MATERIALS AND WELDING GUIDELINES

FOR
BLACK LIQUOR RECOVERY BOILERS

THE BLACK LIQUOR RECOVERY BOILER ADVISORY COMMITTEE

October 2010
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

Table of Contents

GENERAL DOCUMENT FORWARD................................................................................................................................ 4

CHANGES .............................................................................................................................................................................. 5

GENERAL WELDING FORWARD (FOR SECTIONS 1 AND 2) ................................................................................... 6

SECTION 1 - WELDING BULLETINS .............................................................................................................................. 9

1.1 STRESS-ASSISTED CORROSION (SAC) ............................................................................................................................ 9
1.2 WELD REPAIR OF CRACKS IN WATER TUBES ............................................................................................................... 10
1.3 REPAIR OF PRESSURE BOUNDARY MATERIALS IN TUBES ............................................................................................. 11
1.4 REPAIR OF CORROSION RESISTANT WELD OVERLAY APPLICATIONS ON TUBES .......................................................... 11
1.5 REPAIR OF COMPOSITE MATERIALS ON TUBES ............................................................................................................. 12
SECTION 2 – WELDING GUIDELINES & PROCEDURES SECTION ...................................................................... 14
2.1 REPLACING HAND HOLE CAPS (WELD IN STYLE) ........................................................................................................ 14
2.1.0 General ................................................................................................................................................................ 14
2.1.1 Hand Hole Cap Metallurgy.................................................................................................................................. 14
2.1.2 Reusing hand hole caps: ...................................................................................................................................... 15
2.1.3 General Good Practice Items: ............................................................................................................................. 15
2.1.4 Hand Hole Cap Removal Procedure.................................................................................................................... 15
2.1.5 Header Repair Procedure .................................................................................................................................... 16
2.1.6 Hand Hole Cap Installation ................................................................................................................................. 16
2.1.7 Handhole Caps Welding Guidelines – Removal Sequence & Header Repairs .................................................... 17
2.1.8 Handhole Caps Welding Guidelines – Installation Sequence .............................................................................. 18
2.1.9 Detail of ½” Leg Fillet Weld ............................................................................................................................... 20
2.1.10 Weld Traveler..................................................................................................................................................... 21
2.2 WELD REPAIR OF SMALL HOLES / CRACKS IN SUPERHEATER TUBES ........................................................................... 23
2.2.1 Introduction ......................................................................................................................................................... 23
2.2.2 Evaluation ............................................................................................................................................................ 23
2.2.3 Materials .............................................................................................................................................................. 24
2.2.4 Procedure............................................................................................................................................................. 24
2.2.5 Acceptance ........................................................................................................................................................... 24
2.2.6 Reference ............................................................................................................................................................. 25
2.3 REPAIR OF PRESSURE BOUNDARY MATERIALS IN TUBES ............................................................................................. 26
2.3.1 Introduction ......................................................................................................................................................... 26
2.3.2 Evaluation ............................................................................................................................................................ 26
2.3.3 Materials Selection .............................................................................................................................................. 26
2.3.4 Special Restrictions .............................................................................................................................................. 26
2.3.5 Welding ................................................................................................................................................................ 27
2.3.6 Final Inspection ................................................................................................................................................... 27
2.3.7 Documentation ..................................................................................................................................................... 27
2.3.8 References ............................................................................................................................................................ 27
2.4 CORROSION RESISTANT WELD OVERLAY APPLICATIONS ON TUBES (FUTURE) ............................................................ 28
SECTION 3 - MATERIALS ............................................................................................................................................... 29

GENERAL MATERIALS FORWARD ............................................................................................................................. 29

3.1 MATERIALS SURVEYS RESULTS: .................................................................................................................................. 29
3.1.1 Black Liquor Nozzle Wastage .............................................................................................................................. 29
3.1.2 Scope .................................................................................................................................................................... 29
3.1.3 Corrosion Characteristics.................................................................................................................................... 29
3.1.4 Causes of Corrosion ............................................................................................................................................ 29

Page 2
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

3.1.5 Operating Issues .................................................................................................................................................. 30

3.1.6 Mechanical Solutions ........................................................................................................................................... 30
3.1.7 Materials Solutions .............................................................................................................................................. 30
3.2 SMELT SPOUT MATERIALS SURVEY ............................................................................................................................. 31
3.2.1 Scope .................................................................................................................................................................... 31
3.2.2 Corrosion Characteristics.................................................................................................................................... 31
3.2.3 Causes of Corrosion ............................................................................................................................................ 31
3.2.4 Materials Solution – Weld Metal Overlay............................................................................................................ 32
3.2.5 Materials Solutions – Miscellaneous Forms of Corrosion Protection ................................................................. 32
3.3 SMELT SPOUT STEAM SHATTER JET MATERIALS SURVEY............................................................................................ 32
3.3.1 Scope .................................................................................................................................................................... 32
3.3.2 Corrosion Characteristics.................................................................................................................................... 33
3.3.3 Causes of Corrosion ............................................................................................................................................ 33
3.3.4 Materials Solutions .............................................................................................................................................. 33
3.4 MATERIALS – MISCELLANEOUS (FUTURE) ................................................................................................................... 34
SECTION 4 – TEMPORARY REPAIRS (Future) ............................................................................................................ 35

SECTION 5 – REFERENCE SECTION............................................................................................................................ 36

5.1 OEM & SERVICE PROVIDERS ....................................................................................................................................... 36
5.2 TECHNICAL SOURCES: .................................................................................................................................................. 36
APPENDIX A DOCUMENT REVISION HISTORY ....................................................................................................... 37

Table of Figures

FIGURE 1 – FLOW DIAGRAM FOR A SUCCESSFUL WELD REPAIR ................................................................................................. 8

Page 3
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

GENERAL DOCUMENT FORWARD

The BLRBAC Materials and Welding Subcommittee was formed to provide a center of expertise on
recovery boiler materials and welding issues. The subcommittee’s function is to promote safety and
reliability of black liquor recovery boilers through development of materials and welding guidelines.

The following document provides information and guidance on matters relating to recovery boiler
materials, welding and related issues. The term “materials” encompasses pressure and non-pressure
part metals, paints and preservatives and refractories. The term “welding” encompasses precautions,
preparation and procedures.

