Jejej

Gujarat Paguthan Energy Corporation Limited
A CLP Company
Paguthan, Gujarat.
METALLURGICAL TESTING REPORT
VOLUME – III
Life Extension Services
Prepared by Reviewed by
A Balaji Vijay Jadhav

Metallurgist Metallurgist
THERMAX BABCOCK & WILCOX

A DIVISION OF THERMAX LIMITED
VOLUME III
INDEX
SECTION PAGE
CONTENTS
NO. NOS.
Introduction
1 1-6
Metallurgical Testing Results

2 7-14
Tube Laboratory Testing

3 15-27
4 In-situ Metallography (Replication) 28-95
5 Field Hardness Testing 96-100
6 Swell Measurement 101-106
7 Deposit Analysis 107-108

Thermax Babcock & Wilcox
SECTION - 1
INTRODUCTION
LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 1

INTRODUCTION
During the condition Assessment & Remaining Life Analysis GT 3957(HP)/ GT

3958(LP) HRSG boiler, one of the vital areas of inspection activity was
metallurgical testing of pressure parts. In order to find the present condition of
material and to check its healthiness for future operation following metallurgical
tests were conducted:
1. Tube sample laboratory destructive testing

2. In-situ Metallography (Replication)
3. Field hardness testing
4. Dimensional measurement
Methodology adopted for above testing is elaborated in respective section

subsequently.
As a part of metallurgical testing, two tube samples and sixty-one field replicas
were examined by the Metallurgical Laboratory of Thermax Babcock & Wilcox.
The site testing was carried out during 28th Aug 8th Sept 2010.

BOILER DESCRIPTION
A GENERAL DESCRIPTION:
Gujarat Paguthan Energy Corporation
1 Plant name
Pvt.Ltd.
2 Make of Boiler M/s Deutsche Babcock Blacke –Durr Ltd.
3 Year of Commissioning 1998

4 Boiler No. GT 3957(HP)/ GT 3958(LP)
B TECHNICAL:
Boiler Parameters DESIGN OPERATING
MCR Steam Flow
1 227 47
TPH(HP/LP)
Boiler Pressure Kg/cm2
2 102 12.23
(HP/LP)
Outlet Steam Temp
3 530 200
°C(HP/LP)
4 Fuel(s) Fired - -
C CONSTRUCTIONAL FEATURES:
Tube Size OD x Thk
Component Material Spec.
mm.
TUBES
1 HP Super heater – II tubes 38 X 6.30 SA 213 T22
2 HP Super heater – I tubes 38 X 6.30 SA 213 T12
3 HP Evaporator tubes 38/42.4 x 5.6/8.0 SA 192
4 HP Economizer tubes 38 x 5.00 SA 192
5 LP Super heater tubes 38 x 2.90 SA 192
6 LP Evaporator tubes 38/42.4 x 5.6/8.00 SA 209 T1
Condensate Preheater
7 38 x 4.50 SA 192
tubes

Sr. Material
Component Dimension
no. Specification
HEADERS
HP Super heater – II inlet
8 356 x 36 SA 335 P12
header
HP Super heater – II outlet
9 406.4 x 80 SA 335 P22
header
HP Super heater – I inlet
10 324 x 36 SA 335 P1
header
HP Super heater – I outlet
11 355.6 x 36 SA 335 P12
header
HP Evaporator inlet & outlet
12 406.4 x 28 SA 106 GR.B
headers
HP Economizer inlet & outlet
13 273 x 40 SA 106 GR.B
headers
14 LP Super heater inlet header 355.6 x 17.5 SA 106 GR.B
LP Super heater outlet
15 406.4 x 17.5 SA 106 GR.B
header
LP Evaporator inlet & outlet
16 406.4 x 28 SA 106 GR.B
headers
LP Evaporator inlet & outlet
17 273 x 16 SA 106 GR.B
headers
18 HP Feed water line 168.3 x 16 SA 106 GR.B
19 LP Feed water line to drum 114.3 x 6.02 SA 106 GR. B
20 Attemperator header 355.6 x 25 SA 335 P12
21 HP riser pipes 323.9 x 7.1 SA 106 GR.B
22 LP riser pipes 323.9 x 7.1 SA 234 WPB
DRUM
23 HP Drum ID 1700 x 95 SA 516 GR70
24 LP Drum ID 1500 x 22 SA 516 GR70

DETAILS OF TUBE SAMPLE
Sr. Tubes Material Tube Size Location

No. OD X THK
(mm)
1 HP Superheater II SA 213 T22 38.00 X 6.30 HP Superheater II
2 LP Superheater SA 192 38.00 X 4.50 LP Superheater

REPLICA LOCATIONS
Sr. Component Material Number of

No. Replicas
HP Section
1 Steam Drum SA 516 Gr. 70 09
2 Feed Water Pipes SA 106 Gr. B 04
3 Econimizer Inlet Header (Top) SA 106 Gr. B 01
4 Economizer Outlet (Top) SA 106 Gr. B 02
5 Evaporator Inlet Header (Bottom) SA 106 Gr. B 04
6 Evaporator Outlet (Top) SA 106 Gr. B 01
7 Super heater 1 Inlet header (Top) SA 335 P1 02
8 Super heater 1 outlet (Bottom) SA 335 P12 01
9 Attemparator Header SA 335 P12 02
10 Super heater 2 Inlet header (Bottom) SA 335 P12 01
11 Super heater 2 outlet header (Top) SA 335 P22 02
12 Main Steam Line - 02
LP Section
13 Steam Drum SA 516 Gr. 70 08
14 Feed Water Line SA 106 Gr. B 02
17 Super heater Inlet header (Bottom) SA 106 Gr. B 02
18 Super heater outlet header (Top) SA 106 Gr. B 02
19 Main Steam Line --- 03
20 Condensate Preheater Inlet Header (Top) SA 106 Gr. B 04
21 Condensate Preheater Inlet coils (Top) SA 192 02
22 Condensate Preheater outlet Header (Top) SA 106 Gr. B 02

SECTION – 2
METALLURGICAL TESTING RESULTS

METALLURGICAL TESTING RESULTS
Thermax Babcock & Wilcox’s Condition Assessment & Remaining Life

