BTL Presentation

18-03-2019
Training Workshop
Critical Analysis & Prevention of Boiler Pressure
Parts Failure
Ansuman Sen Sharma
India Boiler dot Com
What is our
objective?
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To Understand Analytically How &

Why Boiler Tube Fails
To Increase Reliability of Boiler by

Preventing Tube Failures
Why & How Boiler Tubes Get Damaged

and Fail ??
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Damage Mechanisms for

Boiler Tube Failures
Various Damage Mechanisms in which Boiler Tube

Fails are:
Over heating
Stress
Corrosion
Erosion
Fatigue
Combined Stress & corrosion
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Route from Failures to their Prevention
After each BT Failure

→ Identification of DM
→ Identification of RCs
→ Identification of PMs
→ Implementation of PMs
→ → Prevention of similar BT
failure
But why wait for

the Boiler Tubes to Fail????
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Route to Failure
Generation of RC (Root Cause)

RC develop UC (Undesirable Conditions)
UC initiate DM
DM/s lead to failure
RC →UC →DM → Failure
DM – Irreversible & Accumulative
Almost all DMs i.e. Creep, Fatigue,

Corrosion, Erosion, Embrittlement are
IRREVERSIBLE and ACCUMULATIVE type
damages.
Failure occur whenever there is ‗Total

accumulation of damage/s‘
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Damage Prone Locations
Meaningful damage assessment is

possible if DPL (damage prone locations)
are known.
Each DM may be more effective at

different locations.
Awareness and Updating DPL help in

their periodic examination
Prevention of Boiler Tube

Failures
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We should know
What adverse conditions are

present in the boiler system?
What are the metallurgies of the

pressure parts and what are their
limitations to such adverse
conditions?
What are the indications which

would suggest that the limitations
could be breached?
What are the adverse Conditions

under which a Boiler operates?
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Temperature inside the furnace : 1100 -1200oC
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Water Tube Boiler:
Temperature limit for Oxidation

characteristics of various metal used in
Boiler:
Carbon Steel: 425oC (456oC)

LAS T11: 550oC
LAS T22: 580oC
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Allowable stress: (ASME Section II, Part D[8])
Criterions to be considered to draw the trend

curve
TS/ 3.5
2/3 x YS
A Percentage of creep rupture strength
Primary Secondary Tertiary
For Carbon Steel, creep begins at about 370oC
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Development of Creep:
The Larson-Miller Parameter (LMP) can be used

to determine the expected life of a component.
LMP = (ºF + 460) (C + Log10t) (10-3)
C is a constant taken as
20 for CS and LAS
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What other adverse Conditions?
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Longitudinal Stress & Hoop

Stress in a cylinder:
σL = (P x D) / 4 t
σc = (P x D) / 2 t
σc = (P x D ) / 2 t
When σc exceeds σAllowable……..Tube fails in the

longitudinal direction
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Let us now take a look at the type of

metals, that are being used for Boiler
Pressure parts and their limitations
Sign in front of a Boiler system
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Basic MET of Fe family
IRONS: Irons without any alloying

element.
In past, WROUGHT IRON was very
widely used as building materials.
Presently it is used only as Iron
Utensils.
STEELS: Iron with Carbon as alloying

element up to its maximum ‗solubility‘.
CAST IRONS: Iron with carbon, higher

than the solubility.
Carbon Steel
Plain Carbon Steels: Only Carbon is

alloying element.
[They are also simply called as
‗Carbon Steels‘]
….As per amount of carbon, They are

‗Low carbon‘ (<0.25%),
‗Medium carbon‘ (0.25% - 0.50%)
and
‗High carbon‘ steels (>0.50%)
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Alloy Steels: Alloying element/s in

addition to carbon.
Low Alloy Steels: If total alloying less

than 10%.
High Alloy Steels: If total alloying more

than 10%.
18-8 Stainless Steels & Tool Steels are
some of High Alloy Steels.
Materials used in Boiler Pressure

Parts
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Carbon Steel (low carbon)
Tubes Pipes Plates Forgings Castings
SA179 SA106GrB SA36 SA266CL1 SA216WCA

SA192 SA333Gr1 SA515Gr55 SA350LF1 SA352LCA
SA210GrA1 SA333Gr6 SA515Gr60 SA352LCB
SA334Gr1 SA515Gr65
SA334Gr6 SA516Gr55
SA516Gr60
SA516Gr65
Carbon Steel (medium carbon)
SA210GrC SA106GrC SA515Gr70 SA105 SA216WCB

SA516Gr70 SA266CL2SS SA216WCC
SA299 A350LF2 SA352LCC
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1¼ Cr ½ Mo

SA213T11 SA335P11 SA387Gr11 SA182F11
2¼Cr 1Mo
SA213T22 SA335P22 SA387Gr22 SA182F22 SA217WC9
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9Cr 1Mo ¼ V
SA213T91 SA335P91 SA387Gr91 SA182F91

SA199T91
Cr - Ni
SA213TP304 SA376TP304 SA240TP304 SA182F304 SA351CF3

SA213TP304H SA376TP304H SA240TP321 SA182F321 SA351CF8
SA213TP316 SA376TP316 SA240TP347 SA182F347 SA351CF3M
SA213TP321 SA376TP321 SA336F304 SA351CF8M
SA213TP347 SA376TP347 SA336F321 SA351CF10
SA213TP347H SA376TP347H SA336F347 SA351CF10M
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Material specifications for Heat Exchanging Elements

Sr. Heat Exchanging Elements Specification
No.
I ECONOMISER
Economiser Coils SA 210 Gr. A1
II WATERWALL
1. Wall Panels SA 210 Gr. A1
2. Platen assemblies SA 210 Gr. A1
III SUPERHEATER
1. Radiant roof Panel SA 210 Gr. A1, SA 209 T1
2. SCW – side walls SA 210 Gr. A1
3. SCW – front wall panel -do-
4. SCW – Roof & rear wall panel -do-
5. LTSH (Low temp.) Assembly SA 210 Gr. A1, SA 209 T1,
SA 213 T11
6. Platen S.H. Vertical assembly SA 213 T11, SA 213 T22,
7. Final S.H. Vertical assembly SA 213 TP 347 H
SA 213 T22
IV REHEATER
Reheater coils SA 209, T1, SA 213 T11,
SA 213 T22, SA 213 T91
With Material Selection Limitations BT

Material is ‗just about sufficient‘ in meeting
‗the service conditions‘
And is ‗highly sensitive‘ to even little deviation

in:
 temperature of water & steam
 chemistry of water & steam
 temperature of flue gas
 flue gas velocity
 Stress (i.e. working pressure)
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Temperature Sensitivity:
55°F (30.5oC) rise >>> 90% Creep life loss
10°F (5.5oC) rise >>> 60% Creep life loss
Example: T 22 LAS,
1000°F (538°C) – 3,47,520 hrs.- 40 yrs.
1050°F (567°C) – 49,573 hrs.- 5.7 yrs.
And….…when the temperature is about 1235° (668°C)
only 100 hrs, i.e. 4 days!!!!!!
Stress Sensitivity:
with stress rise of 10%, i.e. working
pressure rise 10%, or thickness
reduction 10%......
>>>>>>>>> 50% Creep life loss
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Flue Gas Velocity Sensitivity:

