodic chemical cleaning should become a part of a preventive maintenance program.

Methods of determining when chemical cleaning is necessary:-

1.Tube failure:-an analysis of the cause for

the tube failure could indicate the need for chemical cleaning. This is a highly undesirable method of determination. 2.Periodic tube sample analysis:-the analysis could indicate the need for chemical cleaning prior to tube failures. 3.Chordal thermocouples:- the increase in external surface metal temperature during operation could be used to gauge the build-up of internal deposition.

Energy loss:-

Loss in external deposits.

Loss in internal deposits.

1.Remove external deposits by sootblowing.

2.avoid internal deposits by chemical cleaning (by acid cleaning)

Corrosion due to combustion product: 1- High temperature corrosion in superheaters

and Reheaters: promoted by sodium and vanadium compounds. sensitive if metal temp. above 600C. 2- Medium temp. Corrosion in evaporators fixed through combustion system adjustment. 3- Low temp. Corrosion in cold areas promoted by sulfur, which turns into sulfuric acid. below dew point : keep temperature above 150C.

Basic principles for design material:

1-Carbon steel. 2-Low alloy steel (Cr<2.5%). 3-Medium alloy steel (Cr>2.5%). 4-High alloy steel (Cr>9%). 5-Stainless steel (Cr>11%). Note:- increase Ni % improve low temperature resistance. Increase Cr % improve high temperature resistance.

Metals of steam boilers: The main materials for boilers are carbon steels

and alloy steels. 1-carbon steel:-steels are used for making steam boiler elements which operate under no-creep conditions. at temperatures not higher than 450 C . 2-alloy steel:- used for making boiler elements for operation under creep condition like superheater elements. Note:-the principle alloying elements in steels are Mo , Cr, Si and Al . Molybdenum increase the long term strength and creep strength .Chromium , Silicon and Aluminum increase scale resistance.

An application for boiler material and design temperature:Material (ASTM)

A 209 GR P1 A 335 GR P11 A 335 GR P12 A 335 GR p22

Design temperature
16 to 412 C 496 to 538 C 496 to 538 C 539 to 593 C

Tube failure mechanisms: 1-Short term over heating failure: The cause of short term over heat is a rapid

elevation of temperature of the tube metal caused by restriction of the water / steam mixture to the tube and resulting in a wide mouth rupture . The edges of the rupture are thin and sharp in the super heater . A short term over heat could result from a blockage of steam flow.

Short time overheating failure

Failures due to scale and long term creep failure: The cause of this type of failure is build-up of

internal scale that leads to gradual increase in temperature of the tube metal . The tube may appear swollen with blisters or bulges . The out side surface may have an elephant hide appearance . Rupture are a thin opening a long the longitudinal axis of the tube . The edges of the failure do not generally experience thinning .

Long time overheating failure

Ash corrosion : Ash corrosion result in a thinning of super

heater and reheater tubing . External wastage of the metal occurs where ash deposits accumulate . When ash deposits on the tube and experiences high temperatures . It becomes semi-molten and corrodes most alloy steels that might be used in super heater construction.

Corrosion by molten ash

Oxygen pitting (Economizer): In-service oxygen pitting appears as random .

Round bottomed pits on the water side of tubes in the economizer . If there is no economizer similar pitting may be present at or above normal water level in the steam drum . Proper mechanical deaeration of feed water is absolutely essential for protection of the pre-boiler equipment ( feed water heater, piping) and the economizer . The addition of an oxygen scavenger such as hydrazine to the deaerator storage tank will permit removal of minute quantities of dissolved oxygen.

Oxygen pitting (superheater): Out-of-service oxygen pitting is

usually found in the bottom loops of the superheater and is result of the exposure of water or condensate that forms in the bends after shutdown in contact with air . The distress is seen as pitting and corrosion of the wetted internal surfaces.

Carry over: The cause for carry over is an incomplete

separation of the steam from the steam/water mixture in the boiler . Possible causes of carry over are high water level , high total dissolved solids concentration in the boiler water , excessive alkalinity , and the presence of oil and/or organics . The result of carry over is a build up of contaminates on the inner surface of the super heater tubes.

Steam blanketing: The cause for steam blanketing is an

improper mass flow in the boiler tube in relation to the heat input and pressure . Causing localized thinning in the tube . This type of attack is sometimes accompanied by a gross accumulation of corrosive product . Steam blanketing is also referred to as DNB (departure from nucleate boiling).

Thinning of tube due to steam blanketing:-

Hydrogen attack or damage: This type of failure is found in high pressure units.
A situation occurs when excessive deposits are present on the tube water side surface that permit boiler chemicals to concentrate under the deposit and corrode the metal . Hydrogen is formed which permeates the metal structure and reacts with the carbon of the metal to form methane . The methane molecule which is much larger than the carbon atom . Exerts pressure and causes the metal to rupture along the grain boundaries . Ruptures are violent , sudden , and can be disastrous.

4H+C=CH4

The effect of hydrogen attack in tubes:-

Cold end corrosion:-

Cold-end corrosion will occur

wherever the temperature of metal drops below the sulfuric acid dew point of the flue gas. It occurs in economizer , air preheater , induced draft fan and stack.

Soot blowers erosion: A misdirected blower allows a high

velocity jet of steam or air carrying condensed water droplets to impinge directed upon tube surfaces rather than to be directed between tubes. Physical abrasion and acceleration oxidation cause metal loss . Erosive thinning often leads to tube rupture.

Foaming: It is a condition in which concentration of

soluble salts create frothy bubbles in the steam space of the boiler . Foaming can form slugs of water that can carried over into the steam system.

How to remove a tube sample for inspection?

When removing a tube sample: 1-the tube section should be dry saw cut

to prevent any slag and/or cutting oil from contaminating the internal deposit. 2-the sample should be cut approximately 8-10 inches above and below the affected area. 3-the exact location should be documented as follows:-

 A-tubes should be numbered and counted

from east to west and north to south. B-the wall (front , rear , right hand side , left hand side) and elevation should be noted and marked on the tube. C-an arrow should be marked to indicate which end of sample is up. D-on a universal pressure unit the sample should be identified as removed from the first , second , or third pass.

Troubles associated to drums:-

Loss of level gauges. water level controllers out of service. corrosion. moisture carry-over in the steam safety valves leaking. leaks of roll-expanded evaporator Tubes. plugging of evaporator tubes.

Trouble associated to air heaters:-

Leakages due to damaged axial or circumferential seals.

Cold end baskets damaged by acid corrosion. Poor sootblowing.

Standby pneumatic or DC motor not working or absent.

New application in air heater:-

The modification: We used to manufacture the air

heater basket material from carbon steel or Corten steel , now they add a new material called enamel to improve quality , reduce cost and extend service life for air and gas heater which increase the existing of element.

The material composition of enamel:-

The enamel layer is basically

composed by a borosilicate glass plus cobalt , fluorine , sodium , potassium , quartz , titanium , borax ..

The benefits of enamel coating include:-

1-greater resistance to the attack of acids. 2-abrasive and wear resistance. 3-high mechanical and thermal shock
resistance. 4-high resistance to erosion by fly ash. 5-smooth and vitreous surface reduces adhesion of solids.

The End

Good luck