Application of the Month – internal oxide scale in boiler tubes

Section 1: application overview

Section 2: typical instrument setups and test procedure(for rep use only)

Section 1: Application overview

Application: Measurement of thickness of internal oxide scale in steam boiler tubing

Potential users: Power generation companies and inspection companies that service the
power generation industry

Recommended instruments: Model 37DL thickness gage with oxide measurement

software option, Epoch 4 or Epoch 4 PLUS flaw detector with wave analysis software
option

Background:

The very high temperatures found inside steam boilers (in excess of 1500 degrees
Fahrenheit or 800 degrees Celsius) can cause the formation of a specific type of hard,
brittle iron oxide called magnetite on the inside and outside surfaces of steel boiler
tubing. At very high temperatures, water vapor will react with the iron in the steel to form
magnetite and hydrogen according to the formula:

3 Fe + 4 H20 = Fe3O4 + 4 H2

The speed of this reaction increases with temperature. Oxygen atoms will diffuse inward
through the magnetite layer, and iron atoms will diffuse outward, so the scale continues
to grow even after the tube surface is completely covered.

Magnetite scale acts as thermal insulation on the pipe, since the thermal
conductivity of scale is only about 5% that of steel. When heat can no longer transfer
efficiently from the flame through the tube into the steam inside, the tube wall will heat
up to temperatures beyond the intended operating range. Long term exposure to overly
high temperatures, combined with the very high pressure inside the tube, leads to
intergranular micro-cracking in the metal and to creep deformation (a slow swelling or
bulging of the metal), which in turn eventually leads to tube failure by bursting.

A secondary issue is oxide exfoliation, in which pieces of oxide scale break off
(usually due to thermal stresses during boiler startup or shutdown). These hard pieces will
be carried by the steam flow into the turbine, where over time they will cause erosion
damage.
 The growth of magnetite scale and the associated metal damage are primary
limiting factors with respect to boiler tube service life. The process begins slowly and
then accelerates, for as the scale grows thicker the tube wall becomes hotter, and that in
turn increases the rate of both scale growth and metal damage. Studies in the power
generation industry have indicated that the effect of scale is relatively insignificant up to
thicknesses of approximately 0.012" or 0.3 mm, but that beyond that thickness the
negative effects of scale increase rapidly. Periodic measurement of scale thickness allows
a plant operator to estimate remaining tube service life and to identify and replace tubes
that are approaching the failure point. Ultrasonic testing provides a quick and
nondestructive method for measuring scale. Hand-held, portable instruments such as the
Model 37DL gage or the Epoch 4 flaw detector can measure internal oxide layers down
to a minimum thickness of approximately 0.125 mm or 0.005 inch.

For specific transducer recommendations and instrument setup information,

contact Panametrics-NDT.

Further detailed information on the subject of oxide scale and its effects on boiler
tubing may be found in the book Metallurgical Failures in Fossil Fired Boilers by David
N. French (John Wiley & Sons, 1983).
Section 2: Further background, typical instrument setups and test procedure
(for internal use only)

(a) Further background on oxide growth

The following chart indicates why measurement of oxide scale thicker than
approximately 0.012” or 0.3 mm is of critical importance to the power generation
industry. The effect of scale below that threshold on boiler tube service life is minimal,
but when scale exceeds approximately 0.012” or 0.3 mm, remaining service life
decreases rapidly. Steam boiler operators use oxide scale thickness, along with remaining
wall thickness, as a parameter for estimating remaining service life for individual boiler
tubes and determining when replacement is required.

Source: R. Viswanathan, Damage Mechanisms and Life Assessment of High

Temperature Components, ASM International, Metals Park, OH, 1989

(b) Instrument selection:

Both the Model 37DL thickness gage (with oxide measurement software option) and the
Epoch 4/4 PLUS flaw detector (with wave analysis option) may be effectively used for
measurement of internal oxide scale. Some users may choose between these instrument
on the basis of other needs, preferring a general purpose corrosion gage versus a flaw
detector, or needing some of the other options associated with the 37DL or Epoch 4.