For fly ash of Indian coal,
Abrasiveness is proportional to 5th
power of velocity..
So…. 10% increase in FG volume may

increase abrasive power by 60%!!!
Water chemistry sensitivity & Flue

Gas chemistry sensitivity…
………is Justified & Necessary
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Damage Mechanisms
DM – Overheating / Creep
At low temperature, metals take

considerable long time for failing in
Creep (i.e. deform with time and
rupture).
At high temperature metals fail

‗significantly‘ (in reasonable time)
in Creep.
These temperatures are called

‗Creep Regime‘.
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With Over heating (actual temp. more

than design temp) BT will fail
‗prematurely‘
Accordingly OH (Over heating) DMs

are categorized as STOH (Short Time
OH ) and LTOH (Long Time OH)
Commonly Large bulge and thin lip

(facture edges) are features of STOH
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Short Time Over Heating
Small bulge and thick lip are features

of LTOH in general.
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Long Time Over Heating
Long Time Over Heating
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Generally, as per prevailing avg.

metal temp., ECO, WW, and SCW-SH
systems are below ‗creep regime‘.
LTOH is almost rare ( except in partial

chocking cases) in these systems.
In WW, with some abnormalities,

STOH failures are common.
Case Study (STOH):

120 MW PF Thermal Plant Boiler
Location: Final SH
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Case Study:
Location: Final SH
Occurrence: R&M completed on 22nd May……and
1st Failure: 31st May
2nd Failure: 7th June
3rd Failure: 13th June
4th Failure: 19th June Replaced tube failed
5 Failure: 26 June
th th
6th Failure: 27th July

7th Failure: 9th August
8th Failure: 18th August
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Visual Inspection
Microstructure
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Metal Temperature was persistently on the higher side

(~ 550-590oC)
Flue gas to inlet of FSH was recorded more than

1000oC
Cause was identified as a case of delayed combustion
Initially burner tilting was adjusted; but problem still

persisted to some extent.
Subsequently inlet SH temperature was reduced by

removing part of Primary SH
Case Study (LTOH):

Location: Hot Reheat
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Failure location: bottom bends of inner two

coils of hot reheat area
Unit commissioned in 1986 and Failure started

after only 12 years( in 1998 )
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Failure at HRH
Initial two occurances believed to be isolated

cases of partial chocking
Few more occurances ruled out partial

chocking
All boiler parameters within limit. Hence

reason for overheating not apparent
Steam temperature was remaining around
550 - 560oC instead of 540oC even after full
attemperation
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18-03-2019
Learnt through discussion:

Excessive De-superheating spraying was
necessary for keeping outlet temperature
within the specified maximum since beginning
of the unit operation
Manufacturers agreed that heat exchanging

surface area is more
Over Heating Causes &

Prevention
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Water Walls
Circulating Water & Steam Circuit:
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Natural Circulation:
Temperature of steam and Water in the
whole Evaporator system is Ts
Water
Mixture of steam
and Water
Furnace Temperature in the range

of 1100o to 1200oC
Carbon Steel; SA 210 Gr. A1/ C
Creep starts in Carbon Steel at 370oC and it doesn’t have

strength against creep
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Nucleate Boiling :
Departure from Nucleate Boiling (DNB):
Film Boiling
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Over Heating Failure
Why the bubbles are getting dislodged

and going up?
Is it because of buoyancy since steam

density is less than water density?
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At Atmospheric pressure the difference is

nearly 1600 times
Whereas at 120 kg/ cm2 absolute drum

pressure, it is only 9.6 times
At critical pressure both densities are same
Steam bubbles are coming out in

Nucleate Boiling : Nucleate Boiling
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Steam bubbles formed and

sticking at the bottom
Departure from Nucleate

Boiling :
But the density difference is nearly

1600 times!
Therefore it is not the buoyancy!!
It is the flow in the water due to natural

circulation, which is influencing the Nucleate
boiling
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Natural Circulation
Down comer
ρr ρd
Riser
ΔP = H ρd g - H ρr g = H g (ρd – ρr)
Natural Circulation
ΔP = H g (ρd – ρr)
Therefore circulation would be maximum at

MCR
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120oC
500
300oC
120
Overheating of evaporator tube and

raptures are caused by:
Poor Circulation
High Heat Flux – more than Critical Heat

Flux
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Natural Circulation
Drum Level
Down comer
ρr ρd
Riser
ΔP = H g (ρd – ρr)
Factors inducing DNB and tube

overheating
Fast Ramp up during cold start
Low drum level
Obstruction due to foreign object fouling

the tube
Formation of scale inside the tube
Flame shifting towards one side wall
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Disturbance of Water Chemistry due to Steam Blanketing:
Increase in concentration of
contaminants
SH & RH Tubes
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Few things to remember:
SH and RH tubes pick up the sensible heat
H = m C ∆t
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Factors inducing SH/ RH tube

overheating
Frequent Low Load Operation LTOH
High Excess Air LTOH in LTSH
Obstruction due to exfoliated oxide scale

accumulation in bends STOH
Delayed combustion LTOH/ STOH
Charcoal start in FBC STOH in BSH
90
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Factors contributing to delayed

combustion:
Fuel fines
Low SA/ PA ratio – High Primary Air
Improper Turbulence – Low SA
High VM coal
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Coal size distribution For PF Boiler.
70% < 200 mesh (75 micron)
Size Distribution : 100 – 150 ~ 30%

75 - 100 ~ 10%
Retention in 50 mesh should be less than 1%
0.2%
70 – 75% < 200 mesh
75 - 80% < 200 mesh
75 - 80% < 200 mesh
80 - 85% < 200 mesh
80 - 85% < 200 mesh
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Effect of higher Primary Air in PF Boilers:
when the primary airflow is very high, the fuel particles

―outrun‖ the secondary air and result in longer-than-
optimum flames
SADC Wind Box Auxiliary Air Distribution

B, C, D, E in service
FF __ %
F __ %
EF __ %
E __ %
Minimum
DE __ %
D __ %
CD __ %
C
EF> DE> CD> BC> AB
__ %
BC __ %
B __ %
AB __ %
A __ %
NIL
AA __ % Minimum
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Indicators
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Damage Mechanisms - Fatigue
DM - Fatigue
MECHANICAL FATIGUE :
If fluctuating stress is only mechanical
than fatigue is called mechanical fatigue
THERMAL FATIGUE :
Cracking of metal due to fluctuating
temperature is called thermal fatigue
CORRSION FATIGUE.
Cracking because of combined actions of
fatigue and corrosion, is called corrosion
fatigue.
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Case Study (Mechanical Fatigue):

