Erosion Shields
Erosion Shields are designed to eliminate major maintenance and downtime costs from boiler and condenser tube failure.
Learn about Boiler Tube Shields and their crucial role in protecting boiler efficiency and safety. Discover how they reduce heat loss, prevent corrosion, and ensure safe operations.
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Boiler tubes operate in harsh conditions. Inside, they have to withstand high pressure and temperature of the working fluid. Outside, they have to withstand flue gas erosion, fly ash abrasion, sootblower cleaning pressure and high furnace temperature. All of these can be potential causes of tube leakage leading to unplanned downtime. There are several ways to prevent this, but a boiler tube shield is the most cost-effective precaution. It's a cheaper solution than replacing damaged tubes, not to mention the downtime and loss of power generation associated with tube leakage.
Erosion & abrasion doesn't affect all boiler tubes equally. Only tubes close to coal burners and soot blowers or windward tubes in certain areas have a higher chance of it. It's about 20% of the boiler heating surface. We can install boiler tube shields selectively in areas prone to tube leakage. Tube shield can protect boiler heating surface such as superheater, reheater, economiser, waterwall and extend the service life to generate more avenue for plant owner.
Tube shields can be customised to suit any tube size. Common tube diameters are 32, 38, 42, 44.5, 48, 51, 57, 60, 63.5, 76, 89mm, etc. Most tube shield could cover 180° segment of tube surface. When used for membrane waterwall, it could be 120-160°. The most popular thickness is 2mm to 5mm.
The thickness of these shields typically ranges from 2mm to 5mm, chosen based on the severity of wear and the need for heat conduction. The cross-sectional shape is often semi-circular (180 degrees), but variations between 120 to 160 degrees are also available, especially for finned tubes.
Boiler Tube shield is made by moulding and pressing machine. For curved tube shield, bending machine is required. Our product is characterised by good weldability, short delivery, smooth surface, beautiful appearance, etc.
By installing these shields, the service life of boiler tubes is significantly enhanced, reducing maintenance costs and preventing unexpected failures.
Most tube shields cover approximately 180 degrees of the tube surface, providing substantial protection. However, when applied to membrane waterwalls, which are specialized sections of boilers where water is contained and heated, the coverage may range from 120 to 160 degrees. This variation accommodates the specific design and heat distribution requirements of these areas.
The thickness of tube shields typically ranges from 2mm to 5mm, with the choice depending on the application's demands. Thicker shields offer greater protection against high temperatures and corrosive environments but may be heavier and more expensive. Materials used can include metallic, ceramic, or composite options, each suited to different operational conditions.
Installation methods may vary, with some shields slipped over tubes like sleeves, while others are welded in place. Given the harsh operating conditions of boilers, regular inspection and maintenance are crucial to ensure the shields' effectiveness and the overall safety of the system.
Boiler tube shields contribute to reducing heat loss and improving boiler efficiency by insulating the tubes and reflecting heat back into the system. This insulation helps maintain optimal operating temperatures and reduces energy consumption.
Boiler tube shields are essential components in boiler systems, offering customizable protection tailored to specific applications. Understanding their design, installation, and maintenance is key to optimizing boiler performance and safety.
To reduce excess wear of boiler tubes within the extreme conditions prevalent inside a fossil fuel fired boiler, Sunny Steel is able to manufacture and supply erosion shield solutions to protect and reduce wear in all applicable boiler related situations. Erosion shields to suit any O/D tube can be manufactured from various alloy and stainless steel materials.
Furthermore our shields are manufactured to fit any configuration of pipe bends to protect both inner and outer bend surfaces. Using our our custom designed roll former we are able to manufacture and supply shields in lengths of up to 12 meters.
The cross-sectional shape of boiler tubes shields is mostly semi-circular (180 degrees), and there are also 120-160 degrees.
It is mainly used on finned tubes (water-cooled walls); boiler tube erosion shields are divided into direct wear-resistant shields, in-curve, anti-wear shields, outer-curve, anti-wear shields, side-curve anti-wear shields, s-curve anti-wear shields, etc.
