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Several waterwall tubes in a power station boiler failed after ten years of service. The boiler is a suspension type equipped with 30 IK boxes where retractable soot blowers are inserted to clean the inside of the boiler using high-pressure steam. The tubes, which operate at 693 deg F (367 deg C) and 2935 psi (20.5 MPa), failed near the IK boxes as a result of thermal fatigue. Thermal fatigue damage was accelerated by repetitive exposure to water droplets from the soot blower and the associated rapid cooling.

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A. El-Batahgy, W. Metwally, Failure Analysis of Boiler Water Wall-Tubes at a Power Generation Plant, ASM Failure Analysis Case Histories: Power Generating Equipment, ASM International, 2019,

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