Assessment team carried out study at Gujrat Paguthan Energy Corporation
Pvt.Ltd. Paguthan,Bharuch,In September 2010.
The Metallurgical test results are presented here. Please refer Volume – I for all
results correlation, conclusions and overall recommendations.
A) TUBE TESTING – RESULTS
1. Visual Inspection:
a) HP Superheater II tube: No abnormalities in terms of erosion, corrosion or

fatigue / stress cracks observed on external surface. Internal surface was
covered with thin adherent black oxide layer.
b) LP Superheater tube: No abnormalities in terms of erosion, corrosion or
fatigue / stress cracks observed on external surface. Internal surface was
covered with thin adherent black oxide layer
2. Chemical testing:
Both tube samples chemical composition confirmed to the specifications.
3. Dimensional measurement:
Dimensional measurement of both the tubes submitted for lab analysis

indicated outer diameter as per specified, however thickness measured were
below specified values. Measured tube thickness is above design thickness.
No major abnormality observed.
4. Physical testing:
Yield strength and tensile strength values are under acceptable limits.
However there was reduction observed in % elongation values. This is on
account of microscopic carbides precipitation during high temperature
application of boiler materials. There will not be adverse effect on the future
usage of the tubes as strength values of the tubes are within acceptable limits.
5. Hardness testing:
Hardness values of tube samples are under acceptable limit. No major

abnormality observed.
6. Optical Microscopy:
Microstructure examination findings are listed in table below:

Tube Microstructure Examination Findings
Sr. Microstructure
Tube Identifications
No. Examination Results
1 Peralite breakdown (SL – III) observed. No
HP Superheater II
creep damage noticed
2 Normal microstructure observed. No creep
LP Superheater
damage noticed
Discussion
The microstructure examination can provide an indication of the extent of material

damage that has been reached to a present condition. There are three
degradation processes possible, being spherodization, creep and decarburization.
Toft and Marsden [ii] developed a system, which represents the degree of carbide
spherodization of pearlitic materials to be categorized into successive stages.
Each degree, Spherodization - (SL-I) onwards shows increasing degree of
spherodization, which to certain extent can be related to softening and reduction
in tensile strength.
Table 1: The various stages of carbide spherodization
Levels Microstructure Condition

As manufactured, typical of the structure of unaffected material, consisting of ferrite
AM
and pearlite.
The first stage of carbide spherodization usually coincides with the appearance of
SL – I
small particles of carbides at the grain boundaries.
An intermediate stage of spherdozation showing more distinct signs of carbide
SL – II spherodization in the pearlite areas, but some cementite plates still evident.
Increased carbide precipitation within the ferrite grains and at the grain boundaries.
Spherodization of carbides virtually complete but still grouped in the original pearlitic
SL – III
pattern.
There is marked increase in the size of some of the carbide particles, partly due to
SL – IV
coalescence.
Remedial action –
Tubes –
i) For SL – I to SL – III : No immediate action required. Re inspect tube after 5

years of boiler operation
ii) For SL-IV : Re-inspection of tube after 5 years of boiler operation is
recommended depending on the testing results - hardness, corrosion attack,
available thickness etc.
7. In-situ Metallography (Replication)

Sr. Component & Replica Microstructure Examination

No. locations Results
HP Section
Drum
1 External surface – LHS ‘C’
Seam
2 External surface LHS ‘L’ Seam
3 External surface MID ‘C’ Seam
4 External surface MID ‘L’ Seam
5 External surface RHS ‘C’ Seam
6 External surface RHS ‘L’ Seam Normal microstructure observed.
7 Internal Surface LHS Parent
Metal
8 Internal Surface RHS Parent
Metal
9 External surface Safety Valve
LH Side Parent Metal
Feed Water Pipe
10 Front Side outlet coil No 1 ‘C’
Seam 30 %
11 Front Side outlet coil No 3 ‘C’
Seam 30%
Normal microstructure observed.
12 Front Side Coil No1 Parent
Metal 100%
13 Front Side Coil No 2 Parent
Metal 100%
Economizer heater – Inlet (Top)
14 LHS – Parent Metal Normal microstructure observed.
Economizer heater – Outlet (Top)
16 RHS – Parent Metal Normal microstructure observed.
Evaporator Inlet (Bottom)
17 RHS to LHS Header No 1 –
Parent Metal
Parent Metal
Parent Metal
Parent Metal
Evaporator Outlet (Top)
21 RHS To LHS Parent Metal Normal microstructure observed.
Super heater – I Inlet (Top) Header
Super heater – I Outlet (Bottom) Header
23 Parent Metal
24 Parent Metal


Attemperator - Header
25 LHS – ‘C’ Seam
26 Near Bend ‘C’ Seam
Super heater – II Inlet (Bottom) Header
Super heater – II outlet (Top) Header
28 LHS – Parent Metal
Total Pearlite Breakdown observed. (SL-IV)
29 RHS – Parent Metal
Main Steam Line
30 Near Safety Valve Total Pearlite Breakdown observed. (SL-IV)
31 On Bend –Parent Metal Total Pearlite Breakdown observed. (SL-IV)
LP Section
Drum
32 External surface – LHS ‘C’
Seam
33 External surface LHS ‘L’ Seam
34 External surface MID ‘C’ Seam
35 External surface RHS ‘C’ Seam
36 External surface RHS ‘L’ Seam Normal microstructure observed.
37 Internal Surface LHS Parent
Metal
38 Internal Surface RHS Parent
Metal
39 External surface Safety Valve
LH Side Parent Metal
Feed Water Pipe
40 Front Side Coil No1 Parent
Metal 100%
41 Front Side Coil No 2 Parent
Metal 100%
Evaporator Inlet (Bottom)
42 RHS to LHS Header
No 1 – Parent Metal
44 RHS to LHS Heade
r No 3 – Parent Metal
Evaporator Outlet (Top)
46 RHS To LHS Parent Metal Normal microstructure observed.
Super heater – I Inlet (Top) Header


