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Boiler Mountings, Accessories and Auxiliaries Part III

6.0 Boiler Accessories and Auxiliaries:

6.1. Superheater and Reheater:
6.1.1 Superheater:
We have seen that in thermal power generation using steam, the cycle efficiency
improves when steam is superheated. Mixture of water and water vapour enters drum
through water separators, where the dry steam is separated and comes out through steam
raiser pipes. The steam coming out from drum through saturated steam pipes is dry and
saturated. The saturated steam flow takes its passage through set of coils, called
Superheater, where further heat is added to increase steam temperature at constant
pressure. Superheater is generally located above furnace, at high radiant and convection
heat zone. Superheating is also done in stages through a set of Superheaters e.g., Primary
Superheater and Secondary Superheater.
6.1.2 Reheater:
Superheated steam at specified pressure and temperature from boiler is supplied to steam
engines/steam turbines. While expanding and doing work over several stages of turbine
wheels, the pressure and temperature drops at every stage and finally reaches a bare
minimum pressure. The final pressure depends on whether it is to be released for process
utilization or the exhaust steam can be condensed in condenser and the condensate is
recycled. In some of the large steam turbines, steam after doing work through a few
stages, substantially looses its pressure and temperature and the enthalpy thus gets
reduced. Cycle efficiency can be improved, if the steam is extracted out from the high-
pressure cylinder and again taken to boiler, where by addition of heat, the steam
temperature is increased. The apparatus where such heat addition is accomplished is
called Reheater and comprises a set of coils of tubes, located in boiler furnace where the
steam is reheated. Reheaters are located ahead of final Superheater in the direction of flue
gases and in the convection zone.
6.1.3 Classification of Superheater and Reheater:
Superheater is classified according to mode of heat transfer process it receives through its
wall, the heating surface, from the furnace or the passing through flue gas, whether it is
radiant or Convective.
6.1.3.1 Radiant Superheater:
Even though the heat transfer takes place by both ways of radiation and convection, the
ratio between them varies according to the location, temperature and velocity of flue
gases at that location. The Superheater, which is located virtually above of the furnace, is
designated as Radiant type. It is so called because mainly the heating surface of this type
of Superheater receives heat by radiation process from the hot combustion zone.
As the heat absorption is by Radiation this is located in high temperature region and its
vertically hanging panels are widely pitched from one another to reduce the velocity of
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gas and increase the exposed area for absorption of heat by radiation. Also they are
arranged in-line with least transverse pitch. Hence this type of Superheater is also termed
as platen Superheater. They are also termed as pendent platen since they are hanging from
roof.
6.1.3.2 Convection Superheater:
The convection Superheater receives heat mainly by transfer through convection process.
The exposed heating surface of the Superheater is in continuous contact with flue gas
passing through. The gas mass coming in contact with metal surface gives up heat to the
steam from across the tube wall.
The Superheater is placed in the flue gas path to transfer heat by radiation and convection
in some proportion such that the outlet steam temperature can be maintained fairly
constant at all loads. But due to practical limitation such as variation in fuel, operating
conditions etc. forces the need for temperature control method such as desuperheater.
6.1.3.3 Horizontal or vertical Superheater:
The Superheater and Reheater can be arranged either horizontally or allowed to be hung
vertically. The vertical arrangement is simpler in supporting and allowing for expansion
and this arrangement is called pendant type. Horizontal superheater needs supporting of
the tubes at multiple points to avoid sagging and expansion movement should also be
permitted. However the horizontal construction provides the advantage of draining. A
superheater which is placed at lower flue gas temperature region is called Low
Temperature Superheater (LTSH). The superheater/reheater can also be arranged as
ceiling or wall and they are termed as ceiling superheater, wall superheater etc.
accordingly.
6.1.3.4 Construction arrangement:
In-line or Staggered Superheater:
Generally the heating surfaces can be arranged either in-line or staggered. Staggered
arrangement requires lesser surface for the same duty but draft losses are higher and on-
load cleaning of surfaces is not as effective as for the superheater with in-line
arrangement. And hence the in-line or staggered arrangement is selected based on fuel
fouling characteristic, operating cost of draft loss, and cost of tube material used at that
location etc.
6.1.3.5 Parallel or Counter Flow Superheater:
The surfaces can be designed or placed in such a way that the flow direction of flue gas
and steam is parallel or opposite. Counter flow arrangement has the advantage of
minimum surface but the metal temperature at the leaving section is high compared to
parallel flow. Hence the counter flow is used in most of the cases except in final section
where the metal temperature limitation calls for parallel flow.
Any number of stages of superheater can be designed but the present trend is to limit to
three stages so that the cost on headers and connecting piping to desuperheater can be
kept minimum. In a typical arrangement the saturated steam from drum enters the low
temperature superheater via ceiling superheater. After LTSH the steam enters platen
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superheater through inter-stage desuperheater and finally through a convection

