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Investigations of the Failure in Boilers Economizer Tubes Used in Power Plants

Article  in  Journal of Materials Engineering and Performance · May 2013

DOI: 10.1007/s11665-013-0567-2

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DOI: 10.1007/s11665-013-0567-2 1059-9495/$19.00

Investigations of the Failure in Boilers Economizer Tubes

Used in Power Plants
Roozbeh Siavash Moakhar, Mehrad Mehdipour, Mohammad Ghorbani, Milad Mohebali, and Behrad Koohbor

(Submitted March 14, 2012; in revised form February 11, 2013; published online May 1, 2013)

In this study, failure of a high pressure economizer tube of a boiler used in gas-Mazut combined cycle power
plants was studied. Failure analysis of the tube was accomplished by taking into account visual inspection,
thickness measurement, and hardness testing as well as microstructural observations using scanning
electron microscopy (SEM), energy dispersive spectroscopy (EDS), and x-ray diffraction (XRD). Optical
microscopy images indicate that there is no phase transformation during service, and ferrite-pearlite
remained. The results of XRD also revealed Iron sulfate (FeSO4) and Iron hydroxide sulfate (FeOH(SO4))
phases formed on the steel surface. A considerable amount of Sulfur was also detected on the outer surface
of the tube by EDS analysis. Dew-point corrosion was found to be the principal reason for the failure of the
examined tube while it has been left out-of-service.

corrosion during pickling process, oxygen pitting, and flow-

Keywords corrosion, dew point, economizer tube, failure
analysis
1. Introduction
Application of economizer dates back to decades ago and as
early as the boiler itself. As its name suggests, economizer
tubes are designed to save fuel consumption by recovering parts
of the heat from fuel gas leaving the boiler to preheat the feed
water when inserted into the boiler drum. Economizer tubes are
mainly used in fossil fuel power plants and are composed of a
series parallel tube circuits. This part is located on the rear gas
pass of the boiler below the rear horizontal superheater. Heat
transfer in the economizer takes place in form of convection,
while its operating temperature usually falls below 400 °C. At
this temperature range, tensile properties are more significantly
affected than creep properties, and special attention should be
drawn to improve the tube’s life (Ref 1).
Corrosion and failure of economizer tube, like the rest of the
pieces of the boiler, are categorized as either water-side or fire-
side (Ref 2-4). The main causes responsible for the failure of
economizer tubes could be itemized as water-side corrosion,
chelant corrosion, acid corrosion during performance, acid
Roozbeh Siavash Moakhar, Department of Materials Science and
Engineering, Sharif University of Technology, Azadi Avenue, P.O.
BOX 11155-9466, Tehran, Iran; and Metallurgy Department, Niroo
Research Institute (NRI), Tehran, Iran; Mehrad Mehdipour,
Mohammad Ghorbani, and Behrad Koohbor, Department of
Materials Science and Engineering, Sharif University of Technology,
Azadi Avenue, P.O.BOX 11155-9466, Tehran, Iran; and Milad
Mohebali, Department of Material and Engineering, K. N. Toosi
University of Technology, Pardis St., Vanak Sq., Tehran, Iran. Contact
e-mails: m_mehdipour1364@yahoo.co.uk and ghorbani@sharif.edu.
accelerated corrosion. Also, the various types of fire-side
corrosion are comprised: cold-end corrosion during perfor-
mance, dew-point corrosion during out-of-service periods, inlet
header cracking due to thermal quenching at startups and hot
banked conditions, and erosion corrosion.
The aim of this study is to analyze the data taken from
experimental evaluations and use them to investigate the failure
of an economizer tube located at the second floor of economizer
tubes section. The fuel was reported to contain 2-3% sulfur and
vanadium, and the water used in the power plant contained
traces of corrosive salts. In this research, after a thorough study
of the failed sample, the mechanism of the failure of the
economizer tube is investigated. Material specification, design,
and operating parameters of the examined tube are summarized
in Table 1.
2. Experimental Procedure
A failed economizer tube was studied by several character-
ization methods. Chemical composition, as detailed in Table 2,
was studied by means of spark emission spectroscopy (QSG
750) according to ASTM 406 standard, and it was found to
conform to BS 3059 440 standard. Corroded area of the sample
was also observed by means of an Olympus optical microscope.
Morphology and chemical composition of corroded regions
were evaluated by scanning electron microscope (SEM)
equipped with energy dispersive spectroscopy (EDS) (Model:
(XL30) Philips C). X-ray diffraction (XRD) was conducted
using a Philips PW1800 diffractometer operating with Cu Ka
radiation at 40 kV and 30 mA over 2h range of 5°-70° at a step
size of 0.04° to identify different phases present in the corrosion
products from the outer surface of the specimen. Macrohard-
ness testing HV 30 was performed at different areas of the
sample taken from the failed tube. An ultrasonic device (Model:
MX-1) was used to measure the sampleÕs dimensions, i.e.,
thickness and diameter.