Super heater – I Outlet (Bottom) Header
49 LH Side Parent Metal
50 RH Side Parent Metal
Main Steam Line
51 Before MSSV – After Bend ‘C’ Normal microstructure observed.
Seam
52 On Bend –Parent Metal Normal microstructure observed.
53 LH Side Parent Meatl
Condensate Preheater Intermediate Header
54 LSH Header No1 Parent Metal Normal microstructure observed.
LHS To RSH Header No 2
55 Normal microstructure observed.
Parent Metal
LSH To RSH Header No 3
Parent Metal
LSH To RSH Header No 4
Parent Metal
58 LHS To RHS Parent Metal Coil Normal microstructure observed.
LSH To RSH Coil No 18 Parent
Metal
LSH TO RSH Header No Parent
Metal
LHS To RHS Header No Parent
Metal
Headers and Drums – No such remedial action as per Neubauer and Wedel
based on spherodization level
However Neubauer and Wedel categorized the degree of creep present in mild
and low carbon alloy steel microstructures. The various characterization and
associated microstructure features are given in table below.
Please note Neubauer and Wedel does not specify degree of sperodization. The remedial
action is based on creep voids observed in the microstructure.
The type of damage observed in high temperature, high stress (pressurized)
components such as these, typically progresses in stages with increasing strain
(plastic deformation) occurring over a considerable period of time. Swelling of the
afflicted component may be observed. Material damage manifests itself in the
microstructure in the form of characteristic void or crack features. In early stages
of creep, micro-voids are formed at the grain boundaries. Voids may form after
mid-life, which then subsequently link up to form micro-cracks. These cracks
increase in size or severity as the end of life condition is approached.

B. Neubauer and U. Wedel, “Rest life Estimation of Creeping Components by

Means of Replicas,” Advances in Life Predication Methods, American Society of
Mechanical Engineers, New York, 1983, pp. 307-314.
Table 2: Microstructure categorization by Neubauer and Wedel.
Class Microstructure Condition Remedial Action

Undamaged No creep damage observed. None.
(UD)
Class A Isolated cavities present on grain Observe
(CP-I) boundaries.
Class B Oriented cavities i.e. the cavities are Requires inspection at
(CP-II) distributed so that an alignment of fixed intervals, usually
damaged boundaries normal to the between 11/2 and 3 years
maximum stress can be seen.
Class C Some micro cracks, coalescence of Requires repair or
(CP-III) cavities causing the separation of grain replacement within 6
boundaries. months.
Class D Macro cracks Requires immediate
(CP-IV) replacement
Decision regarding the overall condition in relation with other non-destructive test
findings is included in Volume 1 of the report.
C) FIELD HARDNESS TESTING – RESULTS.
Details of the test results are given in Section – 5 of the report.

All the measured hardness values of all components are acceptable as per
there respective specifications.

D) SWELL MEASUREMENT – RESULTS.
No major abnormalities observed. All the result are under acceptable limits.
E) DRUM INTERNAL DEPOSIT ANALYSIS – RESULTS.
Details of the test results are given in Section – 7 of the report.

SECTION – 3
TUBE LABORATORY TESTING

TUBE LABORATORY TESTING
Two tube samples were collected from the different components of the boiler to
check their condition. Following tubes were cut for destructive testing.
1. HP Superheater II tube
2. LP Superheater tube
A. Testing methodology
Tube samples were subjected to the following examination:

1. Visual examination.
2. Dimensional measurements.
3. Chemistry of tube material.
4. Internal surface deposit analysis.
5. Physical testing.
6. Hardness testing.
7. Flaring test
8. Flattening test
9. Optical metallography at fire and non-fire side.
B. Procedure for sampling
Before the tube samples were sectioned for the analysis, a line was drawn at the
length of each tube sample for reference. The line was referred to as the 12
O’clock position. In this manner, one could go to a desired part of the tube
circumference merely by knowing its “clock” position. The 6 O’clock position was
the side of the tube facing the gas flow; hence 12 O’clock position was location
opposite the gas flow direction.
Tube samples 1 to 2 were dry saw cut into the following sections for analysis.
1. A full ring section was cut from samples and was shot blasted for outer
diameter and wall thickness measurements.
2. A longitudinal piece of sample @ 100 mm length was used for flaring test.
3. A longitudinal piece of sample @ 50 mm length was used for flattening test.
4. A full ring section was cut adjacent to the ring described in Sr. No. 1 above.
Segments at the 12 and 6 O’clock positions were cut and prepared for
metallographic examination. These segments were used to examine the tube’s
microstructure, measure the oxide scale thickness at the internal surface of the
tube.
5. Balance length of tube sample split longitudinally into two halves.
6. A small piece of samples was used to determine the chemical composition of
the steel.

7. A longitudinal piece of sample was used for physical testing
12 O’clock
9 O’clock 3 O’clock
FLUE GAS
6 O’clock

TESTING RESULTS
A. Visual Inspection
1. HP Superheater II tube
As Received Condition:
External surface of Flue gas and opposite to flue gas side was brownish in
color. Internal surface was blackish in color. Minor adherent black oxide found
on internal surface Refer Photograph No: VI - 01
2. LP Superheater tube
As Received Condition:
External surface of Flue gas and opposite to flue gas side was brownish in
color. Internal surface was blackish in color. Minor adherent black oxide found
on internal surface. Refer photograph No: VI - 02
B. Flattening & Flaring Test.
Flattening and Flaring test was conducted as per SA 450/450M

Tube surface did indicates cracks after test
Refer Photographs No: 03, 04, 05 & 06
C. Chemical Testing
Results of the spectroscopic analysis of tube samples are given below.
Specifie Elements found in Spectroscopy

Sr. Tube
d
No Identification
Material C Si S P Mn Cr Mo
SA 213
1 HP Superheater II 0.019 0.20 0.002 0.017 0.47 2.09 0.93
T22
2 LP Superheater SA 192 0.10 0.14 0.011 0.006 0.47 - -
Chemical composition as per specification:
Material C Si S P Mn Cr Mo
0.05 0.30 1.90 0.87
0.50 0.025 0.025
SA 213 T22 - - - -
max max max
0.15 0.60 2.60 1.13
0.06 0.25 0.27
0.035 0.035
SA 192 - Max - - -
Max Max
0.18 0.63
Test results of all tubes are confirming to specified material

