Intercrystalline Cracking of Boiler Steel and Its Prevention Page: 80
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80 INTERCRYSTALLINE CRACKING OF BOILER STEEL
3. See that adjusting screw in new specimen i turned back so that it will
not touch the block.
4. Center new unbent specimen carefully in groove, and replace clamping
plate with beveled edge bearing on specimen at point near adjusting screw.
Tighten top clamping nuts alternately and equally to force specimen solidly
into place.
5. Tighten bottom clamping nuts solidly.
6. Proceed according to directions 1 to 7 for the "Operation."
B. BRIEF HISTORY OF OPERATION, LEAKAGE AT SEAMS, AND CRACKING
IN THREE CROSS-DRUM BOILERS 55
Boiler 1 placed in service February 3, 1927.
Boiler 2 in service December 24, 1926, but operated only a few days in January;
placed in continuous service in February 1927.
Boiler 4 in service January 6, 1927.
At the time of the initial trials of the three units, leakage was observed
at a considerable number of points along the drum seams.
On February 8, 1927, slight leaks were reported in the longitudinal seam
of boiler 4.
On June 3, 1927, leaks were noted in boiler 1.
On June 24, 1927, a hydrostatic test on boiler 1 showed a number of leaks, and
the majority were eliminated by calking.
On May 5, 1928, boiler 2, under hydrostatic test of 250 pounds, showed leaks
in the longitudinal seam at both ends of the drum and at two rivets. These
leaks were calked. On May 7 a hydrostatic test at 550 pounds still showed
leaks in the longitudinal seam, and three other rivets were leaking. The
leaks were calked. On May 15 an additional hydrostatic test was applied, and a
number of small leaks at the west end of the drum were detected and calked.
A report covering inspection of boiler 2 on July 27, 1928, stated:
The shell plates, heads, and riveted joints were found in good condition with the excep-
tion that light leakage was noted along the longitudinal seam and at the circumferential
reinforcing straps of the drums.
On October 12, 1928, boiler 1 showed light leakage in several places along the
longitudinal joint and also light seepage around several tubes.
In September 1929, boiler 1 revealed a number of small leaks in the longitudinal
seams, which were calked.
On August 14, 1931, boiler 4 showed slight evidence of leakage at the top and
lower seams of the drum.
A report covering boiler 1 on October 5, 1931, stated:
The drum plates, heads, and joints were hammer-tested and were found in good condi-
tion with the exception that slight evidence of leakage was noted at one of the rivets and
small leaks were also noted in the longitudinal seams.
October 20, 1931, leakage was noted in the seams of boiler 4.
On December 15, 1931, the following report was made covering boiler 4:
The drum of the boiler was carefully examined internally and externally. The plates
and butt straps were cleaned with a solution of soda to remove oil-soot deposits and again
cleaned with hydrochloric acid at all points suspected of leakage or defects.
Evidence of leakage was noted at the cracked welds joining the longitudinal and circum-
ferential butt straps and along the lower edge of the butt strap of the ligament longitudi-
nal joint. Several rivet heads have been heavily calked. No external evidence of cracking
or weakness other than that mentioned above was observed.
On January 8, 1932, leakage was noted in three rivets of boiler 2 in the com-
bined longitudinal joint and reinforced ligament. There was also evidence of
slight leakage along the calking edge of the seam at this point.
On September 9, 1932, the outside head was found broken from a rivet in the
longitudinal seam of boiler 2.
On November 9, 1932, two rivets were found cracked in boiler 1.
On December 10, 1932, boiler 2 was given 450 pounds hydrostatic test, and
during hammer-testing two additional rivets failed. Examination inside the
rivet hole showed fine hair lines in drum and butt-strap metal.
A short time later rivets were also found cracked in boiler 4.
The drums on all the boilers were finally removed and were found cracked.
Subsequent examination showed many rivet holes that were not lined up and
that had been drifted. The riveted drums in all the boilers finally were replaced
with welded drums.
66 Operating pressure, 400 pounds.
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Schroeder, W. C. & Berk, A. A. Intercrystalline Cracking of Boiler Steel and Its Prevention, report, 1941; Washington D.C.. (https://digital.library.unt.edu/ark:/67531/metadc12603/m1/84/: accessed April 25, 2024), University of North Texas Libraries, UNT Digital Library, https://digital.library.unt.edu; crediting UNT Libraries Government Documents Department.