Journal of Materials Engineering and Performance Volume 22(9) September 2013—2691

3. Investigation and Results The quality of feed water was also investigated to determine
the main cause for the formation of above mentioned pits. It
The values of macrohardness along the length of the failed was found that the feed water did not contain corrosion
tube were almost equal: around 148 HV. Thickness and inhibitors and deoxidation agents.
diameter of the tube were measured at different points of the Several spherical and uneven shallow pits with a wave-like
sample (from the failed side, as shown in Fig. 1) and the appearance were also observed in the direction of fluid flow, the
measurements are detailed in Table 3. The results indicate that, existence of which could be attributed to erosion corrosion.
while the outer diameter of the sample was not altered, the This aspect was previously reported to be observed in the study
thickness was decreased up to 20% at certain points, i.e., the of Hales et al. (Ref 6).
thickness has decreased from inside of the tube, suggesting Stereographic microscope images from corroded areas of
erosion corrosion caused by the flow of liquid. Figure 2 shows outer surface are shown in Fig. 3 and 4, respectively. Corrosion
an image of the tubeÕs inner surface. Deep, separated, and trails appear only in holes and are negligible in other places,
mostly semispherical pits were observed in the inner surface, suggesting that failure has taken place due to localized
covered by an oxide layer. Consequently, it could be concluded corrosion in the so-called areas.
that the pits inside tubes are likely to be due to the occurrence Microstructure of the tube was studied by optical metallog-
of oxygen corrosion, in consistence with observations of raphy and SEM electron microscopy from the internal and cross
Mukhopadhyay et al. (Ref 5). section of corroded tube wall (Fig. 5 and 6, respectively) as
well as pit region (Fig. 7). Phase of the failed tubeÕs micro-
structure was similar to its initial state, composed of a ferrite-
Table 1 Details of the tubeÕs service condition pearlite structure, but according to Wu (Ref 7), the proportion
of ferrite to pearlite would be increased in the failed one.
Conditions Data Intergranular cracks and oxide products on the outer surface of
the tube reveal that the corrosion had initiated from the outer
Manufacturer of the boiler GEC Company surface which is in agreement with Ref 7.
Water inlet header temperature 220 °C
SEM topography images of the corroded areas of the outer
Water outlet header temperature 300 °C
Temperature of fuel gas before 549 °C surface of tube are shown in Fig. 8. As can be seen, corrosion
economizer has initiated from the outer surface. Corrosion sediments at
Final gas temperature 545 °C vicinity of failure sites were analyzed by EDS and its results are
Maximum working pressure 120 atm shown in Fig. 9. EDS data show high amounts of Sulfur
In-service time 158000 h (11.84%) and Iron (36%), indicating that the sediments are
Nominal power 145 MW sulfide/sulfate compounds rich.
Boiler capacity 522 t/h The XRD patterns are given in Fig. 10. The phases
Material of the tube Steel BS 3059 1968 identified by XRD were Fe2O3, Mn2AlO4, FeSO4, and
ERW 45 TC2 Fe(OH)SO4, indicating the presence of sulfates, and moisture
Fuel type Gas-Mazut
along with Fe2O3. The results indicated that the economizer
Employed water Water with traces
of corrosive salts sediments are mainly composed of Iron sulfate and Iron
Tube outer diameter 38 mm
Tube thickness 3.2 mm Table 3 Thickness and outer diameter of the tube at
different points
Sample 1 2 3 4 5 6 7
Table 2 Chemical composition of the failed tube
Thickness, mm 3 3 3.03 2.67 2.52 2.5 2.59
Element C Si Mn S P Outer diameter, mm 38 38 38 37.8 38.26 38.34 38.18

wt.% 0.172 0.207 1.08 0.0191 0.0254

Erosion corrosion far from

1 2 3 4 5 6 7 failed parts

Fig. 1 Location of the points of the sample used for dimensional

measurement Fig. 2 Inner surface of the tube

2692—Volume 22(9) September 2013 Journal of Materials Engineering and Performance