This document represents a compilation of materials applications and welding guidelines and practices
drawn from experience during boiler manufacture, repair and maintenance. This document is not
intended to be a “Standard” for repairs. Rather, it presents peer reviewed guidelines that can be
considered for repairs and maintenance. The document sections will include the following elements:

 Problem Description
 Classification Indicator
 Details / Causes
 Areas Affected
 Recommended Inspection
 Recommended Actions
 Additional Information

The Subcommittee recognizes that these guidelines are only one small facet to the safe repair and
maintenance of Black Liquor Recovery Boilers. No set of guidelines can cover all situations or specific
problem areas encountered with individual boilers. This document may be helpful in the repair or
upgrading of older boilers but it still should be used as a guide only. The responsibility of the final
decision(s) and or action(s) taken in any and all cases lies with those in charge of recovery boiler
maintenance and is beyond the intent and purpose of this document. It is not the intent of this
Subcommittee to force major designs or operational changes to existing black liquor recovery boilers.

This document will be revised from time to time. Applicable codes and jurisdictional requirements
shall take precedent over this document. This document is not intended to exclude alternative practices,
procedures, codes and standards.

Additional information on recovery boiler welding maintenance and materials is available from TAPPI
TIPs1, AF&PA Maintenance Manual2 and other sources. The reader is encouraged to refer to these
additional references and use the section in this manual’s binder to collect relevant articles.

1
TAPPI TIP’s are available for a nominal fee from www.tappi.org.
2
The AF&PA Recovery Boiler Reference Manual Volume II Maintenance and Repair Analysis: Repair Guidelines and
Practices

Page 4
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

CHANGES

October 2010

“Recommended Good Practice” deleted from document title. This document is a “Guideline”.

Page 5
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

GENERAL WELDING FORWARD (FOR SECTIONS 1 AND 2)

Proper repairs to black liquor recovery boilers may be more critical than repairs to conventional power
boilers. Improper or inadequate repairs may result in smelt/water explosion or extended loss of
production.

An evaluation for permanent repairs should include a failure analysis using the failed component.
However, it is understood that there are situations where it is not economical or feasible to obtain a
sample to perform failure analysis.

Welded repairs should be based upon Jurisdictional requirements, National Board requirements,
applicable standards, and mill requirements.

Several steps are required for successful weld repairs. The steps for a successful repair are to evaluate
the need, determine the extent and type of repair, establish the repair plan, obtain proper inspector
acceptance, review qualification requirements, implement repairs, and finalize repair acceptance
criteria. Figure 1.1 provides the flow diagram for a successful weld repair.

Evaluating the need for repair

Considerations to be used when evaluating boiler repairs should include:

• Can the serviceable life of the defective component be extended without a weld repair
• Should a sample be taken for failure analysis
• Is the repair considered temporary or permanent
• What are the consequences of the selected repair or alteration
o What is the impact of the repair on safety and operation of the boiler
o What is the impact of any modifications on future consideration

Determining the extent of the repairs

A permanent repair may significantly impact repair schedule when a temporary repair would safely
span the interval to the next scheduled outage. However a temporary repair may eliminate the ability to
secure a sample for failure analysis. Availability of materials should be considered prior to making the
repair. Evaluate the nearby components for collateral damage. Adjacent components may be damaged
to gain access to the failed component.

Establishing the repair plan

Items to consider in the repair plan are securing the boiler, cleaning the boiler, accessing the area,
material requirements, safety of personnel, identifying personnel, equipment, and documentation
requirements, communicate the field identification method, and duration of the repair process.
Establish the pressure test requirements, including test pressure.

Page 6
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

Obtaining proper inspector acceptance

Identify the organization that will provide inspector acceptance. Identify the agency that will perform
the inspection. Determine if this is a routine repair, a major repair or an alteration.

Reviewing qualification requirements

Qualifications of the repair organization should be verified. Qualifications to be verified include:

• An approved Welding Procedure Specification(s) is(are) available

• Welding Procedure Specification(s) and welder(s) shall be qualified to ASME Section IX
• Material Lists meet code requirements and may require Mill Test Reports
• Nondestructive Examination process and technician qualifications
• Heat treatment procedure is available if required

Implementing repairs

Implement the traveler. Identify someone to ensure established repair plans and procedures are
followed. Establish inspection hold points.

Finalizing repair acceptance criteria

Conduct the final closure inspection. Complete the final acceptance test procedure. Complete the final
repair documentation. Identify follow-up activities that are required at the next scheduled outage if
temporary repairs were made.

A simple graphical representation or flow chart of the repair process steps follows.

Page 7
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

Figure 1 – Flow diagram for a successful weld repair

Evaluate
Need Repair Return to
for Not Operation
Weld Required
Repair

Repair
Required

Determine
Extent &
Type of
Repair

Jurisdictional
Acceptance
as required

Is
Develop Yes Approved
Welding
Repair WPS &
Required
Plan Welder
Qualifications
No

Complete
Repairs

Inspect
Failed Repairs
Inspection

Passed Repairs
Inspection Documented

Page 8
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

SECTION 1 - WELDING BULLETINS

1.1 Stress-Assisted Corrosion (SAC)

Description: Waterside Stress-Assisted Corrosion (SAC) is a common damage mechanism resulting in

water leaks at weld attachments. SAC should be considered the likely damage mechanism whenever
leaks occur in an area of weld attachments. The problem can occur in any of the water tubes of the
boiler.

Potential for Exposure: Critical and Non-critical.

Details / Causes: The SAC mechanism is based on the premise that the highest stressed zone will
selectively corrode in the boiler feedwater. Studies at the Electric Power Research Institute (EPRI) and
elsewhere have shown that SAC occurs if the local strain on the internal surface of the tube exceeds a
certain level such that the magnetite scale is fissured. This condition leads to corrosion of the steel at
the bottom of the fissure, and also leaves the magnetite scale that eventually reforms at the fissure
weaker, and therefore subject to repeated fracture. Repetitions of stress and/or changes in corrosivity of
the feedwater cause crack-like crevices to grow.

Boiler areas affected: Areas of most concern are lower boiler regions where leaks are likely to
introduce water into the furnace area: waterwalls at primary and secondary windbox scallop bar
attachments, floor-to-sidewall seal bars and corner tubes. Other areas where SAC is common are nose
arch seals, smelt box attachments, buckstay attachments and around port and manway openings.

