Sample of Boiler Tube Failures

M&M Engineering’s Boiler Tube Failure Handbook
Hole—Waterside (Firetube boiler)
Locations Waterside of tube in firetube boiler

Boiler Type Firetube
Industry Process/Heating
Appearance General pitting

Mechanism Acid attack
Comments Improper chemical cleaning with hydrochloric acid can
result in severe and rapid pitting of tubes.
Mechanical & Materials Engineering

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Hole—Waterside
Locations Waterwall
Boiler Type Power
Industry Electric Utility
Appearance Severe corrosion gouging at a weld-backing ring

Mechanism Caustic Gouging
Comments Underdeposit corrosion, may be due to poor control of
boiler water chemistry, or excessive deposits from
feedwater. Considered poor practice to install backing
rings in waterwall circuits since they provide sites for
preferential corrosion.

Hole—Waterside
Locations Economizer
Boiler Type HRSG
Appearance Sharply defined hole

Mechanism Corrosion Fatigue
Comments Corrosion Fatigue typically causes cracking. In this case
the cracks formed an oval section of the tube wall that
was ejected from the tube to create the failure.

Cracks—Near or in weld or attachement—Longitudinal
Locations Waterwall
Boiler Type Power
Industry Pulp and Paper
Appearance Cracks close to attachments

Mechanism Corrosion Fatigue
Comments External attachments provide a restraint and high
operating stress. This, together with marginal water
chemistry particularly during startup, leads to corrosion-
fatigue cracks

Hole—Fireside
Locations Furnace Riser

Boiler Type Cyclone/Power
Industry Utility
Appearance Severe pock-marked corrosion on fireside

Mechanism Corrosion/Thermal Fatigue
Comments Damage caused direct impingement of waste chemical
cleaning solution on riser tube inside cyclone boiler. Tube
failure a combination of corrosion and thermal shock.

Crack—In or near weld or attachment—Longitudinal (random)
Locations Waterwall, Economizer

Boiler Type Recovery
Appearance Multiple cracks associated with attachment on outside of

tube
Mechanism Corrosion-fatigue
Comments External attachment provided a restraint and associated
high operating stress. This, together with marginal water
fatigue cracks

Cracks—In or near weld or attachment—Longitudinal
Locations Waterwall
Boiler Type Power
Appearance Longitudinal ID corrosion-fatigue cracks

Mechanism Corrosion-fatigue
Comments External attachment provided a restraint and associated
high operating stress. This, together with marginal water
fatigue cracks

Crack—Not in or near a weld—Longitudinal
Locations Superheater, Reheater

Boiler Type Power
Appearance Thick-lipped rupture and adjacent longitudinal fissuring

Mechanism Creep
Comments Prolonged exposure (over 40 years) to high-temperature
service.

Locations Superheater
Boiler Type Reformer
Industry Petrochemical
Appearance Irregular cracking

Mechanism Creep
Comments Indicative of end of service life

Crack—In or near weld or attachment—Transverse
Boiler Type Power
Appearance Complete weld separation

Mechanism Dissimilar metal weld failure (DMW)
Comments Dissimilar metals with different coefficients of expansion,
such as he stainless steel filler and the low-alloy base
material result in long-term creep damage accumulation

Deformation—Thinning
Locations Waterwall, Superheater

Boiler Type Power
Industry Common
Appearance External Wastage Beneath Adherent Slag Deposit

Mechanism Corrosion from Slag Attack
Comment Molten ash creates corrosive sulfur species. Alkalisulfates are
formed where metal temperatures are greater than 1000°F and
pyrosulfates where temperatures are greater than 700°F.

Hole—Waterside
Locations Economizer
Boiler Type Power
Appearance Thinning on inside of a u-bend or other change in direction

Mechanism Flow Accelerated Corrosion (FAC)
Comments FAC results from a combination of factors including
material limitations, design, and water chemistry. Failures
are typically catastrophic.


Boiler Type Power
Appearance Smooth surface

Mechanism Fly Ash Erosion
Comments Wall thinning leads to stress rupture failure

Locations Reheater
Boiler Type Power
Appearance External thinning, smooth areas

Mechanism Fireside Corrosion/Erosion
Comments Abrasion from fly ash may cause erosion, corrosion may
also occur as sulfur deposits become acidic during
shutdown or cool gas temperatures. This type of
corrosion is more prevalent in oil-fired boilers and in the
back-end of the gas path i.e., economizers.

Hole—Fireside
Locations Waterwall
Boiler Type Power (oil and natural gas fired)
Appearance Thinning from the fireside, pockmarks on external surface

Mechanism Fireside corrosion
Comments Corrosion associated with acidic deposits from sulfur in the
fuel.

Hole—Fireside
Locations Waterwall
Boiler Type Reformer
Industry Petrochem
Appearance Metal wastage

Mechanism Fireside Corrosion
Comments Corrosion often due to sulfur in the fuel creating acidic deposits.

