Common Forms & Causes of Industrial Chimney Degradation PT 2

There are a number of environmental conditions and operating conditions that can significantly affect the degradation of your smokestack or industrial chimney. During our last blog post, we discussed the common forms and causes of degradation to components like the concrete shell, independent brick liners, corbel supported brick liners, steel liners, FRP liners, gunite liners, and lightning protection systems. This week, we are discussing other common components that can face deterioration over time and how to identify and protect your structure from expensive repairs.

Hood / Cap

Corrosion and structural damage to the hood or cap can occur from extended usage, acid condensation due to cool down effect, or excessive movement from wind loading, etc.

Aviation Warning Lights

AWL systems are often susceptible to burnt out bulbs, corroded conduit & fittings, and damaged and corroded wiring. These minor issues are often caused by age and are easy to address quickly and affordably. On some occasions, these components may get broken during other stack work if maintenance crew is not careful.

Platforms

Atmosphere corrosion, age & extended usage, and wash down effects can cause corrosion at joints or grating of access platforms. All platforms should be thoroughly inspected during regular maintenance to ensure they are in good working condition and do not pose a hazard to team members.

Lining Bands

Corrosion, breakage, and shearing of bolts can be caused by the scrubber operation causing lower temperatures, infiltration of flue gases, and even acid attack.

Monitoring Ports & Platforms

Improper design & inadequate room for movement can cause breakage of monitoring ports, spalling of the concrete wall or brick and deformation. If improper materials have been selected for construction, monitoring ports can suffer from severe corrosion much earlier than under normal conditions.

Breeching Lintel

Acid attacks from flue gas, buildup of fly-ash on top of flue in the annular space, and inappropriate material for operation can cause both corrosion and deflection of breeching lintels.

Breeching Duct Packing

Breeching duct packing can suffer from loss or blowout caused by vibration, thermal movement, incorrect materials, or improper installation.

Buckstay

The buckstay component of an industrial chimney can suffer from a bent vertical axis if it is inadequate to withstand band tension in the weak axis location.

Ladder

Access ladders are extremely susceptible to separation of connection lugs and poor anchorage when they have been constructed without any provision for vertical stack expansion or contraction. If not monitored regularly, separation can occur from the structure leaving it unsafe to use.

Bumper Assembly

Common forms of degradation for bumper assemblies can include bent members, weld failures, and anchor pullout, all caused by inadequate room for thermal expansion and contraction.

Multiple Bumpers & Stayrods

When there is excessive loading on lower bumpers, the stayrods can bend, pull out, or suffer from weld failure.

Liner Support Grillage

Fly-ash buildup or inadequate design can cause over stressing and noticeable deflection on liner support grillage.

Expansion Joints

Expansion joints can become torn, worn out, or ineffective through age, service related wear & tear, or even occasional debris deposits.

Access Doors

Service related wear and tear can cause corrosion, especially on hinges and latches, of access doors.

A comprehensive inspection program can help ensure the long-term structure integrity of your industrial chimney or smokestack. By following a strict maintenance schedule, you can minimize repair expenditures and eliminate unplanned outages which can result in significant cost savings over time. Speak with our rope access experts to find out how we can keep your industrial structures in excellent condition with our affordable & convenient maintenance plans.