Recommended inspection: Several nondestructive test methods (including radiographic testing,

ultrasonic shear wave testing, acoustic emission testing, and remote visual inspection) have been used
to inspect for the presence of SAC. No best method has been identified to inspect for SAC.
Radiography, which has been used more than other methods, is usually the preferred testing method
once the boiler region has been found to have SAC present. It is important that the NDE service
company be experienced and qualified to test for SAC indications, regardless of the inspection method
used.

Recommended Actions:

Inspection: Inspection intervals for SAC are dependent on prior history. A baseline inspection for
SAC should be performed if leaks have occurred at weld attachments, or if the boiler is older than
about 15 years. If SAC is found, the inspection should be expanded to determine the extent of damage.

Repairs: Tube leaks caused by SAC damage should be confirmed by metallurgical examination. An
alternative is to examine the leaking tube by RT to assist in identification of SAC. Repair of SAC
damage by rewelding is not recommended because the extent of ID damage is usually unknown and
not visible to the welder. Therefore, only tube replacement in the SAC affected area is recommended.
Boiler OEMs have developed improved attachment designs to resist SAC; consideration should be
given to use of an improved design for large and/or long-term repairs.

Additional Information & References:

Page 9
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

BLRBAC ESP Document

OEM & Service References:
Babcock & Wilcox Plant Service Bulletin # 29
ANSI/NACE Standard RP0204-2004 Stress Corrosion Cracking (SCC) Direct Assessment Method
TAPPI: SP 05010
EPRI

1.2 Weld Repair of Cracks in Water Tubes

Description: This guideline addresses the repairs of stress propagated defects (cracks) that have gone
some percentage into the tube wall, including through wall. This procedure is limited to repairs that
compromise the pressure-retaining boundary of the tube.

Potential for Exposure: Critical/ Non Critical, depending on the location of the crack and the
potential of creating a smelt water reaction from the introduction of water into the furnace.

Details / Causes: Stress risers and/or corrosion generally assists cracking in boiler tubes. Cracks can
propagate from the external or internal surface of a tube. The quality of fabrication, erection, and welds
are also potential causes of cracking.

Boiler areas affected: Termination welds (fins, membrane), port openings (closure plates), port
openings (composite tubes, weld overlay tubes), tube penetration location where movement of tubes
are not adequately restrained (generating bank, economizer, screen tubes), structural attachment welds
(buckstay, scallop plate), localized overlay weld repairs.

Recommended Inspection: For non destructive testing (NDT) techniques used in initial crack
detection. Some inspection techniques used to assess the severity of the detected indication are, Dye
Penetrant Test, Ultrasonic Inspection, Radiographic Inspection, and magnetic particle inspection.

Recommended Actions: Completely remove the crack with a minimum amount of grinding, perform
NDT examination to ensure complete removal. Weld repair the area using approved weld procedures
and verify the quality of the repair. For through wall crack repairs, consider contamination from
waterside deposits when selecting an appropriate weld repair procedure (reference xxx). Through wall
cracks attributed to stress assisted corrosion (SAC) should not be repaired using the guidelines listed
above. To address cracks caused by SAC refer to the BLRBAC Materials and Welding Subcommittee
bulletin addressing SAC.

Additional Information & References:

OEM & Service References:

The AF&PA Recovery Boiler Reference Manual Volume II Maintenance and Repair Analysis: Repair
Guidelines and Practices 4.5.5
NBIC RB-4480, RD-2020, Appendix K-1032

Page 10
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

1.3 Repair of Pressure Boundary Materials in Tubes

Description: Identification, Repairing and Inspection of pressure retaining materials in tubes.

Potential for Exposure: Critical

Details / Causes: Mechanical erosion, corrosion, impact damage, external pitting, grind marks and
electrode arc-strike. The repair methodology described within this bulletin is for areas where sufficient
material is present to eliminate the possibility of a blow-through with the available weld process
method.

Boiler areas affected: Any tube within boiler

Recommended inspection: Perform visual inspection to identify areas where wall thickness has been
compromised followed by thorough UT of areas of concern.
 PT should be used when corrosion resistant coatings are present to determine exposure of
pressure retaining materials. UT of these exposed areas to quantify wall thickness.
 Routine UT mapping of boiler tubes per BLRBAC guidelines.

Recommended Actions: Compare thickness data versus historical corrosion data to timeline for
reaching minimal wall thickness. Several options exist for managing this challenge after historical data
and next possible inspection date is considered:
1. If corrosion is not severe, it is possible to make no repair and revisit during next inspection
date.
2. Make localized repairs using approved weld build-up procedures (2.3) Repair of Pressure
Boundary Materials in Tubes
3. Replace thinning tube with new tube

Perform post-repair visual inspection to identify general poor welding practices.

Further testing may be required to determine root-cause failure mechanism which may require
sampling and destructive testing.

Additional Information & References:

TAPPI:
OEM & Service References:
NBIC

1.4 Repair of Corrosion Resistant Weld Overlay Applications on Tubes

Description: Identification, Repairing and Inspection of existing corrosion resistant weld overlay
materials

Page 11
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

Potential for Exposure: Non-critical, but if not corrected could lead to critical potential for exposure.
The repair methodology described within this bulletin is for localized thinning of overlay material that
has not yet penetrated to pressure retaining material.

Details / Causes: Mechanical erosion, localized corrosion and electrode arc-strike

Boiler areas affected: Any tube within boiler where corrosion resistant weld overlay has been applied;
in general, but not limited to, waterwall and superheat tubes.

Recommended inspection: Visual inspection of applied weld overlay to identify areas where weld
thickness has been compromised (weld bead ripples versus smoothing of weld overlay); followed by
thorough UT of areas of concern.
 If tube material is removed for replacement, it is recommended to perform Destructive testing
of samples to determine mechanism as chosen material may not be adequate for environment.

Recommended Actions: Compare thickness data versus historical corrosion data to timeline for
reaching minimal wall thickness. Several options exist for managing this challenge after historical data
and next possible inspection date is considered:
1. If corrosion is not severe, it is possible to make no repair and revisit during next inspection
date.
2. Make localized repairs using approved weld repair procedures
3. Replace tubing with appropriate corrosion protection.

Perform post-repair visual inspection to identify general poor welding practices.