Crack—In or near weld attachment—Transverse (random)

Boiler Type Power
Appearance Brittle fracture in heat affected zone of a weld

Mechanism Graphitization
Comments Occurs when a line of graphite nodules form in the heat
affected zone of the weld.

Locations Waterwall
Boiler Type Power
Appearance Catastrophic failure associated with weld overlay

Mechanism Hydrogen damage
Comments Hydrogen damage is an under-deposit corrosion
mechanism. Weld overlay exacerbates hydrogen damage.
High probability that other tubes are similarly affected. All
affected tubes must be replaced.

Hole—Waterside
Locations Water wall

Boiler Type Power
Appearance Thick-lipped rupture, may be very large window missing or a

flap hanging by one edge or a long crack.
Mechanism Hydrogen damage
Comment Hydrogen damage is an under-deposit corrosion mechanism.
Damage occurs in high heat areas (e.g., above burners). Often
associated with one or more low pH excursions in the boiler
and/or long-term contamination (condenser tube leak). High
probability that other tubes are similarly affected. All affected
tubes must be replaced.

Deformation—Bulging
Locations Waterwall
Boiler Type Power
Appearance Bulging tube adjacent to field weld

Mechanism Long term overheat
Comments Boiler tube material has been deformed due to very heavy
deposits on the inside of the tube that insulate the tube
metal from the boiler water and cause overheating.

Deformation—Bulging
Locations Waterwall
Boiler Type Power
Appearance Bulging tube adjacent to field weld

Mechanism Long term overheat
Comments Boiler tube material has been deformed due to very heavy
deposits on the inside of the tube that insulate the tube
metal from the boiler water and cause overheating.

Crack—Not in or near weld or attachment—Longitudinal
Locations Superheater, Reheater, Waterwall

Boiler Type Power
Appearance Longitudinal crack at bend

Mechanism Long-term Overheat
Comment Excessive heat often caused hot spots in the boiler or from
flame impingement. Excessive internal deposits may also
contribute to overheating


Boiler Type Power
Appearance Short longitudinal cracks with numerous parallel cracks

Mechanism Long Term Overheat/ Creep
Comment Caused when steam flow is blocked or partially restricted or
when the heating capacity of the tube exceeds the capacity of
the cooling media.

Crack—Not in or near a weld or attachment—Longitudinal
Boiler Type Industrial
Industry Process/Heating
Appearance Multitude of cracks parallel to tube

Mechanism Long Term Overheat/ Creep
Comments Deposits can accumulate in the bottom bend of
superheaters acting as insulation and contributing to a
long-term overheat condition. (Hole was created by
cutting torch and is not part of the failure)

Cracking—Not in or near a weld—Longitudinal
Locations Waterwall
Boiler Type Power
Appearance Forming lap at tube OD

Mechanism Material defect
Comments Manufacturing defect that was missed by tube mill
inspection

Hole—Waterside
Locations Waterwall, Superheater, Reheater

Boiler Type Power
Appearance ID pitting with corrosion tubercles

Mechanism Oxygen Pitting
Comments Improper lay-up, poor control of oxygen on
startup

Hole—Waterside
Locations Water wall

Boiler Type Power
Appearance Undercut corrosion, multi-color deposits (red, white, black).

This is a View of a tube ID following cleaning.
Mechanism Acid Phosphate Attack
Comment Under-deposit corrosion mechanism caused by reaction of
phosphate with magnetite for form maracite. Most often found
in high heat areas of the boiler. Typically associated with
boilers suffering phosphate hideout and using disodium
phosphate or sodium hexametaphosphate.

Boiler Type Industrial
Industry Process/Heat
Appearance Multiple tight fine cracks

Mechanism Stress Corrosion Cracking
Comments Residual stresses from tube forming combined with caustic
from the environment to cause the cracking.

Crack—Near or in weld or attachment
Locations Riser tube at rolled connection in drum

Boiler Type Industrial/Power
Industry Common
Appearance Transverse cracking in the rolled portion of tube where it

is inserted into the drum
Mechanism Caustic induced stress corrosion cracking
Comments Stresses are introduced into the tube by the rolling
operation. If these rolled connections leak-by, caustic
from the boiler treatment concentrates in the crevice and
leads to failure.

Hole—Fireside
Locations Reheater
Boiler Type Power
Industry Utility
Appearance Deformation and perforation from the outside in

Mechanism Mechanical damage
Comments Damage caused by shotgun slug used to deslag reheater
tubes. Similar failure can occur wherever mechanical
deslagging is performed.

Locations Waterwall, Superheater

Appearance Metal thinning on fireside

Mechanism Smelt/Slag Attack
Comment Molten ash (Slag in a power boiler, smelt in a recovery boiler)
can be corrosive to the boiler tube.

Crack—not in or near a weld—Longitudinal

Boiler Type Power
Appearance Fish-mouth rupture

Mechanism Short-term Overheat
Comment Caused when steam flow is blocked or severely restricted.
Lack of cooling leads to tensile rupture of tube.

