Replacement of the lower radiative part (LRP) of a steam boiler with a steam capacity of 950 tons/hour

[ Year: 2025 ]

[ Country: Ukraine ]

[ Industry: Energy industry ]

 



Main Objective:

To execute the replacement of the lower radiative part (LRP) of the steam boiler with the restoration of heating surfaces, fuel combustion systems, and refractory lining to ensure the subsequent reliable and safe operation of the power unit.

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Key Features:

  • works were executed on high-pressure energy equipment;
  • the operating water pressure in the boiler tubes is 320 atm, which places exceptionally strict requirements on the quality of welded joints;
  • TIG (argon arc) welding was applied to perform critical welding operations;
  • all weld joints underwent multi-level quality control, including ultrasonic testing, tube clearance checks, and hydraulic testing;
  • to prepare the surface for shotcreting, tube studding of the LRP panels was performed using over 1.5 million studs with a pitch of approx. 20 mm;
  • prior to studding, the tubes underwent grit blasting, and following the studding, they underwent repeated grit blasting and treatment with orthophosphoric acid to protect against corrosion;
  • the total weight of the fabricated and installed LRP panels amounted to approximately 100 tons.


Implementation:

1. Dismantling works

  • dismantling of the old brick boiler setting;
  • dismantling of the metal casing cladding;
  • dismantling of the existing lower radiative part panels;
  • dismantling of burner units;
  • dismantling of pulverized coal pipes.

2. Equipment fabrication

  • fabrication of new LRP panels with a total weight of approximately 100 tons;
  • fabrication of headers.

3. Mechanical and construction works

  • installation of the lower radiative part panels;
  • installation of headers;
  • installation of burner units;
  • installation of pulverized coal pipes with internal lining of acid-resistant heat-resistant tiles;
  • grit blasting of the LRP panel tubes;
  • tube studding using a specialized stud welding gun;
  • application of silicon carbide refractory mass via shotcreting;
  • execution of refractory brick lining;
  • installation of the external boiler metal cladding (metal thickness 6 mm);
  • installation of inspection manholes for future maintenance and repair.

4. Quality control and testing

  • various forms of quality control were applied, including ultrasonic testing of welded joints;
  • tube clearance checks after welding (ball drifting);
  • hydraulic testing of tube systems under pressure;
  • quality control of refractory lining works.

5. Commissioning works

  • drying of the shotcrete concrete according to the technological schedule;
  • pre-commissioning and tuning works;
  • commissioning and putting the equipment into operation.

Result:

A complete replacement of the lower radiative part of the steam boiler was accomplished, with the restoration of heating surfaces, refractory lining, and auxiliary systems.
Following the completion of the testing complex, the boiler was successfully put into operation. The implemented engineering solutions ensured reliable performance of the equipment under high temperature and pressure conditions, while increasing the service life of the main boiler unit components.

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