Boiler Tube Failure Analysis is about Corrosion, Stress Cracking Corrosion, Metal Failure or Corrosion Stress:
Boiler tube failure analysis is about corrosion, stress cracking corrosion, metal failure or corrosion stress all causes corrosion using boiler tube analysis.
Steam boiler tube failures of all types and sizes continue to increase boiler tube repairs. For instance, boiler tube failure, why? Stress Cracking Corrosion? Metal Failure? Corrosion Stress? Boiler tube repairs are expensive! So, finding the cause of the boiler tube failure is critical. A boiler tube failure repair 
may not necassarily have been done right or you may be experiencing more expensive boiler tube repairs later.
Boiler tube failure analysis is about corrosion, stress cracking corrosion, metal failure or corrosion stress all causes corrosion using boiler tube analysis.
Steam boiler tube failure corrosion stress cracking can happen for a wide range of reasons, so boiler tube analysis and boiler tube failure analysis can help you make a better decision with your money.
Sometimes, boiler tube failures are hidden from plain sight. When this occurs the boiler tube failure is about corrosion in most cases. Another hidden steam boiler tube failure is stress cracking corroison or embrittlement corrosion, or caustic embrittlement corrosion. When it is about corrosion of this type it can be dangerous. Boiler tube failure of a steam boiler tube isa significant cause of commerial, industrial, and utility boiler forced outages.
A boiler tube cracking failure from caustic embrittlement corrosion in boilers or oil ash corrosion can be found with boiler tube testing and failure anaylsis.
Tube failure analysis and tube testing is well suited for heat exchangers like steam turbine condensers or shell and tube heat exchangers. Heat exchangers of all sizes generally have very-expensive tubes, so replacing the tubing will reach senior decision makers in your facility.
Failure mechanisms are not always clearly identified, then boiler tube failure analysis and testing may be needed. Metallurgical Testing hasyears of experience with boiler tube failures including economiser tube failures, overheated steam drums and water drums (mud drums) as well as boiler headers, superheater tubes and economizer tubes.
Boiler Tube Failure Analysis Finds Stress Cracking Corrosion - It is about Corrosion, Stress Cracking Corrosion
The first step in boiler tube failure analysis by AIS is to perform a visual inspection of the failed tube. Then make preliminary observations and make suggestions on how to proceed in the boiler tube failure analysis or heat exchanger tube failure analysis that fits your budget. Finding boiler tube failure mechanism will require metallurgical failure analysis. Boiler tube failures can have boiler tube cracking corrosion or boiler tube corrosion stress cracking as well as (caustic cracking or embrittlement corrosion) caustic embrittlement in boilers causing replacing boiler tubes in steam boilers. ( stress cracking corrosion, corrosion stress cracking, failure analysis, corrosion stress, cracking corrosion )
Boiler Tube Watersides Corrosion Strees Failures:
- Tube Roll Life and Over-Crushing Tube
- Deposit Analysis (Scale)
- Boiler Tube Cracking Corrosion
- DNB (Departure from Nucleated Boiling)
- Boiler Tube Corrosion Loss
- Deposit Weight Density of Boiler Tube
- Low Water Condition in Boiler
- Steam Drum or Water (mud) Drum Testing and Analysis
- Boiler Tube Under Deposit Corrosion Stress
Boiler Tube Firesides Corrosion and Erosion Failures
- Corrosion (Flue Gas - Biomass, Refuse, Oil, Ash, Sulfur, Chlorides...)
- Erosion from Flue Gas Stream (Biomass, Refuse, Coal Ash) or Steam
- Accumulated Exposure to Elevated Temperatures - Overheated Boiler Tube
- Component Corrosion Failure: Clips, Brackets, Supports, Hangers, Seals, Straps and Membranes
- Overheating from Underside Desposts
- DNB (Departure from Nucleated Boiling)
- Economiser Erosion and Flue Gas Corrosion
- B&W Boiler Tube Failure
Boiler Tube Cold-side Failure
- Mechanical Component Metal Failure Analysis
- Strapping Weld Metal Failure Analysis
- Boiler Tube Overstressing (stress cracking corrosion)
Condenser Tube Failure Analysis
- Condenser Tube Corrosion
- Tube Roll Life
- Condenser Tube Fretting
- Heat Exchanger Tube Failure
A boiler tube cracking failure from caustic embrittlement corrosion in boilers or oil ash corrosion can be found with boiler tube testing and failure anaylsis.