The length of the straight anti-wear shields ranges from 20mm to 3000mm, and the general length of 1000-2000mm is commonly used. The anti-wear shields with bends generally requires a processing drawing and the following parameters should be on the drawing: outer diameter of the pipe used, bending of the pipe Radius R (to the center of the pipe), the degree of bending angle, and the length of the straight sections on both sides of the arc segment of the wear-resistant shields.
The most basic parameter of boiler tubes shields is the outer diameter of the tube used (that is, the inner diameter of boiler tubes erosion shields). The main specifications of the tube are: 32, 38, 42, 44.5, 48, 51, 57, 60, 63.5 , 76, 89mm, etc . the inner diameter of the boiler tubes erosion shields is usually 1-3mm larger than the outer diameter of the tube used, depending on the actual requirements.
The current production process for tube shields is to use high-pressure presses and professional moulds for pressing.
Tube shields from us are manufactured to exacting standards. Advanced equipment and material handling capabilities permit us to offer the fastest turnaround times anywhere.
The current production process for tube shields is to use high-pressure presses and professional moulds for pressing.
The production time is short, the welding performance is good, the welding seam does not fall off, the surface is smooth and the appearance is beautiful. The arc-shaped wear-resistant tile is pressed on a press or bent on a pipe bender with a special mould.
To ensure the accuracy of the material. Positive Material Identification (PMI) of stainless steel sheets for tube shields is critical to verifying the grade and composition of stainless steel before it goes into production.
The raw materials for the production of tube shields are generally purchased directly from standard steel mills, and each batch has an MTC. Due to the sharpe limitations of raw materials, it is inevitable that excess materials will be produced. We can use the excess material to make a smaller size snap ring.
Different types of stainless steel are selected according to the specific conditions of different working conditions.
The boiler was originally designed to be accurate. Different materials have different temperature resistance and mechanical strength, generally has a temperature resistance of 600 ℃ or less.
We can also supply boiler tubes erosion shields of other materials.
Tube shields are custom made to fit perfectly to straight sections, curved sections and even finned and specialised tubing.
Boiler tube erosion shields, also known as anti-corrosion shields, anti-wear plate, anti-wear protection shields, anti-wear cover plate, anti-corrosion cover plate, boiler climbing pipe, anti-wear pressure plate, etc. , which are used in combination with snap rings.
Boiler tube erosion shields are produced using a high-pressure press and professional mould pressing. The production time is short, the welding performance is good, the welding should not fall off, the surface is smooth, and the appearance is beautiful. Boiler tube erosion shields with bends are formed by pressing on a press or bending with a special abrasive on a tube bender.
Boiler tube shields are designed to eliminate major maintenance and downtime costs from boiler and condenser tube failure.
The service life of boiler tubes erosion shields is different in different types of boilers and different use parts.
The normal service life is a period of overhaul (3-5 years) for the boiler. Generally, some boilers will be replaced or retrofitted every time the boiler is overhauled. The main replacements are those of the Boiler Tubes Erosion Shields that are severely thinned and exceeded the standard; those that were not firmly detached during the boiler operation during the previous installation. According to the wear of the Boiler Tubes Erosion Shields during replacement, if the thickness is severely reduced, it needs to be replaced, the deformation is severe, and those that cannot protect the tube also need to be replaced. In addition, some boiler tubes are not equipped with Boiler Tubes Erosion Shields, but during the boiler inspection, it is found that the tubes have a tendency of wear and thinning. Generally, Boiler Tubes Erosion Shields are also installed to prevent further wear of the tubes and cause serious consequences such as boiler explosion.
On the heating surface of superheater and economizer tube bundle of the boiler, in order to prevent the pipe from being worn by high temperature flue gas washing, boiler tubes erosion shields are mostly arranged on the outer side of the pipe in the direction of flue gas flow. The elbow erosion shields solves the abrasion problems of water wall tubes, superheater tubes, economizer tubes and reheater tubes in the furnace, and provides guarantee for the long-term and reliable operation of CFB boiler. With the increase of CFB boiler products, the type and quantity of The elbow erosion shields will increase.