Location: Rear Water Wall
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Case Study (Mechanical Fatigue):

Location: Rear Water Wall
Occurrence after 14 years of service
Three tubes at corner no. 3 from goose neck to bottom ‗z‘
bend were out of their position and broken into three /
four pieces!!
Front
Rear
Tubes were fractured transversely!!!
 No signs of plastic deformation at edges of

fracture
 No signs of corrosion
 No signs of over heating
These indicated Brittle failure due to

Mechanical Fatigue
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It should be noted that the wall construction

was not of Membrane type but of Tangent
type
Membrane Wall Tangent Wall
Root Cause was identified as longer spacing

between the anchor supports leading to
excessive vibration due to water hammering
in the wall tubes
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Case Study (Thermal Fatigue):

Location: HRH …..about 2m below roof
Similar failure twice:
• 3rd may 2001
• 9th may 2001
First failure: appeared to be because of

flue gas erosion
Second failure: also appeared to be of

same reason
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Contradiction: location was not erosion

prone!!!!!
….. After a closer inspection of one of

the failed pieces…..
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Crack: Fatigue due to restriction to thermal

expansion & contraction at welded clit
All other failures were due to secondary

erosion damage
Clits of similar locations cut
Mechanical anchoring provided during next

AOH
Thermal Fatigue Failure
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Usually Creep / Overheating DM

result into ‗longitudinal‘ cracking and
Fatigue DM result into ‗transverse‘
cracking.
Transverse fatigue cracking usually

occur at HAZ of WJs.
This failure occur after many starts

and stops. Regular NDT checks may
detect initiation of this type of
cracking.
Corrosion Fatigue Failure
Corrosion Fatigue
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Damage Mechanisms - Erosion
DM - Erosion
Some very important aspects:

High ‗ash content‘ and higher amount of
‗alpha quartz‘ (and generating full
capacity steam) makes resultant ‗Flue
Gas‘ highly abrasive.
Pure steam, water, air or gas in never

abrasive. Suspended solid particles make
them abrasive/erosive.
High Energy jet of such mediums usually

cause damage by high temperature metal
cutting and not by erosion/ abrasion
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Erosion Damage is referred as EMW (External

Metal Wastage). EMW is a major group in
which tube components loose a part of
external surface
The mechanisms known for EMW are:
FGE (Flue gas erosion)
SJE (Steam jet erosion /cutting)
[secondary damage of adjacent tubes
through escaping steam from a punctured
tube]
WBJE (Wall blower jet erosion Coal air jet
erosion, basically a SJE)
CAE (Coal air erosion)
SAE (Secondary air erosion)
FSE (Falling slag erosion), and
Air ingress assisted ash erosion.
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Case Study (FGE):

Location: Final RH – Rear Assy. No 24
Tube No 2 bend
Occurrence: after 1,60,000Hrs.
• The bent tube shows severe external

metal wastage, wall thinning and
consequent failure with thin lips.
• Some oxide scales are observed on

both the ID and OD surfaces of the
tube
• ….And the service life was

considerably long
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Transverse section of the tube at the

failure as well as a distant ring piece
was micro examined to check over
heating aspect.
Failed lip – Microstructure. Ring section – Microstructure.
No significant difference in the Microstructures

confirmed over all creep degradation and the
failure cause was identified as FGE
Soot Blower Erosion
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Fouling & Slagging:
Fouling & Slagging:
Fusing of ash take place,

If furnace temperature exceeds Initial Deformation range of ash
• Reducing atmosphere lowers the Initial Deformation
Temperature
• Ferrous iron content (Fe2) increases and act as catalyst in
substantially lowering IDT of ash
• When ratio of SiO2 to total oxides is high, slagging is less. At <
0.6 slagging high
• Delay in evacuation of bottom ash, results in build up of slag
• Design features of boiler furnace and bottom hopper
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Fouling & Slagging Indicator:
When percentage Iron Oxide - Fe2O3 in Ash by weight is:

• 3 to 8 -- Non- slagging
• 8 to 15 -- Slagging to some extent
• 15 to 23 -- High slagging property
Base to Acid Ratio 0.4 - 0.6 >> High Slagging possibility
Oxide Range (%) by wt Acidic (A)/ Basic (B)

SiO2 10–70 A
Al2O3 8–38 A
Fe2O3 2–50 B
CaO 0.5–30 B
MgO 0.3–8 B
Na2O 0.1–8 B
K2O 0.1–3 B
TiO2 0.4–3.5 A
SO3 0.1–30 A
when slagging index of Ash is in the range of:

• 1230 to 1340 deg C -- Medium slagging property
• 1050 to 1230 deg C -- High slagging property
• < 1050 deg C -- Severe slagging property
4 IDT + HT IDT - Initial Deformation

Slagging Index Fs is ------------------ Temperature
5 HT - Hemisphere
Temperature
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FEGT should be 50 – 55oC less than IDT
Furnace exit O2 should be more than 3% in case of slagging

coal
PA to SA ratio should be optimum
Damage Mechanisms - Corrosion
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CORROSION:
WATER SIDE CORROSION
• Low pH Corrosion
• Oxygen pitting
• Caustic / Acid Attack
• Caustic Gouging
FIRE SIDE CORROSION:

• Low temperature / cold end corrosion
• Harmful metals, Sulfur and Chlorine
• Corrosive characteristics of ash
• Slag deposits
Combined Stress & Corrosion
Hydrogen Embrittlement
Caustic Embrittlement
Stress Corrosion Cracking
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FIRE SIDE CORROSION

Low Temperature / Cold End Corrosion
FIRE SIDE CORROSION

Low Temperature / Cold End Corrosion
CORROSION MECHANISM
• S + O2 ® SO2
• 2SO2 + O2 ® 2SO3 (V2O5 catalyzes reaction)
• SO2 + O [Atomic Oxygen] ® SO3
• SO3 + H2O ® H2SO4
• SO2 + H2O ® H2SO3 [Sulphurus Acid]
REASONS
• Sulfur in fuel
• Sodium or Vanadium Pentoxide and ferric oxide in
fuel
• Excess Oxygen
• Low Economizer inlet temperature
• Low gas/ air temperature at APH inlet
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FUEL ASH CORROSION
CLOSE-UP VIEW OF TUBE PIT FIRE SIDE CORROSION
FUEL ASH CORROSION

REASONS:
• Presence of sodium and Vanadium in fuel

• Boiler operation under oxidizing
atmosphere
• Formation of low melting (995F)
Pentoxides of Sodium (Na2O) and
Vanadium (V2O5)
• Formation Pyrosulfates of Sodium and
Vanadium
• Release of Sulphur and Chloride
compound by unburnt coal particles due
to incomplete combustion
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Damage Mechanisms Contributed by

