Written by Bill Kitterman | Power Plants

Tube leaks are a part of every boiler/HRSG operator’s life. In fact, more than half of boiler shutdowns are caused by tube leaks, which are the primary reason for generation losses in power plants. That’s why power plants must focus on preventive maintenance and timely repair of these leaks to prevent further damage. The costs associated with fixing or replacing these damaged parts can be significant.

What Steps Can You Take to Deal with Tube Leaks Effectively?

At SVI-BREMCO, we will help you identify the steps you should take to minimize your downtime and headaches. The first thing that you as an operator should do is make sure you have the necessary paperwork and material to be ready for the eventual failure that will occur. As an ASME pressure vessel, your boiler is registered with the National Board, and you have a National Board Number unique to your unit. This number allows you or others to request Data Reports identifying the size and material in each unit section. This information is critical to making any type of repairs to any pressure parts on your unit, and your repair contractor will need this information to develop a repair plan.

Another very important requirement is having the proper material (tube stock), etc., on hand with proper MTRs (Material Test Report) that identifies the material’s properties to ensure that the tube you are using for the repair meets that requirement as defined in your boiler’s data reports. The MTR numbers will be line-marked on the material and will need to be matched to the report identifying the material. It is a good idea for every plant to have a stock of all the needed tubes, sizes, schedules, and materials in their inventory to expedite the repair. This material needs to be stored in a dry environment to protect the tubes from rusting and allow the contractor to ensure that the material is the proper one for that boiler and the area of the boiler (SH, Evap, Econ). A significant amount of time and potential damage (from steam cuts to other tubes, etc.) can be saved by having these tubes in stock, allowing you, the operator, to make the repair promptly rather than searching for the proper tube to make the repair and shipping it in from another source.

Finding Tube Leaks within HRSG Boilers

Once a tube leak is noticed, the process of identifying where in the unit the leak is occurring will trigger other questions and processes that need to be utilized to make the necessary repairs.

  • What section is the leak in?
  • How do we access this section?
  • Does it require scaffolding?
  • Does it require heat treating?
  • What are the NDE requirement?
  • Can we hydro?
  • Do we need to NDE?

These preliminary questions need to be addressed once a tube leak is identified. After that, the actual repair work begins.

Let SVI-BREMCO Help with Your Power Plant’s Tube Repair

At SVI-BREMCO, we dedicate ourselves to delivering outstanding services to our industrial plant customers, particularly those operating HRSGs. We understand the importance of optimizing every component of your system for enhanced efficiency and profitability. Whether you require maintenance for your HRSG, need tube repairs, or are looking into replacements, our skilled team of engineers and technicians is here to assist. Reach out to us today to learn more or to arrange a visit to your power plant site.