Anat omyofaBoi l erFai l ur e—ADi ffer entPer s pec t i v e 0 9 / 3 0 / 2 0 08|ByGa Ga r yJ.Ba s es
Th ep oweri n du s t r y ’ sop er at i n ga ndma i n t e na nc ep r ac t i c eswe r eh el du pt oi n t e ns er e gu l a t o ra ndp ub l i cs cr u t i n ywh eno n No v e mb mb er6 ,2 00 7,aMa s s ac h us e t t spo we rp l a nt ’ ss t e amg en er a t i n gb oi l e re x pl o de da ndt h r e eme nd i e d. Th eDe pa r t me nto fPu bl i cSaf e t y ’ sI nc i dentRepor ti nv es t i gat i on ( PDF)de t e r mi n edt h att h ep r i ma r yc a us eoft h eDomi n i o n En er g yNe w En gl an d’ sSa l e m Ha r b orGen er a t i n gSt at i o nUni t3e x pl o s i o nwa se x t e ns i v ec o r r o si o no fb oi l e rt u be si nt h e di v i s i onwal l att heeas tf ur nac el o wers l opedeadai rs pa ce( Fi gur e1 ) . Thet hr eeop er at or swer ewor k i ngdi r e ct l ybel o wt he f ur nac eonapul v er i z ers eal ai rf anwhent hee xpl os i ono cc ur r ed.The ydi edofb ur nsandr el at edc ompl i c at i ons .Theboi l e rwas oper at i ngat1, 900ps iatt het i meoft hef ai l ur e.Ac ompl et es etofphot osoft hef ai l ur ei si nc l udedi nt heI nc i dentRepor t .
1 .At u ber u pt u r eonNo v e mb mb er6 ,2 00 7,a tDo mi mi n i o nEn er g yNe w En gl a nd ’ sSa l e m Ha r b orGe ne r a t i n gSt a t i o nUn i t3c au s eda f u r n ac ee x pl o si o nt h atk i l l e dt h r e eme n.So ur c e :Co mmo mm nwe al t ho fMa ss ac hu se t t s ,De pa r t me nto fPu bl i cSaf e t yI n ci d en t Re po r t :Do mi mi n i o nEne r g yNe w En gl a nd Sa l e m Ha r b orSt a t i o nBoi l e r#3Fa i l u r e ,d at e dJ ul y3 1,20 08 Th er e po r t c on cl u de dt h atwh ent h et u be sf a i l e dwi t h i nt h ed ea da i rs pa cef o r me db yt h ed i v i s i o nwa l l —a na r ean or ma l l yun der as l i ghtneg at i v epr es s ur e—t hev es t i bul ewa si ns t ant l ypr es s ur i z ed,c au si ngas ec ondar yr upt ur eoft heboi l erc as i ngar ound t h eb ot t o mo ft hef u r na c e.As hand60 0Fs t e am wa st h enr e l e as edi n t ot h ea r e awh er et h et h r e ewo r k e r swe r el o c at e d( Fi gu r e 2) .
