Custom Curved Tube Shields
Custom Curved Tube Shields - seamless steel tube
Coal steam boiler tube erosion shields are essential for economizers in power station boilers, offering 3-5 years of service life. They protect heating tubes from wear, extending boiler efficiency and durability.
Download PDFAn erosion shield is a protective covering applied to the surfaces of boiler tubes, especially in areas exposed to high-velocity flue gases and abrasive particles. In coal steam boilers, economizer tubes are particularly susceptible to erosion due to the combination of high temperatures and particle-laden gases. By installing an erosion shield, the wear on these tubes is significantly reduced, enhancing the overall efficiency and reliability of the boiler.
Erosion shields are used to protect boiler tubes from erosion caused by flue gases coming into contact with the bends of the tubes.
Erosion shields can be installed selectively in areas that are prone to tube leakage.
Erosion shields can protect the boiler's heating surface, such as the economizer, and extend the service life of the boiler.
Austenitic stainless steel tube shields are often used to reduce fuel ash corrosion in corrosive boiler locations. Materials with higher chromium concentrations, generally greater than 20%, have lower fuel ash corrosion rates.
The Coal Steam Boiler Tubes Erosion Shield for Economizer is a critical solution for industries looking to protect their boiler tubes from the damaging effects of erosion. By investing in erosion shields, facilities can increase the durability of their economizer tubes, improve the overall efficiency of their steam boilers, and significantly reduce maintenance costs. This practical and cost-effective solution ensures that boilers run smoothly and efficiently for extended periods, with less downtime and fewer failures.
Coal steam boiler tubes erosion shield used for economizer is a common component of the heating part of tubes.It is usually used in power station boilers.The useful life of tube shield is 3-5years.The tube shield has a variety of material and the selection of the material shall be subject to the original design of the boiler.The tube shield is divided into straight pipe and bend pipe.The main effect of tube shield is to protect the pipe and increase the service life of the pipe. Boiler tube shields are designed to eliminate major maintenance and downtime costs from boiler and condenser tube failure.
Boiler tubes are metal tubes that heat water to produce steam. They are commonly made of carbon steel or alloy steel and are used in a variety of applications, including power generation, fossil fuel plants, and industrial processing plants.
Sunny Steel supplies seamless boiler tubes in compliance with GB, ASME, ASTM, EN, DIN and JIS standards.
| Standard System | Specification | Description |
|---|---|---|
| GB Chinese National Standards |
GB 3087 |
Seamless steel tubes for low and medium pressure boilers |
GB 5310 |
Seamless steel tubes for high pressure boilers | |
GB 13296 |
Seamless steel tubes for boilers and heat exchangers | |
GB 6479 |
Seamless steel tubes for high-pressure chemical fertilizer equipment | |
GB 9948 |
Seamless steel tubes for petroleum cracking | |
| ASME American Society of Mechanical Engineers |
ASME SA-106 |
Seamless carbon steel pipe for high-temperature service |
ASME SA-192 |
Seamless carbon steel boiler tubes for high pressure | |
ASME SA-209 |
Seamless carbon-molybdenum alloy-steel boiler tubes | |
ASME SA-210 |
Seamless medium-carbon steel boiler and superheater tubes | |
ASME SA-213 |
Seamless ferritic and austenitic alloy-steel boiler and heat exchanger tubes | |
ASME SA-178 |
Electric-resistance-welded carbon steel boiler and superheater tubes | |
| ASTM American Society for Testing and Materials |
ASTM A213 |
Ferritic and austenitic alloy-steel boiler and heat exchanger tubes |
ASTM A106 |
Seamless carbon steel pipe for high-temperature service | |
ASTM A192 |
Seamless carbon steel boiler tubes for high pressure | |
ASTM A210 |
Seamless medium-carbon steel boiler and superheater tubes | |
ASTM A335 |
Seamless ferritic alloy-steel pipe for high-temperature service | |
| EN European Union Standard |
EN 10216-2 |
Seamless steel tubes for pressure purposes |
| DIN German Industrial Standards |
DIN 17175 |
Seamless tubes of heat-resistant steels |
| JIS Japanese Industrial Standards |
JIS G3461 / G3462 / G3463 |
Carbon steel / Alloy steel / Stainless steel boiler and heat exchanger tubes |
Ends are perpendicular to the longitudinal axis and free from burrs.