superheater.
Similarly in reheater also, any number of stages can be designed. Normally most of the
reheater surfaces are placed in hotter zone so that the surface requirement is kept as
minimum to reduce the pressure drop in steam to keep the cycle efficiency maximum.
The connection between the superheater headers are done crosswise so that steam
flowing on the left side in the gas path in one superheater will flow in the right side in
the gas path in the other superheater. This arrangement facilitates equalizing of steam
temperature even with certain amount of non-uniform gas-flow between left and right
side.
The following figures show the arrangement of superheaters and reheaters in different
types of boilers.

Fig. 24
Radiant boiler for pulverized coal

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Fig. 25
A two drum natural circulation steam generator

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1 UPPER DRUM 10 CASTABLE REFRACTORY 19 OBSERVATION PORT

2 LOWER DRUM
3 BOILER TUBES
4 FURNACE SIDE WALL TUBES
5 FURNACE RARE WALL TUBES
6 FURNACE ROOF TUBES
7 BAFFLE WALL TUBES
8 FURNACE FRONT WALL (FIRE BRICK)
9 FURNACE FLOOR (TILE)
11 SUPERHEATER INLET HEADER
12 SUPERHEATER OUTLET HEADER
13 SUPERHEATER ELEMENTS
14 SUPERHEATER HEADER ENCLOSER
15 DRUM ENCLOSER
16 RIBBED OUTER CASING
17 BURNER THROAT
18 BURNER
20 ROTARY SOOT BLOWER
21 DRUM STEAM O/L CONNECTION
22 SUPERHEATER CONNECTING LINK
23 MAIN STEAM LINE
24 SAFETY VALVE NOZZLES
25 START-UP VENT CONNECTION
26 STEAM GAUGE AND DRUM VENT
27 SUPERHEATER HEADER DRAIN

Fig. 26
Cut Away view of a package boiler

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6.1.3.6 Reason for combination of Radiant and Convective Superheater:

Installation of convection Superheater alone is not favored in large steam generation units
with high superheat demands plant. The use of Convective type Superheater alone is
rather impractical because of two fundamental reasons:
a) Convective Superheaters are not considered suitable for high degree of heat
absorption, as are radiant Superheaters. As a result, much of the generated heat in the
boiler furnace is lost to flue gases escaping at higher temperature. This means loss of
overall performance of the steam generation plant.
b) Due to the problem of slagging, the flue gas temperature at the furnace exit is fixed
and furnace parameters should be controlled so as not to allow the flue gas
temperature to exceed this limit. The use of a Convective Superheater alone in a large
steam generation unit will not allow the flue gas exit temperature to be brought down
below the prescribed limit.
6.1.3.7 Factors influence the design of convective superheaters:
a) Flue gas velocity.
b) Steam velocity.
c) Temperature difference between the flue gas and steam.
d) Direction of gas flow-parallel or cross flow.
e) Degree of Cleanliness of the tube surface.
6.1.3.8 Factors primarily influence the design of radiant superheaters:
a) Temperature of the furnace.
b) Temperature of steam.
c) Amount of heat absorbing surface exposed to radiant heat.
d) Degree of cleanliness to the tube surface.
6.1.3.9 Superheater tube burnout:
It will occur under conditions where there is insufficient steam flow to cool the
superheater tubes adequately and such conditions may arise:

