Chemical Engineering October 2020 - 33

FIGURE 5. Advanced automation technologies can
contribute to more rapid resolution of maintenance
and repair tasks
Going the extra mile
The strength of the boiler tubes with
thicknesses between 2 and 2.5 mm
were also enhanced before the automated
weld overlay to obtain optimum
results. These parts, which accounted
for 3 m2 of the total surface
area, were pre-treated by means of
carbon-steel buildup. This consists of
applying a layer of parent material to
the existing tubes before coating the
surfaces with refractory Inconel 625.
Once completed, the repair passed
independent non-destructive tests
(NDT) to evaluate the quality of the
procedure. In particular, suitable, homogeneous
thickness levels were
found using direct-thickness checks.
Similarly, dye penetrant inspection
(DPI) unveiled the absence of surfacebreaking
flaws and discontinuities that
could otherwise compromise erosion
resistance and equipment service life.
Even more, positive material identification
(PMI) analyses revealed a suitable
elemental composition of the
weld overlay.
A thorough final inspection report
was provided, detailing the general
conditions of the boiler that the plant
could use to effectively set up future
preventative-maintenance activities.
In addition, this confirmed the quality
and compliance with key requirements
and regulations. The combined
repair and maintenance projects were
completed in only twelve days of
downtime and the plant could restore
operations at its boiler line.
When unexpected equipment failures
occur, the top priority for businesses
is restoring their operations
as quickly and as effectively as possible.
A skilled maintenance and
repair specialist plays a key role in
enabling plants to meet these goals.
In particular, a team with the right expertise
can streamline these activities
by quickly mobilizing teams, offering
rapid consultations and feedback,
as well as leveraging experience
and advanced solutions to shorten
processing times.
■
Edited by Mary Page Bailey
Author
Adam Crosswell is Automated
Weld Overlay manager for the ERA
region at Sulzer Chemtech (Email:
adam.crosswell@sulzer.com).
With
an extensive
engineering
background, he is an experienced
maintenance and repair specialist
and has managed numerous projects
in the petrochemical and energy
sectors. These include both
on-site and workshop-based turnkey automated weld
overlay solutions. Crosswell also holds a M.S. degree in
mechanical engineering from Southampton Solent University
in the U.K.
High-Performance Gas Cleaning, Emission Control and
Gasification Solutions from Beltran Technologies
Beltran Technologies, Inc.
www.beltrantechnologies.com
Beltran Wet Electrostatic Precipitator Systems are specified for cleaning
a wide range of gas streams. WESP's are used for metallurgical
processing operations and sulfuric acid gas cleaning. WESP's are also
used downstream from wet or dry flue gas desulfurization units, which
cannot capture fine particulates and acid aerosols. They are superior on
high ash content and sticky residues (which may also contain mercury
and heavy metals), oily residues/tars, mercury (as condensed oxide),
emissions from municipal solid waste (MSW) in waste-to-energy applications
and biomass syngas cleaning.
*Ultralow emission of submicron particulate, acid mist and visible plumes
*Advanced modular design-minimized field assembly,
flexible configuration
*Available in corrosion-resistant alloys, conductive composites or
FRP construction
For details visit adlinks.chemengonline.com/76995-01
CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2020
33
http://www.beltrantechnologies.com http://adlinks.chemengonline.com/76995-01 http://WWW.CHEMENGONLINE.COM
Chemical Engineering October 2020

Table of Contents for the Digital Edition of Chemical Engineering October 2020