2.TheMas sac hus et t sDepar t mentofPubl i cSaf et y ’ soff i c i al I nc i dentRepor tf oundt hate xt ens i v ec or r os i onoft heboi l ert ubes , c au se db yas hca pt u r e di nt h el o we rs l o peai rs pa cet h ath admi x e dwi t hwa t e ri n t r o du ce db yf u r n ac ewas h es ,wa st h ec au se o ft hee xp l o si o n.So ur c e:Co mmo nwe al t hofMa s sa chu s et t s ,De pa r t men to fPu bl i cSa f e t yI n ci d en tRe po r t :Do mi n i o nEn er g y Ne w En gl a nd Sal em Ha r b orSt a t i o nBo i l e r# 3Fa i l u r e ,d at e dJ ul y31 ,2 00 8 Ther epor tal s os ummar i z edi nt er v i ewswi t hpl antoper at i onss t affonst andar dpl antoper at i ngandmai nt enanc eha bi t s . Be ca us et h epl a nth asop er at e da sac y c l i n gu ni tf o rt h ep as t1 0y e ar sors o,p l a nn edou t a ge swer es or e du ce di nl e ngt ht h at r equi r edmai nt ena nc eac t i v i t i eswer eno tc ompl et ed.Att het i meoft heac c i dent ,appr o xi mat el y2, 500wor kor der swe r e p en di n g. Th er e po r t a l s on ot e dt ha tt h ede ada i rs p ac eh adn otb ee no pe ne do ri n sp ec t e di na tl e as t1 0y e ar san dwa sf ul l o fa sha tt h e t i meoft heex pl os i on.Ther ep or tc on cl udedt hatt het ubee xpl os i ont hatbl e wo utt heout erwal loft hef ur nac ewa sc aus edb y as handwat erf r om boi l erwa shi ng,c omi ngi nt oc ont ac twi t ht ubes .Thatmi x t ur ec aus edc or r o si ont hatr e sul t edi ne x ces s i v e t ubeme t al l os s . Ther epor thel dt hec hi efengi neerandt heout s i deboi l eri ns pec t ordi r ec t l yr e s pons i bl ef ort hee xpl os i onbec aus et heyf ai l edt o p er f o r m aco mp r e he ns i v ei ns p ec t i o na sr e qu i r e db yMa ss a ch us et t sl a w.I not h erwo r d s,t heca t as t r op heco ul dha v eb ee n p r e v en t e di fp r o pe ri n sp ec t i on sh adb ee nma deo ft h ee nt i r ef u r n ac ean dmo r et h anv i s ua li n sp ec t i o nt e chn i q ue sh adb ee n us ed.TheOc cupat i onal Saf et yandHeal t hAdmi ni s t r at i onsi nc ehasf ound10ser i ouss af et yv i ol at i onsatt hepl ant ,i nc l udi ng f ai l ur et oe nt erandi ns pec tt hear eawher et het uber up t ur eo cc ur r ed. Wemus tn otc l o set heboo kont hi st r age dyandch al ki tupt obadl uc kont hepar toft hi spl ant ’ ss t aff .Ther ei smu chmo r et o t hes t or yt hanwhati swr i t t eni nt heI nc i dentRepor t .Her ei st hek eyques t i ont hatt her epor tf ai l edt oans wer :Whatc aus edt he v es t i bul et of i l l upwi t hfl yas hi nt hef i r s tpl ac e( Fi gur es3and4) ?
3.T y pi c al v es t i bul el oc at edbehi ndt hest eam dr um.Not et hefly as hbui l d up.Co ur t es y :BRI LI n c.
4 .T y pi c al up pe rf ur n ac ede adai rs pa cewi t hmu chfly a shb ui l d up .Co ur t e sy :BRI LI n c . Ibel i e vet hatt her ootc aus eoft heac ci dentwasr e f r ac t or yf ai l ur et hatal l owedt hewat erandas ht oent ert hev es t i bul ei nt he f i r s tpl ac e.Apr oper l yi ns t al l edandmai nt ai nedr ef r ac t or ysur f ac ewoul dhav epr ev ent edt hec or r os i onand,t hus ,t heac ci dent .
Goodboi l e rde si gnpr a ct i c e Ther epor ts t at est hatt heboi l er ’ sl owerv es t i bul ewasf ul loffl y as handhadbeenf orav er yl ongt i me.Pos t ac ci dentoper at or i n t er v i e wss ug ge stt h efl y a shma ybeha v eb ee nt h er easl o ngas1 0y e ar s .Po orma i nt e na nc ean di n sp ec t i o np r a ct i c esi g no r e d t hi senc l os eds pac e.Nots ur pr i s i ngl y ,t hi sl ac kofat t ent i oni scommont hr oughoutt hepo weri ndus t r y .
Theboi l eri sa1957v i nt age120MW c oal f i r edr adi antpowerboi l er .Thi swasac ommonboi l erdes i gnf orv i r t ual l yal l ut i l i t y b oi l er sbu i l tf r o mt h emi d 1 94 0st hr o ug ht h e1 960 s.I twa sn otu nt i l1 96 4t h att h eme mb r a net u bewa l l d es i g nwa sd ev e l o pe d andbec amet henor mi nut i l i t yboi l erpr ac t i c e.Dur i ngt hi st i meper i odappr o xi mat el y400boi l er soft hi sdes i gnwer ebui l ti nt he U. S. ,andmos tar es t i l l i noper at i on.Al loft hes eboi l er shads i mi l ars t eam c apac i t y ,t ubewal l c ons t r uc t i on,v es t i bul es ,and r ef r ac t or y / t ubewal l des i gn.Doest heboi l erc r o ss s ec t i oni nFi gur e5l ookf ami l i art oy ou?
