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Economizer tube failure due to steaming

Wednesday, October 03, 2018   By: Reinaldo [2275] 0 Stars
Hello, I am trying to get detail information regarding economizer tube failure due to steaming but it seems difficult. I am facing tube failures in a vertical tube horizontal flue gas flow economizer of a HRSG with visible internal lost of material near or at tube-to-header welds like cavitation. In the economizer vertical tubes flow downwards and upwards simultaneously until leaving the economizer vertically upwards. Failures are in the top part of downward tubes specifically at the inward side of the tube-to-header 180º flow turn. My analysis is that economizer is steaming and at the last downward set of tubes steam condensates and creates cavitation-like process. I have already investigated thoroughly about other types of failures corrosion-fatigue, FAC, under-deposit corrosion, etc but my case does not seem to match any of those. Can somebody confirm my analysis? Where could I find information regarding failures due to steaming in economizer?

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Wednesday, October 03, 2018   By: c.a.molanes@gmail.com [50] 4 Stars
Mr. Reinaldo:

Unfortunately I have no direct experience with HRSG, a very intereresting piece of equipment. As for the erosions you have detected, they remind me of a similar type of erosion appearing in some smoke-tube boilers. A boiler builder, here in Buenos Aires, told me about them and tought me that they appear due to erosion of gases whilst turnig abruptly around the edge of the protruding tubes, I mean those customarily 5mm from the sheet plate.

He solved the problem by placing a line of weld around every tube mouth after mandrelling. In the case of the economizer, perhaps the tubes are fixed by welding and are flush with the header, in which case the problem is absolutely different, if such be the case, please forgive me.

Claudio Molanes

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Wednesday, October 03, 2018   By: Jim Watts [764] 5 Stars
this link may be of interest


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Friday, October 05, 2018   By: basem belal [2194] 2 Stars
I am not sure if I understand you well, do mean the problem happened on the external surfaces of tubes? or you mean its on internal surfaces of tubes?
is it from water side or gas side?
if it is from water side, so it will be O2 problem in the water because O2 attack economizer tubes at welding points as you describe.
if it is from gas side, then more information about fuel and flue gas parameter every point in the boiler beside tubes material and welding procedures.
I am sorry that I am not useful for you by my answer.

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High Sulfite Residual
By: Ross. [390]

First, I want to say that large amounts of Sodium Sulfite NaSO3 becomes a contaminate because it will produce foaming and other problems, but foaming is the primary problem.

Your 500-psi Water Tube Boiler is seems to have reasonable level of residual Sodium Sulfite NaSO3 remaining in the boiler water. Nice pH too.

Your 300-psi Waste Heat Recovery Boiler has twice what I would expect for Sodium Sulfite NaSO3 at ranging 80-ppm to 100-ppm. pH is good so you are getting a good yield.

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