Water Quality
What makes Boiler Water Chemistry

Critical for the O&M Engineers?
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10Ca2+ + 6PO
$ßĦ¥ŦŲΏλ 3– + 2OH– →
+ σπςЊμ→
4 βζρЛξ
[Ca3(PO4)2]3·Ca(OH)2
Water Flow diagram in Boiler
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Power Boiler Flow Diagram
HP IP / LP
GEN
CRH
HRH SH-1 SH-2
comer
Down
Deaerator
Economizer
HP Heater
LP Heater
Condenser
Boiler Feed Pump
APH
PA / FD Fan Cond. Extraction Pump
FROM FUEL HANDLING SYSTEM
ID Fan
ESP
Water Analysis:
What do we check in the Feed Water, Boiler Water & Steam?
Analysis Feed Water Boiler Water Steam Cond.
pH √ √ √ √
Conductivity √ √ √ √
Silica √ √ √ √
Residual √
Hydrazine
Residual √
Phosphate
P Alkalinity √
M Alkalinity √
Chloride √
Iron & Copper √
Residual √
Ammonia
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What are the consequences of faulty

Water Chemistry in Boiler?
Scale
Corrosion
Carry Over
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Scale and Corrosion :
Carry Over :
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Carry Over :
Impurities in Water
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Source of Water:
Surface Water - River, Canal, Reservoir, etc.
Ground Water
Sea Water
Water has been called a

universal solvent
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IMPURITIES
The natural surface water picks up:
• Minerals and salts from the earthen layer –

dissolved condition
• Organic and inorganic impurities
• Decayed vegetation and marine lives

• Coarse and un-dissolvable substances in suspended
form, mainly silt and clay matters - turbidity
• Siliceous matters, in dissolved as well as in

colloidal forms
• Various gases, mainly Oxygen, and others like

Carbon dioxide etc.
SOLID IMPURITIES:
Suspended (> 1 micron) Increases Turbidity
Dissolved (< 0.001 micron) Increases Conductivity
Colloidal (< 0.5 micron)
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Dissolved Solids:
Ionization of dissolved NaCl → Na+ + Cl-
Suspended (> 1 micron) Non Reactive
Dissolved (< 0.001 micron) Reactive
Colloidal (< 0.5 micron) Non Reactive
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Dissolved Ions in Natural Water:

Mainly mineral salts
CATION (Basic Radical) ANION (Acidic Radical)

Ca++ (Calcium) HCO3– (Bicarbonate)
Mg++ (Magnesium) CO3– – (Carbonate)
Na+ (Sodium) SO4– – (Sulphate)
Cl – (Chloride)
NO3– (Nitrate)
PO4– – – (Phosphate)
HSiO3– (Bisilicate)
Scale Formation
t2 = t4 + (1/α + D/ k2) x Q
Where,
t2 = inner skin temperature of tube (°C)
t4 = boiler water temperature (bulk) (°C)
α = heat transfer coefficient of boiling surface
(kcal/ m2·h·°C)
D = scale thickness (m)
k2 = thermal conductivity of scale (kcal/ m·h·°C)
Q = heat flux (kcal/m2·h)
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Thermal Conductivity of various scales
Substance Thermal conductivity

(kcal/m2·h·°C)
Silica scale 0.2–0.4
Calcium carbonate scale 0.4–0.6
Calcium sulfate scale 0.5–2.0
Calcium phosphate scale 0.5–0.7
Iron oxide (hematite) 3–5
scale
Iron oxide (magnetite) 1
scale
Carbon steel 40–60
Most deposits can be classified as one of two types
 scale that crystallized directly onto tube surfaces

 sludge deposits that precipitated elsewhere and were
transported to the metal surface by the flowing water
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What is Hard Water?
Dissolved Ions in Natural Water:
CATION (Basic Radical) ANION (Acidic Radical)

Ca++ (Calcium) HCO3– (Bicarbonate)
Mg++ (Magnesium) CO3– – (Carbonate)
Na+ (Sodium) SO4– – (Sulphate)
Cl – (Chloride)
NO3– (Nitrate)
PO4– – – (Phosphate)
HSiO3– (Bisilicate)
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Scale formation is a function of two

criteria
1. The concentration and solubility limits of the

dissolved salt
2. The retrograde solubility (inversely

proportional to temperature) characteristic
of some salts
The principal scaling and fouling ions are:

Calcium, Magnesium, Iron and bicarbonate and
carbonate
Silica
Carry Over
A. Chemical Carry Over
B. Mechanical Carry Over
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mass dissolved in steam

Distribution Ratio (DR) =
mass dissolved in water
ms
mw
DR α P
For most solids, P >> 221 bar; DR >> 1
But not for silica
Factors that make Managing Silica difficult

Above 28 kg/ cm2 pressure, silica DR starts increasing
almost logarithmically
Silica DR starts decreasing above 9 pH
Boiler Water pH > 9.2
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In the turbine, the solubility sharply decreases after around
15 kg/ cm2 pressure
The need of Managing Silica
Forms hard glassy deposit on turbine blade
Decrease Enthalpy drop across stages
Increase specific steam consumption
May lead to imbalance and vibration

sometimes
82
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Dissolved Silica is weakly ionized
Silica sometimes enter in colloidal state, particularly

during high run off condition
Colloidal Silica can not be detected by Molybdate

reaction test
Colloidal Silica becomes reactive silica at high

temperature in the drum
Super heater
MS
Economizer
BW
FW
√
Colloidal Silica in the system
83
18-03-2019
Pre-treatment
Clariflocculator:
The ―precipitator‖ operates on the ―sludge blanket‖

principle
Managing Silica
ms Silica < 0.01 - 0.02 ppm

MS
mw
Boiler Water pH – 9.2 to 9.8

BW
Silica < 0.5 ppm
FW
84
18-03-2019
Managing Silica
SiO22 in steam in ppm SiO2 in boiler (mg/L)
Pressure in bar
Managing Silica
ms Silica < 0.01 ppm

MS
mw
Boiler Water pH – 9.2 to 9.6

BW
Silica < 0.3 ppm
FW
Silica < 0.01 ppm
85
18-03-2019
Managing Silica
Silica Control:
Clariflocculator
Strong Based Anion
Mix Bed
Ultra Filtration
Reverse Osmosis
Drum Separator
Unwanted intrusion
B. Mechanical Carry Over:
Factors related to Operating control,

causing Priming:
Operation at the high water level
Rapid fluctuation of heat load
Failure of flow control
Factors related to the mechanical structure

of boiler:
Inadequate, or, poor condition of the water

and steam separator
86
18-03-2019
Checking of Drum Separators to avoid

mechanical carry over
Corrosion
Low pH Oxygen corrosion
High pH Caustic corrosion (Gouging)
Low pH Acid Chloride corrosion
Low pH Acid Phosphate corrosion
Combined Stress & Corrosion

