Tube Plugging of Firetube Boilers

BY ROBERT E. FERRELL, SENIOR STAFF ENGINEER

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he plugging of leaking tubes in retube boilers has been an industry practice for many years. The purpose of plugging is to provide a quick x. This allows the boiler to continue operating until it can be shut down and the tube replaced. It should be understood a plugged tube is a temporary x. This type of x is not addressed in any new construction code. However, it is addressed in the National Board Inspection Code (NBIC) through Interpretation NBI 95-35.1

How many tubes can be plugged before affecting combustion in the boiler or the stay requirements?

Before plugging a tube, determine the cause of the leak. For instance, if the leak is at the tube to tubesheet joint, this leak could affect the plug's holding power. If it is a through wall leak resulting from corrosion, it implies the tube wall strength has been compromised. If the leak is a through wall leak resulting from a longitudinal heat stress (hoop stress) crack such a crack usually occurs from the tip of the tube inward across the tubesheet to the waterside (Figure 1) the crack may be closed by installing the plug. However, it will eventually open up again.

Although plugging a tube looks like a relatively simple operation, some considerations must be taken into account: How will the plug be installed? Will it be hammered into the tube using a tapered plug, or will it be welded into the tube? What type of operational cycling will this plug see?

Figure 1 If you ask an old salt boiler inspector (i.e., a navy veteran) about the percentage of tubes allowed to be plugged, he will without hesitation say 10 percent. Although that is probably true of a watertube boiler on a US Navy ship, it is not necessarily true of a civilian retube boiler. The navy boiler may be over designed to

Interpretation NBI 95-35, R-200 Denition of Terms, 1992 Edition with the 1994 Addendum. Question 1: Is the welding of a plug to seal tubes in a boiler or pressure vessel considered a repair? Reply 1:Yes Question 2: Does the NBIC apply to plugging tubes by welding plugs to tubes and/or their joints to tube sheets of tubes that have leaked, tubes that have corroded to an unacceptable thin wall thickness, and tubes required to be removed from service for operating reasons in boilers and pressure vessels? Reply 2: Yes

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allow for tube plugging, but the civilian retube boiler is probably not. There are two operational concerns for the boiler when a tube is plugged: the rst involves the effects on the waterside pressure boundary or membrane; the second is the effects on the combustion process throughout the boiler. The waterside membrane is a concern because the tube plug creates a at head segment on the tube sheet. An analysis should be done to determine if the new at head segment exceeds the allowable pitch of the stays. Initially the tube may act as a stay, but there are several problems with that assumption. If there is a through wall leak, the tube will ll with water. This reside water doubles the corrosion rate on the tube, limiting its time

to be used as a stay. Even if theres no through wall leak, most plug suppliers advise boiler owners to puncture the tube before installing a plug so that pressure wont build up in the tube and loosen the plug. Therefore, there will always be water on the inside of the tube. This water will apply a pressure load on the plug, which will transmit across the tube sheet to the next unplugged tube. This can be shown using the Power Boiler Code (PFT-31.2) to calculate the tube acting like a stay tube. The diagrams in (Figure 2) illustrate the load increase on surrounding unplugged tubes. Lets assume the re tubes are 2-inch OD, 0.095 wall, SA-178-A with an allowable tensile stress of S= 11400 psi. Thickness of the at head tubesheet is 0.75 inches and the SA- 285-C steel has an allowable tensile of

Plugged Tubes

Plugged Tubes

Plugged Tubes

Plugged Tubes
Maximum Pitch Exceeded

Figure 2

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S= 15700 psi. Calculated pitch for the stays in this at head tube sheet is 10 inches. The MAWP is 200 psi. As shown in Figure 2, the incremental increase in stress on the surrounding tubes is compounded as the number of plugged tubes increases. Therefore, a combination of tube plugs could exceed the code maximum stay pitch. Sometimes the plug is welded to ensure it doesnt leak or blow out and turn into a projectile. When it is welded, the plug should have a material test report. The welding must be done in accordance with the jurisdictions requirements. As shown in Figure 3, the llet weld may only attach to the tube. The holding strength of the plug depends on holding strength of the leaking tube. When it comes to combustion process, the impact of plugging tubes results in back pressure of combustion gases through the boiler. A plugged tube reduces the cross sectional area of the ow path. Reduction in area reduces the ow through the boiler and increases pressure drop across Figure 3

P + 2 in. (50mm) 2 (PFT-27.3)

P 2 P P P P P P 2

PFT 27.9.2

(PFT-27.1) p max.

Maximum pitch p may measured circumferentially and radially only

the boiler. Increase in pressure reduces the air output of the blower (forced draft or induced draft). Less air reduces boiler capacity and contributes to incomplete combustion that produces carbon monoxide and soot and thus increases the cost of boiler operation. Smaller boilers would be more sensitive to this impact on combustion because there are fewer tubes per pass. Although plugging has been an industry practice for many years and can be safely applied in accordance with jurisdictional requirements, boiler owners always need to remember this x is temporary, and the condition will continue to deteriorate, affecting the pressure boundary stability. They also need to remember this x immediately impacts the pressure containing capability of the pressure boundary and the safe and efcient process of combustion in the boiler unit. Thus, when convenient, they need to shut down the boiler and replace the tube.

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