Functionally, the primary difference is that the automatic oxide layer measurement
function of the 37DL will be more convenient for many users than the manual cursor
placement required when using the wave analysis option of the Epoch 4. On the other
hand, a trained operator using the Epoch 4 may be able to better measure oxide in some
difficult situations where low echo amplitude or signal distortion makes the 37DL’s
automatic measurement less effective. Range and accuracy will typically be comparable
between the two instruments.
(c) Transducer selection:

A number of transducers may be used for internal oxide scale measurement. For most
common steel boiler tubes, with a pipe wall thickness under 12.5 mm (0.5”), the
recommended transducers are the M2017 with DLH-134 delay line for 20 MHz
longitudinal wave measurements, and the V2120 for 20 MHz shear wave measurements.
The M2017 transducer can measure internal oxide thickness down to a minimum of
approximately 0.25 mm (0.010”), while the V2120 can measure down to a minimum of
approximately 0.125 mm (0.005). The lower resolvable minimum thickness when using
the V2120 is due to the slower velocity of shear waves in steel and oxide scale. Note that
shear wave measurements require use of special high viscosity shear wave couplants,
which can be less convenient for field use. Shear wave measurements of this type also
require greater coupling pressure than typical longitudinal wave tests.

For boiler tube thicknesses greater than 12.5 mm or 0.5”, consult Panametrics-NDT for
specific transducer recommendations and instrument setup information.

Transducer Frequency Wave Type Minimum Scale

Thickness
M2017 w/DHL-134 20 MHz Longitudinal 0.010” or 0.25 mm
V2120 20 MHz Shear 0.005” or 0.125 mm

(d) Surface preparation:

Oxide scale measurement requires a much smoother coupling surface than what is
adequate for measurement of total wall thickness. The outside of the pipe must be clean
enough to permit intimate contact between the transducer and the metal. While a thin
layer of smooth scale on the outside surface usually isn’t a problem, thick or rough
buildup on the outside of the pipe must be removed at measurement points. Surface
cleaning down to bare metal is recommended.

(e) Typical setup for Model 37DL gage with M2017 transducer:

Detailed instructions on the use of the 37DL gage with M2017 transducer for oxide scale
measurement may be found in Section 6 of the Model 37DL operating manual, entitled
“Setting up and Calibrating the 37DL PLUS for the Measurement of Boiler Tubes and
Internal Oxide Scale Measurement”. Please refer to that document.
 Typical internal oxide measurement with M2017

(f) Typical setup for Model 37DL gage with V2120 transducer:

Gage setup with a V2120 transducer is similar to that with an M2017, except that the
main bang blank and echo window lengths must be reset to accommodate the delay line
length of the V2120. First, review section 6 of the Model 37DL operating manual to
familiarize yourself with the basics of oxide measurement. Then, starting from the DEF-
OXIDE/M2017 default setup, change the following parameters to the indicated values:

Echo Window – 7.30 uS

Interface Blank – 428.70 nS

As with any transducer, max gain may also be adjusted as necessary for reliable echo
detection.

Perform velocity and zero calibration as described in Section 6.4, using shear wave
couplant. Note that the resulting velocities will be shear wave velocities (approximately
3.250 mm/uS or 0.1280 in/uS), not longitudinal wave values.

Typical internal oxide measurement with V2120

(g) Typical setup of Epoch 4 with M2017 transducer

The screen below shows a typical oxide scale measurement with an M2017 longitudinal
wave transducer transducer, along with recommended starting parameters for the setup.

The Wave Analysis software option is typically used for measurement of time intervals
associated with oxide scale measurements. Use of this option is described in detail in
Section 9.11 of the Epoch 4 operating manual.
(h) Typical setup of Epoch 4 with V2120 transducer

The screen below shows a typical oxide scale measurement with a V2120 shear wave
transducer transducer, along with recommended starting parameters for setup.

The Wave Analysis software option is typically used for measurement of time intervals
associated with oxide scale measurements. Use of this option is described in detail in
Section 9.11 of the Epoch 4 operating manual.
(i) Identifying disbonded oxide

A trained operator may use either the Model 37DL gage or the Epoch 4 flaw detector to
identify disbonded oxide that is subject to exfoliation, by observing the pattern of the
echoes. At points where oxide is disbonded, the first negative peak echo seen in each of
the waveforms above (representing the steel/oxide interface) will become significantly
larger, and the second echo (representing the oxide/air interface) will disappear. If only a
single echo appears from the inside of tubing that is known to internally coated with
oxide whose thickness is within the range of measurement, then disbonding is implied,
and the tube may warrant further inspection by other means.