 Failed parts

Fig. 3 Outer surface of the failed tube

Fig. 4 Stereographic images from outer surface of the tubeÕs failed parts

hydroxide sulfate phases. Phases formed due to the reaction of These diagrams are shown in Fig. 11 for Fe-S-O in 723 and
gas with metal surface could be modeled by thermodynamics 823 K.
(Ref 8, 9). In its simplest form, the isotherm region curves As highlighted in Fig. 11, the reaction between gas and
( log PSO2 - log PO2 ) can be used for thermodynamic analyses. metal surface at 823 K leads to the formation of Fe2O3 and at

Journal of Materials Engineering and Performance Volume 22(9) September 2013—2693

 Dark areas: Perlite

Light areas: Ferrite

20 µm

Fig. 5 Optical metallographic image of the cross section of the sample

Fig. 6 Optical metallographic images of outer surface of failed parts: (a), (b) before etching, and (c), (d) after etching

2694—Volume 22(9) September 2013 Journal of Materials Engineering and Performance

723 K leads to the formation of Fe2(SO4)3. In other words,
formation of Iron sulfate is preferred in economizer, according
to its actual working conditions. Thermodynamics analysis also
suggests the formation of hematite in the high-pressure areas
Monte
Oxide layer
Pit
and hematite plus sulfuric acid in the low-pressure zones of the
economizer. XRD results also confirm the formation of
hydrated Iron sulfate in the mentioned regions. The formation
of hydrated Iron sulfate and hydroxyl sulfate of Iron in XRD
patterns are in agreement with the results of Srikanth et al.
(Ref 8). Iron sulfate is a yellow hygroscopic rhombic salt which
is soluble in water. The yellow color and sticky nature of the
sediments of the economizer is thus a result of the solution of
Iron sulfate in water.

50 µm
4. Discussion of Failure Mechanism

Fig. 7 Stereographic images of outer surface of the tubeÕs failed Mazut fuel used in plants contains Sulfur which reacts to the
area exposed oxygen to form SO2, and to a less extent SO3, when

Fig. 8 Morphology of failed parts of the tube by SEM

Element Weight%
CK 12.72
OK 38.06
Mn K 1.11
Si K 0.26
SK 11.84
Fe K 36.01
Totals 100

Fig. 9 EDS analysis of the oxide scales formed on the fire-side surface of the failed area (slightly away from the hole) of the tube

Journal of Materials Engineering and Performance Volume 22(9) September 2013—2695

combusted. CO2 and water vapor are always present in
combustion gas. SO3 reacts with water to form H2SO4 through
two different routes: (i) The reaction of SO2 with atomic
oxygen in flame region, which depends on the amount of extra
air and Sulfur available; and (ii) Catalytic oxidation of SO2 with
vanadium oxide from the vanadium contained in the fuel. It has
been shown that 1-5% of SO2 transforms into SO3, therefore,
assuming a 2% transformation, the vol.% of SO3 would be
4 ppm (Ref 10).
At dew point, H2SO4 condenses on the metallic surface and
corrosion initiates. The dew point of H2SO4 depends on the
concentration of SO3 and water vapor and is given as a function
of its partial pressure in Eq 1 (Ref 11):
Fig. 10 XRD pattern of the oxide scales scratched from outer surface
of the examined tube
Fig. 11 log PSO2 - log PO2 diagram for Fe-S-O system at 723 and 823 K (Ref 9)
2696—Volume 22(9) September 2013
1000=TDP ¼ 2:276  0:0294 lnðPH2 O Þ  0:0858 lnðPH2 SO4 Þ
þ 0:0062 lnðPH2 O Þ lnðPH2 SO4 Þ
ðEq 1Þ
where, TDP is the dew point in K, and P is the partial pres-
sure in mmHg. Using these values and inserting them with
appropriate units in Eq 1, the dew-point temperature is found
to be 403 K. The dew point is usually increased by an
increase in the SO3 concentration and water vapor. The con-
centration of SO3 increases with extra air, gas residence time,
the gas temperature and the amount of Sulfur in the fuel. The
humidity of the gas can be ascribed to the leaks in boiler
tubes and the vapor due to carbon black blowing.
When the temperature of the tube falls below the dew point
of gaseous H2SO4, the acid is condensed on metalÕs surface and
corrosion initiates. This type of corrosion is known as dew-
point corrosion and is often encountered in parts of the boiler
exposed to lower temperatures, such as economizer, air heater,
shelves, etc. The significant factors in corrosion of the low-
temperature parts of the boiler are availability of sufficient
concentrations of SO3, humidity of the air and presence of a
metallic surface with a temperature lower than the dew point of
H2SO4. It should be noted that in this type of corrosion, the
metalÕs critical temperature is of greater importance than the gas
temperature. Even if the temperature of the gas is higher than
the dew-point, corrosion may still occur in the metallic parts
whose temperature falls below the dew point.
The mean temperature of the bare economizer tubes is often
determined according to Eq 2 (Ref 11):