Additional Information & References:

TAPPI:
OEM & Service References:
The AF&PA Recovery Boiler Reference Manual Volume II Maintenance and Repair Analysis: Repair
Guidelines and Practices 4.5.5.4
NBIC

1.5 Repair of Composite Materials on Tubes

Description: Identification, Repairing and Inspection of existing corrosion resistant composite

materials

Potential for Exposure: Non-critical, but if not corrected could lead to critical potential for exposure.
The repair methodology described within this bulletin is for localized thinning of composite material
that has not yet penetrated to pressure retaining material.

Details / Causes: Mechanical erosion, localized corrosion and electrode arc-strike

Boiler areas affected: Any tube within boiler where composite tubes have been installed; in general,
but not limited to waterwall and superheat tubes.

Page 12
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

Recommended inspection: Perform visual inspection of composite tube to identify areas where alloy
thickness has been compromised followed by thorough UT of areas of concern.
 If tube material is removed for replacement, it is recommended to perform Destructive testing
of samples to determine mechanism as chosen material may not be adequate for environment.

Recommended Actions: Compare thickness versus historical corrosion data to timeline for reaching
minimal wall thickness. Several options exist for managing this challenge after historical data and next
possible inspection date is considered:
1. If corrosion is not severe, it is possible to make no repair and revisit during next inspection
date.
2. Make localized repairs using approved weld repair procedures
3. Replace tubing with appropriate corrosion protection.

Perform post-repair visual inspection to identify general poor welding practices.

Additional Information & References: (Section to be completed)

TAPPI:
OEM & Service References:
NBIC

Page 13
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

SECTION 2 – WELDING GUIDELINES & PROCEDURES SECTION

2.1 Replacing Hand Hole Caps (Weld in Style)

2.1.0 General

Some older recovery boilers utilize new and old style hand hole caps of varying size and metallurgy. It
is common that new style hand hole caps are installed during rebuilds. There are instances when
OEM’s suggested an alloy upgrade of all caps to avoid complication. Care must be taken when
removing alloy caps and returning to carbon steel. Best practice is to consult the OEM or other
competent technical advisor.

2.1.1 Hand Hole Cap Metallurgy

Hand hole caps are available in carbon steel (SA-181-70) or 2 ¼ Cr-1 Mo (SA-182 F22 CL3). The
material identification for a typical B & W hand hole cap is stamped on the bottom (rounded) surface.
Newer style B & W hand hole caps fabricated with carbon steel are stamped as 80MM, SM17, SM16,
or SM70SI; and caps fabricated with 2 ¼ Cr-1 Mo are stamped as 78MM, AM17, AM16, or AM70SI.
The old style B & W hand hole caps sizes are 3-1/4" and 4-1/2". There are also “Master” caps, and
“Standard” which the Owner should have new spares in stock.

Typical Hand Hole Material – Filler Metals selection

ELECTRODE SELECTION BASED ON MATERIAL

Hand Hole Cap Material Header Material

Carbon Steel 1 ¼ Cr-1/2 Mo (P4 2 ¼ Cr-1 Mo (P5A Material)

(P1 Material) Material)
Carbon Steel E7015-A1 Unacceptable Unacceptable
combination between combination between
E7016-A1 header and hand hole header and hand hole
E7018-A1 cap cap

E7015-A1 E9015-B3
2 ¼ Cr-1 Mo E8016-B2
E7016-A1 E9016-B3
E8018-B2
E7018-A1 E9018-B3

PREHEAT AND INTER-PASS TEMPERATURES

Preheat – Refer to WPS and code of construction

Inter-pass - Refer to WPS and code of construction

Page 14
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

2.1.2 Reusing hand hole caps:

It is recommended to replace all weld-in hand hole caps removed with a new cap. However, in the
event a new cap is unavailable, re-using an old hand hole cap is acceptable if the cap can be adequately
cleaned up; any removed cap material be replaced with weld metal and liquid dye penetrant testing
performed.

2.1.3 General Good Practice Items:

a. The Contractor and Owner should agree on hand hole cap removal and installation
requirements. t is advisable to have the Owner’s representative and the Contractor both mark
the specific hand hole caps that are to be removed, and verify there are the correct replacement
caps in hand, before removing any caps.
b. Owner’s representative should monitor the hand hole cap removal and installation. (See
suggested welder guidelines and welding traveler).
c. NDE work should be performed by technicians qualified according to SNT TC-1A for the test
work performed. A minimum of Level II technician is required to interpret results.
d. Weld acceptance criteria, including VT, is to be in accordance with ASME Section I.
e. All welders who will be performing the cap removal and installation process should receive
training on the procedure and QC requirements.
f. When a large amount of caps are to be replaced such as for a boiler cleaning, it is best practice
to set up a mock assembly for testing welder proficiency.
g. If there are alloy caps in the superheater headers, and carbon steel in the balance of headers, it
is good practice to paint code both the header and the caps.
h. Account for all the removed caps (caps have been left in the headers, just out of sight).
i. Each header should be inspected internally by the owner’s representative prior to closure.

2.1.4 Hand Hole Cap Removal Procedure

a. Only the seal weld is to be removed. The seal weld may be removed by arc gouging or
grinding. Care needs to be taken so that excessive metal is not removed from the header and the
header seat is not damaged.
b. Remove cap from the header. Account for all removed caps.
c. After cap removal, lightly prepare the header opening area to clean it up for inspection. Grind
the header surfaces for at least ½" on each side of the welding area to remove any pitting,
rusting or other surface oxides. Thoroughly clean the header seat and bore as well as all
welding surfaces of weld spatter, oil or grease, debris, oxides, paint or other substances. Use a
cleaning solvent to remove grease and oil if present.

Page 15
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

d. Liquid dye penetrant examination should be performed on the header opening.

e. Determine whether header repairs are required. (Shoulder must be square, hole diameter within
tolerances, header thickness in seat area within tolerance, no linear indications in parent header
metal, no visual defects).
f. Remove any defects and perform a dye penetrant examination to assure no defects remain.

2.1.5 Header Repair Procedure

a. Header build up procedure is to be established by the contractor and approved by Owner. Weld
inspection QC should verify proper weld metal, procedures, preheat and weld interpass
temperatures. No repair to the header should be performed while welding in the hand hole cap,
it should be done before installing the cap.
b. Clean the surface of all grease, oil and dirt.
c. Ensure preheat has normalized through the header per WPS and code of construction.
d. Build up the header opening and grind, or machine the surface to the original hole
configuration. Verify that the header edge is square and is of proper thickness.
e. Final prepared surface to be VT, PT or MT examined, prior to welding to verify sound repairs
and no porosity, cracks, etc.
f. Perform internal inspection of header before closure.

