Technical Paper

Induction Heating Tube Shrinking for Generating Bank Re-Tubing

W. Blaser, G. Gemmell and G. Bedford Babcock & Wilcox Canada, Ltd. Cambridge, Ontario, CA

Presented to: 91st Annual Meeting of the Pulp and Paper Technical Association of Canada February 10, 2005

BR-1759

INDUCTION HEATING TUBE SHRINKING FOR GENERATING BANK RE-TUBING Wade Blaser
Babcock & Wilcox Canada, Ltd. 11191 Coppersmith Place Richmond, BC V7A 5H1

George Gemmell
Babcock & Wilcox Canada, Ltd. 11191 Coppersmith Place Richmond, BC V7A 5H1

Greg Bedford
Babcock & Wilcox Canada, Ltd. 581 Coronation Blvd. Cambridge, Ontario NIR 5V3 ABSTRACT Induction heating is used to rapidly heat generating bank tubes in situ to 1000 degrees C, which causes plastic deformation due to thermal expansion under restraint by the tube sheet (drum). When cooled, the tube shrinks, breaking contact with the drum, allowing ease of removal. The process is safe, clean, and eliminates the risk of tube seat damage often caused by the traditional tube removal processes of arc air gouging or flame cutting. This paper describes the technology, the process and experience in removing tubes during a recent power boiler generating bank replacement. OVERVIEW Review of traditional generating bank retubing approach and methodology. Induction Heating Tube Shrinking (IHTS) technology description. The initial developer of the IHTS technology, Dai-Ichi High Frequency Co., Ltd. and its exclusive North American licensee, Babcock & Wilcox Canada, Ltd. Job planning and execution. Safety features. Summary of the benefits of IHTS technology. TRADITIONAL GENERATING BANK RETUBING Babcock & Wilcox Canada, Ltd. (Babcock & Wilcox) has several decades of experience in safe

and efficient generating bank tubing replacement. Many thousands of tubes have been replaced as part of ongoing boiler maintenance and rebuilding projects. Babcock & Wilcox averages three to five major generating bank tubing replacement projects annually. Traditional methods of tube removal are timeconsuming and highly labour intensive, create a poor work environment (smoke, sparks, fumes, heat and noise), demand extraordinary safety precautions, and carry significant risks to schedule and cost. Traditional methods also depend heavily on trade skills and inevitably result in significant repair and rework to the drum seats. Carbon arc gouging is typically used extensively in the demolition phase of all generating bank re-tubing jobs both for splitting of tube stubs in the drum seats of both steam and mud drums, and in cutting of the tube straights between the drums into manageable lengths for removal from the boiler and boiler house. Carbon arc gouging is also typically employed for the removal of the belled tube ends (where required), as well as for the removal of tube-todrum seal welds that are encountered in many jobs. The arc gouging process, although fast and effective, has several limitations and safety implications. If not carefully performed by a highly skilled operator, it can result in significant repair requirements to the drum tube seat area. Due to the nature of this process, special protective clothing and breathing equipment are needed, and there is a requirement for ventilation of fumes from the work area. While gouging is in progress, very limited activity is permitted in the immediate area and in areas below the work. This places the tube removal work on the critical path of the generating bank re-tubing job, with little opportunity to shorten schedule because of confined space and associated work hazards. IHTS TECHNOLOGY DESCRIPTION Induction heating technology revolutionizes tube removal by eliminating the need for carbon arc gouging, which permits more work to be done in parallel, thus reducing the span of critical path work. The reduction of tube seat dressing and elimination of tube seat repairs adds certainty to scheduling and reduces the risk of a hydrostatic test failure. The IHTS hardware consists of a high frequency power unit, an induction heating coil, an output-matching transformer, a remote on-off

switch, and interconnecting coaxial cables and cooling water hoses. Optional auxiliary water cooling units may be used if suitable plant water is not available. Many aspects of IHTS involve patents and proprietary knowledge. Induction heating is a technique for heating metal by utilizing the interaction between current and magnetic flux. It permits the selective, rapid, concentrated, local heating of metals without contact. The subject tube stub heats up rapidly (in seconds) to approximately 1000 degrees C. Once the tube stub has been heated over the entire tube seat area, the induction coil is removed from the tube stub and compressed air is introduced into the heated area to rapidly cool the tube stub. Because the heated area of the tube stub is constrained by the drum seat, it expands beyond its elastic limit. Rapid cooling causes the tube stub to shrink to a smaller outside diameter, which loosens it from the drum. The loosened stub is then simply removed with the use of hand tools. There is no physical contact between the induction heating coil and the tube stub. The process is entirely computer controlled, safe, simple, clean, and extremely effective in loosening tube stub ends from the boiler drums without any damage to the tube seats. THE INITIAL DEVELOPER OF THE IHTS TECHNOLOGY, AND ITS EXCLUSIVE NORTH AMERICAN LICENSEE, BABCOCK & WILCOX CANADA, LTD. The initial developer of the IHTS technology, Dai-Ichi High Frequency Co., Ltd. (DHF) of Tokyo, Japan, was established in 1950. The company has two manufacturing plants and twelve sales offices. There are four divisions involving high frequency induction heating techniques: large diameter heavy wall pipe bending, metallurgical heat treatment, equipment development and applications, and research. IHTS was developed by DHF and has been used for many years. Thousands of boiler tubes have been removed using this method. The process has also been used on United States Navy marine boilers. Induction heating used for removing hightension (hold down) bolts was also developed by DHF and is available through another North American licensee.

