NDE2019, 069, v1: ’In-situ Metallography a NDE Tool for Remaining Life Assessment of . . .

In-situ Metallography a NDE Tool for Remaining Life Assessment

of High Temperature Thick Section Boiler Components

M Venkateswara Rao1, K T Varughese1 and M Janardhana1

1
Central Power Research Institution, Prof. Sir C V Raman Raod, Sadashivanagar, Bangalore, India
More info about this article: http://www.ndt.net/?id=25724

mvrao@cpri.in

Abstract

Boiler is a key system in thermal power plants to produce the steam at required high pressure, temperature and
flow for running a steam turbine to generate electric power. Boilers consist of various components such as tubes,
pipes, headers, valves and they are exposed to high temperatures during operation. Different materials such as
carbon steels, low alloy steels and stainless steels are used in boilers depending on the temperature exposure.
Due to continuous exposure to high temperatures and pressures, the low alloy steel components undergo creep-
metallurgical deformation. Accelerated stress or creep rupture tests are used to calculate the remaining life of
components. These tests are limited to boiler tubes, as it is possible to draw tube samples only from boiler.
Whereas in thick section components like super heater headers and pipelines, sampling is not possible
(impractical) due to non-availability of huge spare components. In-situ metallography is a Non Destructive
Evaluation (NDE) tool to assess the metallurgical degradation in high temperature components and further it can
help in calculating the remaining life by Neubauer Wedel structural cavity classification method.

In this paper, test results are discussed for in-situ metallography carried out in high temperature super heater
headers of a 500 MW boiler. The operating parameters of 500MW capacity boiler are - steam flow : 1675 t/hr,
pressure : 178 kg/cm2 and temperature : 540 0C. In-situ metallography was carried out at different spots of base
& weld metal of platen super heater inlet and outlet headers. The microstructure developed on the components
was transferred to a thin film and preserved for laboratory microstructural analysis at higher magnification. Inlet
header of platen super heater revealed microstructure as undamaged level of degradation and the outlet header
revealed ‘A’ level of degradation. The undamaged level of degradation microstructure is close to the original
microstructure of ferrite and pearlitic structure. The microstructure of ‘A’ level degradation consists of initial
deformation of pearlite with pearlite colonies intact and some isolated cavities are also seen in the
microstructure. Remaining life was calculated based on structural cavity classification method and estimated
that there is a remaining life of around 6 lakh hours and 1 lakh hours respectively for undamaged and ‘A’ level
degradation. The recommendations were given for re-inspection by in-situ metallography after 6 years of service
to monitor the level of degradation and take further preventive actions.

Keywords: In-situ metallography, Boiler components, Super heaters, Creep, Remaining life.

1.0 Introduction

Boilers are widely used in Thermal Power Plants, Combined Gas Power Plants, Captive Power Plants, Process
Industries like Fertilizer plants & Cement plants. The major contribution in power generation is by thermal
power plants. The total installed capacity of power stations in India is 3,63,370 MW out of which thermal based
generation is 2,28,601 MW (around 63%) [1].

Residual Life Assessment study of boiler covers various tests to assess the healthiness of all the critical
components. Which is generally taken up after 1,00,000 running hours or 25 years of operation and
subsequently after every six years of operation as per Indian Boiler Regulations. Boiler consists of various
components such as tubes, pipes, headers, valves and they are exposed to high temperatures and pressures
during operation. Different materials such as carbon steels, low alloy steels and stainless steels are used in
boilers depending on the temperature exposure. Due to continuous exposure to high temperatures and pressures,
2 NDE2019, 069, v1: ’In-situ Metallography a NDE Tool for Remaining Life Assessment of . . .

the low alloy steel components undergo creep-metallurgical deformation. Accelerated stress or creep rupture
tests are used to calculate the remaining life of components. These tests are limited to boiler tubes, as it is
possible to draw tube samples only from boiler. Whereas for thick section components like super heater &
reheater headers and pipelines, sampling is not possible (impractical) due to non-availability of huge spare
components. In-situ metallography is a Non Destructive Evaluation (NDE) tool to assess the metallurgical
degradation in high temperature components and further it can help in calculating the remaining life by
Neubauer and Wedel structural cavity classification method. The assessment of extent of degradation of
components, life consumption and remaining life assessment of high temperature components is significant for
reliable and safe operation of the boiler components [2-6].