5.At y pi c al 1957v i nt ageonepas sboi l ert hati ssus cept i bl et oaf ai l ur es i mi l art ot hate xper i enc edatSal em Har borUni t3. Ther ear eappr o xi mat el y400oft hes eboi l er si nac t i v es er v i c et oda y .Sour c e:BRI LI nc .
Thes ear econs i der edflat s t udd edort an gent i al t y peboi l er s .The ydonoth av emembr anet ubewal l s ,butr at herus eei t herfl at s t uddedt ubesorbar el oos et ubest of or mt heboi l erandf ur nac ewal l s .T ok eept hef i r e( andfly as h)i ns i det hef i r ebo x, r ef r ac t or yi sappl i edov ert heout s i deoft het ubest of or m apr ot ec t i v e,i ns ul at i ngwal l . Boi l er soft hi st y peus edei t heran“ al l r ef r ac t or ydes i gn”wi t hr ef r ac t or y( 1t o2i nc hest hi c k)ont hebac ks i deoft het ubesoran “ i nner c as edde si gn, ”whi c hus esat hi nl a y erofr ef r ac t or yap pl i edfl us hwi t ht heb ac ksi d eoft het ubesanda10gaug eme t al c as i ngi ns t al l edov ert her ef r ac t or y bac k edt ubes .Theal l r ef r ac t or ydes i gnwasl es sc os t l y ,es pec i al l yi nar eass uc has v es t i bul esandenc l os ur es ,andwast her ef or et hemos tc ommonl yus eddes i gn.Fort hi sdi s c us s i on,If oc usont he“ al l r ef r act or ydes i gn. ” I nes senc e,t her ef r ac t or ymus tk eept hef i r ei ns i det hebo xi nor dert ok eept heboi l eroper at i ngeff i c i ent l yandt opr e ventfl y as h f r om penet r at i ngorent er i ngt hev es t i bul esi nandar oundt heboi l er( Fi gur es6and7) .( Pl eas enot et hatt hef ol l owi ng pho t ogr aphswer enott ak enatSal em Har bo rUni t3butatuni t soft hesameboi l erdes i gnandconf i gur at i on. )
6.At y pi c al r ef r ac t or yf ai l ur ei ns i deaboi l erv es t i bul e.Cour t es y:BRI LI nc .
7.At y pi c al r ef r ac t or yf ai l ur ei ns i deal owerf ur nac ev es t i bul et hat ’ ssi mi l art ot hatofSal em Har borUni t3.Cour t es y:BRI LI nc . Th es ev e s t i b ul e sa nde nc l o su r e sa r el o cat e du nd ert h es up er h ea t era r e a,a bo v et h er o oft ub es ,un de rd r u ms ,a r o un dt h e b ur n era r e a,a ndb el o wo rj u stu nd er n ea t ht h ef u r n ac eho pp ers l op et u be swh er et hef a i l u r eo cc ur r e d( Fi g ur e s8a nd9 ) .
8.At y pi c al r ef r ac t or yf ai l ur ei nt hes uper heat erv es t i bul e.Not et hef ur nac ewal lwi t he xpos edmet al .Cour t es y :BRI LI nc .
9 .At y pi c al b ur n era r e ai ns i d eawi n db oxwi t he x po se dme t a lwe l d edt ot u be s.Co ur t e sy :BRI LI n c. Theboi l erd es i gn er sandmanuf ac t ur e soft hes et y pesofb oi l er sk newt hati twasv er yi mpor t antt okee pfl y as houtoft hes e v es t i bul esbec aus eoft hec hemi c alc ons t i t uent soffl y as h.Fl y as hi saby pr oduc tofbur ni ngc oalandt y pi c al l ycont ai nsal k al i s , s uc ha ss odi um andpo t as s i um t hatc anf or mc or r os i v emi x t ur esi nt hepr e sen ceofwat er ,ors ul f ur ,whi c hc anf or ms ul f ur ousor s ul f ur i c t y peac i d s—bo t hofwhi c hc ancor r odeorweak enst r uc t ur al s upp or t sandt ubesi nt hepr e senc eofwat er .Fi gur es10 t hr ough14i l l us t r at et hes epoi nt si naboi l ers i mi l art oSal em Har borUni t3’ si ndes i gnandc ons t r uc t i on.
