Presentation on

Boiler Maintenance (Tube Failure and Welding)

By Ajay Kumar A.E. PTPS-II ,HPGCL

Definition of Boiler
Steam boilers under IBR means any closed vessel exceeding 22.75 liters in capacity and which is used expressively for generating steam under pressure and includes any mounting or other fitting attached to such vessel which is wholly or partly under pressure when the steam is shut off.

Tube Failure
Cause
 Corrosion  Erosion  Overheating

Maintenance after tube failure

Basic Requirement to carry out any Welding Related Maintenance

Permit to Work Approved Procedure Knowledge of Applicable Codes and Drawing Manpower-(Qualified Welders, Grinders) Material-(Welding Rods, Grinding Wheels etc.) Qualified NDT Person

Procedure to Repair Failed Tube

The minimum replacement tube length should be not less than 150 mm. A damaged tube should be cut off at least for a length of 75 mm each side of the defective area. Backing rings must be used in welding heat absorbing tubes carrying water or a mixture of steam and water . If a backing is not used, the first pass of the weld must be made by inert gas-arc or oxy-acetylene. Prior to welding, clean the tube ends to bright metal, inside and outside for at least 40 mm from the weld area. Remove all deposits of oxide, boiler water salts and slag to avoid gas or slag inclusions in the weld.

 Allow for shrinkage in welding. A butt weld in a tube will shorten the total tube length of about 1.5 mm. First complete the weld at one end .Do not start welding other end of the replacement tube until both the replacement and existing tubes have cooled to ambient temperature. Carry out The NDT If there is some fault attend and correct it

Welding
Basics WPS PQR Weld Map / Weld Plan Types of Welding NDT Welding Faults and Remedies

What is Welding
Welding is Process of Joining Metal By Heating them with or without Applying Pressure.

WPS Welding Procedure Specifications

It is a formal document describing welding procedures. Shows Working Range for Various Parameters Purpose of the document is to guide welders to the accepted procedures to get desired output. WPS is supported by a Procedure Qualification Record (PQR)

PQR Procedure Qualification Record

PQR as a record of welding variables used to produce an acceptable test weldment .

Commonly Used Welding Processes

SMAW Shielded Metal Arc Welding SAW Submerged Arc Welding TIG Tungsten Inert Gas Welding MIG/FCAW/GMAW Flux Cored Arc Welding

Types of joints

SMAW Shielded Metal Arc Welding

SAW Submerged Arc Welding

SAW/Automatic Machine

TIG Tungsten Inert Gas Welding

MIG/FCAW Flux Cored Arc Welding

Position of the weld symbols on the drawings

WELDING DEFECTS AND REMEDIES

DEFECT IS A DISCONTINUITY, WHICH IS NOT ABLE TO MINIMUM ACCEPTANCE STANDARDS THREE MAIN SOURCES OF DISCONTINUITIES
DESIGN RELATED WELDING PROCESS RELATED METALLURGICAL

WELDING PROCESS RELATED DEFECTS

UNDERCUT SLAG INCLUSION POROSITY OVERLAP TUNGSTEN AND OXIDE INCLUSION LACK OF FUSION (LOF) LACK OF PENETRATION (LOP) ARC STRIKES

UNDERCUT

Slag

POROSITY

Incomplete Fusion

OVERLAP

SPATTER

EXCESSIVE WELD REINFORCEMENT

UNACCEPTABLE WELD PROFILES

ARC STRIKES

NDT Non Destructive Testing

DPT Dye Penetrant Test MPT Magnetic Particle Test RT Radiography Test UT Ultrasonic Test

DPT Dye Penetrant Test

 PT may be used to locate defects which are open to the surface.

MPT Magnetic Particle Test

 MT may be used for surface and near-surface linear defect flaw detection. instrument consists of an electro-magnetic yoke which sets up a magnetic flux field around a weld.

RT Radiography Test

 RT may be specified for internal flaw detection. RT is sensitive to cracks, lack of fusion, lack of penetration, slag inclusions and porosity defects. It does produce a permanent film record.

UT Ultrasonic Test