Hydrogen Cracking (Embrittlement)
Caustic Cracking (Embrittlement)
Flow Accelerated Corrosion (FAC)
87
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Low pH Oxygen corrosion
The degree of oxygen attack depends on
• The concentration of dissolved oxygen
• The pH and
• The temperature of the water
Corrosion
Oxidation of Fe in Boiler water:
Fe + ½O2 + H2O  Fe(OH)2
4Fe2 + 3O2 + 6H2O → 2Fe2O3 6H2O
3Fe + 4H2O = Fe3O4 + 4H2
Magnetite
88
18-03-2019
Corrosion
Boiler internals with stable magnetite Without stable magnetite layer

layer
With Phosphate-Hydrazine, and AVT (R)
Corrosion
Courtesy…..TAQA Neyveli Power Company Pvt.Ltd.,
FeOOH (Ferric Oxide Hydrate) with AVT (O), and OT
89
18-03-2019
Formation of Magnetite:
N2H4 + 6Fe2O3 → 4Fe3O4 + N2 + 2H2O
8.75
8.9
9.0
9.2
9.4
9.6
Deaeration:
Dissolved oxygen is
removed by thermo-
mechanical action.
Temperature is raised with
steam to lower the
solubility of gas and trays
are used to atomize the
water
Oxygen removal up to
0.007 ppm
90
18-03-2019
Solubility of Oxygen depends on :
Temperature
…… 0 solubility at saturation temperature
Partial pressure of Oxygen on water surface
PT LT TE
181
LOW pH CORROSION AND OXYGEN PITTINGS
91
18-03-2019
Galvanic Corrosion:
Anode:
Fe  Fe2+ + 2e¯
Cathode:
½O2 + H2O + 2e¯  2OH¯
Overall:
Fe + ½O2 + H2O  Fe(OH)2
Galvanic Corrosion:
It occurs when a metal or alloy is
electrically coupled to a different metal or
alloy while being immersed in an
electrolyte
Anything that results in a difference in

electrical potential at discrete surface
locations can cause a galvanic reaction,
such as:
 scratches in a metal surface
 differential stresses in a metal
 differences in temperature
 conductive deposits
92
18-03-2019
Galvanic Corrosion:
Effect of Temperature:
Influence of temperature on carbon steel

corrosion in water including dissolved oxygen
In a closed system like boiler feed water degree of

corrosion is directly proportional to temperature
93
18-03-2019
Effect of pH:
Anode:
2Fe (solid) → 2Fe2+ (aq) + 4e-
Cathode:
O2 (gas) + 4H+ (aq) + 4e- → 2H2O
(liquid)
Further oxidation of
Fe2+(aq) ions at Anode:
4Fe2+(aq) + 3O2 (gas) + 6H2O
(liquid) → 2Fe2O3 .6H2O (solid)
The H+ (aq) are available, when the medium is

acidic. Therefore low pH increases the rate of corrosion.
pH
The pH indicates the concentration of hydrogen ion in an
aqueous solution and is used as an index showing the
acidity or alkalinity of water.
Water only slightly dissociates into hydrogen ion (H+) and

hydroxide ion (OH–); H2O → H+ + OH–
The ion product of water is a constant and it is 1 X 10–14 at

25°C; [H+] x [OH–] = 1 X 10–14
The pH is calculated from the H+ concentration by using the

equation; pH = log 1/[H+] = - log [H+]
In case of pH 7, [H+] and [OH–] are equal at 1 X 10–7 and

this water is said to be neutral.
94
18-03-2019
Effect of pH:
The corrosion rate of carbon steel at high
temperature is minimized in the pH range of 11
to 12 as shown in Figure below.
Caustic Corrosion (Gouging ):
Typical gouging caused by caustic attack developed under

an original adherent deposit. Note irregular depressions
and white (Na2CO3) deposits remaining around edges of
original deposit area.
95
18-03-2019
Caustic corrosion (gouging) occurs when

caustic is concentrated and dissolves the
protective magnetite (Fe3O4 ) layer.
Na3PO4 + H2O  Na2HPO4 + NaOH
4NaOH + Fe3O4 → Na2FeO2 + 2NaFeO2 + 2H2O
2NaOH + Fe → Na2FeO2 +2H
UNDER DEPOSIT BOILING
Water and Steam
Porous Oxide
Protective
Protective Oxide Oxide
Fe3O4
Tube metal wall
Wick Boiling
96
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Na3PO4 + H2O ↔ Na2HPO4 + NaOH
Case study:
30 MW BFB Boiler
Location: Bed Coil Tubes
Size & Spec : Ø 51 x 6.35 mm & SA 210
Gr.A1
Bed Temperature: 905°C
Service: less than 1 year
97
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Tube Location
Bed Coil Tube
BFB Boiler
Failed Tube
Failed Bed Coil Tube
98
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Failed Tube
Damage at 12 O Clock position
Failed Tube
Deposits near damage
99
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During discussion, it was noted :
all three boilers are operated at nearly 25% over

loading conditions
Charcoal is used as start up fuel
Recently drum level maintained at 8 – 12% lower
than normal level to avoid mechanical carry over
(which was observed taking place)
Residual Phosphate was also maintained at 2-3 ppm
instead of 6-8 ppm as required for the same reason
Fuel Distribution plates were found in damaged
condition.
Acid Phosphate Corrosion:
Thick corrosion product and deposit layers covering

crater at location of phosphate corrosion damage
100
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Mutually intersecting, undercut, rounded pits formed

within a narrow zone where phosphate corrosion occurred
Critical Factors:
Low sodium-to-phosphate molar ratios in

the boiler water
Increased salt concentration mechanism like
Wick boiling in porous metal oxide deposits
Steam water stratification (steam blanketing)
Phosphate hideout
101
18-03-2019
Acid Phosphate reaction mechanism:
2Na2HPO4 + Fe3O4 → NaFePO4 + Na3PO4 + Fe2O3

+ H2 O
2Na2HPO4 + Fe + ½ O2 → NaFePO4 + Na3PO4

+ H2O
3NaH2PO4 + Fe3O4 → 3NaFePO4 + ½ O2 + H2O
The presence of maricite (NaFePO4) and/or

iron phosphate on a corroded surface is
strong evidence that phosphate corrosion
has occurred
Energy-dispersive spectroscopy using the SEM

would reveal approximately equivalent
concentrations of sodium, iron, and
phosphorus, which would confirm that the
crystalline material is indeed maricite.
102
18-03-2019
Acid Attack:
This results in a visually irregular surface appearance,

as shown in Figure. Smooth surfaces appear at areas of
flow where the attack has been intensified.
ACID CHLORIDE CORROSION
MgCl2 + H2O → MgO + 2HCl
Fe3O4 +HCl → FeCl2 + FeCl +H2O
Fe + 2HCl → FeCl2 + H2
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Stress Corrosion
HYDROGEN DAMAGE (EMBRITTLEMENT)
Thick Lip Brittle Appearance
Violent rupture Hydrogen Damage
104
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Mechanism:
4NaOH + Fe3O4 → 2NaFeO2 + Na2FeO2 + 2H2O