10.T ypi c al s t r uc t ur al s uppor t si ns i deal owerv es t i bul e.Cour t es y :BRI LI nc .
11.T ypi c al t ubesi ns i deal owerv es t i bul ee xpos edb yr ef r ac t or yf ai l ur e.Cour t es y :BRI LI nc .
12.T ypi c al l owerf ur nac ev es t i bul ewi t hv i s i bl ywetas h.Cour t es y :BRI LI nc .
13.Super h eat erv es t i bul ewi t has t ai no nt her ef r ac t or ywal l f r om wat erwa shi ng.Cour t es y :BRI LI nc .
14.Anot herv i ewofas uper he at erv es t i bul ewi t hs t ai nsont her ef r ac t or ywal l c aus edb yf ur nac ewas hdr ai nage.No t et he fl y a s ha c c umu l a t i o nwa sr e mo v e db ef o r et h ep ho t o gr a phwa st a k en .Co ur t e s y :BRI LI n c .
Poorr ef r act or ypr act i ces Boi l er soft hi svi nt ageandde si gnus er ef r ac t or yont heb ac ks i d eoft ubesl oc at edi ns i dev es t i bul esandenc l o sur es .The r ef r ac t or yi sappr o xi mat el y1i nc ht hi c kf r om t hef ac eoft het ubeandr equi r e sas uppor ts y st em.I nmyex per i en ce,t he r ef r ac t or ycanf ai l f oran ynumberofr eas ons ,i nc l udi ngt hes e: • Poorr ef r ac t or ymi x i nga ndh andl i ngp r a c t i c es . • Poori ns t al l at i onpr ac t i c es( i nc l udi ngcur i nganddr y i ng) . • I mpr ope rwat er was hi n gt ec hni ques . • I mpr ope rr ef r ac t or yat t a chments y s t ems .
Thewayt opr ev entf ai l ur ei st omi x ,handl e,andi ns t al l r ef r ac t or ycor r ec t l yandf ol l owpr operwat er was hi ngpr ac t i c es . Ref r ac t or ymi x i ng,handl i ng,andi ns t al l at i oner r or scanbeel i mi nat edbyf ol l owi ngt hegui del i nespr o vi dedb yanyr e put abl e r ef r ac t or ymanuf ac t ur era ndf ol l owi ngc ommoni ndus t r ypr ac t i c esf ori ns t al l i ngt her ef r ac t or y .Ref r ac t or ydes t r uc t i onb ywat er wa sh i n gc a nb ea v oi d edb yn otwat erwa sh i n gi na r e aswh er ev e s t i b ul e sa nde nc l o s ur e sa r el o c at eddi r e ct l ybe hi n dt h e wat er wal l t ubes .I fy oumus twat erwas h,t hendonots pr a ydi r ec t l yi nt ot her ef r ac t or y ,whi c hi sl oc at edbet weent het ubes . Unf or t unat el y ,mye xper i en ceha sal s ob eent hatman ypl ant sha veani mpr operr ef r ac t or yat t ac hments y s t em t hati sb yf art he mos tc ommonr ea sonf orar ef r ac t or yf ai l ur ei ns i dev es t i bul e sandenc l o sur es .Ar ef r ac t or yat t ac hments y s t em wi l l s uppor tt he r ef r ac t or y ,e vendur i ngboi l ere xpans i on,r egar dl es sofho wt her ef r ac t or yi si ns t al l ed.( Thegunni ngi ns t al l at i onmet hodus es pr es s ur et of or c edr ymat er i al f r om t hech ar gi ngc hambert hr oughah os et ot hepoi ntofpl a cement ;wat eri saddedatt he di s char genoz zl e.Thet r owelmet hodr equi r esappl i c at i onofr ef r ac t or ybyhand. ) Mos tpl ant spa yl i t t l eornoat t ent i ont ot heat t ac hments y s t em f orhol di ngr ef r a ct or yi n si dev es t i bul ear eas .Themos tc ommon pr a ct i c esf orhol di nge xpa ndedmet alatp owerpl ant sf ol l ow: • Nos uppor ts y st em.Ther ef r ac t or ywi l lno tl as tv er yl ongwi t houtas uppor ts y s t em duet hes t r es s esas s oc i at edwi t hboi l er e xpans i on( Fi gur e15) .
