METALLURGICAL ASPECTS OF BOILER TUBE FAILURE

ASME* APPROVED BOILER TUBING STEELS

Number Title of ASME* Specification

SA-178

Electric Resistance Welded Carbon Steel Boiler Tubes

SA-192 Seamless Carbon Steel Boiler Tubes For High Pressure Service SA-209 Seamless Carbon Molybdenum Alloy Steel Boiler And Supurheater Tubes SA-210 Seamless Medium Carbon Steel Boiler And Supurheater Tubes SA-213 Seamless Ferritic And Austenitic Alloy-Steel Boiler, Supurheater, And Heater Exchanger Tubes SA-226 SA-250 Electric-Resistance-Welded Carbon Steel Boiler And Supurheater Tubes For High Pressure Service Electric-Resistance-Welded Carbon-Molybdenum Alloy-Steel Boiler And Supurheater Tubes

*ASME Boiler and Pressure Vessel Code, Section I, Paragraph PG-9 and Section II, Part II, Part A, Material Specifications for Ferrous Materials.

MINIMUM STRENGTHS AND NOMINAL COMPOSITION OF COMMONLY USED BOILER TUBE STEEL GRADES
Tube steel type ASME Specification Grade Minimum Tensile Strength (MPa) Minimum Yield Strength (MPa) Nominal Composition

Carbon Steel
ERW Seamless Seamless ERW SA-178 SA-192 SA-210 SA-226 A C A1 C 324.3 41.4 324.3 41.4 483 324.3 179.4 225.3 179.4 255.3 276 179.4 0.15%C 0.35%C Max 0.15%C 0.27%C Max 0.35%C Max 0.15% C

Ferritic Alloy
ERW Seamless Seamless SA-250 SA-209 SA-213 T1 T1 T2 T11 T12 T22 T91 379.5 379.5 414 414 414 414 586.5 207 207 207 207 207 207 414 C0.5Mo C-0.5Mo 0.75Cr-0.5Mo 1.25Cr-0.5Mo 1.00Cr-0.5Mo 2.25Cr-1.0Mo 9Cr-1Mo

Austenitic Stainless Alloy

Seamless SA-213 TP304H TP316H TP321 TP347 517.5 517.5 517.5 517.5 207 207 207 207 18.Cr-8Ni 16Cr-12Ni 2Mo 18Cr-10Ni-Ti 18Cr-10Ni-Cb

Maximum Tube-Metal Temperatures Permitted By ASME Code And Boiler Manufacturers

Tube steel type ASME ASME 0F Specification (0C) No.
1000 (538) 1000 (538) 1000 (538) 1000 (538) 1000 (538) 1200 (649) 1200 (649) 1500 (816) 1500 (816) 1500 (816)

Babcock and Wilcox 0 0 F( C)

950 (510) 950 (510) 950 (510) .. 975 (524) 1050 (566) 1115 (602) 1400 (760) .. 1400 (760)

Combustion Engineering 0 0 F( C)
850 (454) 850 (454) 850 (454) 900 (482) .. 1025 (552) 1075 (580) .. 1300 (704) 1300 (704)

Carbon steel SA-178 C Carbon steel SA-192 Carbon steel SA-210 A1 C-MO C-MO C-MO SA-290 T1 SA-209 T1a SA-213T11 SA-213T22 Stainless Stainless Stainless SA-213 321H SA-213 347H SA-213 304H

SHORT-TERM OVERHEATING TYPICAL LOCATIONS

Short-term overheating can occur in steam-cooled and water-cooled tubes at locations that: Have become plugged by debris, scale, or condensate from incomplete boil out. Have exposure to high heat transfer rates from improper firing of fuel burners. Have experienced low coolant flow due to poor circulation or upstream tube leak.

PROBABLE ROOT CAUSES.

Overheating is caused by either abnormal coolant flow or excessive combustion gas temperature. Abnormal coolant flow can be caused by a blockage in the tube circuit, loss of boiler water drum level, loss of water circulation, and incomplete boil out of steam-cooled tubes during startup. Excessive combustion gas temperature can be produced by over firing.

