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: 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 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: 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 method of inspecting a tube header bore comprises scoring an oxide scale layer within the bore using a hard scribing tool. The bore is then cleaned using one or more honing brushes having flexible bristles with carbide tips. After sufficiently cleaning the inner surface of the bore a florescent dye is applied to the surface for highlighting surface defects and a visual inspection is made. For easy access to the interior of the bore, the tube is cut at a point spaced from the bore. After the inspection is complete a new length of tube is connected such as by welding.

Abstract: A nozzle to header or pressure vessel connection includes a sleeve preferably of stainless steel extending within the bore of the nozzle and preferably cantilevered therefrom to extend into the aligned flow passage of the header. A portion of the sleeve preferably has an elliptical cross-section which traverses at least part of the distance of the bore and contacts the inner wall of the nozzle for press fitting of the sleeve to the nozzle.