a) During start-up:
Until or unless steam generation begins and steam flows in to protect the Superheater
tubes, the heat absorbing surface of the radiant Superheater is cooled by radiation to
the water wall tubes. Now if steam flow fails to be established in the Superheater
tubes or a series of tubes while the furnace attains the operating temperature, there is
a chance of tube burnout in the Superheater.
b) Non-drainable superheater:
If a portion of the superheater is not completely drainable, then it will hold some
quantity of steam condensate when the superheater is under shutdown. Now when the
superheater is taken in line, there will be no flow of steam through the superheater
circuit until this stored condensate evaporates or is blown out. Because of stoppage of
steam flow, the superheater will starve, causing tube burnout.
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c) Improper design:
If the areas adjacent to burner ports are not properly designed, it may give rise to
deflection of the flame which in turn may strike the superheater tubes causing
burnouts.
6.1.3.10 Sequence of flow path in superheaters:
The flow path of steam in Superheaters is starting from Steam Drum steam lows to
Ceiling and primary superheaters and then to radiant. Finally the steam enters Convection
zone superheater and then goes out of boiler through main steam line.
The radiant section of the superheater operates under the most heavily heated conditions.
So it runs the greater risk of the tube surface temperature exceeding the rated value.
Hence it must be adequately cooled to keep tube metal temperature within the upper limit
of the admissible temperature. Hence steam slightly above saturated condition (relatively
much colder than main steam temperature) steam is fed to the radiant superheater straight
from the steam drum rather than the superheated steam from the Convective section of
the superheater. By this method, the reliability of operation of superheater tubes is
enhanced.
6.1.3.11 Reason for locating Reheater in a zone of moderate heating:
It is because if the reheater is placed in a high temperature zone, the intensive heating of
the external surfaces of the reheater tubes can lead to an inadmissible rise to temperature
due to a low value of the coefficient of heat transfer from the inner wall to the steam. This
may turn out to be too high for the pearlite class of steel from which reheater tubes are
made.
6.1.3.12 Methods of Control of Superheater Temperature:
Since the flow path of steam is from low temperature region of primary superheater to
high radiant zone and then to moderate heat zone of convection superheater, the rate of
heat pick is different in different zone and the temperature pick up may not be uniform
and requires be watching and controlling. There are several methods of control of
temperature in superheaters. Such methods of controls are:
(a) Excess air control
(b) Gas recirculation
(c) Gas by-pass control
(d) Adjustable burner or tilting burner control
(e) Control of combined Radiant-Convective superheaters
(f) Control of differently fired twin furnaces
(g) Control of separately fired superheaters.
(h) Control by diverting damper for superheater and reheater.
(i) Control of superheat with soot blowers
6.1.3.13 Excess air control:
We have already seen that Radiant superheater receives heat mainly by radiation from
furnace high heat zone. The transmission of heat by radiation is proportional to 4 th degree
of the temperature, i.e. T4, in the radiation zone. When excess air is increased the mass
flow of the product of combustion is also increasing. But the amount of cold air added to
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combustion air cools down the furnace. Hence considerably the furnace temperature
drops down. Proportionally the heat transmission by radiation reduces.
But the increase in excess air adds to the mass flow. Due to increase in mass flow of
gases the velocity of gasses in the superheater zone increases. Since the convection zone
superheaters receive heat only by convection heat transfer, Convection heat transfer
proportionally increases with the increase velocity of gas mass flow. Hence convection
zone picks up more heat.
So, with increase in excess air up to certain limit, radiant zone tends reduce steam
temperature and the convection zone tends to increase the temperature. Ultimately the
temperature effect gets balanced and the final temperature tries to maintain.
With the increase in excess air further to the above limit will tend to increase the velocity
further and the convection pick up will be more. But the radiant zone will become
constant without much variation in furnace temperature. At this stage the final steam
temperature will go high.
However, increasing the excess air also increases the stack loss, which reduces the boiler
efficiency. Therefore excess air is not used as a principal steam temperature control
system.
6.1.3.15 Gas recirculation method:
Recirculation of a portion of the combustion products to the furnace increases the mass
flow rate of the flue gases through the convective superheater and that increases the
superheated steam temperature at the outlet of the convective superheater. Flue gas
from the furnace takes U turn and passes into the convective pass and gives up heat to
primary SH, Secondary air for combustion and feed water. The temperature of flue gas
becomes very low. This low temperature flue gas before the economiser region is
tapped off and introduced below the hot combustion zone. The combustion zone gets
diluted and the furnace temperature drops down. Further the recirculation of flue gas
adds to the mass flow. Combination of radiant and convective superheating balances the
temperature. With increase in recirculation gases mass flow the final main steam
temperature can be increased. Therefore, by regulating the percentage of re-circulating
combustion gases, the desired superheat steam temperature can be maintained. The
following figure explains the system.

