Boiler Tube Failures in Power Plants

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  Importance of Power Plants
  Power plants are essential for industrial development. Boiler failures, particularly tube failures, cause forced shutdowns, economic loss, and reduced power supply.

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• Causes of Boiler Tube Failures
  Failures stem from multiple factors, including overheating, creep, erosion, corrosion, fatigue, manufacturing/material defects, and operational errors.

• Impact of Failures

  • Unscheduled plant shutdowns

  • Increased maintenance and repair costs

  • Reduced plant load factors

  • Loss of available power

• Need for Investigation
  Investigating root causes is critical to prevent recurrence, assess remaining tube life, and ensure reliable power supply.

• Book’s Contribution

  • Shares extensive expertise in metallurgy, material science, and failure investigations.

  • Covers basics of metallurgy, materials used in boiler tubes, and mechanisms of failure.

  • Provides case studies with real field examples, photographs, and microstructures.

  • Highlights advanced material characterization techniques and role of water chemistry in tube failures.

• Audience
  Intended for plant engineers, maintenance teams, boiler manufacturers, R&D personnel, academicians, and students. It aims to enhance awareness and improve communication with experts.

• Acknowledgements
  The authors thank the Indian power industry, power plant management, TCR Group, and ASM International for support in preparing the book.

Key takeaway:
Understanding boiler tube failures requires metallurgical knowledge, proper investigation, and preventive strategies to improve plant reliability and efficiency.