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Stress development in epoxy coatings applied in water ballast tanks (WBT) on ships can lead to cracking, corrosion, and failure of ship’s hulls, with catastrophic consequences to the environment as well as loss of seamen at sea. Typically, these cracks do not appear during application and curing of the coating but after some finite time of service. The financial wellbeing of the ship’s owner can suffer greatly. To avoid such cracking, it is critical to have a clear understanding of the underlying mechanisms and primary controlling factors behind the coating cracks.
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Steel structures are often galvanized to ensure durability in harsh environments. However, on occasion, incidents of cracking have occurred in galvanized structures that appear to be induced during the galvanizing process. Such cracking incidences produce a significant cost to the industry, in that repair procedures are often necessary to eliminate any flaws present directly after galvanizing.
Boiler system is one of the most critical systems for a utility plant. A utility plant had experienced high percentages of boiler downtime owing to boiler tube sheet cracking failures. Investigations carried out revealed high stress at the tube-to-tube sheet joint in the boiler fire-side entrance. Tube-to-tube sheet joints at the boiler fire-side entrance had been fabricated by strength welding and without any expansion. The strength welded joint had created undue stress leading to cracking of the weld joint by thermal expansion. A higher quality expanded joint consisting of expanding, flaring and seal welding the fire-side entrance was implemented during the re-tube process. The utility plant has now zero downtime due to boiler tube failure. This article summarizes the description and history of failures with the boiler at the utility plant; investigations and corrective actions carried out; and the present improved condition of the boilers.