Professional Documents
Culture Documents
Purpose
Tube Configuration
Gas Flow Conditions
Circulation
Shape
Fuel Firing Type
Production Method
Process - Industrial
Power - electricity
Energy recovery
Fire-Smoke Tube
Water Tube
Sample
Most waterwalls have a membrane panel construction. Membrane and filler wire material
typically match the tubing material. For example, if the waterwall material is SA-213 T11 (1-
1/4% chrome and 1/2% molybdenum), the membrane material would be SA-387 Gr. 11 and the
filler metal material would be E8018 (EB2).
Bends in panels are typically performed on a panel gang bender to assure proper alignment of
tubes at nose arches, ash hoppers, and wall-to-floor transitions.
Some waterwall designs are individual tubes with a tangent or near-tangent design. In these
configurations, it is extremely important to hold very tight tolerances to assure that, once
installed, overall wall width is within tolerance. Special bending dies and procedures must be
used to assure that there is no flattening of the tube. To assure that a tangent or near-tangent
waterwall loose tube will fit properly in the field, it is imperative that it be fit in the shop to a jig
that replicates the field environment.
Package Boiler - Furnace Wall The furnace wall tubes in package boilers are
tangent tubes that form the gas pass. In "D","A", and "O" style package boilers,
there are two style furnace tubes. Their configuration is identical except where
they enter the steam and mud drums on different hole rows. In some cases, the
tubes are seal-welded to form a completely gas-tight area. Refractory is used to
protect the drums and prevent gas leakage at the top and bottom.
Depending on the extent of the replacement and the experience of the installing contractor,
outside wall tubes may be installed as individual tubes or as panel sections. Supplying these
tubes as small panel sections can save significant installation time.
"D" style package boiler furnace walls are often supplied as membrane panels. These panels
need to be moderate in size (six to eight tubes wide) for easy installation. See our section on
Waterwalls for general information about panel fabrication.
The panels would be gang bent, and a half-wide membrane is used on the outside tubes to permit
fin-to-fin field welding when joining two panel sections together. This method of construction
minimizes the onsite time associated with seal-welding each individual tube.
For "D" style package boilers, the superheater is typically nested in the rear of the boiler just
prior to the generating pass. The headers are parallel and adjacent to the mud and/or steam
drum. These units often have alignment or support mechanisms tied to the steam drum and
adjacent generating tubes. Support systems on older package boilers with headers at the mud
drum often fail prematurely. Excess stress develops, which causes failures at support systems
and at the superheater header-to-tube joints. These problems can be addressed by a variety of
design solutions, including the use of extruded headers and flexible supports of high alloy
content. Typically, the only practicable way to replace these superheaters is as a complete shop-
assembled module.
SUPERHEATED STEAM - Steam with its temperature raised above that of saturation. The
temperature in excess of its saturation temperature is referred to as superheat.
Industrial
Boilers
Industrial
Boilers
Sample1
Industrial
Boilers
Sample2
Industrial
Boilers
Sample3
Industrial
Boilers
Sample4
Industrial
Boilers
Sample5
Often, having new panels shop-fabricated with a shop-applied weld overlay can
result in significant savings. Because the outage duration for the installation of
new panels is usually shorter than the outage duration for the field weld overlay of
existing panels, savings can be realized from the cost associated with the shorter
outage period.
New panels with a shop-applied weld overlay provide the additional benefits of
new, full-thickness tubing and a weld overlay applied under ideal conditions,
resulting in a product superior to the field overlay of existing waterwalls.
Utility Boiler
Sample
Recovery Boiler
Recovery Boiler
Sample1
Recovery Boiler
Sample2
Older units are extremely difficult to repair because of limited access. Often a
replacement economizer is shop-modularized for field erection. Some modern
designs use individual platen assemblies with small-diameter headers at each
end. These individual platens can be replaced more easily.
Superheaters often have tight radius bends which may require hot forming. Ak
Mhendislik has specific hot-forming procedures to assure an acceptable bend
geometry and material mechanical characteristics for use in your unit.
All pressure retaining tube-to-tube welds will be done using the GTAW welding
process for both root and cover pass.
The carbon and alloy tubing portions of each unit are protected with one clear
coat of Conlux or equal on the outside surface exposed to the atmosphere.
Marine Boilers
Marine Boilers
V Type
Marine Boilers
H Type
Single Pass
Two Pass
Three Pass
Multi Pass
Single Pass
Two Pass
Natural Circulation
Forced Circulation
Cylindrical ( Scotch )
Rectangular
Gas Fired
Oil Fired
Solid-Waste Fired
Unfired ( Waste Heat )
Samples
Package
Samples
Industrial
Field Erected
Boilers