This book presents failure mechanisms of different boiler components and preventive measures. It illustrates the basic steam flow and circuit design of steam boiler, boiler design parameters, boiler components materials and their behavior at different temperatures. The book aims to identify the cause(s) of in-service failure of secondary superheater tube, platen superheater tube and furnace water wall tube and also presents the solutions to avoid the future failures. This volume will be of interest to researchers and professionals working in the areas of energy, power generation, electric power plants, thermodynamics, industrial chemistry, etc.
Author(s): Atanu Saha
Series: Springer Tracts in Mechanical Engineering
Publisher: Springer
Year: 2023
Language: English
Pages: 135
City: Singapore
Preface
Acknowledgements
Contents
About the Author
Part I Overview of Failure Mechanisms
1 Introduction
1.1 Material for Steam Boilers
1.2 Design Life of Components
1.3 Conclusion
References
2 Failure/Damage Mechanism of Boiler Tube
2.1 Short-Term Overheating
2.2 High Temperature Creep
2.2.1 Temperature Measurement Based on Steam Side Oxide Scale Thickness Measurement
2.3 Hydrogen Damage
2.4 Caustic Corrosion/Gouging
References
Part II Case Studies
3 Case 1A: Short-Term Overheating
3.1 Scope of Work
3.2 Examination Details
3.2.1 Visual Inspection
3.2.2 Dimensional Measurement
3.2.3 Chemical Analysis
3.2.4 Mechanical Properties (Tensile Test)
3.2.5 Metallographic Examination
3.2.6 Estimation of Peak Temperature
3.2.7 Discussion
3.2.8 Conclusion for Case Study 1A
References
4 Case IB: Short-Term Overheating
4.1 Scope of Work
4.2 Examination Details
4.2.1 Visual Inspection
4.2.2 Dimensional Measurement
4.2.3 Chemical Analysis
4.2.4 Metallographic Examination
4.2.5 Discussion
4.2.6 Conclusion for Case Study IB
5 Case IIA: High-Temperature Creep
5.1 Scope of Work
5.2 Examination Details
5.2.1 Visual Inspection
5.2.2 Dimensional Measurement
5.2.3 Chemical Analysis
5.2.4 Metallographic Examination and Hardness Measurement
5.2.5 Scale Thickness Measurement and Estimation of Tube Metal Temperature
5.2.6 Discussion
5.2.7 Conclusion for Case Study IIA
6 Case Study IIB: High-Temperature Creep
6.1 Scope of Work
6.2 Examination Details
6.2.1 Visual Inspection
6.2.2 Dimensional Measurement
6.2.3 Chemical Analysis
6.2.4 Metallographic Examination
6.2.5 Discussion
6.2.6 Conclusion for Case Study IIB
7 Case Study III: High-Temperature Failure
7.1 Scope of Work
7.2 Examination Details
7.2.1 Visual Inspection
7.2.2 Dimensional Measurement
7.2.3 Chemical Analysis
7.2.4 Metallographic Examination
7.2.5 Discussion
7.2.6 Conclusion for Case Study III
8 Case Study IV: Erosion Failure
8.1 Scope of Work
8.2 Examination Details
8.2.1 Visual Inspection
8.2.2 Dimensional Measurement
8.2.3 Chemical Analysis
8.2.4 Metallographic Examination
8.2.5 Discussion
8.2.6 Conclusion for Case Study IV
9 Case Study VA: Dissimilar Metal Weld
9.1 Scope of Work
9.2 Examination Details
9.2.1 Visual Inspection
9.2.2 Dimensional Measurement
9.2.3 Chemical Analysis
9.2.4 Metallographic Examination
9.2.5 Discussion
9.2.6 Conclusion for Case Study VA
9.2.7 Suggestion
10 Case Study VB: Dissimilar Metal Weld
10.1 Scope of Work
10.2 Examination Details
10.3 Discussion
10.4 Conclusion for Case Study VB
References
11 Case Study VIA: Hydrogen Damage
11.1 Scope of Work
11.2 Examination Details
11.2.1 Visual Inspection
11.2.2 Dimensional Measurement
11.2.3 Chemical Analysis
11.2.4 Metallographic Examination and Hardness Measurement
11.2.5 Discussion
11.2.6 Conclusion for Case Study VIA
12 Case Study VIB: Hydrogen Damage
12.1 Scope of Work
12.2 Examination Details
12.2.1 Visual Inspection
12.2.2 Dimensional Measurement
12.2.3 Chemical Analysis
12.2.4 Metallographic Examination
12.2.5 Discussion
12.2.6 Conclusion for Case Study VIB
13 Case Study VIIA: Fireside Corrosion
13.1 Scope of Work
13.2 Examination Details
13.2.1 Visual Inspection
13.2.2 Dimensional Measurement
13.2.3 Chemical Analysis
13.2.4 Metallographic Examination
13.2.5 Discussion
13.2.6 Conclusion for Case Study VIB
14 Case Study VIIB: Fireside Corrosion
14.1 Scope of Work
14.2 Examination Details
14.2.1 Visual Inspection
14.2.2 Dimensional Measurement
14.2.3 Chemical Analysis
14.2.4 Metallographic Examination
14.2.5 Discussion
14.2.6 Conclusion for Case Study VIIB
15 Case Study VIII: Failure Due to Manufacturing Defect
15.1 Scope of Work
15.2 Examination Details
15.2.1 Visual Inspection
15.2.2 Dimensional Measurement
15.2.3 Chemical Analysis
15.2.4 Metallographic Examination
15.2.5 Discussion
15.2.6 Conclusion for Case Study VIII
16 Case Study IX: Corrosion Fatigue
16.1 Scope of Work
16.2 Examination Details
16.2.1 Visual Inspection
16.2.2 Dimensional Measurement
16.2.3 Chemical Analysis
16.2.4 Metallographic Examination
16.2.5 SEM/EDX Analysis
16.2.6 Discussion
16.2.7 Conclusion for Case Study IX
16.3 Conclusion