D. Dimensional measurement, Internal deposit weighing
Measurements of the outer diameter and wall thickness around the circumference
of grit blasted full ring sections were measured. Results of measurements are as
follows.
Specified Measured Internal

Sr.
Tube sample O.D X THK Deposit
No OD Thick
(mm) mg/cm2
1 HP Superheater II 38.0 X 6.3 38.3-38.5 5.58-5.65 3
2 LP Superheater 38.0 X 4.5 38.2-38.4 3.57-3.67 4
E. Physical testing
Results of physical testing are as below:
Ultimate Tensile Percentage

Yield Strength
Sr. Specified Strength Elongation
(N/mm2)
No. Tube Material (N/mm2)
F NF F NF F NF
HP
1 SA 213 T22 451.04 472.97 516.70 519.98 18.0 16.0
Superheater II
LP
2 SA 192 349.25 349.41 426.86 431.89 23.0 21.0
Superheater
NOTE: F - Fire or Flue gas side NF - Non Fire or Opposite of flue gas side.
Sr. Yield Strength Ultimate Strength *Percentage

Specified values Elongation
No (N / mm2) (N / mm2)
1 SA 213 T22 620 min. 400 min 20 min.
2 SA 192 180 min 325 min 35 min
* Minimum Percentage elongation in longitudinal direction (All the tube samples tested in
longitudinal direction only). Single values in above table indicate minimum required value
at room temperature. Percentage elongation is a measure of ductility. Primarily reduction
in % elongation observed in tubes are due to microscopic carbide precipitation due to
prolonged usage of tube, hence it is bound to show reduction. However there will not be
any adverse effect on tubes during future operation. Percentage elongation or ductility is
important at the time of fabrication for operations like bending.
F. Mid-wall hardness measurements
Hardness measurements taken at the mid-wall of the tube wall thickness of

samples 1 to 2 are given in table below.
Hardness in HRB
Sr.No. Tube Material
F NF
1 HP Superheater II SA 213 T22 77-79 77-78
2 LP Superheater SA 192 55-57 58-59

Hardness values are within specified values as per ASME specifications.
ASME Material Specification Specified values

SA 213 T 22 85 HRB (max.)
SA 192 77 HRB (max)
All samples exhibited hardness with no significant differences between the gas
flow side and opposite to gas flow side. Hardness values of all the tubes found
within limit as per ASME standard.
G. Microstructure Analysis
Through-thickness spherodization and creep microstructure characterization for

the 12 and 6 O' clock position of all tube samples. Refer Optical Microscopy
0.5 mm below Midway 0.5 mm below

Position
outer surface Position inner surface
Damaged
Sperodization Creep Sperodization Creep Sperodization Creep
mechanism
HP Superheater
SL - III UD SL - III UD SL - III UD
II
LP Superheater AM UD AM UD AM UD
Refer Table 1 and 2 for nomenclature used.
Microstructure examination of tubes did not indicate any hydrogen damage or

decarburisation.
The microstructure examination can provide an indication of the extent of material
damage that has been reached to a present condition. There are three
degradation processes possible, being spherodization, creep and decarburization.
Toft and Marsden [ii] developed a system, which represents the degree of carbide
spherodization of pearlitic (1Cr-11/2Mo) materials to be categorized into
successive stages. Each degree, Spherodization I (SL-I) onwards shows
increasing degree of spherodization, which to certain extent can be related to
softening and reduction in tensile strength.


As manufactured, typical of the structure of unaffected material, consisting of ferrite
AM
and pearlite.
The first stage of carbide spherodization usually coincides with the appearance of
SL – I
small particles of carbides at the grain boundaries.
An intermediate stage of spherdozation showing more distinct signs of carbide
SL – II spherodization in the pearlite areas, but some cementite plates still evident.
Increased carbide precipitation within the ferrite grains and at the grain boundaries.
Spherodization of carbides virtually complete but still grouped in the original pearlitic
SL – III
pattern.
There is marked increase in the size of some of the carbide particles, partly due to
SL – IV
coalescence.
Remedial action - For SL-IV the re-inspection of tube after 3 to 5 years of boiler
operation is recommended depending on the testing results - hardness, corrosion
attack, available thickness etc.
Similarly, Neubauer and Wedel categorized the degree of creep present in mild
and low carbon alloy steel microstructures. The various characterization and
associated microstructure features are given in table above. In early stages of
creep, micro-voids are formed at the grain boundaries. These voids can link up to
produce micro-cracks, which, if continued, may result in stress rupture.
Table 2: Microstructure categorization by Neubauer and Wedel.
Class Microstructure Condition Remedial Action

Undamaged (UD) No creep damage observed. None.
Class A Isolated cavities present on grain Observe
(CP-I) boundaries.
Class B Oriented cavities i.e. the cavities are Requires inspection
(CP-II) distributed so that an alignment of at fixed intervals,
damaged boundaries normal to the usually between 11/2
maximum stress can be seen. and 3 years
Class C Some micro cracks, coalescence of Requires repair or
(CP-III) cavities causing the separation of grain replacement within 6
boundaries. months.
Class D Macro cracks Requires immediate
(CP-IV) replacement

AS RECEIVED CONDITION: EXTERNAL SURFACE INSPECTION
PH No. 01: Tube external surface blackish-brown in colour. No abnormality like

corrosion or erosion on external surface.


LES: 2010: GPEC-CLP- GT: 3957/3958:03 PAGE NO: 22

PHOTOGRAPHS: FLATTENING TEST
PH No. 03: After Flattening No cracks were present at edges after test. Hence it is
acceptable.
PH No. 04: After Flattening No cracks were present at edges after test.Hence it is
acceptable.