1 5.L on gt e r mr e f r a ct o r yd ama ges ho wst h atn oe x pa nd edme t a lr e ma i n si ns omear e asoft h ev e s t i b ul ewa l l s .Co ur t e sy :BRI L I n c . • Al i ght gaugeat t ac hmentwi t hcl i ps .Thi sappl i c at i onus esat hi ngaugeat t ac hmentwi t hi ns ul at i ont y pespeedcl i pst o s uppor tt hee xpandedmet al .Thi sdes i gni sbet t erf ors uppor t i ngc er ami cmodul ei ns ul at i onappl i c at i onst hanr ef r ac t or y .The t hi ng augeoft hes t udandc l i pdoesno tl as tv er yl ongwhene xpos edt os t r es s esas s oc i at edwi t hboi l ere xpans i on( Fi gur e16) .
16.I ns ul at i ons t udan dc l i ph ol di ngt hee xpandedme t al .Cour t es y :BRI LI nc . • Wel di n gdi r ec t l yt ot het ubes .Thi sappr oac hdoesnota l l o w enoug hs uppor toft her ef r ac t or ybe caus emos toft her ef r ac t or y ma t er i a li sl o c at e dab ov et h ee x pa nd edme t al .Du et os t r es s esas s oc i a t edwi t hb oi l e re x p an si o n,e x pa nd edme t a ls h oul db e pl ac edi nt hemi ddl eoft her ef r ac t or yt ogi v et heop t i mum s upp or t( Fi gur e17) .
17.Ref r ac t or ye xpandedmet al waswel deddi r ec t l yt ot heboi l ert ubesi nt hi sboi l er .Thi si st hel eas tac cept abl er ef r ac t or y i ns t al l at i onpr ac t i c e.Cour t es y:BRI LI nc . • Th es t u dan dc l i pme t h od .Th i si sago odme t h odf o rh ol d i n ge x pa nd edme t a la sl o ngasac l i pi sp l a ce db ot hun de ra nd a bo v et h ee x pa nd edme t a l .Th ec l i ps ho ul dbeah ea v y d ut ys p ee dc l i p( s u c ha sSN3 )a ndl a r g ee no ug ht oc ov e rt h ed i a mo nd s ha peoft h ee x pa nd edme t a lo pe ni n gs .Th ep r o bl e m wi t ht h i ss y s t e mi st hedi ff i c ul t yo fk e ep i n gt heex pa nd edme t a lt h es ame di s t an cef r om t het ub ef ac e.Thedi s t anc eoft hee xpandedme t al f r om t het ubef ac ei scr i t i c alf ort hes uc c es sandl o nge vi t yof t hes ys t em ( Fi gur e18) .
18.As i ngl es t udandcl i phol di ngt wodi ff er ents i z esofe xpandedme t al .Cour t es y :BRI LI nc . • Ahe xnuta ndt hr ea dedst udwi t hwas her s .Thi ss y st em i sav ar i at i onoft hest udandcl i pex c eptt hati tus eshe xnut sand wa sh er sf o rh ol d i n gt h ee x pa nde dme t a li n st e ado fas p eedcl i p .Th i si sag oo dme t h odf o rh ol d i n ge x pan de dme t a lasl o ngas t h ewa s h er sa r ep l a c edbo t hun de ra ndab o v et h ee x p an de dme t a l .Th eh ea v y d ut y( 1 2g au gemi n i mu m)wa s he r ss h ou l db e l a r g ee no ug ht oc o v ert h edi amon ds ha peo ft hee x pa nd edme t a lo pe ni n gs .Th ep r ob l e m wi t ht h i ss y s t e mi st h ed i ff i c ul t yof k e ep i n gt heex pa nd edme t a lt h es amedi s t an c ef r o mt h et u bef a ce .Th ed i s t a nc eoft h ee x pa nd edme t a lf r o mt h et u bef a cei s c r i t i c al f ort hes uc ces sandl ongev i t yoft hi ssy st em ( Fi gur es19) .