In this paper, test results are discussed for in-situ metallography carried out in high temperature platen super
heater headers of a 500 MW boiler.

2.0 History

The history and service conditions of platen super heater inlet & outlet headers of 500 MW boiler is given in
Table 1.

Table 1 – History and Service condition of 500MW Boiler components

Description Parameters
Unit Capacity 500MW
Outlet steam pressure 178 kg/cm2
Outlet steam flow 1675 t/hr
Outlet steam temperature 540 0C
Total running hours 1,02,366 hrs
Material 2.25Cr-1Mo steel
Platen super heater inlet header OD 406.4 mm &
& thickness
Platen super heater outlet header OD 509.0 mm &
& thickness

The plant has completed one lakh running hours and as per Indian Boiler Regulations Remaining Life
Assessment (RLA) is carried out for further usage of the boiler. In this paper, results of metallurgical analysis
and remaining life estimation of high temperature thick section components of Platen super heater inlet & outlet
headers are presented.

3.0 Methodology

Outside diameter/swell measurement, in-situ metallography (replication) and in-situ hardness tests were carried
out to assess the creep metallurgical damage and to estimate the remaining life of high temperature platen super
heater inlet & outlet headers.

3.1 Outside Diameter / Swell measurements

The outside diameter/swell measurements are carried out using calibrated outside calipers for both platen super
heater inlet & outlet headers at three different locations and the results are given in Table 3. Percentage of
swelling is calculated by using the formula given in eq. 1.
 NDE2019, 069, v1: ’In-situ Metallography a NDE Tool for Remaining Life Assessment of . . . 3

𝑀 𝑎 𝐷𝑖𝑎 −𝐷 𝑖 𝐷𝑖𝑎
𝑃 𝑎 𝑆 𝑖 = 100 ----- (1)
𝐷 𝑖 𝐷𝑖𝑎

3.2 In-situ Metallography (Replication)

In-situ Metallography (Replication) is a nondestructive sampling procedure which records and preserves the
topography of a metallographic spot on a replica film (normally made up of a thin plastic foil).

The replication method involves various steps like rough grinding for removal of oxide scale on the metal
surface, followed by fine grinding with empery paper nos. 120, 220 and 400 in order. Final polishing is done by
either electro-polishing or mechanical polishing with polishing cloth and alumina solution or diamond paste.
The surface then thoroughly cleaned and dried with acetone to remove the stains and dust before etching the
spot. A standard etchant of 2-5% Nital is used to etch the finished spot to reveal the microstructure of low alloy
steel (2.25Cr-1Mo steel). The etchant spot is examined with the help of portable microscope to ascertain the
quality of microstructure. After this, the replica film is softened with a solvent and pressed against the surface
until the replica becomes again hardened. The replica then pulled off carefully, mounted on a microscope slide
and preserved to keep it dry and free from dust. The replication process is carried out as per standard ASTM
E1351 [7]. The preserved replicas are analysed in the laboratory under optical microscope at higher
magnifications.

In-situ metallography was carried out on base and weld metal of platen super heater inlet & outlet headers at
different locations and observations are given in Table 4.

3.3 In-situ Hardness Measurement

A portable hardness tester is used for in-situ hardness measurement of high temperature platen super heater inlet
& outlet headers. Hardness measurement aids in assessment of metallurgical status/ condition of the component.

One of the technique for hardness test is based on dynamic method, predicated upon the principle of energy
measurement. During hardness test, an impact body, equipped with a spherically shaped tungsten carbide test
tip, impacts under spring force against the test surface from which it rebounds. Impact and rebound velocities
are measured in a contactless manner at the precise resolution. This is accomplished by a permanent magnet
built in the impact body, during the impact test, it passes through a coil. Due to the forward and rebound
movement, electrical voltages are induced which are proportional to the velocities. The measurement values
derived from the impact and rebound velocities are processed into the hardness number.