RING SECTION OF TUBE SAMPLE
PH 1
PH 2
PH No. 07 - HP Superheater II tube

PH No. 08 - LP Superheater tube
Ring Section inspection did not show any thickness reduction on external and
internal surfaces.
2 2 5
OPTICAL MICROSCOPY
Tube Name HP Superheater II Client GPEC-CLP
Material of Construction SA 213 T22
FIRE SIDE OPPOSITE TO FIRE SIDE
INNER EDGE
Magnification: 250 X Magnification: 250 X

OUTER EDGE

MID WALL

Microstructure Observation
Inner Edge Grains of Ferrite and pearlite observed .
Outer Edge Decarburization observed on outer edge.
Mid Wall Grains of ferrite and pearlite observed.
Damage Classification
Spherodization Level Spherodization Level III observed.
Creep Damage Undamaged

OPTICAL MICROSCOPY
Tube Name LP Superheater Client GPEC-CLP
Material of Construction SA 192
FIRE SIDE OPPOSITE TO FIRE SIDE
INNER EDGE

OUTER EDGE

MID WALL

Inner Edge Grains of ferrite and pearlite observed.
Outer Edge Grains of ferrite and pearlite observed.
Mid Wall Grains of ferrite and pearlite observed.
Spherodization Level Normal microstructure observed.

SECTION – 4
IN SITU METALLOGRAPHY

IN-SITU METALLOGRAPHY
Materials exposed to high temperature-high pressure service conditions are

susceptible to long-term material degradation mechanisms. These mechanisms
include material degradation processes such as creep, creep fatigue and thermal
fatigue. The surface replication technique permits early detection and continued
monitoring for creep damage evolution.
The replica locations were selected in regions where material degradation is

expected to occur, which is based on Thermax Babcock & Wilcox’s experience.
This report contains the results of the laboratory replica examination and
evaluation.
Replication procedures
Field replication is an effective means of obtaining an image of a component
surface. This permits laboratory examination and evaluation of the metallurgical
condition of the material. The examination is completed without having to cut out a
portion of the component, and is capable of determining metallurgical data in fine
detail. The principle of the surface replication technique is illustrated as follows:
The surface to be replicated is polished by successively finer grinding grits and

developed electo-polishing technique. The surface is then etched to reveal the
microstructural detail. A plastic film (tape) is applied, cured, and carefully
removed. The surface of the film in contact with the polished area retains a
precise, reverse image of the etched component surface. In the laboratory, with
the help of standard optical microscope the replicas are examined.
Discussion of creep failure mechanism
The type of damage observed in high temperature, high stress (pressurized)

components such as these, typically progresses in stages with increasing strain

(plastic deformation) occurring over a considerable period of time. Swelling of the

afflicted component may be observed. Material damage manifests itself in the
microstructure in the form of characteristic void or crack features. Voids may form
after mid-life, which then subsequently link up to form cracks. These cracks
increase in size or severity as the end of life condition is approached.
The first published attempt to relate creep-life consumption of plant components to
cavitation was that of Neubauer and Wedel*. The characterized cavity evolution in
steels at four stages i.e., isolated cavities, oriented cavities, linked cavities
(microcracks), and macro-cracks. They estimated the approximate time intervals
required for the damage to evolve from one stage to the next under typical plant
conditions. They formulated recommendations corresponding to the four stages of
cavitation. Creep-life assessment based on cavity classification is illustrated
below:
B. Neubauer and U. Wedel, “Restlife Estimation of Creeping Components by

Means of Replicas,” Advances in Life Predication Methods, American Society of
Mechanical Engineers, New York, 1983, pp. 307-314.
They concluded that for Class A damage, no remedial action would be required.
For Class B damage, consisting of oriented cavities, re-inspection within 1-1/2 to 3
years would be required. For Class C damage, repair or replacement would be
needed within six months. For Class D damage, immediate repair would be
required. They built considerable conservatism into their recommendations and
viewed their technique more as a monitoring technique than as a life-prediction
technique. Their procedure, because of its simplicity, has found worldwide support
with power plant operators.
Similarly Toft and Marsden [ii] developed a system for carbon steel, which
represents the degree of carbide spherodization of pearlitic (1Cr-11/2Mo) materials
to be categorised into successive stages. Each degree, Spherodization I (SL-I)
onwards shows increasing degree of spherodization, which to certain extent can
be related to softening and reduction in tensile strength.


As manufactured, typical of the structure of unaffected material,
AM
consisting of ferrite and pearlite.
The first stage of carbide spherodization usually coincides with the
SL – I
appearance of small particles of carbides at the grain boundaries.
An intermediate stage of spherdozation showing more distinct signs
of carbide spherodization in the pearlite areas, but some cementite
SL – II
plates still evident. Increased carbide precipitation within the ferrite
grains and at the grain boundaries.
Spherodization of carbides virtually complete but still grouped in the
SL – III
original pearlitic pattern.
There is marked increase in the size of some of the carbide particles,
SL – IV
partly due to coalescence.
Details of replicated components
Sr. Number
No Component Material of
. Replicas
HP Section
1 Drum SA 516 Gr. 70 09
2 Feed Water Pipes SA 106 Gr. B 04
3 Econimizer Inlet Header (Top) SA 106 Gr. B 01
4 Economizer Outlet (Top) SA 106 Gr. B 02
7 Super heater 1 Inlet header (Top) SA 335 P1 02
8 Super heater 1 Outlet (Bottom) SA 335 P12 01
9 Attemparator Header SA 335 P12 02
10 Super heater 2 Inlet header (Bottom) SA 335 P12 01
11 Super heater 2 Outlet header (Top) SA 335 P22 02
12 Main Steam Line __ 02
LP Section
13 Drum SA 516 Gr. 70 08
14 Feed Water Line SA 106 Gr. B 02
17 Super heater Inlet header (Bottom) SA 106 Gr. B 02
18 Super heater Outlet header (Top) SA 106 Gr. B 02
19 Main Steam Line __ 03
20 Condensate Preheater Inlet Header (Top) SA 106 Gr. B 04
21 Condensate Preheater Inlet coils (Top) SA 192 02
22 Condensate Preheater Outlet Header (Top) SA 106 Gr. B 02

Specifications
Replica preparation and As per ASTM E 1351-90, Section 3, Volume 03.01

Evaluation
Etching agent 2% Nital, As per E-407, ASTM Section 3, Volume 03.01
Microstructure As per ASTM E 883-83, Section 3, Volume 03.01
photomicrography

Replica No R1 Client GPEC-CLP

Component HP Drum
Location LH Side Circumferential Seam
Material of Construction SA 516 GR.70
PARENT METAL
Magnification : 250X Magnification : 500 X

HEAT AFFECTED ZONE WELD METAL
Magnification : 500X Magnification : 250X
Microstrucutre Observation
Parent Metal Grains of ferrite and uniformly distributed pearlite observed.
Heat Affected Zone Grains of ferrite and fine carbides observed.
Weld Metal Grains of veiny ferrite and pearlite


Component HP Drum
Location LH Side Longitudinal Seam
PARENT METAL



Component HP Drum
Location Middle Circumferential Seam
PARENT METAL



Component HP Drum
Location Middle Longitudinal Seam
PARENT METAL

Parent Metal Grains of ferrite and resolved pearlite observed.