| Parameter | Value |
|---|---|
| Tube OD | 26.7 – 114.3 mm |
| Tube WT | 3.2 – 12.5 mm |
| Tube Length | 4 – 13 m |
| Deburring Angle α | 30° +5° / 37° ±2.5° |
| Dimension c | 1.6 ± 0.8 mm |
Deburred or specially prepared ends for welding applications.
All boiler tubes are supplied with comprehensive inspection and testing:
Hot combustion gases pass through tubes submerged in a water-filled shell. Heat is transferred through the tube walls by conduction, generating steam for process or power use. Fire tube boilers are typically used for low- to medium-pressure applications.
Water circulates inside tubes heated externally by combustion gases. Steam separates naturally in the steam drum, with saturated steam drawn from the upper section. Water tube boilers are preferred for high-pressure, high-capacity applications such as utility power plants.
Boiler tubes are pressure-retaining components used to generate steam by heating water.
Two principal designs exist: water-tube boilers and fire-tube boilers. In water-tube boilers, water circulates inside the tubes while hot gases flow externally. In fire-tube boilers, hot gases pass through tubes submerged in water.
| Steel Grade Family | Standard | Typical Application | ||
|---|---|---|---|---|
| GB (China) | ASME (USA) | DIN / EN (Europe) | ||
| Carbon Steel |
10 20 20G 20MnG 25MnG |
SA-106B SA-192 SA-210A1 SA-106C SA-210C |
P195GH P235GH P265GH St35.8 St45.8 |
Economizer tubes Water wall tubes |
| Mo Steel |
15MoG 20MoG |
SA-209 T1 SA-209 T1a SA-209 T1b |
15Mo3 16Mo3 |
Water wall tubes Superheater tubes Reheater tubes |
| Cr-Mo Steel |
12CrMoG 15CrMoG 12Cr2MoG 12Cr1MoVG 10Cr9MoVNb |
SA-213 T11 / T22 / T24 SA-213 T91 A335 P1 / P2 / P5 / P9 / P11 |
13CrMo4-5 10CrMo5-5 10CrMo910 12Cr1MoV 14MoV63 X10CrMoVNb91 |
Superheater tubes Reheater tubes |
| Cr-Mo-W Steel | 12Cr2MoWVTiB |
SA-213 T23 / T91 / T92 / T122 A335 P23 / P91 / P92 / P122 |
— |
Superheater tubes Reheater tubes |
| Austenitic Stainless Steel | — |
TP304 / TP304H TP321 / TP321H TP347 / TP347H TP316 / TP316H S30432 / TP310HCbN |
— |
Superheater tubes Reheater tubes |
Boiler tubes are used in fire-tube boilers, where hot combustion gases pass through tubes surrounded by water in a sealed shell, transferring heat by conduction to generate steam.
Proper surface preparation improves appearance, corrosion resistance and coating life. During rainy seasons, hydrogen pickup in steelmaking may increase surface defects such as hairline cracks, which must be removed before service.
Typical applications include superheater tubes, reheater tubes, economizers, main steam piping and petrochemical furnace tubes.
Hardness testing evaluates mechanical properties related to formability, machinability and service performance.
Mechanical testing is mandatory for all pressure tube materials referenced in ASME and EN standards.
A steam boiler converts thermal energy into steam by heating water. The steam is used for power generation, process heating and space heating.
Continuous helical fins are attached to the base tube by HFW, producing a forged, solid-state bond without filler metal. Both solid and serrated fins are available.
Widely used in boilers, fired heaters and heat recovery units.
Improper heat treatment can leave residual stresses or unstable microstructure, reducing high-temperature performance and affecting the entire heating system.
Finned tubes increase the external surface area available for heat transfer between hot gases and the tube wall.
Heat transfer rate depends on:
Common forming operations include finning, bending (serpentine coils) and end machining. These processes are essential during fabrication and site installation of boiler systems.