1 9.An uta nds t u dwi t hwa s he r sc anb eu s edf o rh ol d i n ge x pa nd edme t a l .Co ur t e s y :BRI LI n c . Apr oper l ysuppor t edr ef r ac t or yshoul dl as t10y ear sormor ei ft her ef r ac t or yi si ns t al l ed( anddr i ed)c or r ec t l y .Al l oft he s y s t e msme nt i o ne da bo v eh av es omed r a wb ac k st h atc o ul dc o mp r o mi s et h es t r e ng t ho ft h er e f r a c t o r ys up po r ts y s t e ma nd , c ons equent l y ,affec tr ef r ac t or yl ongev i t y .
Her ei samet hodf orhol di ng1i nc ht hi c kr ef r ac t or yov ert hebac ks i deoft ubesl oc at edi ns i deav es t i bul eorenc l os ur et hathas t heb es tc hanc ef orl as t i ng10y ear sormor e: 1. Wel da&f r ac 12; i nc hc ar bonst eel he xnutf ac ed own( n otoni t sed ge)di r e ct l yt ot het ubef ac eon12i nc hhor i z ont al x18i n chv er t i c alf orfl atar e asand12i nc hx12 i nc hc ent er sons l o pedoro ve r h eadar eas .Th e&f r ac 12; i n chnutwi l l ac tasa s t andoff,s ot hee xpandedmet al wi l l bel oc at ede xac t l yi nt hemi ddl eoft her ef r ac t or y .2. 2 . We l d1&f r a c1 2; i n c hx9 g au ge( 1 3g aug emi n i mu m)n on fl a t t e ne de x pan de dme t a ldi r e ct l yt ot h eh exn ut .Us i n gt h i ss i z e o fe x pa nd edme t a lwi l l a l l o wb ot ht h ef i n esan dc ou r s eag gr e gat eg r a i nt op en et r a t et h r o ug ht h ee x pa nd edme t a l .Us i n ga s mal l ers i z eofe xpand edme t al wi l l c au seas epar at i onbe t ween st hef i nesandc our s egr ai nsi nt her ef r ac t or y .Thats ep ar at i on r educ est hes t r engt hoft her ef r ac t or yandwi l l affec ti t sl ongev i t y . 3. Theex pand edme t al s ho ul dbeov er l ap pedby1i nc ht o3i n chesi nal l di r ec t i ons .Thi so v er l appi nghel psl o cat et he e xpandedmet al s owel di ngi spos si bl eatal l he xnutl oc at i onsandwi l l t ak eupt hest r es sesas soc i at edwi t hboi l ere xpans i on. Th ee x pa nd edme t a li sne v erwe l d edi nt h eo v er l a pa r e as( Fi g ur e2 0) . 6. 4 . Ap pl yame di u mwe i g ht2 , 0 00 Fmi n i mu m,4 5% a l u mi n ac eme nt b on de dr e f r a c t o r y1i n c ho v e rt h ef a c eoft u be st h r o ug h t hee xpandedmet al .I tt ak esappr o xi mat el yanaddi t i onal &f r ac 12; i nc ht hi c knes sofr ef r ac t or yt oc ompl et el yco vert he e xpandedme t al .Remembe rt hatus i ngmor er ef r ac t or yt hanr equi r eddoesno tgi v ey ouas t r onge rorbe t t err ef r ac t or y appl i c at i on. 5. Cur et hei ns t al l edr ef r ac t or yf or24hour sbys pr a yi ng/ wet t i ngt hesur f ac eoft her ef r ac t or ywi t hwat erev er yt wohour sorby s pr a yi ng/ pai nt i ngt hesur f ac eoft her e f r ac t or ywi t hwat er bas edac r y l i cc ur i ngandseal i ngcompound. 6. Dr yt her ef r ac t or ydur i ngboi l ers t ar t upbyr ai s i ngt heboi l ert emper at ur e75Fperhourunt i lt hewat er / s t eam t emper at ur e i n si det hef ur nac ewal l t ubesr e ac hesbe t ween250Fand40 0Fan dhol di tt her ef ort woho ur s .Thi swi l ld r i v eoutt he me chani c al wat erus edi nt hemi x i ngpr oc es sf r om t her ef r ac t or y .Thent ak ey ourboi l erupat75Fperhourt ooper at i ng t emp er a t u r e .
