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Book Chapter
Life Prediction for Boiler Components
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 1989
DOI: 10.31399/asm.tb.dmlahtc.t60490183
EISBN: 978-1-62708-340-9
... Abstract This chapter covers the failure modes and mechanisms associated with boiler components and the tools and techniques used to assess damages and predict remaining component life. It begins with a review of the design and operation of a utility boiler and the materials used...
Abstract
This chapter covers the failure modes and mechanisms associated with boiler components and the tools and techniques used to assess damages and predict remaining component life. It begins with a review of the design and operation of a utility boiler and the materials used in construction. It then describes the various causes of failure in boiler tubes, headers, and steam pipes, explaining how and why they occur, how they are diagnosed, and how to mitigate their effects. The final and by far largest section in the chapter is a tutorial on damage and life assessment techniques for boiler components and assemblies. It demonstrates the use of various methods, including analytical techniques that estimate life expenditure based on operating history, component geometry, and material properties; predictive methods based on the extrapolation of failure statistics; methods that predict life based on dimensional measurements; methods based on metallographic studies; methods based on temperature estimates; and a method for estimating remaining life under creep conditions based on stress-rupture testing of service-exposed material samples. The chapter also discusses the use of fracture mechanics and presents a number of cases in which life assessments are made based on the integration of several methods.
Book Chapter
Introduction to Boiler Technology
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.fibtca.t52430001
EISBN: 978-1-62708-253-2
... Abstract Boilers are engineered systems designed to convert the chemical energy in fuel into heat to generate hot water or steam. This chapter describes boiler applications and types, including firetube boilers, watertube boilers, electric boilers, packaged boilers, fluidized bed combustion...
Abstract
Boilers are engineered systems designed to convert the chemical energy in fuel into heat to generate hot water or steam. This chapter describes boiler applications and types, including firetube boilers, watertube boilers, electric boilers, packaged boilers, fluidized bed combustion boilers, oil- and gas-fired boilers, waste heat boilers, and black liquor recovery boilers. It also describes the operation and working principle of utility or power plant boilers, covering conventional subcritical and advanced supercritical types.
Book Chapter
Metallurgy of Steels and Related Boiler Tube Materials
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.fibtca.t52430027
EISBN: 978-1-62708-253-2
... of diffusion, nucleation, and growth. It also discusses alloying, heat treating, and defect formation and briefly covers condenser tube materials. alloying elements austenitic stainless steels boiler tubes condenser tubes continuous cooling transformation diagram creep-resistant steels ferritic...
Abstract
This chapter describes the metallurgy, composition, and properties of steels and other alloys. It provides information on the atomic structure of metals, the nature of alloy phases, and the mechanisms involved in phase transformations, including time-temperature effects and the role of diffusion, nucleation, and growth. It also discusses alloying, heat treating, and defect formation and briefly covers condenser tube materials.
Book Chapter
Materials for Boiler Tubes
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.fibtca.t52430087
EISBN: 978-1-62708-253-2
... Abstract Boilers are often classified based on the maximum operating temperature and pressure for which they are designed. Classifications, in ascending order, are subcritical, supercritical, ultra-supercritical, and to advanced ultra-supercritical. At each higher operating point comes greater...
Abstract
Boilers are often classified based on the maximum operating temperature and pressure for which they are designed. Classifications, in ascending order, are subcritical, supercritical, ultra-supercritical, and to advanced ultra-supercritical. At each higher operating point comes greater efficiency, as well as greater demand on construction materials. This chapter discusses the primary requirements for boiler tube materials, including oxidation and corrosion resistance, fatigue strength, thermal conductivity, and the ability to resist creep and rupture. It also provides information on various steels and alloys, covering cost, engineering specifications, and ease of use.
Book Chapter
Tools and Techniques for Material Characterization of Boiler Tubes
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.fibtca.t52430107
EISBN: 978-1-62708-253-2
... Abstract This chapter describes some of the most effective tools for investigating boiler tube failures, including scanning electron microscopy, optical emission spectroscopy, atomic absorption spectroscopy, x-ray fluorescence spectroscopy, x-ray diffraction, and x-ray photoelectron...
Abstract
This chapter describes some of the most effective tools for investigating boiler tube failures, including scanning electron microscopy, optical emission spectroscopy, atomic absorption spectroscopy, x-ray fluorescence spectroscopy, x-ray diffraction, and x-ray photoelectron spectroscopy. It explains how the tools work and what they reveal. It also covers the topic of image analysis and its application in the measurement of grain size, phase/volume fraction, delta ferrite and retained austenite, inclusion rating, depth of carburization/decarburization, scale thickness, pearlite banding, microhardness, and hardness profiles. The chapter concludes with a brief discussion on the effect of scaling and deposition and how to measure it.
Book Chapter
Role of Water Chemistry in Boiler Tube Failure
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.fibtca.t52430379
EISBN: 978-1-62708-253-2
... Abstract Water chemistry is a factor in nearly all boiler tube failures. It contributes to the formation of scale, biofilms, and sludge, determines deposition rates, and drives the corrosion process. This chapter explains how water chemistry is managed in boilers and describes the effect...
