Abstract: A low NOx Cyclone furnace steam generator including redesigned or modified Cyclone furnaces, air flow distribution, and new or relocated air ports maintains and/or minimizes NOx emission levels from the Cyclone furnace steam generator while minimizing Cyclone furnace and steam generator furnace tube wastage.

Abstract: End support for parallel tubes of a superheater or reheater with a bend tubular portion, a linear tubular portion extending away from each end of the bend tubular portion, and a supporting member formed on a curved section of the bend tubular portion. The tubular portions form a connection between two consecutive parts of a fluid passage. In a preferred embodiment, the tubular portions and the supporting member are integrally formed, molded or cast of a suitable material, such as carbon steel, stainless steel, chromium-nickel alloy, or other suitable alloys that have high temperature strength and oxidation resistance. The supporting member is configured to securely attach the end support configuration to the wall support brackets on the wall support tube. Preferably, the supporting member and the wall support bracket slide on one another to provide relative movement between the superheater tubes and the wall support or boiler tubes.

Abstract: A structural framework for supporting the heat exchanger of a steam generator, the former being comprised of serpentine tubes having sloped segments to facilitate the drainage of water from the heat exchanger when the steam generator is shutdown. The structural framework includes paired groups of vertically and diagonally extending first support members contiguously straddling the sloped-tube segments. The paired first support members are rigidly connected by second support members which extend between adjacent sloped-tube segments. The structural framework preserves the spacing between the sloped-tube segments and prevents direct contact between adjoining tube surfaces, but is not attached to the straddled tube segments and, thus, provides a tube supporting fit that is loose enough to permit the tubes to move freely due to expansion and contraction at different rates from that of the structural framework.

Abstract: End support for parallel tubes of a superheater or reheater with a bend tubular portion, a linear tubular portion extending away from each end of the bend tubular portion, and a supporting member formed on a curved section of the bend tubular portion. The tubular portions form a connection between two consecutive parts of a fluid passage. In a preferred embodiment, the tubular portions and the supporting member are integrally formed, molded or cast of a suitable material, such as carbon steel, stainless steel, chromium-nickel alloy, or other suitable alloys that have high temperature strength and oxidation resistance. The supporting member is configured to securely attach the end support configuration to the wall support brackets on the wall support tube. Preferably, the supporting member and the wall support bracket slide on one another to provide relative movement between the superheater tubes and the wall support or boiler tubes.

Abstract: A low NOx Cyclone furnace steam generator including redesigned or modified Cyclone furnaces, air flow distribution, and new or relocated air ports maintains and/or minimizes NOx emission levels from the Cyclone furnace steam generator while minimizing Cyclone furnace and steam generator furnace tube wastage.

Abstract: A structural framework for supporting the heat exchanger of a steam generator, the former being comprised of serpentine tubes having sloped segments to facilitate the drainage of water from the heat exchanger when the steam generator is shutdown. The structural framework includes paired groups of vertically and diagonally extending first support members contiguously straddling the sloped-tube segments. The paired first support members are rigidly connected by second support members which extend between adjacent sloped-tube segments. The structural framework preserves the spacing between the sloped-tube segments and prevents direct contact between adjoining tube surfaces, but is not attached to the straddled tube segments and, thus, provides a tube supporting fit that is loose enough to permit the tubes to move freely due to expansion and contraction at different rates from that of the structural framework.

Abstract: A bank of horizontally oriented boiler tubes which are periodically exposed to the abrasive action of a stream of blowing fluid cleaning medium. Portions of the boiler tubes, located at the top of the bank, are provided with spaced shields for protection from the fluid cleaning medium. An anti-vibration bar extends vertically between the protective shields to suppress vibration of the boiler tubes. A cap is fitted over the top end of the anti-vibration bar. The cap is sized to overlap adjacent portions of the protective shields thereby covering any gaps between the anti-vibration bar and the shields that would expose the boiler tubes to the action of the fluid cleaning medium.

Abstract: A series of upright boiler tubes periodically exposed to the abrasive action of a stream of blowing fluid cleaning medium. Vertically spaced shields mounted on the boiler tubes for protection from the fluid cleaning medium. A split ring casting located between the protective shields to maintain the boiler tubes in an aligned and fixed spaced relationship. The split ring casting is sized to overlap adjacent portions of the protective shields thereby covering any gaps exposing the boiler tubes to the action of the fluid cleaning medium.

Abstract: A method of welding together the parts of a boiler tube wall panel includes placing at least two parts of the panel to be welded together along a weld line and adjacent each other, and forming a weld along the weld line using a laser beam. The method can advantageously be used to weld boiler tube wall panels solely from one side of the panel. A GMAW process can also be used in combination with the laser beam to form the weld. Where the boiler tube wall panel includes a membrane between tubes, the membrane may be beveled.

