Jim:
That sounds interesting. Are you sure that the wastage is due to electrolysis? (Not that I doubt you.)
I would have to go back to plate theory to evaluate the condition from a strength standpoint.
Can you give me some more details? Such as depth, and whether this wasted area is 1 to 1 1/2 diameters from the centerline of the stay or from the OD of the stay. Also, what is the radial width of the wasted area, as well as, the staybolt diameter and plate thickness.
Naturally, in this forum, I can do this only for illustration and not for the evaluation of a particular boiler.
If you want, you can e-mail me seperately.