Our understanding of and commitment to the steam and power generation business enables us to solve your boiler tube erosion or corrosion problems efficiently. Our technical staff can quickly recommend the proper material type and configuration to meet your needs…and can quote your outage delivery requirements on a month basis.
Do you accept a special order?
A: Yes, we do. We can manufacture all kinds of chemical equipments according to your technical drawings(Before you givethem to us, will sign the contract and confidentiality agreement with you. You don’t need to worry about that.)
Can you make a design for us?
A: Yes, we can. What we supply is not only product, but also solution and design. And if you make the product in our factory,the design will be free. If not, design fees will be charged accordingly.
Q: Do you provide after-sales service?
A: Yes, we do. This product is guaranteed up to one year from purchase unless manmade damage. If there is anything wrongwith product itself quality problem,we will change or repair it at our charge.If not, we will provide aftersales service at your charge.
Tube erosion shields are mainly used on the windward side of the heating surface of the boiler, such as superheaters, reheaters, economizers, and water-cooled wall pipes.
Erosion shields are used to protect boiler tubing from the highly erosive effects of high temperatures and pressures thereby greatly extending tube life.
We offer shielding for tubing, covering straight, bent and finned sections, as well as the clips that hold these in place.
In the long term, these shields more than pay for themselves, preventing the costly replacement of tubing and avoiding the downtime that results from tube breakdown and leaks.
In general, most of them are called “wear-resistant tile” and “wear-resistant cover plate”. Erosion Shields are special boiler accessories.
Generally, most of them are used in power station boilers, small boilers are used less, and some coal chemical industries will also use them.
The main role is to protect the heating surface of the boiler pipes, reduce pipeline wear, and increase the heating surface of the pipes.
Generally, boiler tubes erosion shields are also installed to prevent further wear of the tubes and cause serious consequences such as boiler explosion.
The main role is to protect the heating surface of the boiler pipes, reduce pipeline wear, and increase the heating surface of the pipes.
The snap ring is a short section that is installed on the pipe in conjunction with the wear-resistant tile. Generally, it is welded to the wear-resistant tile by lap welding, that is, to cover the wear-resistant tile slightly, so it is larger than the wear-resistant tile. The opening arc is around 190-200 degrees, the welding position needs to be set aside to facilitate welding and fixing. The width of the snap ring must not be less than 20mm.
The installation requirements of anti-friction tiles of different shapes are slightly different. Basically, each anti-friction tile is installed with not less than 2-4 snap rings. The snap ring and the anti-friction tile are welded together to prevent expansion due to heat. The tiles fall off, and the joints are required to be fully welded.
Generally, boiler tubes erosion shields are also installed to prevent further wear of the tubes and cause serious consequences such as boiler explosion.
The main role is to protect the heating surface of the boiler pipes, reduce pipeline wear, and increase the heating surface of the pipes.
Ceramic lined pipe is made through self-propagating high-temperature synthesis (SHS) technique.
Cast basalt lined steel pipe is composed by lined with cast basalt pipe, outside steel pipe and cement mortar filling between the two layers.
Ceramic tile lined pipes have very uniform coating of specially formulated ceramic material that is affixed to the inner of the pipe.
The material of the rare earth alloy wear-resistant pipe is ZG40CrMnMoNiSiRe, which is also the grade of rare earth alloy steel.
Tubes Erosion Shields are used to protect boiler tubing from the highly erosive effects of high temperatures and pressures thereby greatly extending tube life.
The ASTM A213 T91 seamless tubes are primarily used for boiler, superheater, and heat-exchanger.
When you partner with Sunny Steel, you can stop worrying about meeting deadlines thanks to our responsive and timely service. You'll also say goodbye to unnecessary shopping around. Instead, you'll get white glove service from an expert who understands your needs and can get you the materials you need quickly.
