Failure Investigation Of Boiler Tubes A Comprehensive Approach

Failures or forced shutdowns in power plants are often due to boilers, and particularly failure of boiler tubes. This comprehensive resource deals with the subject of failure investigation of boiler tubes from basic fundamentals to practical applications. Coverage includes properties and selection of materials for boiler tubes from a metallurgical view point, damage mechanisms responsible for failure of boiler tubes, and characterization techniques employed for investigating failures of boiler tubes in thermal power plants and utility boilers of industrial/commercial/institutional (ICI) boilers. A large number of case studies based on the actual failures from the field are described, along with photographs and microstructures to allow for easy comprehension of the theory behind the failures. This book is geared to practicing engineers and for studies in the major area of power plant engineering. For non-metallurgists, a chapter has been devoted to the basics of material science, metallurgy of steels, heat treatment, and structure-property correlation. A chapter on materials for boiler tubes covers composition and application of different grades of steels and high temperature alloys currently in use as boiler tubes and future materials to be used in supercritical, ultra-supercritical and advanced ultra-supercritical thermal power plants. A comprehensive discussion on different mechanisms of boiler tube failure is the heart of the book. Additional chapters detailing the role of advanced material characterization techniques in failure investigation and the role of water chemistry in tube failures are key contributions to the book. The authors have long-standing experience in the field of metallurgy and materials technology, failure investigation, remaining life assessment (RLA) and fitness for service (FFS) for industrial plant and equipment, including power plants. They have conducted a large number of failure investigations of boiler tubes and have recommended effective remedial measures in problem solving for power and utility boilers.

Covers how boiler tubes fail in use, and more importantly, why they fail under seemingly normal operating conditions. Suggests ways to prevent future failures by analyzing failures and shows many ways to trace the reason for failure. Contains over two-hundred photographs of metallurgical faults and tube failures. Offers ways to prevent tube failure and avoid boiler shutdowns. Applicable to all industries utilizing boilers. Provides the basic engineering theories on metal failure for background.

Corrosion Atlas Case Studies: 2023 Edition gives engineers expedient daily corrosion solutions for common industrial equipment no matter the industry. Providing a purely operational level view, this reference is designed as concise case studies categorized by material and includes content surrounding the phenomenon, equipment appearance supported by a color image, time of service, conditions, cause and suggested remedies. Additional reference listings for deeper understanding beyond the practical elements are also included. Rounding out with an introductory foundational layer of corrosion principles critical to all engineers, this book delivers the daily tool required for engineers today to solve their equipment’s corrosion problems. Corrosion engineers today spend enormous amounts of time and money searching multiple detailed sources and variable industry-specific standards to locate known remedies to corrosion equipment problems. Corrosion Atlas Series is the first centralized collection of case studies containing challenges paired directly with solutions together in one location. The third release of content in the series, Solves equipment failure with easy-to-find remedies organized by essential elements such as materials, system, part, cause, environmental, and phenomenon Grasps fundamental corrosion elements on all major industrial pieces of equipment Identifies failures by appearance with color figures within each case study Provides correlation between avoiding corrosion and net zero

This book illustrates and explains virtually all common failure modes which adversely affect boiler reliability. Each failure mode is well illustrated with case histories. The corrective steps necessary to reduce or eliminate each failure type, as well as precautionary notes, are provided. The book is a comprehensive, authoritative field guide for the identification and elimination of boilure failures. Boilers of virtually all pressures and many construction designs are presented.

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.

Practical, up-to-date techniques for identifying and eliminating common causes of boiler failure Filled with more than 200 color images, The Nalco Guide to Boiler Failure Analysis, Second Edition categorizes distinct failure modes that typify nearly all boiler problems and walks you, step by step, through their solutions. Each type of failure is classified according to its location, general description, critical factors, identification, elimination, cautions, and related problems. Real-world case histories are included throughout. This authoritative resource contains new chapters on: Phosphate corrosion Stress-assisted corrosion Steam and condensate damage Flow-accelerated corrosion Comprehensive coverage includes: Water- and steam-formed deposits * Short- and long-term overheating * Caustic corrosion * Low-pH corrosion * Hydrogen damage * Chelant complexing * Oxygen corrosion * Corrosion during cleaning * Corrosion fatigue cracking * Stress corrosion cracking * Graphitic corrosion * Dealloying * Cavitation * Erosion * Waterwall fireside corrosion * High-temperature furnace corrosion * Cold-end corrosion * Dew point corrosion * Fireside corrosion * Welding defects

Aluminium is an important metal in manufacturing, due to its versatile properties and the many applications of both the processed metal and its alloys in different industries. Fundamentals of aluminium metallurgy provides a comprehensive overview of the production, properties and processing of aluminium, and its applications in manufacturing industries. Part one discusses different methods of producing and casting aluminium, covering areas such as casting of alloys, quality issues and specific production methods such as high-pressure diecasting. The metallurgical properties of aluminium and its alloys are reviewed in Part two, with chapters on such topics as hardening, precipitation processes and solute partitioning and clustering, as well as properties such as fracture resistance. Finally, Part three includes chapters on joining, laser sintering and other methods of processing aluminium, and its applications in particular areas of industry such as aerospace. With its distinguished editor and team of expert contributors, Fundamentals of aluminium metallurgy is a standard reference for researchers in metallurgy, as well as all those involved in the manufacture and use of aluminium products. Provides a comprehensive overview of the production, properties and processing of aluminium, and its applications in manufacturing industries Considers many issues of central importance in aluminium production and utilization considering quality issues and design for fatigue growth resistance Metallurgical properties of aluminium and its alloys are further explored with particular reference to work hardening and applications of industrial alloys

Practical, up-to-date techniques for identifying and eliminating common causes of boiler failure Filled with more than 200 color images, The Nalco Guide to Boiler Failure Analysis, Second Edition categorizes distinct failure modes that typify nearly all boiler problems and walks you, step by step, through their solutions. Each type of failure is classified according to its location, general description, critical factors, identification, elimination, cautions, and related problems. Real-world case histories are included throughout. This authoritative resource contains new chapters on: Phosphate corrosion Stress-assisted corrosion Steam and condensate damage Flow-accelerated corrosion Comprehensive coverage includes: Water- and steam-formed deposits * Short- and long-term overheating * Caustic corrosion * Low-pH corrosion * Hydrogen damage * Chelant complexing * Oxygen corrosion * Corrosion during cleaning * Corrosion fatigue cracking * Stress corrosion cracking * Graphitic corrosion * Dealloying * Cavitation * Erosion * Waterwall fireside corrosion * High-temperature furnace corrosion * Cold-end corrosion * Dew point corrosion * Fireside corrosion * Welding defects