2.1.6 Hand Hole Cap Installation

a. Do not “prick punch” the cap seating surface, on a B&W style cap. The CE Style caps need this
for shrinkage allowance of the weld metal.
b. Position the cap in the hole oriented per the drawings. The cap should be centered in the hand
hole. Verify dimensions 90 degrees apart. There should be no excessive gap between the header
and cap. Verify that cap dimension is correct, and check fit up gap.
c. Pull a non CE Style cap up into the socket using a strongback, this helps to hold the hot hand
hole cap and can eliminate the need for tack welds. Tack welds are best avoided, if possible,
but if a cap pulling fixture is not available, place minimum 1” tacks, and feather the start and
stop of each and VT examine, do not reduce the preheat if using tacks.
d. For CE Style caps, “prick punch” the cap seating surface using a center punch or chisel to apply
several punch marks to the end of the mating face of the cap. This is to upset the mating faces
and allow for shrinkage of the weld.
e. For other cap styles, refer to manufacturers guidelines for installation procedures.
f. Apply a preheat (refer to code to determine correct temperature for different metallurgies of cap
and header) to the header and cap. Use temperature indicating crayons to confirm temperature

Page 16
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

is within parameter. The greater of 15 minutes or 15 minutes per inch of thickness should be
allowed for temperatures to normalize. Check the header temperature approximately 1/2” and
3” away from the weld area. Confirm the cap for temperature at the same time.
g. Once temperature has been verified, hold and maintain the temperature, with periodic
temperature verification throughout completion of the welding and NDE QC inspecting.
h. Root pass requires a VT inspection. Welder is to clean up the weld root pass of all slag for
inspection. Maintaining the interpass and preheat temperature are vital.
i. Make a 3/8” throat fillet weld (1/2” or less leg) per specifications (refer to drawings in this
guideline). Weld in excess of 3/8” throat will require PWHT as per ASME I-PW-39, or
Alternate Rules to PWHT per NBIC.
j. The weld starts and stops are to provide continuous overlap of the previous weld pass (a
staggered bead).
k. The root pass should provide uniform weld penetration into both the cap and header.
l. The completed weld is to be cleaned for inspection.
m. NDE final examination should include VT (including weld dimension) and MT if temperature
is over 200F, or PT or WFMT if cooled off.
n. Insulate the cap and surrounding area for slow cooling after final welding.

2.1.7 Handhole Caps Welding Guidelines – Removal Sequence & Header Repairs

R E M O V E FILLE T Remove the header hand - hole cap seal weld by arc
gouging or grinding.
STEP 1
3

CAP 1 2
Take care to remove only the old weld. Watch closely
CAP while gouging for any cracks.
REMOVAL
If there is any indication of cracks forming during the
HEADER gouging process then preheat the header to 200o F
minimum before further gouging.
R E M O V E FILLE T &
G R IN D H A N D H O LE A S R E Q .
Clean the header hand hole prep area by grinding; if
cracks are present; use a rotary burr, to avoid “pushing,
STEP 2 or chasing the crack”.
Check fit up with the replacement cap.
CLEAN /
GRIND / Visually inspect for cracking or porosity. Porosity
DYE – CAP REMOVED
indicates old weld remains.
PENETRANT HEADER

Perform MT or PT on weld prep surface area.

Page 17
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

R E M O V E E XC E S S W E LD B Y G R IN D IN G
H A N D H O LE A R E A .
PREHEAT. (may vary with alloy, follow WPS).
STEP 3
Make any necessary weld repairs around the hand hole
HEADER opening. Depth of repair may involve PWHT or NBIC
WELD Alternate Rules to PWHT.
REPAIRS
HEADER The weld repairs should make a smooth base for the
final hand hole cap fillet weld.

STEP 4 OLD CAP REMOVED, NDE examination should include VT and MT if

WELD REPAIRS MADE, temperature is over 200F, or PT or WFMT if cooled
FINAL PT or off.
&
MT BEFORE
CAP
CALL FOR INSPECTION.
INSTALL.

2.1.8 Handhole Caps Welding Guidelines – Installation Sequence

GRADE 70, CARBON STEEL FORGING

Examine the handhole cap to assure that it is stamped
with the material designation (e.g., SA 181–70 or SA
STEP 5 SA - 181 - 70 181–60). Manufacturer markings must be verified to
identify code material. Check for appropriate welding
CHECK CAP procedure.
FOR
PROPER Clean the area to be welded using a clean wire brush
MARKING. and/or light abrasive wheel.

STEP 6 For B& W Style Caps go to next step.

For C.E. Style Caps: Using a center punch or chisel –
CAP PREP apply several punch marks to the end of the mating face
of the cap – this is to upset the mating faces and allow
for shrinkage of the weld, which will pull the cap into the
header.

PREHEAT AREA IS DARK REGION

STEP 7 Insert the cap through the counter bored header

handhole. The cap must be passed through the handhole
INSERT and then rotated 90o so you can see the center boss
CAP AND thread.
PREHEAT Use the threaded boss to center the cap during welding.
HEADER HAND HOLE OPENING
Preheat cap and header (may vary with material; follow
WPS and code of construction).

Page 18
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

SECTION VIEW THRU HANDHOLE PLUG

Welding may be performed with SMAW (STICK) OR
STEP 8 Uniform clearance
GTAW (TIG). DO NOT EXCEED MAXIMUM
INTERPASS TEMPERATURE; follow WPS and code
TACK of construction.
WELD, If a welding fixture is used to pull the cap into the seat,
FEATHER LONGITUDINAL AXIS OF HEADER omit the tacks; if not, apply 2 tack welds about 1” long
TACKS (CE (not a button weld) on each side of the cap.
Style cap)
Clean & “feather grind” each tack such that no slag
remains from the tack welding. A rotary burr works well
for feathering.