Crack—Not in or near weld—Longitudinal
Locations Waterwall
Boiler Type Power
Appearance Fishmouth Opening

Mechanism Hot Tensile Overload
Comments Usually caused by starvation or severe wall loss due to
erosion or oxidation.

Crack—Not in or near a weld—Transverse
Locations Studded Waterwall

Appearance Fine cracks around studs

Mechanism Thermal Fatigue
Comments Thermal cycling from intermittent wetting by slag/smelt
causes fatigue.

Crack—Not in or near a weld or attachment—Transverse
Locations Waterwall
Boiler Type Power
Appearance Circumferential cracking

Comments Large thermal cycles caused by slagging/deslagging

Boiler Type Power
Appearance Complete failure at weld

Mechanism Thermal Fatigue, DMW Creep
Comments Failure of Pressure Induction Weld

Locations Evaporator
Boiler Type HRSG
Industry Co-Gen
Appearance Transverse crack near support

Comments The fast cycling that occurs in HRSG units can put
tremendous strains on restrained tubing creating thermal
fatigue.

Hole—Waterside
Locations Evaporator Section

Boiler Type HRSG
Industry Co-Gen
Appearance Severe corrosion on side of tube facing gas turbine/duct

burners
Mechanism Multiple underdeposit corrosion mechanisms including
caustic gouging, phosphate attack, and hydrogen damage
Comments Corrosion caused by a combination of pre-construction
deposits, poor chemistry control, and high heat flux from
duct burners.

Hole—Material Defect
Boiler Type Power
Appearance Porosity in weld

Mechanism Weld Defect
Comments Weld porosity may be due to inadequate shield gas flow or
contamination on the surface of the material.

Hole—Fireside/Material Flaw
Locations Waterwall, Superheater, Reheater

Boiler Type Power
Appearance Defect at wear bar attachment

Mechanism Weld/Materials defect
Comments Poor shop welding practice

Crack—In or near weld or attachment—Longitudinal or random
Boiler Type Power
Appearance Longitudinal cracks adjacent to weld

Mechanism Wrong material/Creep
Comments Cracks are in oxide scale and may or may not extend into
tube wall. Tube wall is deformed.


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M&M Engineering’s Boiler Tube Failure Handbook

Hole—Waterside (Firetube boiler)

Locations Waterside of tube in firetube boiler

Appearance General pitting

Mechanical & Materials Engineering

Appearance Severe corrosion gouging at a weld-backing ring

Mechanical & Materials Engineering

Appearance Sharply defined hole

Mechanical & Materials Engineering

Cracks—Near or in weld or attachement—Longitudinal

Appearance Cracks close to attachments

Mechanical & Materials Engineering

Locations Furnace Riser

Appearance Severe pock-marked corrosion on fireside

Mechanical & Materials Engineering

Crack—In or near weld or attachment—Longitudinal (random)

Locations Waterwall, Economizer

Appearance Multiple cracks associated with attachment on outside of

Mechanical & Materials Engineering

Cracks—In or near weld or attachment—Longitudinal

Appearance Longitudinal ID corrosion-fatigue cracks

Mechanical & Materials Engineering

Crack—Not in or near a weld—Longitudinal

Locations Superheater, Reheater

Appearance Thick-lipped rupture and adjacent longitudinal fissuring

Mechanical & Materials Engineering

Crack—Not in or near a weld—Longitudinal

Appearance Irregular cracking

Mechanical & Materials Engineering

Crack—In or near weld or attachment—Transverse

Appearance Complete weld separation

Mechanical & Materials Engineering

Locations Waterwall, Superheater

Appearance External Wastage Beneath Adherent Slag Deposit

Mechanical & Materials Engineering

Appearance Thinning on inside of a u-bend or other change in direction

Mechanical & Materials Engineering

Locations Superheater, Reheater

Appearance Smooth surface

Mechanical & Materials Engineering

Appearance External thinning, smooth areas

Mechanical & Materials Engineering

Appearance Thinning from the fireside, pockmarks on external surface

Mechanical & Materials Engineering

Appearance Metal wastage

Mechanical & Materials Engineering

Crack—In or near weld attachment—Transverse (random)

Locations Superheater, Reheater

Appearance Brittle fracture in heat affected zone of a weld

Mechanical & Materials Engineering

Crack—In or near weld or attachment—Transverse

Appearance Catastrophic failure associated with weld overlay

Mechanical & Materials Engineering

Locations Water wall

Appearance Thick-lipped rupture, may be very large window missing or a

Mechanical & Materials Engineering

Appearance Bulging tube adjacent to field weld

Mechanical & Materials Engineering

Appearance Bulging tube adjacent to field weld

Mechanical & Materials Engineering

Crack—Not in or near weld or attachment—Longitudinal

Locations Superheater, Reheater, Waterwall

Appearance Longitudinal crack at bend