Component HP Drum
Location RH Side Circumferential Seam
PARENT METAL



Component HP Drum
Location RH Side Longitudinal Seam
PARENT METAL

Spherodization Level Normanl microstructure observed.


Component HP Drum
Location LH Side Parent Metal (In Side)
PARENT METAL
Heat Affected Zone NA
Weld Metal NA


Component HP Drum
Location RHS Parent Metal Inside
PARENT METAL
Weld Metal NA


Component HP Drum Safety Valve
Location LH Side Parent Metal
PARENT METAL
Weld Metal NA

Thermax Babcock & Wilcox (A division of Thermax Ltd)

Component Feed Water Pipes No.1
Location Front Side Circumferential Seam
Material of Construction SA 106 Gr.B
PARENT METAL

Parent Metal Grains of ferrite and pearlite observed. Normal microstructure observed.


Component Feed Water Pipes No-3 30%
Location Front Side Circumferential Seam
PARENT METAL



Component Feed Water Pipes No.1 100%
Location Front Side Parent Metal
PARENT METAL
Weld Metal Tempered martensite and fine carbides observed.


Component Feed water Pipes No.2 100%
Location Front Side Parent Metal
PARENT METAL
Weld Metal NA


Component Economiser Inlet Header (Top)
Material of Construction SA 106 GR. B
PARENT METAL
Parent Metal Grains of ferrite and resolved pearlite observed. Normal microstructure
observed.
Weld Metal NA
Creep Damage NA


Component Economiser Outlet Header (Top)
PARENT METAL
Weld Metal NA


Component Economiser Outlet Header (Top)
Location RH Side Parent Meatal
PARENT METAL
Weld Metal NA


Component Evaporator Inlet Header No.01
Location RHS To LHS Parent Metal
PARENT METAL
Weld Metal NA


PARENT METAL
Weld Metal NA


PARENT METAL
Weld Metal NA


PARENT METAL
Weld Metal NA


Component Evaporator Outlet Header (Top)
Location RHS Side Parent Metal
PARENT METAL
Weld Metal NA


Component Superheater 1 Inlet Header (Top)
Material of Construction SA 335 P1
PARENT METAL
Weld Metal NA


Component Superheater 1 Inlet Header (Top)
Location RH Side Parent Metal
PARENT METAL
Weld Metal NA


Component Supeheater -1 Outlet Header (Bottom)
Location LH Side Parant Meatl
PARENT METAL
Weld Metal NA


Component Attemperator Header
PARENT METAL



Component Attemperator Header
Location Near Bend Circumferential Seam
PARENT METAL

Parent Metal Grains of ferrite and resolved pearlite observed. Normal microstructure
observed.
Creep Damage NA


Component Superheater 2 Inlet Header (bottom)
Location LHS Parent Metal
PARENT METAL
Weld Metal NA


Component Superheater 2 Outlet Header (Top)
PARENT METAL
Parent Metal Grains of ferrite and totally degraded pearlite observed.
Weld Metal NA
Spherodization Level Total pearlite breakdown observed (SL-IV)


Component Superheater 2 Outlet Header (Top)
PARENT METAL
Weld Metal NA

Replica No R30 Client GPEC- CLP

Component Main Steam Line Near Safety Valve
Location LHS Circumferential Seam
Material of Construction ---
PARENT METAL

Heat Affected Zone Grains of ferrite and finely distributed carbides observed.
Weld Metal Degradation observed.


Component Main Steam Line On Bend
Location Parent Meatal
Material of Construction ---
PARENT METAL
Weld Metal NA


Component LP Drum
Material of Construction SA 516 GR. 70
PARENT METAL

Parent Metal Grains of ferrite and evenly distributed pearlite observed.
Heat Affected Zone Grains of ferrite and fine distributed carbides observed.
_______________________________________________________________________________________________
LES: 2010: GPEC: GT: 3957/3958: 03 PAGE NO: 65

Component LP Drum
Location LH Side Longitudinal Seam
PARENT METAL



Component LP Drum
Location Middle Side Circumferential Seam
PARENT METAL

Weld Metal Grains of veiny ferrite and pearlite.


Component LP Drum
Location RH Side Front Longitudinal Seam
PARENT METAL



Component LP Drum
PARENT METAL



Component LP Drum
PARENT METAL

Weld Metal Tempered martensite and pearlite observed.


Component LP Drum
Location LHS Front Parent Metal(Inside)
PARENT METAL


Component LP Drum
Location LH Side Front Circumferential Seam (Inside)
PARENT METAL



Component LP Drum
Location RH Side Front Parent Metal (Inside)
PARENT METAL


Component Feed Water Line No 1
Location LHS To RHS Parent Metal
PARENT METAL
Weld Metal NA
_______________________________________________________________________________________________

Component Feed Water Line No 2
PARENT METAL
Weld Metal NA


Component Evaporator Inlet Header No.1 (Bottom)
Location LHS To RSH Parent Metal
PARENT METAL
Weld Metal NA


Component Evaporator Inlet Header No.2(Bottom)
PARENT METAL
Weld Metal NA


PARENT METAL
Weld Metal NA


PARENT METAL
Weld Metal NA


Component Evaporator Outlet Header (Top)
PARENT METAL
Weld Metal NA


Component Superheater Inlet Header (Bottom)
PARENT METAL
Weld Metal NA


Component Superheater Inlet Header (Bottom)
PARENT METAL
Weld Metal NA
Creep Damage NA