Some Steam Boiler Tube Failure Analysis Cases: Steam Boilers Burning - Bio-Mass, Gas Fired, and Oil-Fired
Evaluating the Watersides failures or
Superheater Boiler Tube Failed at Small Utility Station – Biomass Steam Boiler Burning Light Refuse Supplement
Steam Boiler Superheater Tube Failure: High-temperature Oxidation: The (unit) boiler had an unscheduled shutdown with expensive penalties. A boiler superheater tube experienced a rupture when the tube wall thinned from erosion in the presence of localized high-temperature oxidation where the outside boiler tube surface temperature relative to the oxidation limit of the tube material was excessively elevated. Owner did not have to replace the superheater again after taking appropiate steps from the boiler tube failure analyis.
Boiler Tube Replacement at Institution – High-Temperature Hot Water (HTHW) Fire Tube Boiler - Rear Tube Sheet – Buring Fuel Oil
Boiler experienced a poor or low flow water condition in the fire tube scotch marine (FTSM) boiler requiring a boiler repair by retubing. The boiler rear tube sheet appeared visually acceptable and was initially considered safe by others. However, the boiler rear tube sheet was found to have a reduction in boiler plate strength and the boiler plate microstructure changed and that was consistent with moderate to long term localized elevated temperatures in the ASME carbon steel plate that was specified when built decades ago. Boiler repairs were minimized after taking appropiate steps from the boiler tube failure analyis.
Boiler Tube Repairs at Facility with a High-Temperature Hot -Water Tube (HTHW Generator) Boiler: Fuel Oil and Gas Fired
The HTHW Generator (hthw boiler) had been experiencing multiple boiler tube repairs and unexpected costly shutdowns during the heating season. It is about corrosion! These boiler tubes were failing from corrosion (under deposit corrosion) from the watersides. The boiler tube corrosion were isolated pitting corrosion. The root cause was determined and the owner did not have to replace the boiler or retube the boiler after taking appropiate steps from the boiler tube failure analyis.
Instructions on Shipping Your Boiler Tube to 'Get a Free Consult'
We know steam boilers, so naturally we understand the differences between a reheater tube or a waterwall tube as well as these boiler / 
generators -
- Refuse Burners
- Bio-Mass
- Fossil Fuel - Coal, Fuel Oil and Natural Gas
- Heat Recovery Generator
Is this important to you? We will let you be the judge of that!
Boiler Tube Failure Analysis - What To Do Before Shipping Boiler Tube
First (Step One), before shipping or removing the steam boiler tube for analysis take a picture of the boiler tube or heat exchanger tube in the boiler and the tube sheet that the heat exchanger tube came from. (MAKE SURE THE TUBE IS NOT CLEANED - NEED TUBE 'AS IS CONDITION') When possible include a diagram of there the tube sample was located in the boiler or heat exchanger such as:
- Type of boiler and location in Boiler
- Heat Pass location and flow direction
- Elevation such as at the steam drum (how close)
- Type of boiler tube: screen wall tube or furnace wall tube, boiler bank, generating bank, superheater (radiant, convection), economizer.
- Boiler pressure, temperature, steaming rate, operating hours
- Diagrams or drawing sheets showing location(s)
- Boiler Tube material (what it is supposed to be)
- Boiler Tube repair history
- Description of steam boiler water treatment program
The above information is not always provided; however, when the information is given early in the tube analysis the boiler tube analysis results benefit.
Sponsoring -
High-Pressure Boiler Training
High Pressure Boiler Course
Steam Boiler and Power Plant Forum (For Your Questions and Answers)
www.steamforum.com
Aboveground Storage Tank Forum (For Your Questions and Answers)
www.ast-forum.com
National Association of Stationary Operating Engineers
www.national-engineers.org
Preparing Shipping BoilerTube and Tube Shipping Instructions:
Boiler Tube Shipping:
Step Two: 'Dutchman' the boiler tube that is needed for testing and failure analysis. the boiler tube length should normally be a length of 3-feet (1-meter) but not less than 1- 1/2-foot in length. This is also true for a heat exchanger tube or condenser tube. Tap the ends immediately and wrap tube carefully
Step Three: Contact Laboratory .
Step Four: Drop the Steam Boiler Tube Shipping Container off to your nearest shipper.
Ship to:
Boiler Tube Testing
Attn: Boiler Tube Testing
212 Elmwood Ave Ext.
Gloversville, NY 12078
Inside the shipment leave a note who to telephone, an email address and a mailing address for correspondence.