Proper heat treatment ensures strength, toughness and long-term reliability under cyclic high-temperature service.
| Material | Standard | Material |
|---|---|---|
| Stainless Steel | ASTM | 201, 202, 301, 304, 304L, 304N, XM21, 304LN, 305, 309S, 310S, 316, 316Ti, 316L, 316N, 316LN, 317, 317L, 321, 347, 329, 405, 409, 430, 434, 444, 403, 410, 420, 440A, etc. |
| EN | 1.4372, 1.4373, 1.4319, 1.4301, 1.4306, 1.4315, 1.4303, 1.4833, 1.4845, 1.4401, 1.4571, 1.4404, 1.4429, 1.4438, 1.4541, 1.4550, 1.4477, 1.4462, 1.4002, 1.4512, 1.4016, 1.4113, 1.4509, 1.4521, 1.4006, 1.4021, 1.4028, etc. | |
| JIS | SUS201, SUS202, SUS301, SUS304, SUS304L, SUS304N1, SUS304N2, SUS304LN, SUS305, SUS309S, SUS310S, SUS316, SUS316L, SUS316TI, SUS316N, SUS316LN, SUS316J1, SUS316J1L, SUS317, SUS317L, SUS321, SUS347, SUS329J1, SUS329J3L, SUS405, SUH409, SUS410L, SUS430, SUS434, SUS444, SUS403, SUS410, SUS420J1, SUS420J2, SUS440A, SUS440B, SUS440C, etc. |
The cross-sectional shape of boiler tubes shields is mostly semi-circular (180 degrees), and there are also 120-160 degrees.
It is mainly used on finned tubes (water-cooled walls); boiler tube erosion shields are divided into direct wear-resistant shields, in-curve, anti-wear shields, outer-curve, anti-wear shields, side-curve anti-wear shields, s-curve anti-wear shields, etc.
The length of the straight anti-wear shields ranges from 20mm to 3000mm, and the general length of 1000-2000mm is commonly used. The anti-wear shields with bends generally requires a processing drawing and the following parameters should be on the drawing: outer diameter of the pipe used, bending of the pipe Radius R (to the center of the pipe), the degree of bending angle, and the length of the straight sections on both sides of the arc segment of the wear-resistant shields.
The most basic parameter of boiler tubes shields is the outer diameter of the tube used (that is, the inner diameter of boiler tubes erosion shields). The main specifications of the tube are: 32, 38, 42, 44.5, 48, 51, 57, 60, 63.5 , 76, 89mm, etc . the inner diameter of the boiler tubes erosion shields is usually 1-3mm larger than the outer diameter of the tube used, depending on the actual requirements.
The current production process for tube shields is to use high-pressure presses and professional moulds for pressing.
Tube shields from us are manufactured to exacting standards. Advanced equipment and material handling capabilities permit us to offer the fastest turnaround times anywhere.
The current production process for tube shields is to use high-pressure presses and professional moulds for pressing.
The production time is short, the welding performance is good, the welding seam does not fall off, the surface is smooth and the appearance is beautiful. The arc-shaped wear-resistant tile is pressed on a press or bent on a pipe bender with a special mould.
To ensure the accuracy of the material. Positive Material Identification (PMI) of stainless steel sheets for tube shields is critical to verifying the grade and composition of stainless steel before it goes into production.
The raw materials for the production of tube shields are generally purchased directly from standard steel mills, and each batch has an MTC. Due to the sharpe limitations of raw materials, it is inevitable that excess materials will be produced. We can use the excess material to make a smaller size snap ring.
Tube erosion shields are precision-engineered to fit straight, curved, finned and specialty tubing, providing continuous protection against fly ash erosion and high-temperature corrosion.
Also known as anti-wear plates or boiler climbing shields. Installed with retaining snap rings to ensure long-term stability on heating surfaces.
Manufactured by high-pressure die forming with dedicated tooling. Bent profiles use press forming or precision mandrel bending for close tube contour conformity.
Robust, weld-friendly assemblies with smooth aerodynamic surfaces. Mitigate tube wall thinning, reduce unplanned maintenance and extend boiler availability.