Component Superheater Outlet Header (Top)
PARENT METAL
Weld Metal NA


Component Superheater Outlet Header (Top)
PARENT METAL
Weld Metal NA


Component Main Stem Line Before Safety Valve
Location Parent Metal
PARENT METAL
Weld Metal NA


Component Main Steam Near Insulation Valve
Location Parent Metal
PARENT METAL
Weld Metal NA
Creep Damage NA


Component Main Steam Line
Location LH Side Parent Meatl
Material of Construction NA
PARENT METAL
Weld Metal NA


Component Condensate Preheater Intermediate Header No.1
Location LSH Parent Metal
PARENT METAL
Weld Metal NA


Component Condensate Preheater Intermediate Headers No.2
PARENT METAL
Weld Metal NA


Location LSH To RSH Parent Metal
PARENT METAL
Weld Metal NA


Location LHS TO RHS Parent Metal
PARENT METAL
Weld Metal NA


Component Condensate Preheater Intermediate Inlet Coil (Top)
PARENT METAL
Weld Metal NA


Component Condensate Preheater Intermediate Inlet Coils No18
PARENT METAL
Weld Metal NA


Component Condensate Preheater Intermediate Outlet Headers
Location LHS TO RHS Parent Metal
PARENT METAL
Weld Metal NA


Component Condensate Preheater Intermediate Headers
PARENT METAL
Weld Metal NA

SECTION – 5
FIELD HARDNESS TESTING
LES: 2010: GPEC-CLP-GT: 3957/3958:03 PAGE NO: 96

HARDNESS TESTING
The hardness readings on replica location taken on Boiler Unit No.GT 3957/58 is
listed below.Hardness is taken such as to cover the patent metal, heat affected
zone and weld metal.
All the above hardness values measured with Equotip portable hardness tester
were found to be acceptable.
The specification limits apply only to as produced components. The hardness

values reported refer to ex-service components and are typical of components
that have been exposed to long term service. However for given material chemical
composition and strength properties the measured hardness vales found to be
acceptable.
Hardness Testing Readings HP Boiler
Component / Location Material Hardness HV

HP Drum
PM120 – 124
LH Side Circumferential Seam HAZ 141 – 144
WM 198 – 200
PM 121 – 123
LH Side Longitudinal Seam HAZ 144 – 145
WM 197 – 201
PM 190 – 122
Middle Circumferential Seam HAZ 140 – 143
WM 199 – 200
PM 119 – 124
Middle Longitudinal Seam SA 516 GR.70 HAZ 140 – 142
WM 199 – 201
PM 162 – 164
RH Side Circumferential Seam HAZ 187 – 190
WM 248 – 253
PM 129 – 131
RH Side Longitudinal Seam HAZ 187 – 190
WM 198 – 200
LH Side Parent Metal (In Side) PM 118 – 120
RHS Parent Metal Inside PM 119 – 123
LH Side Parent Metal PM 160 – 162
Feed Water Pipes
PM 122 – 126
Front Side Circumferential Seam SA 106 Gr.B HAZ 148 – 151
WM 182 – 185
Front Side Circumferential PM 121 – 123
Seam HAZ 146 – 150
WM 182 – 183

Front Side Parent Metal No.1 PM130 – 132
Front Side Parent Metal No.2 PM 129 – 132
Economiser Inlet Header (Top)

LHS Side Parent Metal 13 Cr Mo 44 PM 128 – 131
Economiser Outlet Header (Top)
LH Side Parent Metal 13 Cr Mo 44 PM 129 – 131
RH Side Parent Meatal 13 Cr Mo 44 PM 140 – 145
Evaporator Inlet Header (Bottom)
Evaporator Inlet Header No.1 PM 133 – 136
SA 106 GR. B
Evaporator Inlet Header No 4 PM 126 – 130
Evaporator Outelet Header (Top)
LH Side Parent Metal SA 106 GR. B PM130 – 132
Superheater 1 Inlet & Outlet Header
RH Side Parent Metal SA 335 P1 PM 133 – 135
LH Side Parant Meatl (Outlet) PM 131 – 133
Attemperator Header
PM 160 – 162
LH Side Circumferential Seam SA 335 P12 HAZ 124 – 130
WM 228 – 302
PM 154 – 158
Near Bend Circumferential
Seam
13 Cr Mo 44 HAZ 218 – 220
WM 278 – 281
Superheater 2 Inlet Header (bottom)
LH Side Parent Metal SA 335 P12 PM 118 – 120
Superheater 2 Outlet Header (Top)

SA 335 P12
RH Side Parent Metal PM 133 – 135
Main Steam Line

PM 144 – 148
LHS Circumferential Seam NA HAZ 170 – 173
WM 198 – 204
Parent Meatal NA PM 148 – 150

Hardness Testing Readings LP Boiler
Component / Location Material Hardness HV

LP Drum
PM 135 – 138
LH Side Circumferential Seam HAZ 160 – 165
WM 218 – 220
PM 123 – 125
LH Side Longitudinal Seam HAZ 154 – 158
WM 192 – 194
PM 141 – 142
Middle Circumferential Seam HAZ 172 – 174
WM 230 – 232
PM134 – 138
RH Side Circumferential Seam SA 516 GR.70
HAZ 174 – 176
WM 210 – 212
PM136 – 138
RH Side Longitudinal Seam HAZ 162 – 164
WM 208 – 210
PM142 – 144
LH Side Circumferential Seam
(Inside) HAZ 155 – 158
WM 178 – 180
LH Side Parent Metal (In Side) PM 128 – 130
RH Side Parent Metal (Inside) PM 128 – 132
Feed Water Pipes
LHS To RHS Parent Metal 30% PM128 – 130
SA 106 Gr.B
LHS To RHS Parent Metal 100% PM 104– 108
Evaporator Inlet Header (Bottom)
SA 106 GR. B
Evaporator Inlet Header No 4 PM 116 – 120
Evaporator Outelet Header (Top)
LHS To RHS Parent Metal SA 106 GR. B PM 118 – 121
Superheater 1 Inlet & Outlet Header
RH Side Parent Metal PM 118 – 121

SA 335 P1
LH Side Parant Meatl (Outlet) PM 118 – 121
RH Side Parent Metal (Outlet) PM 118 – 121

Main Steam Line

Parent Metal PM 118 – 121
Parent Meatal NA PM 120 – 124
LH Side Parent Meatl PM 118 – 119
Condensate Preheater Intermediate Header
LHS Header No1 Parent
Metal PM137 – 138
LHS To RHS Header No2
LHS To RHS Header No 3
LHS To RHS Header No 4
SA 106 GR. B
LHS To RHS Parent Metal
Coil PM 137 – 138
LHS To RHS Coil No 18
LHS TO RHS Header No
LHS To RHS Header No
Legends:
PM: Parent Metal. WM: Weld Metal. HAZ: Heat Affected Zone.
References:
ASTM A 956-96: Standard Test method for Equotip Hardness Testing of Steel
products.