The weld root shall be made so as to tie-in the header and

cap with no greater than 1/32” undercut, and no coldlap,
or visible porosity. Weld out the root pass on one half of
the cap. Complete the root pass and remove any slag.
3 /8 " F IL L E T DO NOT EXCEED MAXIMUM INTERPASS
STEP 9 TEMPERATURE; follow WPS and code of
construction.
3

WELD & CAP 1 2

The weld must have an effective throat of less than 3/8”
LIMIT which can be performed with a 3 pass or multi pass joint
INTERPASS with a leg of less than 1/2”.
TEMP. A 3-pass fillet is shown.
HEADER
Run bead number 2 with its start point staggered inside
of and against the header side of the root pass. Use a
staggered start / stop weld bead sequence, grinding the
starts and the stops completely off to sound metal, to
allow consistent weld height, and removal of any start
porosity.
Complete the weld with bead number 3, placed so as to
tie the passes 1 & 2 to the cap itself. This bead may be a
stringer cover or a slightly weaved cover pass.
For multipass welds greater than 3 pass, (refer to section
2.1.8 below to see additional detail 6 pass weld showing
½” leg fillet profile).

Page 19
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

Perform final VT (visual inspection) and assure a

STEP 10
maximum 3/8” EFFECTIVE THROAT fillet weld.
FINAL INSP A fillet weld with a ½” leg will typically have a 3/8”
throat.
Final MT if temperature is over 200F, or PT or WFMT
if cooled off.
Fillet welds with a throat over 3/8” require PWHT.

2.1.9 Detail of ½” Leg Fillet Weld

When necessary or requested, a multi pass weld with 6 passes is common, and it still has a throat of
3/8”. This is shown as an option to the standard 3-pass fillet weld, as illustrated on the Handhole Caps
Removal & Welding Guidelines installation sequence ~ handhole - cap.

Page 20
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

2.1.10 Weld Traveler

Unit I.D. &

Pressure Part:
Welding Procedure

Header & Cap(s):

H = Hold Point, No work to proceed beyond the task item until the hold item is checked, and signed off.
V = Verification, Work may proceed beyond the task, but it shall be noted as being checked, by leadman, foreman, or
supervisor on shift, so as not to hold up the work. There will be a final sign off of this “V” by owners’
representative.

HOLD

HOLD

HOLD
STEP

ITEM & DESCRIPTION Contractor CUSTOMER A.I.

Hand Hole Cap Installation Sign-Date Sign - Date Sign-Date

1 REMOVAL OF EXISTING HANDHOLE

CAP
2 CLEAN-UP HEADER AND SEAT

3 NDE-EXAMINATION OF CLEANED
HEADER – PT/MT

4 WELD BUILD UP OF HEADER (IF

REQUIRED)
Preheat Monitored@_________F

5 NDE - EXAMINATION OF HEADER

BUILD UP – PT/MT
(may be waived for final PT)

6 INTERNAL HEADER INSPECTION (prior

to closure)
7 FIT –UP OF NEW CAP – ORIENTATION &
TACKING
Review weld bead sequence
8 PREHEAT – MONITORED
@ ___________F

9 ROOT PASS

10 WELDING OUT

11 INSPECTION – COMPLETED WELD –

FINAL VISUAL / PT, WFMT or MT Dry

Page 21
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

References:
1. Master Hand Hole (MHH) Plug Welding Recommendations, Babcock & Wilcox Plant Service
Bulletin # 53, Babcock .com
2. ALSTOM's APComPower's Quarterly Newsletter "Tidbits", Issue #107, October - December 2002

Page 22
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

2.2 Weld Repair of Small Holes / Cracks in Superheater Tubes

2.2.1 Introduction

a. This procedure applies once the need for a repair has been determined. Refer to Forward and Associated
Technical Bulletin for guidelines to determine need for repair. Jurisdictional requirements should be
considered and followed.
b. Small holes/cracks in superheater tubes may be weld repaired. The tubes being steam-filled, the
internal surfaces should be free of deposits; therefore, there is little risk of weld contamination.
c. Types of holes/cracks in tubes that may be repaired if the criteria in 2.0 are met
d. Crack originating on the external surface at an attachment weld
e. Torch cut occurring during repairs
f. Excessive grinding during repairs
g. Deliberate grinding for known purposes, such as draining of superheater tubes
h. Mechanical damage from sharp tools driven into tubes
i. Attachment weld pulled from tube, which pulls out tube metal
j. Arc strikes that are severe enough to blow a hole in a tube
k. If the cause is internal corrosion pitting or fatigue, the tube section must be replaced.

2.2.2 Evaluation

a. Criteria for weld repair of small holes/cracks in superheater tubes

b. After preparation for welding the excavation does not exceed:
c. 1/8” in width at the root
d. 25% of the tube circumference for circumferential length and 2” for longitudinal length (the
limit on circumferential length is due to stresses in welds that do not run the entire
circumference. These stresses are not a problem in longitudinal welds. The longitudinal length
limit is intended to restrict the length of longitudinal repairs in lieu of sectioning).
e. Root cause is known, i.e., torch cut mechanical damage, etc.
f. Assuming there are no other thin areas, tube thickness adjacent to the area to be repaired is not
less than Code minimum.
g. There are no branched cracks running from a crack intended to be repaired, as determined by
MT or PT examination
h. The tube area adjacent to the repair area is free of distortion inward or outward from the normal
plane of the tube surface

Page 23
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

2.2.3 Materials

a. Welding materials shall be qualified for use by the Welding Procedure Specification (WPS).

2.2.4 Procedure

2.2.4.a Weld repair procedure for a torch cut, grinder cut, sharp tool damage or severe arc strike

a. Measure the hole

b. Take thickness measurements immediately adjacent to the hole and compare the measurements
to minimum allowable wall thickness
c. Remove all contaminants at the edge of the hole and bevel the edges to an approximate 37 ½
degree angle as for a butt weld
d. Make the repair per approved welding procedure.
e. Ensure interpass temperature for the chrome-moly material is not exceeded.
f. The root pass, and preferably the hot pass, should be made by the GTAW process to assure a
full penetration weld if the repair is through-wall.

2.2.4.b Weld repair procedure for cracks

a. Determine the length of the crack by MT or PT examination. Ensure that there are no branched
cracks.
b. Take UT thickness measurements adjacent to the crack to ensure Code minimum thickness
c. If a crack adjacent to a tie weld or a spacer type tie (dovetail, “D” link or hinge pin sleeve) is to
be repaired, remove the tie weld or spacer tie. When a spacer tie is removed, check the area
adjacent to the weld repair with a copper sulfate solution to identify any remaining stainless or
alloy material. All stainless or alloy material must be removed prior to making the weld repair.
d. Grind out the crack. Check for complete removal by MT or PT examination. The crack must be
completely removed.
e. Make the repair per approved welding procedure.
f. Ensure interpass temperature for the chrome-moly is not exceeded.
g. The root pass, and preferably the hot pass, should be made by the GTAW process to assure a
full penetration weld if the repair is through-wall.
h. Reinstall the tie 2”, +/- 0.5”, above or below the weld repair.