The service life of boiler tubes erosion shields is different in different types of boilers and different use parts.
The normal service life is a period of overhaul (3-5 years) for the boiler. Generally, some boilers will be replaced or retrofitted every time the boiler is overhauled. The main replacements are those of the Boiler Tubes Erosion Shields that are severely thinned and exceeded the standard; those that were not firmly detached during the boiler operation during the previous installation. According to the wear of the Boiler Tubes Erosion Shields during replacement, if the thickness is severely reduced, it needs to be replaced, the deformation is severe, and those that cannot protect the tube also need to be replaced. In addition, some boiler tubes are not equipped with Boiler Tubes Erosion Shields, but during the boiler inspection, it is found that the tubes have a tendency of wear and thinning. Generally, Boiler Tubes Erosion Shields are also installed to prevent further wear of the tubes and cause serious consequences such as boiler explosion.
On the heating surface of superheater and economizer tube bundle of the boiler, in order to prevent the pipe from being worn by high temperature flue gas washing, boiler tubes erosion shields are mostly arranged on the outer side of the pipe in the direction of flue gas flow. The elbow erosion shields solves the abrasion problems of water wall tubes, superheater tubes, economizer tubes and reheater tubes in the furnace, and provides guarantee for the long-term and reliable operation of CFB boiler. With the increase of CFB boiler products, the type and quantity of The elbow erosion shields will increase.
Tube erosion shields are installed on the windward side of boiler heating surfaces, including superheaters, reheaters, economizers and water-wall tubes.
Erosion shields protect boiler tubes from high-temperature, high-velocity flue gas and fly ash, significantly extending tube service life.
We supply shields for straight, bent and finned tubes, complete with retaining clips for secure installation.
By minimizing tube wall thinning and leakage risks, erosion shields reduce unscheduled downtime and lifecycle maintenance costs.
These components—often referred to as wear-resistant tiles or cover plates—are widely used in utility boilers and coal-chemical plants.
Generally, boiler tubes erosion shields are also installed to prevent further wear of the tubes and cause serious consequences such as boiler explosion.
The main role is to protect the heating surface of the boiler pipes, reduce pipeline wear, and increase the heating surface of the pipes.
The snap ring is a short section that is installed on the pipe in conjunction with the wear-resistant tile. Generally, it is welded to the wear-resistant tile by lap welding, that is, to cover the wear-resistant tile slightly, so it is larger than the wear-resistant tile. The opening arc is around 190-200 degrees, the welding position needs to be set aside to facilitate welding and fixing. The width of the snap ring must not be less than 20mm.
The installation requirements of anti-friction tiles of different shapes are slightly different. Basically, each anti-friction tile is installed with not less than 2-4 snap rings. The snap ring and the anti-friction tile are welded together to prevent expansion due to heat. The tiles fall off, and the joints are required to be fully welded.
Generally, boiler tubes erosion shields are also installed to prevent further wear of the tubes and cause serious consequences such as boiler explosion.
The main role is to protect the heating surface of the boiler pipes, reduce pipeline wear, and increase the heating surface of the pipes.
Ceramic lined pipe is made through self-propagating high-temperature synthesis (SHS) technique.
Cast basalt lined steel pipe is composed by lined with cast basalt pipe, outside steel pipe and cement mortar filling between the two layers.
Ceramic tile lined pipes have very uniform coating of specially formulated ceramic material that is affixed to the inner of the pipe.
The material of the rare earth alloy wear-resistant pipe is ZG40CrMnMoNiSiRe, which is also the grade of rare earth alloy steel.
Tubes Erosion Shields are used to protect boiler tubing from the highly erosive effects of high temperatures and pressures thereby greatly extending tube life.
The ASTM A213 T91 seamless tubes are primarily used for boiler, superheater, and heat-exchanger.
When you partner with Sunny Steel, you can stop worrying about meeting deadlines thanks to our responsive and timely service. You'll also say goodbye to unnecessary shopping around. Instead, you'll get white glove service from an expert who understands your needs and can get you the materials you need quickly.