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Fig. 27

6.1.3.16 The advantages of the gas recirculation method of superheat control:

a) The efficiency of the process is relatively high
b) Ensures close regulation over a wide operating range
c) Minimizes slagging that helps to prolong plant operation.
d) Befits well with high-capacity modern units.

6.1.3.17 Disadvantages of gas recirculation method:

a) High initial investment.
b) Relatively higher operation cost.
c) The hot ash-laden flue gas which passes through the flue gas recirculation fan is very
abrasive and represents a difficult fan application, with high maintenance
requirements.

6.1.3.18 Gas-bypass control:

In this case the superheater is designed oversize so that at partial load conditions, say
70-80%, it is capable of producing the required degree of superheat. The boiler tube
banks are disposed in such a manner that a portion of the combustion gas can be by-
passed around the superheater elements with the aid of by-pass dampers. These
dampers can be controlled manually or automatically to ensure the desired superheat
temperature of the steam at the superheater exit. See figure below.

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Fig. 28

Whenever the final steam temperature is to be increased the gas damper is opened more
to superheater and the heat pick increases. When the steam temperature is to be reduced
the damper is closed and gas is partially bypassed.

6.1.3.19 Other suitable methods of final steam temperature control:

a) Blending the superheated steam with the returned steam.
b) Raising the steam velocity through the superheater.
c) Recirculating a portion of the superheated steam back to the steam and water drums.

6.1.3.20 Recirculating part of superheated steam method:

Since steam flow is increased higher than the demand to establish partial recirculation to
drum, the heat pick up is distributed to higher mass flow through superheater coils and
ultimately the final steam temperature is kept under control. By recirculation of a part of
the superheated steam back to boiler drum, the additional heat picked up is transferred
into the system through the drum.

6.1.3.21 Characteristics of radiant and convection superheater with boiler load:

The control characteristics of these Radiant and Convective superheaters are represented
by temperature vs. Gs (the steam load) curves as shown in the figure below.

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Fig. 29

The steam temperature at radiant superheaters falls down with the increase of boiler load.
Whereas it is the reverse, i.e. increase in steam temperature, in convective superheater,
with rise in boiler. The steam temperature in combined superheaters, having properly
selected dimensions of the radiant and convective sections gets balanced effect and tries
to remain constant.
Combustion temperature, flame emissivity and the thermal efficiency of the water walls
are the parameters affecting the heat transfer characteristics of radiant superheater. As the
boiler load is increased, the quantity of fuel burning is increased. However this increased
rate of fuel burning influences very little those parameters that govern the quantity of heat
absorbed by the radiant heating surfaces. The furnace temperature almost becomes steady
after certain load conditions of the boiler. The radiant effect, which is proportional to the
temperature, also becomes steady. But with increase in boiler, load mass flow of steam
increases. Therefore, the heat absorption in a radiant superheater does not increase in the
same scale as the flow rate of steam through it. As a result, the heat absorption per unit
steam flow rate decreases. Heat pick up having become steady, with the additional steam
flow, the temperature tends to fall in radiant zone.
In the case of convection superheaters the reverse effect is taking place. With increase in
demand for more boiler load, rate of fuel burning is increased. With more fuel burning,
products of combustion increases. With increase in mass flow of flue gasses, the velocity
of flue gasses increases, resulting in an increased rate of convective heat transfer in
proportion to the power of 0.6-0.65 of gas velocity.
Thus as a result of increased rate of fuel combustion, the radiant heat absorption in the
furnace decreases bringing about higher exit temperature of flue gases from the furnace.
Therefore, the temperature gradient in the region of the convective superheater becomes
higher.
The increased gas velocity and the higher furnace exit temperature of flue gases with the
increase of boiler load are responsible for the superheated steam-temperature increasing
at a higher rate than does the boiler load.
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6.1.3.22 Operating parameters affecting the superheat temperature;