2.2.5 Acceptance

a. Traveler documented at the discretion of the owner and repair contractor.

Page 24
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

b. Final inspection, testing, and documentation of repairs

c. Examine the finished weld, visually and by MT or PT.
d. Documentation of hole/crack repairs in superheater tubes is at the discretion of the plant,
however, a Report of Welded Repair may be required by jurisdictional requirements. If the
repair is required because of an unscheduled outage, the repair should be documented in a
failure report.
e. Information concerning the repair should be recorded as outlined below.
i. Date of repair
ii. Platen number, tube number, row number and elevation should be recorded.
iii. Cause of the hole
iv. Size of the hole
v. Person authorizing the repair
vi. Welding inspector accepting the repair

2.2.6 Reference

The AF&PA Recovery Boiler Reference Manual Volume II Maintenance and Repair Analysis: Repair
Guidelines and Practices 3.7.1.112

Page 25
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

2.3 Repair of Pressure Boundary Materials in Tubes

2.3.1 Introduction

This procedure applies once the need for a repair has been determined. Refer to the General Welding
Forward and Associated Technical Bulletin for guidelines to determine need for repair. Jurisdictional
requirements should be considered and followed.

Erosion or corrosion of boiler tubes may occur over large areas or may be confined to relatively small
spots. The repair options vary according to the severity of the metal loss, the area of coverage, the type
boiler, the location in the boiler, etc. Weld buildup may be used for repair of eroded, corroded, or
mechanically damaged tubes when the defects do not exceed those listed under Special Restriction in
this document.

2.3.2 Evaluation

Ultrasonic thickness measurement or other nondestructive techniques shall be used to map the extent
of thinning and assess the size of the area to repair. Visual examination shall also be conducted to look
for any evidence of cracking or bulging of tubes. It is recommended that the last water wall tube
sample data be reviewed to determine if water side deposits is a contributing factor to the thinning
observed. Also, if there are high amounts of copper present in the waterside deposits, a problem with
tube metallurgy (embrittlement) could be caused during welding.

2.3.3 Materials Selection

The area can be repaired using material conforming to the original code of construction including the
material specification requirements.

2.3.4 Special Restrictions

This procedure should only be used on recovery boilers only when the following criteria are met:
 The remaining thickness of the pressure boundary base material is:
o Sufficient to prevent burn through dependant upon welding process
o If below minimum wall thickness additional considerations should be applied
 Size of thinned area
 Location in unit
 Local jurisdictional requirements
 Remaining wall thickness
 Other applicable codes and regulations
 When the tube surface is free of defects such as bulges or cracks
 The surface must be free of material that could be detrimental to welding. This normally
requires grit blasting to a white metal finish, or localized grinding.

Page 26
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

2.3.5 Welding

During the welding process, there should be a welding inspector onsite to witness the entire repair as it
is being performed.

Welding Technique
Welding current that will produce complete-fusion without burn through. Fill the repair area with a
series of stringer beads, except that weaving is permitted in the vertical position to a maximum width
of about 2-1/2 times the electrode diameter. Deposit thin beads to minimize melt through.

More than one layer is permitted if the first layer does not completely fill the wasted area.

Cleaning and Removing Defects

All unfused weld metal, voids, slag, weld splatter, and irregularities should be removed from each
weld bead before depositing a succeeding weld bead. If burn through or melt through is suspected, the
tube section should be replaced or examined radiographically or ultrasonically (see final inspection).

Weld Finish
The surface of the completed weld shall be ground free of weld surface irregularities. The edge of the
weld shall merge smoothly into the surface of the tube, but the tube should not be ground under-gauge.
A slight crown or reinforcement up to 1/16” may remain and shall not exceed the width of the wasted
area by more than 3/16 of an inch.

2.3.6 Final Inspection

Close visual examination by a welding inspector is required for all welded repairs.
The integrity of the repair shall be verified by one of the following methods for pressure boundary
repairs where a failure is not likely to allow water to enter the furnace:
 Magnetic particle testing (MT)
 dye penetrant examination (PT)
 hydrostatic test
For repairs where failure is likely to allow water to enter the furnace MT or PT shall be performed
prior to a hydrostatic test.

Hydrostatic Testing
The hydrostatic test pressure shall be adequate to verify the integrity of the repair.

2.3.7 Documentation

The location, extent, filler materials and base material shall be documented and maintained for future
reference.

2.3.8 References

ASME PCC-2 – 2006 Article 3.4

Page 27
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

2.4 Corrosion Resistant Weld Overlay Applications on Tubes (Future)

Page 28
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

SECTION 3 - MATERIALS

GENERAL MATERIALS FORWARD

Recovery boiler operation at higher pressures, temperatures and liquor solids has resulted in increased
corrosion and deterioration of furnace tubes and boiler components. Examples of significant new
materials introductions in the past 30 years to resist recovery boiler corrosion are composite and
chromized tubes, weld overlaid tubes and different thermal metal spray coatings. Likewise, new
refractories and nonmetals have been introduced in efforts to protect fireside components, and for
application in specialized use areas such as smelt spouts. Duplex stainless steels have been more
recently used to provide resistance to stress corrosion cracking of tanks and vessels.

The BLRBAC Materials and Welding Subcommittee provides a format to review areas where
materials applications have been successful, as well as where there have been failures. This is done
using the combined expertise of the subcommittee membership – personnel representing OEM’s,
owner-users, repair contractors, insurance and consultants.

The subcommittee has also initiated surveys to evaluate current materials practices, and the relative
success of these practices. The objectives of the surveys are to assist the subcommittee in defining
damage mechanisms, causes, operating issues and materials solutions. Examples have been surveys on
materials for black liquor nozzles, smelt spouts and smelt spout steam shatter jets.

The Materials and Welding Subcommittee welcomes comments and suggestions for new materials’
applications, or ideas where materials may be better used for solving old and arising recovery boiler
problems.