Abstract: A method of corrosion protecting a tube having an end portion extending into a tube receiving hole of a mud drum of a boiler and the tube produced by that method. The end portion of the tube is provided with a corrosion resistant cladding layer which may contain chromium. Laser cladding is used to produce the corrosion resistant cladding layer, which advantageously tapers along a length of the end portion of the tube. The tube may be swaged before or after the cladding is applied and suitable heat treatments may be performed on the bare or clad tube to develop suitable properties in the tube, the cladding, or a tube-cladding interface.

Abstract: A method of welding together the parts of a boiler tube wall panel includes placing at least two parts of the panel to be welded together along a weld line and adjacent each other, and forming a weld along the weld line using a laser beam. The method can advantageously be used to weld boiler tube wall panels solely from one side of the panel. A GMAW process can also be used in combination with the laser beam to form the weld. Where the boiler tube wall panel includes a membrane between tubes, the membrane may be beveled.

Abstract: A method of corrosion protecting a tube having an end portion extending into a tube receiving hole of a mud drum of a boiler and the tube produced by that method. The end portion of the tube is provided with a corrosion resistant cladding layer which may contain chromium. Laser cladding is used to produce the corrosion resistant cladding layer, which advantageously tapers along a length of the end portion of the tube. The tube may be swaged before or after the cladding is applied and suitable heat treatments may be performed on the bare or clad tube to develop suitable properties in the tube, the cladding, or a tube-cladding interface.

Abstract: A method for producing chromium carbide coatings on steel provides a steel component having a surface which is carburized to contain at least about 0.40% by weight carbon and is followed by chromizing the surface to form a chromium carbide coating on the surface.

Abstract: A method of corrosion protecting a tube having an end portion extending into a tube receiving hole of a mud drum of a boiler and the tube produced by that method. The end portion of the tube is provided with a corrosion resistant cladding layer which may contain chromium. Laser cladding is used to produce the corrosion resistant cladding layer, which advantageously tapers along a length of the end portion of the tube. The tube may be swaged before or after the cladding is applied and suitable heat treatments may be performed on the bare or clad tube to develop suitable properties in the tube, the cladding, or a tube-cladding interface.

Abstract: An improved process for chromizing and chrome-siliconizing 400-series stainless steel components, and in particular, 430 stainless steel components, such as boiler panel studs. The process includes the addition of between 0.12%-0.25% by weight of calcium fluoride salt to the conventional 4% by weight of ammonium chloride activator salt to the coating composition used in known diffusion coating processes. In a more preferred embodiment, small amounts of silicon powder, such as between about 0.12%-0.25% by weight, are added to the two salts and the diffusion coating material. A coating composition is provided as well.

Abstract: A boiler attachment used to support a boiler component within the furnace or boiler chamber is composed of a similar material to the boiler component it is welded to, in order to eliminate the dissimilar weld failure. The boiler attachment is coated using a diffusion coating method to cover the attachments with a coating of aluminum, chromium, silicon or a combination thereof.

Abstract: A spacing arrangement for tubes of a reheater or superheater tube section uses a spacer bar that is sufficiently long to span a space across a plurality of tubes in the tube section. The spacer bar has a plurality of holes therein which are spaced apart by a selected spacing corresponding to a desired spacing between the plurality of tubes in the section. A plurality of sleeves is provided with one sleeve on adjacent tubes in the section. A tab is fixed to each sleeve and extends outwardly from the sleeve to which it is fixed so that the tabs of all the sleeves extend outwardly from a common plane containing all the adjacent tubes in the section. The tabs extend into respective holes in the spacer bar and fillet welds fix the tabs to the spacer bar adjacent the holes and at a location spaced from the sleeves.

Abstract: A retainer shield for a split ring retains boiler tubes aligned therein and dissipates heat from a front weld thereon. The retainer shield is preferably made from about 50% chromium and about 50% nickel and is welded to one end of the split ring to assist in holding the two halves of the split ring together. The retainer shield draws heat therefrom and dissipates it to prevent oxidation of the welds holding the two halves of the split ring together.

Abstract: A support lug casting for supporting a ferritic tube from an adjacent tube comprising male and female lugs formed on a ring shaped member and engaged around but not welded to each tube. The male lug of one tube engages into the female lug of an adjacent tube. The lugs and rings are made of austenitic material which resist corrosion and heat and which avoids the problem of welding dissimilar materials to each other since no welded connection is established between the austenitic casting and the ferritic tube. The casting is axially fixed on the tube by one or more ferritic stops or weld areas which are at one or both axial ends of each casting.

Abstract: A remotely operable boiler tube wall cleaning and inspection system including a collapsible "H" frame capable of being inserted through the boiler manway access ports and being positioned at will over the full area of the tube wall.