The temperature of the superheated steam is affected by certain operating conditions such
as:
a) Temperature of the BFW
b) Excess air ratio in the furnace
c) The degree of cleanliness (regarding slagging) of water walls and the superheater
d) Moisture content of the fuel.
Boiler feed water temperature influences the superheated steam temperature very much.
For drum-type boilers, the decrease of feed water temperature results in higher
superheated steam temperature. It is because, for drum type boilers, the heating surface of
the superheater is fixed and as the feed water temperature decreases the steam generation
capacity of the water wall decreases with the effect that for constant fuel consumption the
quantity of heat absorbed by the superheater from the flue gases increases per unit flow
rate of steam.
For once-through boilers lower feed water temperature leads to reduced superheated
steam temperature. It is because, as the feed water temperature decreases, the temperature
of the generated steam decreases and as the rate of heat absorption in the superheater, per
unit flow rate of steam remains constant, this results in a drop in superheated steam
temperature.
6.1.3.23 Reasons for high superheated steam temperature with constant load:
a) Too high excess-air.
b) Too low feed water temperature.
c) Slagging up furnace.
d) Secondary combustion.
e) Malfunctioning of steam temperature indicating and controlling equipment.
6.1.3.24 Reasons for low superheated steam temperature with constant load?
a) Too low excess-air.
b) Too high feed water temperature.
c) Excessive slagging of superheater tubes (external surface).
d) Excessive moisture carryover from the boiler drum.
e) Malfunctioning of steam temperature indicating and controlling equipment.
6.1.3.25 Steam and Gas control:
Measures to allow the superheated steam temperature to vary within the admissible limits
are by Steam control and Gas control. These methods should be effective enough to
maintain the superheated steam temperature within the specified limit in the load range
from 30% to 100% while in the case of reheated steam from 60% to 100% of the rated
value.

Steam control method is based on curtailing the enthalpy of the superheated steam by
transferring a part of its heat to the feed water or by injecting polish water (deeply
deionized water) to the superheating steam. As a result, the temperature of the

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superheated steam decreases. Steam control is accomplished by surface-type

attemperators as well as in spray-type attemperators.
6.1.3.26 Control by attemperation:
The attemperator (desuperheater) is basically a heat exchanger in which the superheated
steam is cooled either by a direct heat exchange with cold condensate sprayed into the
flow of the superheated steam (SPRAY-TYPE) or indirect heat exchange with feed water
in tube-and-shell type heat exchanger (SURFACE-TYPE).

Fig. 30

Normally only feed water is used for attemperation of superheat steam temperature
control. Feed water is tapped of just before the feed control valve and the water injection
is done in two or three stages. The first stage injection is done just after the primary
superheater and second after the radiant superheater.
6.1.3.27 Gas control:
Gas control method is based on the fact that if, by any suitable means, the rate of heat
absorption on the fireside of the heating surfaces can be reduced or regulated then as a
consequence the temperature of the superheated steam can be reduced or regulated.
Means of rate of heat absorption on the fireside of heating surfaces are:
a) Changing the flame position in the furnace.
b) Recirculating the combustion products.
c) Bypassing a portion of combustion products around the superheater.

