Abstract
This study addresses a comprehensive analysis of the failure mechanism in the grill tubes of a mixed boiler used to generate saturated steam in a manufacturing plant. After a renovation in 2020, early pipe failure in 2021 raised concerns. Methods such as liquid penetrants, thickness measurement and computer simulation were used in this study. Results indicated that the work regime, thermal cycles and mechanical flexural loading contributed to the failures. Deviations in the original design, such as the lack of reinforcements and the reduction in recommended tube thicknesses, were also identified. The multidisciplinary analysis strengthened the evidence of the failure mechanism due to corrosion, fatigue and cracking. The study identified causes and also provided valuable information to improve boiler reliability and performance.
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