2 0.Ex pa nde dme t a lmu sta l s ob ep r o pe r l yo v er l a pp edf o rt h er ma le x pa ns i o n.Co ur t e sy :BRI LI n c.
Lookt ot hef ut ur e Ther ootc aus eoft het r agedyi nMas sac hus et t sshoul dha vebeeni dent i f i edasr ef r ac t or yf ai l ur er at hert hant ubef ai l ur e.I twas t hef ai l edr ef r ac t or yl i ni ngt hatal l owedfl y as handwat ert openet r at ei nt ot hel owerf ur nac ev es t i bul e.Thenat ur al c ons equenc e o fl a r g ea shdep os i t smi x e dwi t hwat e ra n dp ac k eda r o un db oi l e rt u be swa sp r e v en t a bl e . Th et r a ge dyi nMa ss ac hu se t t swo ul dn ev e rh av eoc c ur r edi fpr o pe rb oi l eri ns p ec t i o na ndma i nt e nan c ep r a ct i c e sh adbe en f ol l owed.I ti st i mef orev er y onewor k i ngi noraff i l i at edwi t ht hepoweri ndus t r yt odot hei rpar tt omak es ur et hi sk i ndofac ci dent wi l l n ev e rh ap pe na ga i n . Th ei n du st r yc anh on ort h eme mo r yo ft h os el o stb ye ns u r i n gt h atas i mi l a ra c c i d entn ev e ro c c ur sag ai nb y : • Ens ur i ngt hatboi l erout agesal l ows uffi c i entt i mef ori ns pec t i onandr epai rofr ef r ac t or y . • Fol l owi ngpr operpr oc edur esf orhandl i ngandi ns t al l i ngr ef r ac t or y . • Pa yi ngv er yc l os eat t ent i ont ot her e f r ac t or ys uppor ts y st em i ns i dev es t i bul es . • Al l owi ngenought i medur i ngboi l ers t ar t uppr oc edur est odr yt her ef r ac t or y . • Av oi di ngwat er was hi ngt ubewal l si nv es t i bul ea r e as . • Re gul ar l yi ns pec t i ngv es t i bul esa nddeadai rs pa cesa ndqui c k l yr epai r i ngdamag edr ef r ac t or y .
—Gar yBases( 3306652931orbr i l i nc @r oadr unner . c om)i st hepr es i dentofBRI LI nc. ,ani ndependentc ons ul t i ngf i r m s pec i al i z i ngi nbr i c k,r ef r ac t or y ,i ns ul at i on,andl aggi ng.Hei sal s ot heaut horofTheBr i l Book( acompl et egui det obr i c k, r ef r ac t or y ,i ns ul at i on,andl aggi ngs ys t ems )andTheBr i lBookI I( at ec hni c almanualt hati nc l udesbr i l appl i c at i ondr awi ngsf or t hepo werg ener at i ngi ndus t r y ) .
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Daryl
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5 years ago
is it common to use to use a chill ring for a water tube. It is shown in picture 31 of the Incident Report investigation. chetan • 6 years ago By going through the report this is the !rst "ind of e#plosion that i have seen. In our thermal plants the importance given to refractory materials and its proper use in the !eld is not seriously viewed. But only good practice that we have is after every annual overhauling refractory lining will replaced with new one this will be insured by the maintenance stagg as well as the boiler inspector whose clearance is a must in starting the plant. I than" u for eloborate report that u people made which will ma"e use more conscious. o
Joe Hofmann • 6 years ago $here is every reason to promote the correct installation maintenance and repair of refractory but the best of refractory will never seal a tangetial tube boiler from gas %y ash or water lea"age. $he build up of %y ash in the dead air spaces cannot practically be avoided &seal air 'usti!cation e#cluded(. )ith a cycling duty boiler you do what you can to "eep it hot. In every case you must do all possible to "eep the entire boiler dry for the very reasons mentioned in the article. It would seem di*cult to envision su*cient cause for a boiler wash down+ it is worry enough for the e#ternal corrosion of the lower boiler in the event of a waterwall tube lea".