Fe + 2NaOH → Na2FeO2 + 2H
4H+ + Fe3C → CH4 + 3Fe
MgCl2 + H2O  MgO + 2HCl

Fe3O4 +HCl  FeCl2 + FeCl +H2O
Fe + 2HCl  FeCl2 + 2H
4H+ + Fe3C → CH4 + 3Fe
Decarburization weakens tube

Gas generated collects in grain boundaries
and form fissures as pressure builds up
which eventually grow
Failure occurs when the ruptured section can no longer

withstand the internal pressure. Ruptures are violent and
sudden, and can be disastrous
105
18-03-2019
Case Study:
120 MW Oil Fired Boiler
Location: Goose Neck Rear Water Wall
Size : Ø 76.1 x 5.5 mm
Specification: SA210 GR A1
Working Temp. & Pressure: 350°C & 90
kg/cm²
Service: 250000 Hrs
The middle tube has burst opened with thick

lips
106
18-03-2019
Dimensional Measurement (mm):

Tube location Outside Diameter Thickness
0°-180° 90°-270° 0° 90° 180° 270˚
Near failed lip - - 4.08 - 6.12 -

Ring section 74.15 78.73 3.97 5.60 5.78 5.67
Flattening Test: Test Method ASTM A370

A flattening specimen was taken near the
failed region. The flattening test showed
cracks on ID surface, indicative of hydrogen
embrittlement.
The middle tube was transverse sectioned

and micro examined at the failed region. The
failed lip shows a lot of oxide filled
discontinuous cracks starting from ID
surface
Decarburization is observed near the crack

edges throughout this region.
107
18-03-2019
• Opposite
On a ring to the failed
section region, the
a littleaway from the failed
microstructure
region, a similarconsists
structureof is
polygonal
observedgrains
of ferrite and pearlite
Conclusion:
Several oxide filled discontinuous cracks are
observed on the ID surface of the tube. The
flattening test result indicates hydrogen
embrittlement.
The failure of the tube is attributed to

hydrogen embrittlement.
108
18-03-2019
Caustic Stress Crack
REASON
For caustic embrittlement to occur, three
conditions must exist:
 The boiler metal must have a high level of
stress
 A mechanism for the concentration of
boiler water must be present
 The boiler water must have embrittlement-
producing characteristics

Fine cracks adjacent
and parallel to the weld
joint can be seen on a
Super heater tube.
Surface branching of
the crack is apparent
109
18-03-2019

Micro-structural examinations may
reveal branched cracks running
across the grains (trans-granular)
and originating on the internal
surface. The cracks are located in
the heat-affected zone immediately
adjacent to the weld.
Case study:
Heat Recovery Steam (HRSG)
Location: Super heater inlet header
Size & Spec : 2-in. (5.1-cm) outer diameter;
T22 and T91 low-alloy steels weld joint
Drum Pressure: 60 bar
Service: less than 1 year
110
18-03-2019
A thick-walled, circumferential fracture occurred

along a circumferential weld joining sections of T22
and T91 low-alloy steel tubing
The fracture edges were generally covered

with a thin oxide layer that was overlaid in
places by powdery white deposits that
produced an alkaline solution when mixed
with distilled water
SEM-EDS analysis of material on the fracture

edge indicated the presence of sodium,
silicon, and calcium
Micro-hardness measurements indicated a

large increase in hardness within the weld
and surrounding heat-affected zone (HAZ),
relative to locations away from the weld
111
18-03-2019
Microscopic examinations revealed that tight, highly

branched, inter-granular cracks originated from the
internal surface within the fusion zone of the
circumferential weld
Conclusion:
The cracks were possibly caused by caustic
stress corrosion cracking due to boiler water
carryover.
Residual stresses from welding most likely

contributed significantly to the formation of
stress corrosion cracks.
Applied bending stresses due to thermal
expansion and contraction may have also
contributed since it was near a dissimilar
weld joint
112
18-03-2019
CAUSTIC EMBRITTLEMENT
REMEDIAL ACTION
 Proper stress relieving of all welded or

rolled section
 Application of a coordinated pH/phosphate
control
Damage Mechanism: Flow Accelerated

Corrosion
HP Economizer drain Feed Pipe

tube
Feed Pipe
113
18-03-2019

Corrosion
Flow-accelerated corrosion (FAC) is a well-

known damage mechanism that affects carbon
steel components carrying water or two-phase
flow. Caused by the mechanically-assisted
chemical dissolution of the protective oxide and
base metal.

Corrosion
It has lead to failures or severe wall thinning
in:
Economizer/preheater tubes at inlet headers.
Economizer/preheater tube bends in regions where
steaming occurs.
Vertical LP evaporator tubes on Horizontal HRSGs,
especially in the bends near the outlet headers
LP evaporator inlet headers which have a tortuous fluid
entry path and where orifices are installed.
LP riser tubes/pipes to the LP drum.
LP evaporator transition headers.
Feed Water Line.
114
18-03-2019

Corrosion
FAC is a mass-transfer process in which the
protective oxide (mostly magnetite) is removed
from the steel surface by flowing water.
Material wear rate depends on
(1) Steel composition, temperature, flow
velocity and turbulence,
(2) Water and water-droplet pH, and
(3) The concentrations of both oxygen and
oxygen scavenger.
FLOW ASSISTED CORROSION

FAC affectedthinning
 Localized by:
Temperature
 Dissolution of protective
oxide and base metal
 pH
 Occurs in single or two
 O2 concentration
phase water
 Mass flow rate
 Low pressure system bends
Geometry
 in evaporators,
 Quality of fluid
Risers and economizer
tubes
 Alloys of construction
 Feed water cycle
115
18-03-2019

Effect of temperature on normalized
wear rate of various metallurgies
Greatest potential for FAC occurs around 150 ºC

pH has significant effect on normalized
wear rate of carbon steel
Nearly forty (40) fold reduction between

pH 8.6 and 9.4
116
18-03-2019

Dissolved oxygen has direct impact
 FAC minimized above 30 ppb O2

 FAC increases exponentially below 30 ppb O2

Effect of Velocity
 Normalized wear rate minimal below 10 ft/sec

 Rate increases by 2.8 times at 100 ft/sec
117
18-03-2019

Location
Geometry affects location of FAC, regardless of

Reynold’s Number
Formation of Magnetite:
When carbon steel is exposed to oxygen-free
water, the following reaction occurs:
Fe + 2H2O ⇒ Fe2+ + 2OH- +H2 ⇔ Fe(OH)2 + H2 (1)
This reaction is then followed by the Schikorr

reaction where precipitated ferrous hydroxide is
converted into magnetite:
3Fe(OH)2 ⇒ Fe3O4 + 2H2O + H2 (2)
118
18-03-2019
Dissolution of Magnetite

