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    Boiler Maintenance

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    Ajay Chauhan
    This document provides an overview of boiler maintenance procedures related to tube failure and welding. It defines what constitutes a boiler and describes common causes of tube failure such as corrosion and erosion. The document outlines permit and safety requirements for welding work and the procedure for repairing failed tubes, including cutting, cleaning, and welding requirements. It also discusses welding process specifications, qualification records, common welding processes like SMAW and GMAW, joint types, welding defects and non-destructive testing methods for inspections.

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    Download as PPT, PDF, TXT or read online from Scribd

    Boiler Maintenance

    Uploaded by

    Ajay Chauhan
    365 views39 pages
    This document provides an overview of boiler maintenance procedures related to tube failure and welding. It defines what constitutes a boiler and describes common causes of tube failure such as corrosion and erosion. The document outlines permit and safety requirements for welding work and the procedure for repairing failed tubes, including cutting, cleaning, and welding requirements. It also discusses welding process specifications, qualification records, common welding processes like SMAW and GMAW, joint types, welding defects and non-destructive testing methods for inspections.

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    This document provides an overview of boiler maintenance procedures related to tube failure and welding. It defines what constitutes a boiler and describes common causes of tube failure such as corrosion and erosion. The document outlines permit and safety requirements for welding work and the procedure for repairing failed tubes, including cutting, cleaning, and welding requirements. It also discusses welding process specifications, qualification records, common welding processes like SMAW and GMAW, joint types, welding defects and non-destructive testing methods for inspections.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    365 views39 pages

    Boiler Maintenance

    Uploaded by

    Ajay Chauhan
    This document provides an overview of boiler maintenance procedures related to tube failure and welding. It defines what constitutes a boiler and describes common causes of tube failure such as corrosion and erosion. The document outlines permit and safety requirements for welding work and the procedure for repairing failed tubes, including cutting, cleaning, and welding requirements. It also discusses welding process specifications, qualification records, common welding processes like SMAW and GMAW, joint types, welding defects and non-destructive testing methods for inspections.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 39

    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

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