DHF is research- and development-focused, and many aspects of its technology are being patented throughout the world. BABCOCK & WILCOX HAS EXCLUSIVE RIGHTS TO USE THE IHTS TECHNOLOGY FOR TUBE REMOVAL ON ALL TYPES OF BOILERS AND HEAT EXCHANGERS IN NORTH AMERICA. Babcock & Wilcox has carried out an extensive evaluation process on this technology since 2003. Mock field trials were conducted at the British Columbia Institute of Technology. Field trials were conducted at a customer site in British Columbia, and an entire 1,426 tube power boiler generating bank was replaced using this technology at a New Brunswick customer site. Extensive analyses of set-up, safety, and skill requirements have been conducted. Typical tube stub removal rates have been established. The potential impact to the drum seats has been thoroughly analyzed and determined to be negligible. Drum shell heat absorption has been measured and determined to be well within acceptable limits. Extensive testing and development of ancillary and support tooling has been carried out within Babcock & Wilcox facilities and on jobsites. This technology represents significant investment, analysis, development, and licensing costs for Babcock & Wilcox. Babcock & Wilcox is committed to an ongoing program for the development, optimization, and refinement of auxiliary and support processes and tooling for the realization of additional benefits from the IHTS technology in North America. JOB PLANNING AND EXECUTION A preliminary assessment of the work area is carried out prior to planning the job. This assessment includes the boiler bank layout, dimensions, tube count, steam drum internal arrangement, seal-welded or plugged tubes, areas for staging and pre-storage, building access and egress, hoist well location, locations of concrete and grating floors, adjacent structural steel, potential areas for power unit location, cable and cooling water hose run access, pre-determination of tube stub internal diameter range for advanced custom fabrication of the coils, and determination of facilities for training.

Planning includes all job set-up requirements, sequencing, and scheduling of tasks after full determination of the specific job methodology. Site utilities requirements are standard and include 220-240 volt power supply, sources of cooling water and plant air. Heating of the tube stubs is accomplished by one operator handling the gun/coil by means of a remote control on-off switch. The coil is inserted in the tube stub and the tube stub is inductively heated. The drum shell restricts thermal expansion of the tube stub; the tube stub yields. Thermal contraction during cooling reduces the tube diameter. The stub is removed from the drum. The induction heating coil is water-cooled and includes highly heat-resistant materials and insulation. Cooling of the heated tube stubs is accomplished with a simple compressed air nozzle fitted with a self clamp to hold the nozzle in the stub during the short cooling cycle in instances where the stubs are located overhead. Extraction is accomplished by the stub falling out of the drum or removal by hand. If required, especially where multiple grooves are located in the tube seat, a hammer and anvil set is employed to remove the stub. A second heat cycle may be required in a few cases. Minor cleaning (brushing) of the tube seat is all that is required before stabbing and rolling of the new replacement tubes. In contrast, traditional removal techniques typically result in damage to the tube seat and require time-consuming repairs. SAFETY FEATURES Key safety features include full digital control with touch-screens; separate monitoring of the power unit outside of the drums; and no sparks, smoke, fumes, ultraviolet flashes or radiation. As a result, less protective clothing is required and several other job steps can run concurrently in the area during the stub removal procedure because of the non-intrusive and cleaner environment around the IHTS process. SUMMARY OF KEY BENEFITS 1. The IHTS process enables significantly reduced generating bank replacement outage duration through the overlapping of several job steps. Heating, cooling, extraction, hole inspection, and straights demolition may all occur concurrently.

2. Minor cleaning of the tube sheet is all that is required. In contrast, traditional tube removal techniques typically result in damage to the tube seat and require timeconsuming repairs. 3. Dry hydro. 4. Low heat input to drum. No risk of damage to ligaments. No hardening of tube seat surface. 5. No flame, no sparks, no smoke. 6. Reduced skill requirements. 7. Greatly improved safety and work environment. Noise, dust and fumes are eliminated. 8. Opportunity to carry out other work tasks during the re-tubing due to a cleaner work environment. 9. Reduced tube stub removal time; shorter outages.
The information contained herein is provided for general information purposes only, and is not intended or to be construed as a warranty, an offer, or any representation of contractual or other legal responsibility. 2005, Babcock & Wilcox Canada Ltd. All rights reserved. Disclaimer Although the information presented in this work is believed to be reliable, this work is published with the understanding that The Babcock & Wilcox Company and the authors are supplying general information and are not attempting to render or provide engineering or professional services. Neither The Babcock & Wilcox Company nor any of its employees make any warranty, guarantee, or representation, whether expressed or implied, with respect to the accuracy, completeness or usefulness of any information, product, process or apparatus discussed in this work; and neither The Babcock & Wilcox Company nor any of its employees shall be liable for any losses or damages with respect to or resulting from the use of, or the inability to use, any information, product, process or apparatus discussed in this work.