Corrosion
Precaution:
For HRSG and fossil fired boiler plants with
all-ferrous feedwater systems the feedwater
chemistry should be AVT(O) to avoid single-
phase FAC in the feedwater and LP
evaporator circuit.
The basic idea of AVT is to minimize corrosion

and FAC by using deaerated high purity water
with elevated pH. The pH elevation should be
achieved by the addition of ammonia.
119
18-03-2019
Effect of Temperature and Ammonia on

iron dissolution
Effect of pH on FAC
120
18-03-2019

Corrosion
Precaution:
Turbulences should be minimized by proper
design
For new replacement and for new units

material of construction may be changed to
P11 or P22
Regular inspection of susceptible components

by ultrasonic (UT) examination needs to be
undertaken to prevent any catastrophic
failure

Corrosion
Precaution:
For the carbon steel materials operating
under reducing feedwater chemistry the
oxide formed is Fe3O4 (magnetite) and its
solubility is strongly influenced by the
reducing conditions.
This constitutes the highest probability for

FAC in a fossil plant with highest solubility
being around 1500C.
121
18-03-2019

Corrosion
Precaution:
Changing the feedwater to an oxidizing
treatment by eliminating the reducing agent
and/or adding oxygen will result in the
formation of FeOOH (ferric oxide hydrate).
This reduces the solubility of the surface
oxide by at least two orders of magnitude in
the temperature range up to about 3000C.
Reliability Issues of HRSG
122
18-03-2019
Common damage mechanisms:
Low Cycle Thermo-mechanical Fatigue
Flow Accelerated Corrosion
Cold end gas-side corrosion
123
18-03-2019
Some Techno-Commercial issues

affecting HRSG Reliabilities
The two paramount concerns of most purchasers of

CCGT installations are low installed cost and high
fuel efficiency
High efficiency has driven rapid increases in GT

exhaust flow and temperature imposed on HRSGs
GE CCGT Model Exhaust Temperature Gas Flow
(oC) (TPH)
5371 (PA) 485 446
7121 (EA) 536 1070
9171 (E) 543 1484
9351 (FA) 608 2318

The two paramount concerns of most purchasers of

CCGT installations are low installed cost and high
fuel efficiency
High efficiency has driven rapid increases in GT

exhaust flow and temperature imposed on HRSGs
Compared to highly rated large GTs, HRSGs are

perceived as low-risk equipment
Low-cost HRSG designs which just meet the

requirements of specifications and boiler design code
124
18-03-2019

Horizontal HRSGs are constructed with tubes arranged
vertically in ―harps.‖
These harps are rigid structures requiring that adjacent

tubes remain at similar temperatures to avoid severe
thermal-mechanical fatigue damage and premature
failure.
HRSGs operating at high pressure are having
sufficiently thick walled drum superheater and
sometimes reheater outlet headers that require careful
management of heat up and cool down rates to avoid
internal cracking
Since combustion turbine ramp rates directly affect
HRSG component temperature ramp rates, the push to
rapid CT start ups results in greater ramp rates in HRSG
hot section components
Damage Mechanism: Thermo-mechanical

Low Cycle Fatigue
125
18-03-2019

Low Cycle Fatigue
Location:
HP Superheater and outlet manifold
HP Steam Drum and Evaporator circuit
Economizer

Low Cycle Fatigue
Reasons:
Rapid increase in GT Exhaust temperature
during starts from any condition
Header thickness
Header to tube connection geometry
Quench cooling due to improper
condensate drain
Over spraying of attemperator/ faulty
attemperation spray
126
18-03-2019
Differential expansion amplifies drain lateral

displacement
Bowing in panel tube
Watch for bend tubes and deflection of

superheater floor pipe penetrations during
startup and shutdown

Low Cycle Fatigue
127
18-03-2019

Low Cycle Fatigue
Precaution:
Care to be taken both for ramp up and
coasting down rate
ETM to be used for 9FA machines

Low Cycle Fatigue
Precaution:
Hold the GT load at a nominal block

load until steam flow is established in
the superheater
control the GT loading rate to ensure that the

temperature difference between the steam
temperature and the average header wall
temperature remains at or below the initial
difference on first admission of steam
128
18-03-2019

Low Cycle Fatigue
Precaution:
Unloading the GT (and using ETM on

7FA/9FAs) until outlet steam temperature is
about 50oC above the prevailing HP saturation
temperature, then holding at that load for few
minutes to let the header‘s through-wall
temperature gradient equalize before shutting
down the GT

Low Cycle Fatigue
Condensate quenching precaution:
Low-point drains are open during startup to

purge water/condensate prior to admitting
steam to tube panels
Drains are open sufficiently early in the

startup process to ensure that all condensate
actually will be drained prior to steam
admission
129
18-03-2019

Low Cycle Fatigue
Condensate quenching precaution:
Proper sizing of drains is critical
Locate blowdown tanks below header drain

locations
check to see that HP, IP, and LP drains are

not combined in a common collection pipe
upstream of the blowdown tank.

Low Cycle Fatigue
Over spraying of attemperation; reasons:
Typical causes include leaking spray-water

supply valves, hunting, poor piping
arrangements, overspray, and a
primary/secondary superheater surface
arrangement that is incompatible with a given
turbine‘s performance at startup or low load.
130
18-03-2019

Low Cycle Fatigue
Over spraying of attemperation; reasons:
Poor atomization of spray water because of

probe/nozzle damage or partial plugging
Improper piping design—in particular an
insufficient straight run of pipe upstream
and/or downstream of the attemperator
An arrangement of superheater surface that
allows overspray to occur at startup or low
load, because all the water cannot be
evaporated.

Low Cycle Fatigue
Over spraying of attemperation; Precautions:
first things to investigate is spray valve

behaviour at steady load
Check thermocouple reading upstream and
downstream when spray valve is closed
prevent spray down below 30oC of superheat
at the attemperator outlet
If too much surface is installed, remove fins
and/or gas baffles, or use tube shields, to
reduce heat transfer
131
18-03-2019

Low Cycle Fatigue
Economizer:
reasons:
In panel-type economizers, water goes up

and down in each panel, or harp
Return-bend economizers usually have
alternating upflow and downflow tubes in the
same row. In some cases, water flows up one
row, down the next—a serpentine arrangement
a temperature differential between tube rows
of from 30 to 100 deg F can cause thermal
shock, which contributes to fatigue failure

Low Cycle Fatigue
Economizer:
Economizer tube leak at weld caused by thermal shock
132
18-03-2019

Low Cycle Fatigue
Economizer:
reasons:
During startup, operators expect drum level to

swell and the feedwater control valve is closed;
no water is flowing through the boiler. During
this time, economizer panels ―soak‖ to
temperatures higher than normal.
When HP drum level finally starts to drop, the

feedwater control valve opens and ―cold‖ water
―shocks‖ the economizer.