3.1 Materials Surveys Results:

3.1.1 Black Liquor Nozzle Wastage

3.1.2 Scope

A survey was conducted to identify the common causes and solutions to corrosion of black liquor
nozzles and piping.

3.1.3 Corrosion Characteristics

Wastage of black liquor nozzles and piping have been reported to have the following characteristics:
 Corrosion at the top of the 45 elbow before the nozzle
 Corrosion of the nozzle body
 Corrosion of the splash plate

3.1.4 Causes of Corrosion

The following were reported to be suspected causes of corrosion of black liquor nozzles and piping:

Page 29
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

 Extension of nozzle too far into the furnace

 Plugging (scaling) of piping and subsequent overheating
 Small liquor gun port size and subsequent minimal cooling air flow
 Insufficient port cleaning and subsequently reduced cooling air flow

3.1.5 Operating Issues

The following operating issues were found to be directly related to the occurrence of liquor nozzle and
piping corrosion:
 Excessive carryover and the adoption of suspension firing caused smelt to flow down the
furnace walls and onto the liquor nozzles.
 Increasing the black liquor solids from 68% to 76% resulted in liquor nozzle corrosion.

3.1.6 Mechanical Solutions

 Retract liquor guns closer to the furnace wall

 Rod/clean liquor gun ports more frequently
 Position liquor gun at the center of the port to achieve even air flow around gun
 Increase secondary air flow

3.1.7 Materials Solutions

The following materials were reported to provide satisfactory life of liquor nozzles and piping in order
of decreasing effectiveness:

 Allstel (55 % Cr / 45 % Ni)

 50% Cr/ 50% Ni
 Stellite
 Duplex (example 2205)
 Inconel
 Type 316 stainless steel
 Type 304 stainless steel

Black liquor nozzle life was reported to range from two months to 12 months using stainless steel. The
life of stainless steel black liquor piping was reported to be in the range of three months to two years.

Page 30
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

3.2 Smelt Spout Materials Survey

3.2.1 Scope

A survey was conducted to identify common materials and operating solutions for addressing
corrosion of carbon steel smelt spouts. The specific form of corrosion being addressed involves
wastage of the spout at the smelt exit end in the vicinity of the steam shatter jets.

3.2.2 Corrosion Characteristics

The smelt spout wastage is characterized as affecting as little as the lower six inches of the smelt spout
trough to as much as 75% of the trough length. Corrosion can also affect the discharge lip of the spout,
the bottom of the outer trough, end plate and any cooling piping located in the vicinity of the smelt
exit. The corrosion does not necessarily affect all smelt spouts on the boiler to the same degree.

3.2.3 Causes of Corrosion

The following were cited as possible causes of corrosion of smelt spouts at the smelt exit end:
 Low cooling water temperature
 Condensation of vapors within the smelt spout enclosure
 High dissolving tank level resulting in excessive vapor formation
 Inadequate venting through the dissolving tank vent stack
 Splashing due to excessive smelt shattering
 Misalignment of the smelt shatter jets and splashing on the spout

Page 31
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

 Splashing of weak wash onto the spouts

3.2.4 Materials Solution – Weld Metal Overlay

The following materials applied in the form of weld overlay were reported to be successful in resisting
corrosion and provide a minimum service life of twelve months.

 Austenitic Alloy Steel (18% Cr)

 Austenitic Alloy Steel (25% Cr)
 Inconel 625 (8 % Mo)
 Inconel 622 (12 % Mo)
 Hastelloy C276
 Alloy 72 (40 % Cr)

Weld overlay should be done from 3:00 to 9:00 positions on the spout to cover the tide line; overlay
can be done over one foot at the discharge tip of the spout, and should cover the end plate, and wrap
around to cover the bottom one inch of the outer trough. The transition inside the trough should be
ground to provide a smooth transition of the different materials, or it can be applied the entire length of
the spout trough.
The following material(s) applied in the form of weld overlay were reported to perform satisfactorily
in some cases but not in others:
 Hastelloy C
The following material(s) applied in the form of weld overlay were reported to perform poorly:
 Inconel 600
Erosion at the transition from an eddy effect can cause early failure if a smooth transition is not
prepared.

3.2.5 Materials Solutions – Miscellaneous Forms of Corrosion Protection

The following forms of corrosion protection were reported to perform satisfactorily in some cases but
not in others:
 Thermal spray coating (45CT)
 Chromizing

3.3 Smelt Spout Steam Shatter Jet Materials Survey

3.3.1 Scope

A survey was conducted to identify materials solutions for wastage of smelt spout shatter jets and
associated piping/assemblies.

Page 32
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

3.3.2 Corrosion Characteristics

Wastage of smelt spout shatter jets and associated piping/assemblies have been reported to have the
following characteristics:
 Wear of steam holes
 Wastage on top of shatter jet assembly
 Wastage of steam feed piping

3.3.3 Causes of Corrosion

The following were reported to be suspected causes of corrosion of steam shatter jets and associated
piping/assemblies:
 Erosion of steam holes due to high velocity
 Smelt corrosion
 Insufficient cooling due to smelt pluggage

The survey showed that steam shattering systems are operated in the range of 60 – 165 psi and 310 –
400F. There was no relationship between the occurrence of corrosion and the pressure or temperature
of the shattering steam.

3.3.4 Materials Solutions

Type 304L stainless steel was reported to be effective in minimizing corrosion of steam shatter jets and
associated piping/assemblies. Type 304L stainless steel was reported to perform satisfactorily when
used as a monolithic and as a weld overlay over carbon steel.

316 can be used in nozzle designs to preserve attachment welds.

Page 33
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

3.4 Materials – Miscellaneous (Future)

Page 34
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

SECTION 4 – TEMPORARY REPAIRS (Future)

Page 35
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

SECTION 5 – REFERENCE SECTION

5.1 OEM & Service Providers

1. Babcock and Wilcox

2. Alstom Power
3. Southeastern Mechanical Services
4. George Bodman, Inc.

5.2 Technical Sources:

AF&PA, API, ASME, ASNT, TAPPI, BLRBAC, NBIC, NACE,

Page 36
 Black Liquor Recovery Boiler Advisory Committee
Materials and Welding Guidelines for Black Liquor Recovery Boilers October 2010

APPENDIX A DOCUMENT REVISION HISTORY

April 2009

First publication of document.

Page 37