6.1.3.28 Reheat temperature control:

Reheat temperature control can be accomplished by feed water attemperation, if the
reheat temperature is low.
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6.1.3.29 Live-steam Reheater employed:

It is used to equalize the temperature between the superheated steam (live steam)
produced in the radiant superheater and that (reheated steam) produced in the reheater.
A decrease in boiler load is accompanied by a sharp rise in the temperature of the live
steam in the radiant superheater and a substantial drop in the reheated steam temperature
in the convective Reheater.

Fig. 31
Hence to equalize the temperature in both, it is justifiable to abstract some of the heat
from the live steam (main steam) and transfer the same to the reheated steam. This is
achieved in a heat exchanger that is called live-steam reheater.
6.1.4 Operation and Maintenance of Superheaters and Reheaters:
6.1.4.1 Operation
The following points must be taken care of to ensure longer life and higher availability of
the pressure parts:
a) The metal temperature at all the locations should be kept within permissible value.
This can be accomplished by keeping the steam temperature at the end of each section
within a particular value. Desuperheaters are used to maintain the steam temperature
and this will serve for the metal temperature restriction also except at primary
superheater outlet before which there is no desuperheater. During design stage
sufficient margin is kept between the permissible temperature and predicted
temperature to take care of most of the operating conditions. However, operating the
boiler with low feed water temperature along with high excess air may result in
exceeding the limit. There should be no hesitation to bring down the load on the
boiler if this temperature cannot be brought under control by other means. Tilting the
burners down, operating the lower tier burners, soot blowing the water walls,
reducing excess air, raising the feed water temperature will help reducing the heat
pick-up in superheaters.

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b) The raising and lowering of steam parameters should be restricted to the value given
in the starting diagram. Exceeding these values will result in reduced fatigue life of
pressure parts.
c) The superheaters and reheaters are to be soot blow down to keep them reasonably
clean. Indian coals have high silica content and hence no problem is faced in keeping
the surface clean.
d) In the case of tube failure which can be identified by hearing the noise in the boiler
gallery and cross checked by difference in steam and water flow, gas and steam
temperature, the boiler should be shut down at the earliest by regular procedure for
maintenance work, otherwise large number of tubes may fail due to steam erosion and
impingement.
e) Drum level should be maintained at recommended level both during starting and at all
conditions of operation to avoid carry over and in extreme cases flooding of
superheaters.
f) Entry of wet steam into superheater first rows or after desuperheater will result in
removal of the oxide film due to thermal shock. Boiler salt in the steam will
accelerate the corrosion. Austenitic steel is the worst affected due to stress corrosion
in this case. Hence the temperature after the desuperheater should be maintained well
above the saturation point in the case of direct spray type.
g) Reheater starvation should be prevented at all conditions of operation. During starting
till sufficient flow through the reheater is established, furnace exit gas temperature
should be kept below 540`C. During emergency shut down or turbine trip fire should
be put off automatically by operating master fuel trip if flow through reheater cannot
be established automatically by-pass station (if provided).
h) The reheater temperature can be controlled normally by the method provided for.
However the desuperheater has to be kept as a ready stand-by to meet emergencies,
but passing of regulating valve of water injection should be avoided by keeping the
isolating valve in closed position.
i) The flue gas and steam temperature difference between left and right should be
minimized to the extent possible by adjusting the burner loading, location and loading
of left and right side of draft fans.
6.1.4.2 Maintenance
When the boiler is shut down and is cool enough to enter and make an external inspection
of superheaters and reheaters. Clean the firesides, where necessary, and examine all tubes
for evidence of corrosion, erosion, swelling, warping blistering etc.
Swelling of superheater tubes indicates overheating which may have been caused by
bringing the boiler up to pressure too quickly, failure to vent the superheater sufficiently
during start-up or scale on the internal surface due to carry over. Slight warping is not
serious if steps are taken at once to determine and eliminate the cause.
Check the conditions of setting, manhole doors, and casings for leaks and rectify.
Remove the hand hole caps if provided and inspect the internal tube surfaces.