In-situ hardness measurement was carried out on base and weld metal of platen super heater inlet & outlet
headers at different locations and the hardness readings are given in Table 4 along with microscopic
observations.

3.4 Remaining Life Assessment Methodology

The phenomenon of creep is guided by the factors such as temperature, stress, time & material properties. When
a material subjected to constant temperature and stress (internal pressure in boiler components) for longer
periods, creep damage accumulate in the material. The Neubauer and Wedel was related the creep-life
consumption of plant components based on cavity classification as shown in the Figure 1.
4 NDE2019, 069, v1: ’In-situ Metallography a NDE Tool for Remaining Life Assessment of . . .

Figure 1 - Creep-life assessment based on cavity classification

They characterized cavity evolution in steel at five stages – i.e., undamaged, isolated cavities, oriented cavities,
linked cavities (micro-cracks), and macro-cracks. They also formulated the recommendations corresponding to
the different stages of cavitation. For undamaged & class A damage, no remedial action would be required. For
class B damage, consisting of oriented cavities, re-inspection within 1 ½ to 3 years would be required. For class
C damage, repair or replacement is needed within six months. For class D damage, immediate repair is required.
Details of various classifications, action needed for preventing failures and expended life fractions are given in
Table 2 [8-9].

Table 2 – Structural classification, action needed and expended life fractions

Structural Microstructure Action needed Expended life

Classification features fraction
Undamaged Ferrite & pearlite None 0 - 0.14
A Isolated cavities None until next major scheduled 0.05 - 0.47
maintenance outage.
B Oriented cavities Replica test at specified interval 0.27 - 0.53
preferably within 1 ½ to 3 years
C Linked cavities Limited service until repair and better to 0.29 - 0.84
(micro-cracks) inspect within 6 months
D Macrocracks Immediate repair 0.7 - 1.0

The remaining life estimations based microstructure for platen super heater inlet & outlet headers are given in
Table 5.

4.0 Results & Discussions

The outside diameter measurements are carried out at different locations of platen super heater inlet & outlet
headers and percentage of swelling are given in Table.3.
 NDE2019, 069, v1: ’In-situ Metallography a NDE Tool for Remaining Life Assessment of . . . 5

Table 3 – Outside diameter measurements & % swelling of components

Sl. Particulars OD in mm X-X % of OD in mm Y-Y % of swelling

No. swelling
1. Platen super heater inlet
header -
Left hand side 406.0 0.00 406.0 0.00
Centre location 407.0 0.15 406.5 0.02
Right hand side 406.5 0.02 407.0 0.15
2. Platen super heater outlet
header -
Left hand side 510.0 0.19 511.0 0.39
Centre location 512.0 0.59 512.0 0.59
Right hand side 509.0 0.00 509.0 0.00

All the measured outside diameter readings are close to the design value and the percentage of swelling is found
less than 1%, which indicates that there is no swelling / bulging in the components due to creep deformation.

The replication is carried out at different locations of platen super heater inlet & outlet headers and
microstructures of corresponding spots are analysed in optical microscope. The microstructural observations
along with hardness values are given in Table.4 and photomicrographs are given in figure nos. 2 to 9.

Table 4 – Replication locations, microstructure observations and hardness values of components

Sl. Particulars Replica Microstructure Level of Hardness

No. No. Observations Degradation in BHN
1. Platen super heater inlet
header -
Left hand side base R1B Uniaxial ferrite and pearlite Undamaged 150-160
material
Left hand side weld R2W Tempered bainite Undamaged 190-200
material
Right hand side base R3B Uniaxial ferrite and pearlite Undamaged 155-165
material
Right hand side weld R4W Tempered bainite Undamaged 195-205
material
2. Platen super heater outlet
header -
Left hand side base R5B Degenerated pearlite and ‘A’ Level 165-175
material isolated cavities
Left hand side weld R6W Tempered bainite Undamaged 200-210
material
Right hand side base R7B Degenerated pearlite and ‘A’ Level 160-170
material isolated cavities
Right hand side weld R8W Tempered bainite Undamaged 180-190
material
6 NDE2019, 069, v1: ’In-situ Metallography a NDE Tool for Remaining Life Assessment of . . .

