Nalco Guide To Boiler Failure Analysis Jun 2026

Usually caused by a breakdown in water chemistry or improper chemical cleaning, leading to generalized thinning. B. Waterside Deposition (The Insulator)

The NALCO guide includes several case studies and examples of boiler failures, which illustrate the application of the methodologies and best practices. These examples demonstrate how effective boiler failure analysis can help prevent costly repairs, reduce downtime, and improve overall boiler reliability. nalco guide to boiler failure analysis

| Step | Action | |------|--------| | 1 | – Document fracture orientation, internal deposits, wall thinning. | | 2 | Deposit Analysis – Measure deposit weight density (g/ft²). Identify composition (Fe, Cu, Si, Ca, P). | | 3 | Metallography – Examine cross-section for decarburization, intergranular attack, or spheroidization. | | 4 | Water Chemistry Review – Compare historical pH, conductivity, O₂, and phosphate trends. | | 5 | Operational Correlation – Match failure timeline to startup events, low-water trips, or chemical upsets. | Usually caused by a breakdown in water chemistry

“Understand why it failed, and you will know how to prevent the next one.” – Adapted from the NALCO method. Identify composition (Fe, Cu, Si, Ca, P)