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If the unit is shut down for considerable time, lay up procedure given in the water
treatment chapter has to be followed.
Washing of heating surfaces of superheaters and reheater are seldom required for boilers
firing Indian coals. But oil firing may require washing. Washing can be effectively done
by using hot water (30 kg/cm2 and 200`C). In severe cases, caustic or soda ash may be
added to water. Care should be taken to arrange draining of the wash water effectively.
The air/gas ducts should be blanked to avoid entry of water into air heater, other gas duct,
air duct etc. The hoppers should be cleaned of ash before starting the wash. Huge amount
of water is needed and complete thorough washing should be attempted to avoid
acceleration of corrosion and plugging due to left out soot. Immediately after washing,
the surfaces should be dried by firing boiler at low rate.
Most of the Indian coals used for high capacity boilers are having high percentage of ash
and the ash is predominantly silica. And hence erosion due to fly ash is inherent and
superheater reheaters, economizers are vulnerable for this. Screen tubes, terminal tubes,
and bends are to be checked for this erosion. Erosion around the soot blower may also
occur due to steam erosion. Boiler design parameters are based on conservative
possibility of erosion. However there is still possibility of localized erosion.
Erosion is indicated by polished surface appearance, gauging, holes in duct expansion
joints, etc. Reduction of tube diameter can be verified by micrometer readings. The effect
of erosion can be controlled by protecting the affected area (Pad welding, installation of
replaceable tube shields, refractory coating etc.) or by dispersing the flue gas stream by
the use of deflector plates or wire mesh baffles. But care should be exercised when
installing deflectors or baffles so that it will not create new areas of erosion or shift
erosion from one area to another.
Fuel oil contains contaminants such as Sulfur, Vanadium, and Sodium etc. Hence mainly
in oil fired boilers gas side corrosion is experienced. The life of the pressure parts can be
increased by providing stainless steel shield in front of first row and by operating at less
excess air.
Remnant Life of pressure parts can be easily assessed by non-destructive testing methods
available. Ultrasonic thickness gauge can be used to measure the tube thickness, which
will reveal external and internal corrosion, erosion and pitting. Radiography can also be
utilized. Special camera and scopes are available to see the internal surfaces of the
headers and pipes. In extreme cases tubes at suspected points may be cut and subjected
for test on Oxide layer thickness measurement and creep strength tested.
Failure of superheaters and reheaters may occur due to various reasons. In a newly
commissioned unit the most likely reason is overheating by blockage of foreign material
which may not be traceable after failure if blown out by the failure. Erosion by ash or
soot blowers may cause failure if not inspected and rectified in time. Due care is taken
during design stage in selecting material and allowance is given for stratification of flue
gas and water/steam. Corrosion and pitting on steam side may result in tube failure if feed
water and boiler water conditioning are not satisfactory. The failure caused by material
defect, material mix-up and welding defect are minimized to a greater extent by tight
inspection and quality control methods used currently.

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 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEERS PROFICIENCY EXAMINATION
DLP/BOE-II/ 2-III - 29112001

The maintenance of high-pressure parts requires storing of correct material, correct size
tube and welding consumables. Highly skilled and qualified welder has to do the hob as
per the approved method of the national code and recommended procedure for the
particular job. Pre and/or post heat treatment and subsequent inspection and testing are
essential to ensure freedom from harmful defects.
Normally spray type desuperheaters are fitted with renewable liners to protect the main
superheater shell from erosion of spray water and thermal shock. See figure Below.
Excessive noise usually indicates the work on liner.

Fig. 32
Whenever a work is carried out on pressure part all precautions should be taken to avoid
the entry of foreign material inside the pressure part, as this will cause another failure.
Surroundings should be kept clean. Ash, firebrick, dust etc. are also harmful as these
contain high silica. Extreme care should be taken in this regard when a work on
desuperheater or valves is taken up since the possibility of foreign material entry is much
favourable.

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