Fig. 2 - Replica No.-R1B Mag. : 100 X Fig. 3 - Replica No.-R2W Mag. : 100 X

Fig. 4 - Replica No.-R3B Mag. : 100 X Fig. 5 - Replica No.-R4W Mag. : 100 X

Fig. 6 - Replica No.-R5B Mag. : 100 X Fig. 7 - Replica No.-R6W Mag. : 100 X
 NDE2019, 069, v1: ’In-situ Metallography a NDE Tool for Remaining Life Assessment of . . . 7

Fig. 8 - Replica No.-R7B Mag. : 100 X Fig. 9 - Replica No.-R8W Mag. : 100 X

The microstructure of platen super heater inlet header revealed uniaxial ferrite and pearlitic structure which
corresponds to undamaged level of degradation. Whereas for platen super heater outlet header the
microstructure is degenerated pearlite and isolated cavities which corresponds to ‘A’ level degradation. The
remaining life of components is calculated using the expended life fractions and results are given in Table 5.

Table 5 – Remaining life calculations based on microstructural classification

Damage level Undamaged level ‘A’ level

Expended life fraction max (a) 0.14 0.47
Running hours of plant 1,02,336 hrs 1,02,336 hrs
1 1
Remaining life trem trem = texp x ( −1) trem = texp x ( −1)
𝑎 𝑎
1 1
= 1,02,366 x ( −1) = 1,02,366 x ( −1)
0.14 0.47
= 6,28,820 hrs = 1,15,434 hrs

The remaining life of undamaged components is around 6 lakh hours and ‘A’ level damage component have a
life around 1 lakh hours.

5.0 Conclusions

Based on the test results and remaining life calculations of platen super heater inlet & outlet headers, it is
concluded that both the headers have remaining life for more than 10 years. The recommendations are given for
re-inspection by in-situ metallography after 6 years of operation to monitor the level of degradation and to take
further preventive actions.

6.0 Acknowledgement

The authors are grateful to the management of CPRI for their kind permission to publish this paper. The authors
also wish thanks to officials of Materials Technology Division for their help & cooperation to work in
department.

7.0 References

[1] Central Electricity Authority (CEA) monthly reports as on 30.09.2019, from CEA website.

[2] A.K. Ray, Y.N. Tiwari, R.K. Sinha, S. Chaudhuri, R. Singh, Residual life prediction of service exposed main
steam pipe of boilers in a thermal power plant, Journal of Engineering Failure Analysis, 7, (2000), 359-376.
8 NDE2019, 069, v1: ’In-situ Metallography a NDE Tool for Remaining Life Assessment of . . .

[3] N.S. Cheruvu, Degradation of mechanical properties of Cr-Mo-V and 2.25Cr-1Mo steel components after
long term service at elevated temperatures, Journal of Metallurgical Transactions A, 1988, Vol 20A, Jan. 87-97.

[4] Greg. J. Nakoneczny, Carl C. Schultz, Life Assessment of High Temperature Headers, Babcock & Wilcox,
American power conference April 18-20, 1995, Chicago, Illinois, USA.

[5] Viswanathan R, Damage mechanism and life assessment of high temperature components, Metals Park, OH:
ASME International: 1989.

[6] Heloisa Cunha Furtado and Iain Le May, Metallography in life assessment of power plants, Elsevier journal
of Materials Characterization 36: 175-184 (1996).

[7] ASTM E 1351 – 01 (Reapproved 2006) – Standard practice for production and evaluation of field
metallographic replicas.

[8] Jiri Janovec, Daniela Polachova and Michal Junek, Lifetime Assessment of a Steam Pipeline, Journal of
Acta Polytechnica Vol.52 No. 4 / 2012.

[9] N. Neubauer and U. Wedel, Restlife estimation of creeping components by means of replicas, in ASME
International Conference on Advances in Life Prediction Methods, D.A. Woodford and J.R. Whitehead, eds.
ASME, New York, pp. 307-313 (1983).