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Furnace Convection Section Remaining life analysis

Furnace Convection Section Remaining life analysis

Furnace Convection Section Remaining life analysis

(OP)
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.  

RE: Furnace Convection Section Remaining life analysis

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.
 

RE: Furnace Convection Section Remaining life analysis

(OP)
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.

 

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