tw ¼ 0:5 t þ tg  U tg  t ð1=ha  1=hÞ ðEq 2Þ
where h is the heat conduction coefficient inside the tube in
J/m2 h K, ha is the heat conduction coefficient outside the
Journal of Materials Engineering and Performance

Fig. 12 Corrosion rate as a function of surface temperature
(Ref 11)
tube in J/m2 h K, t denotes the temperature of the water
inside the tube in terms of K, tg the temperature of the gas
outside the tube in K, tw is the mean temperature of the tube
wall in K, and U represents the total heat conduction coeffi-
cient in J/m2 h K obtained from Eq 3 (Ref 11):
1=U ¼ 1=h þ 1=ha ðEq 3Þ
In the calculations performed in this study, it was assumed
that h = 44360 J/m2 h K, ha = 665.4 J/m2 h K, and U = 655.19
J/m2 h K.
In case of economizer tube, its temperature is calculated to
be 499 K. It could be seen that the temperature of the metal is
higher than the dew point; thus, corrosion of the cold parts has
not taken place during the working period and has probably
occurred when left out of service.
As indicated by Ganapathy et al. (Ref 12), the maximum
rate of corrosion occurs in temperature range much lower than
the dew point (Fig. 12).
When left out of service, dew-point corrosion may cause
severe corrosion in metallic surfaces. When boiler cools down,
the temperature of the outer surface of the tubes may fall below
the dew point, and thus, water is formed on the surface of the
tubes. Reaction of water with sulfuric sediments forms an
acidic electrolyte causing corrosions with a 12.7 mm/year rate.
Dew-point corrosion can occur in economizer and other
parts of the boiler, because the outer surface of tube which is
covered with sulfuric sediments is capable of forming acids,
during out of service period. The causes of this type of
corrosion include (i) Settlement of sulfur-containing ash on the
tube surface, and (ii) Temperature drop of the metal below the
dew point of sulfuric acid.
In the presence of humidity, the Sulfur-containing ash forms
an acidic electrolyte which may cause corrosion. When these
sediments are removed from the surface, a simple visual
inspection can identify the occurrence of corrosion. Parts of the
metal are often corroded, while the rest remains intact. The
severity of the corrosion is very high when sour gas is used,
while it would be much lower for fuel oil. The corrosion
severity is at minimum in case of coal utilization. Upon
combustion of natural gas, high amounts of water vapor are
produced; therefore, by simultaneous combustion of natural
gas, and mazut containing Sulfur and Vanadium, a more severe
condition is provided, in comparison with the time that only
petroleum fuels are used.
The corrosion is often limited to the surface covered with
Sulfur-containing ash. As it was observed in visual inspections,
topography, metallography and SEM studies, in case of the
examined economizer, local corrosion has occurred following a
Journal of Materials Engineering and Performance
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dew-point mechanism at the outside of layers, and is limited to
the surfaces most susceptible of being covered with Sulfur-
containing ash.
5. Conclusion
Visual inspection of the failure site showed that the
corrosion has been local and has initiated from the outer
surface. Microstructure was found to be ferritic-pearlitic in
various regions of economizer tube, and no phase transforma-
tion was observed. Failure analysis studies revealed that during
out-of-service periods of the boiler or during maintenance
times, as a result of inadequate preservation, the temperature of
the metal had fallen below the acid dew point, and thus, H2SO4
had condensed on the outer surface of the economizer tubes
causing severe corrosion. XRD and EDS analyses also confirm
that the corrosion of economizer is a result of the reactions
between sulfuric compounds in gaseous form with exposed
metal surface. The corrosion of the economizer is directly
related to the formation of hydrated Iron sulfates inside the
economizer, which is thermodynamically favored in low
temperatures (below 773 K) and in the presence of high
amounts of SO2 and oxygen. Consequently, thinning of
metallic tube has led to failure and rupture of the economizer.
Acknowledgments
The authors gratefully acknowledge the valuable help extended
by Mostafa Soltanloo.
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Volume 22(9) September 2013—2697