SECTION – 6
SWELL MEASURMENT

SWELL MEASUREMENT
Swell measurement was carried out on parts sustaining to high temperature, such
as main steam line, Superheater headers etc, which are prone to undergo creep.
The components undergoing creep tend to deform. By measuring the
circumference of this line it is easy to determine whether the component has
undergone creep deformation.
Creep is the long-term effect of a state of high stress at high temperatures and is
a relaxing of physical dimensions due to microstructural degradation or change in
phases. It gets gradually worse, but for a majority of the life of pressure parts the
rate of degradation is constant (linear), and therefore predictable. However, as a
pressure parts approaches it, ultimate failure by creep, the rate of deterioration
increases sharply. It is important to know the state of creep degradation of
pressure parts as they age if remaining life predictions are to be valid.
Thus by carrying out swell measurement we get a preliminary idea of the creep
degradation, if any, of the component. However, it is to be noted that swell
measurement cannot solely determine the state of deterioration and so to provide
adequate information to judge the components’ in situ (field metallography) was
done.
Swell measurement was done on Superheater headers, Attemperator Headers,

Main Steam line. All the components test results are found within acceptable
limit.
Details of various components are listed below in tables.






SECTION – 7
DEPOSIT ANALYSIS
REPORT

DEPOSIT ANALYSIS REPORT
Internal deposits from Steam Drum collected during the site study. The analysis
report is enclosed below.
TEST RESULTS
Parameter Unit Percentage (%)
Appearance / colour - Black colour
PH ( 1% Solution ) - 6.47
Silica (SiO2) % 1.5801
Iron (Fe) % 63.7764
Phosphates ( PO4) % Nil
Loss on Ignition at 1000c - Nil
Calcium ( CaO) % 0.1996
Sodium (Na2O) % 0.3730
Magnesium (MgO ) % 0.1150
Sulphur (S) % 0.4191
Potassium (K2O) % 0.0144
Total Chlorides (Cl) % 0.00688
Total Acid Insoluble % 1.5801
Copper (Cu) % 0
1. Phosphate in the deposit found to be on higher side. Refer following

discussion
Deposit Location: The deposits collected are from opening of downcomers.
Phenomena of deposit accumulation: When boiler is shut & drained naturally
by opening all drain lines, water flows from drum surface get drained. The
loose scales on drum surface come down along with water and get settled at
corners. Once dried out by natural way, this will appear in deposit.
Effect of Constituents: above phenomena shows that such kind of deposit
accumulation is normal. Hence Phosphate concentration on higher side is a
normal phenomenon in this case. There is no concern from integrity point of
view.
2. Iron content in deposit is 63.7764 %. This is due to regular corrosion of drum

internal surface over period of time. It is recommended to follow preservation
practice as per O & M manual.

Jejej

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Gujarat Paguthan Energy Corporation Limited

METALLURGICAL TESTING REPORT

Life Extension Services

A Balaji Vijay Jadhav

THERMAX BABCOCK & WILCOX

Metallurgical Testing Results

Tube Laboratory Testing

4 In-situ Metallography (Replication) 28-95

5 Field Hardness Testing 96-100

6 Swell Measurement 101-106

7 Deposit Analysis 107-108

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 1

During the condition Assessment & Remaining Life Analysis GT 3957(HP)/ GT

1. Tube sample laboratory destructive testing

Methodology adopted for above testing is elaborated in respective section

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 2

3 Year of Commissioning 1998

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 3

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 4

DETAILS OF TUBE SAMPLE

Sr. Tubes Material Tube Size Location

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 5

Sr. Component Material Number of

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 6

METALLURGICAL TESTING RESULTS

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 7

METALLURGICAL TESTING RESULTS

Thermax Babcock & Wilcox’s Condition Assessment & Remaining Life

A) TUBE TESTING – RESULTS

a) HP Superheater II tube: No abnormalities in terms of erosion, corrosion or

Both tube samples chemical composition confirmed to the specifications.

Dimensional measurement of both the tubes submitted for lab analysis

Hardness values of tube samples are under acceptable limit. No major

Microstructure examination findings are listed in table below:

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 8

Tube Microstructure Examination Findings

The microstructure examination can provide an indication of the extent of material

Table 1: The various stages of carbide spherodization

Levels Microstructure Condition

i) For SL – I to SL – III : No immediate action required. Re inspect tube after 5

7. In-situ Metallography (Replication)

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 9

Sr. Component & Replica Microstructure Examination

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 10

Sr. Component & Replica Microstructure Examination

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 11

Sr. Component & Replica Microstructure Examination

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 12

B. Neubauer and U. Wedel, “Rest life Estimation of Creeping Components by

Table 2: Microstructure categorization by Neubauer and Wedel.

Class Microstructure Condition Remedial Action

C) FIELD HARDNESS TESTING – RESULTS.

Details of the test results are given in Section – 5 of the report.

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 13

D) SWELL MEASUREMENT – RESULTS.

E) DRUM INTERNAL DEPOSIT ANALYSIS – RESULTS.

Details of the test results are given in Section – 7 of the report.

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 14

TUBE LABORATORY TESTING

LES: 2010: GPEC-CLP- GT: 3957/3958: 03 PAGE NO: 15

TUBE LABORATORY TESTING

Tube samples were subjected to the following examination:

B. Procedure for sampling