Low Cycle Fatigue
Economizer:
Precautions:
Trickle-feed water through the HP economizer

as soon as drum pressure begins to increase
Assure positive feedwater flow thoughout the
startup period
blow down as needed to control drum level
133
18-03-2019
Failures Case Studies
Case 1:
Location: Primary SH Coil
Size : Ø 57.15 x 4.2 mm
kg/cm²
Service: 243000 Hrs
134
18-03-2019
The tube shows bulging (OD=61.5 mm) and burst

opened like a fish mouth
Dimensional Measurement (mm):

Tube location Outside Diameter Thickness
0°-180° 90°-270° 0° 90° 180°
270˚
Near failed lip -- -- 3.03 -- 4.27 --
Ring section 59.21 61.81 3.35 3.68 3.93 3.82
little away
Burst section is having thick lip
135
18-03-2019
Transverse section of the burst lip reveals

oxidation of the edges.
Several oxides filled rounded pits are
observed on the edges of the lip as wells on
the ID surface of the tube.
No significant deformation / decarburisation
of the adjoining grains of the pit edges are
observed.
The microstructure consists of polygonal
grains of ferrite and pearlite.
Opposite to the burst and a ring section little

away from the burst also show similar type
of microstructure. Oxides filled pits are
observed in both the sections examined.
136
18-03-2019
Conclusion:
Micro examination indicates several rounded
pits filled with oxides on the ID surface of
the tube.
The failure is attributed to waterside

corrosion.
However, take the case of a similar failure

in the same Boiler
Tube shows bulging (OD= 83.5 mm) and burst

opened with thin lips. No significant amount of
deposits is observed on ID and OD surface.
137
18-03-2019
Some rounded pits filled with oxides are

observed on the ID surface tube in all the
three sections examined.
138
18-03-2019
Transverse section of the burst lip shows oxidation of

the edges and the structure consists of bainite.
Opposite to the burst the structure shows polygonal

grains of ferrite and pearlite.
A ring section little away from the burst shows

transformed ferrite and pearlite along the axis of
burst and polygonal grains of ferrite and pearlite,
opposite to the burst axis.
Above observations suggests that the tube has been

overheated to above AC3 temperature for the steel
for a short period of time.
139
18-03-2019
Case 2:
Location: LHS Water Wall
Size : Ø 76.1 x 5.5 mm
Specification: SA210 GR A1
kg/cm²
Service: 254378 Hrs
The tube shows blisters at four locations (OD = 80

to 82 mm) in the spool piece between two weld
joints.
140
18-03-2019
A circumferential crack is observed near the fusion

line of one of the butt joint. Heavy deposits are
observed on the ID surface of the tube.
Wall thickness at 0o was measured as 1.5

mm
Micro examination of Transverse sections of
the tube at two out of four blisters reveal
oxides on the blister edges and ID surface of
the tube
141
18-03-2019
Oxides filled rounded pits are observed on

the ID surface.
Copper coloured copper rich phase
segregation is observed near the blister
edges and ID surface
No significant deformation / decarburisation

of the adjoining grains of the pit edges and
blister edges are observed.
The microstructure consists of polygonal
grains of ferrite and pearlite
142
18-03-2019
Transverse section of the weld joint where

the circumferential crack was observed
reveals segregation of copper rich phase
near the ID surface.
Several discontinuous grain boundary cracks
with decarburisation of the adjoining grains,
typical of Hydrogen embrittlement cracks are
observed in the spool piece PM, HAZ and
weld metal of the butt joint
One more transverse section of the weld

joint at about 180° from the circumferential
crack was also micro examined. Mismatch
between the tube members, lack of sidewall
fusion, incomplete root penetration and slag
are observed
143
18-03-2019
Conclusion:
Micro examination reveals presence of
copper coloured copper rich phase on the ID
surface and blister edges of the tube. Also
damage due to Hydrogen embrittlement is
observed in the PM, weld and HAZ regions of
the weld joint.
The blisters observed on the OD surface is
attributed to waterside corrosion may be
due to condenser leakage.
The circumferential crack observed near the
fusion line of the butt joint is attributed
Hydrogen embrittlement caused by
waterside corrosion.
Swab analysis shows presence of some
chloride and sulphur with a pH value of 7.8.
144

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18-03-2019

Ansuman Sen Sharma

India Boiler dot Com

To Understand Analytically How &

To Increase Reliability of Boiler by

Why & How Boiler Tubes Get Damaged

Damage Mechanisms for

Various Damage Mechanisms in which Boiler Tube

Route from Failures to their Prevention

After each BT Failure

But why wait for

Generation of RC (Root Cause)

RC →UC →DM → Failure

DM – Irreversible & Accumulative

Almost all DMs i.e. Creep, Fatigue,

Failure occur whenever there is ‗Total

Damage Prone Locations

Meaningful damage assessment is

Each DM may be more effective at

Awareness and Updating DPL help in

Prevention of Boiler Tube

What adverse conditions are

What are the metallurgies of the

What are the indications which

What are the adverse Conditions

Temperature inside the furnace : 1100 -1200oC

Water Tube Boiler:

Temperature limit for Oxidation

Carbon Steel: 425oC (456oC)

Allowable stress: (ASME Section II, Part D[8])

Criterions to be considered to draw the trend

Primary Secondary Tertiary

For Carbon Steel, creep begins at about 370oC

The Larson-Miller Parameter (LMP) can be used

LMP = (ºF + 460) (C + Log10t) (10-3)

What other adverse Conditions?

Longitudinal Stress & Hoop

When σc exceeds σAllowable……..Tube fails in the

Let us now take a look at the type of

Sign in front of a Boiler system

Basic MET of Fe family

IRONS: Irons without any alloying

STEELS: Iron with Carbon as alloying

CAST IRONS: Iron with carbon, higher

Plain Carbon Steels: Only Carbon is

….As per amount of carbon, They are

Alloy Steels: Alloying element/s in

Low Alloy Steels: If total alloying less

High Alloy Steels: If total alloying more

Materials used in Boiler Pressure

Carbon Steel (low carbon)

Tubes Pipes Plates Forgings Castings

SA179 SA106GrB SA36 SA266CL1 SA216WCA

Carbon Steel (medium carbon)

Tubes Pipes Plates Forgings Castings

SA210GrC SA106GrC SA515Gr70 SA105 SA216WCB

Tubes Pipes Plates Forgings Castings

Tubes Pipes Plates Forgings Castings

SA213T22 SA335P22 SA387Gr22 SA182F22 SA217WC9

Tubes Pipes Plates Forgings Castings

SA213T91 SA335P91 SA387Gr91 SA182F91

Tubes Pipes Plates Forgings Castings

SA213TP304 SA376TP304 SA240TP304 SA182F304 SA351CF3

Material specifications for Heat Exchanging Elements