Abstract
Water chemistry is a factor in nearly all boiler tube failures. It contributes to the formation of scale, biofilms, and sludge, determines deposition rates, and drives the corrosion process. This chapter explains how water chemistry is managed in boilers and describes the effect of impurities and feedwater parameters on high-pressure boiler components. It discusses deposition and scaling, types of corrosion, and carryover, a condition that occurs when steam becomes contaminated with droplets of boiler water. The chapter also covers water treatment procedures, including filtration, chlorination, ion exchange, demineralization, reverse osmosis, caustic and chelant treatment, oxygen scavenging, and colloidal, carbonate, phosphate, and sodium aluminate conditioning.
Book Chapter
Remaining Life Assessment of Boiler Tubes
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.fibtca.t52430409
EISBN: 978-1-62708-253-2
... Abstract The power generating industry has become proficient at predicting how long a component will last under a given set of operating conditions. This chapter explains how such predictions are made in the case of boiler tubes. It identifies critical damage mechanisms, progressive failure...
Abstract
The power generating industry has become proficient at predicting how long a component will last under a given set of operating conditions. This chapter explains how such predictions are made in the case of boiler tubes. It identifies critical damage mechanisms, progressive failure pathways, and relevant test and measurement procedures. It describes life assessment methods based on hardness, wall thickness, scale formation, microstructure, and creep. It also includes a case study on the determination of the residual life of a secondary superheater tube.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2018
DOI: 10.31399/asm.tb.fibtca.9781627082532
EISBN: 978-1-62708-253-2
Image
Thin-lip rupture in a boiler tube caused by rapid overheating. This rupture...
Available to PurchasePublished: 30 November 2013
Fig. 7 Thin-lip rupture in a boiler tube caused by rapid overheating. This rupture exhibits a “cobra” appearance as a result of lateral bending under the reaction force imposed by escaping steam. The tube was a 2-½ in. outside diameter, 0.250 in. wall boiler tube made of 1.25Cr-0.5Mo steel
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Image
Results of corrosion probe tests for various alloys in a boiler at Charlest...
Available to Purchase
in Waste-to-Energy Boilers and Waste Incinerators
> High-Temperature Corrosion and Materials Applications
Published: 01 November 2007
Fig. 12.25 Results of corrosion probe tests for various alloys in a boiler at Charleston Resource Recovery. The corrosion probes were installed in the convection path with the exposure time of 4492 h. Ferritic steels included carbon steel, T-22, and T-91. Austenitic steels included Type 304
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Image
in Black Liquor Recovery Boilers in the Pulp and Paper Industry
> High-Temperature Corrosion and Materials Applications
Published: 01 November 2007
Fig. 13.1 Recovery boiler. Source: Ref 6
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Image
Recovery boiler illustrating three zones of reactions in the furnace. Sourc...
Available to Purchase
in Black Liquor Recovery Boilers in the Pulp and Paper Industry
> High-Temperature Corrosion and Materials Applications
Published: 01 November 2007
Fig. 13.2 Recovery boiler illustrating three zones of reactions in the furnace. Source: Ref 8
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Image
in Black Liquor Recovery Boilers in the Pulp and Paper Industry
> High-Temperature Corrosion and Materials Applications
Published: 01 November 2007
Fig. 13.3 Char beds formed in the sloped floor boiler. Source: Ref 9
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Image
in Black Liquor Recovery Boilers in the Pulp and Paper Industry
> High-Temperature Corrosion and Materials Applications
Published: 01 November 2007
Fig. 13.4 Char beds formed in the decanting hearth boiler. Source: Ref 9
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Image
General view of the alloy 625 overlay smelt run floor tubes in the boiler. ...
Available to Purchase
in Black Liquor Recovery Boilers in the Pulp and Paper Industry
> High-Temperature Corrosion and Materials Applications
Published: 01 November 2007
Fig. 13.7 General view of the alloy 625 overlay smelt run floor tubes in the boiler. Source: Ref 31
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Image
Locations, marked as 1, in the boiler that are susceptible to hydrogen atta...
Available to PurchasePublished: 01 November 2007
Fig. 17.6 Locations, marked as 1, in the boiler that are susceptible to hydrogen attack. The area marked as 2 shows other modes of waterside corrosion that are outside of the current discussion topic. Source: Stultz and Kitto ( Ref 4 ) Courtesy of Babcock and Wilcox
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Image
Published: 01 November 2007
Fig. 10.3 Bubbling fluidized-bed boiler. Source: Ref 1 . Courtesy of Babcock & Wilcox
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Image
Coal-fired boiler, showing two main areas for discussion of materials probl...
Available to PurchasePublished: 01 November 2007
Fig. 10.4 Coal-fired boiler, showing two main areas for discussion of materials problems in a boiler: the furnace combustion area (i.e., furnace walls) and the heat-absorbing surfaces in the convection path, such as superheaters and reheaters. Source: Ref 5
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Image
A corroded carbon steel tube sample from the waterwall of a boiler (subcrit...
Available to PurchasePublished: 01 November 2007
Fig. 10.19 A corroded carbon steel tube sample from the waterwall of a boiler (subcritical unit) retrofitted with a low NO x burner system with overfire air ports. The waterwall tube suffered accelerated wastage after the furnace was retrofitted with NO x burner system. Courtesy of Welding
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Image
Melting temperatures of various salts that are likely to form in WTE boiler...
Available to Purchase
in Waste-to-Energy Boilers and Waste Incinerators
> High-Temperature Corrosion and Materials Applications
Published: 01 November 2007
Fig. 12.10 Melting temperatures of various salts that are likely to form in WTE boilers. The temperatures of waterwall saturated fluid and superheater steam are also indicated for comparison. Source: Ref 30
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