Wall Thinning Monitoring in Boiler U-Bends: A Review and Future Prospects with Fiber Optic Sensing

Tube boilers are extensively employed in oil and gas refineries, as well as in petroleum, energy, and power generation industries, where they serve critical functions in local steam-generation units and combined-cycle gas turbine (CCGT) plants. However, these boilers are prone to defects arising from waterside corrosion (e.g., thinning of U-bend tubes), fireside corrosion, and material degradation caused by stress or creeping. Among these issues, wall thinning of tube bends is particularly severe, as it results in localized metal loss, reduced structural integrity, and an elevated risk of tube rupture or failure under high-temperature and high-pressure operating conditions. Such failures can significantly compromise boiler safety and efficiency, potentially leading to forced outages, costly unplanned repairs, or catastrophic damage if not detected in time. The current condition-monitoring policy for U-bends relies on scheduled preventive maintenance and unscheduled corrective interventions. In practice, this involves randomly checking approximately 10–20% of the tubes through spot scanning, partial scanning, or full scanning, with repairs typically carried out only after an undetected failure occurs. Such maintenance strategies generally require plant shutdowns, making the process time-consuming, labor-intensive, and ultimately not cost-effective. This paper reviews existing solutions, technologies, and research addressing the problem, and introduces femtosecond laser micromachined fiber optic sensors as a transformative approach for real-time monitoring of wall thickness reduction in U-bend boiler tubes, thereby opening pathways for further research.