Furnace Convection Section Remaining life analysis 1

[rustbuster]

I have been tasked with estimating remaining life of some furnace convection sections.

I am hoping some of you folks may have done similar and can offer some ideas. things that come to mind initially are;

• What types of inspection data we need
• Historical failures
• Damage mechanisms
• Structural integrity
• Refractories

I'm looking for a pro-active approach vs. reacting to failures. We have far exceed desing life.

Thanks in advance for your thoughts and experience.

 

[metengr]

If the furnace convection sections are actual tube elements, here is what I would suggest.

- review of past tube leaks, locations in the bundle and type of leaks (pin hole versus cracks versus fish mouth ruptures).
- review past operating history and try to compare actual field data (temperature and pressure) with stated operating conditions.
- inspection options will be based on known damage mechanisms, OD or ID wastage. Inspections should focus on wall thickness, ID oxide thickness, attachment welds, butt welds.
- I would schedule removal of tube samples, nothing better than getting your hands on actual furnace tube material. Send to a reputable metallurgical laboratory for general evaluation.

 

[rustbuster]

Thanks metengr,

This was the approach I proposed but I'm facing reluctance to remove sections for analysis. I have taken two shock bank samples but have little access to the upper sections (superheaters, economizers).

I was hoping someone might have justified replacements based on economics, energy savings, etc.