HIGH TEMPETATURE CREEP

TYPICAL LOCATIONS High temperature creep can occur in steam-cooled tubes at locations that: Have become partially blocked by debris, scale, or deposits. Have exposure to radiant heat or excessive gas temperature or are just before the final outlet header.

 Are just before the change to a higher grade of steel or have incorrect or lower grade of steel material. Have high stresses due to welded attachments. PROBABLE ROOT CAUSES. High temperature creep is caused by insufficient boiler coolant circulation, elevated boiler gas temperature, or inadequate tube material properties.

CAUSTIC CORROSION
TYPICAL LOCATIONS. Water cooled tubes can experience caustic corrosion at locations that: Have flow descriptions such as welded joints with backing rings or protrusions, bends, or deposits. Have horizontal or inclined tubing. Have high heat flux or flame impingement. PROBABLE ROOT CAUSES. When porous deposits build up in high heat input areas, sodium hydroxide can concentrate within the deposit to a locally corrosive level. An increase in the tube metal temperature due to the heat transfer resistance of the deposit supports the concentrating mechanism.

HYDROGEN DAMAGE
TYPICAL LOCATIONS. Water-cooled carbon steel tubes can experience hydrogen damage at locations that: Have flow disruptions such as welded joints with backing rings or protrusions, bends, or deposits. Have horizontal or inclined tubing. Have high heat flux. PROBABLE ROOT CAUSES. Hydrogen damage is caused by operation with low pH water chemistry from ingress of acidic salts through condenser leakage, contamination from chemical cleaning or malfunction of the chemical control components, and concentration of the corrosive contaminants within deposits on the internal tube wall.

(LOCALIZED CORROSION) TYPICAL LOCATIONS. Pitting can occur anywhere in the boiler including economizers, supurheaters, reheaters, and water wall tubes. Locations where high levels of oxygen can be present are likely to experience pitting. PROBABLE ROOT CAUSES. Pitting is caused by exposure of the tube to water with a high concentrate oxygen. In economizer tubing, the cause of pitting is likely to be high levels of oxygen in the feed-water entering the economizers during boiler startup and low load operation periods. In supurheater and reheater tubing, the cause of pitting is likely to be collection of condensate in bends during outages.

PITTING

LOW TEMPERATURE CORROSION

TYPICAL LOCATIONS. Low temperature corrosion can at locations in the economizer that: have boiler tube metal temperatures below the acid dew point, so that condensate will from on the metal. have flue gas temperatures below the acid dew point, so that condensate will from on the fly ash particle. PROBABLE ROOT CAUSES. Low temperature corrosion is caused by the formation and condensation of sulfuric acid from the flue gases. The amount of sulfer trioxide (SO3) formed in the combustion process is an important factor since an increase in the SO3 concentration results in an increase in the acid dew point temperature.

WATER WALL FIRE-SIDE CORROSION.

TYPICAL LOCATIONS. Water wall fire-side corrosion can occur at locations that: have incomplete combustion conditions and a reducing atmosphere at the water wall. have corrosive ash deposits. have steady or periodic flame impingement. PROBABLE ROOT CAUSES Water wall fire-side corrosion is caused by corrosive conditions in the combustion zone which are due to inadequate oxygen supply, high concentration of sulfure and increased chlorides in the fuel, improper alignment of the fuel burners, and formation of molten ash on the water wall tubes surface.

HIGH TEMPERATURE COAL ASH CORROSION

TYPICAL LOCATIONS. High temperature coal ash corrosion can occur at locations in supurheaters and reheaters that: have tube surface metal temperature between 593 0C and 7040C (Maximum corrosion rates occur at 6490C) have slag type corrosive ash deposits that are strongly bonded to the tube. PROBABLE ROOT CAUSES. Cool ash corrosion is caused by the formation of complex alkali-irontrisulfates in the ash deposits when the tube metal temperature is between 11000F (5930C) and 13000F (7040C) Certain coals contain constituents which from ash deposits that are corrosive in the molten from.

FLY ASH EROSION

TYPICAL LOCATIONS. Fly ash erosion can occur at locations that: have gaps between the tube bank and the duct walls. have gas by-pass channels where the velocity of the flue gas can be much higher than that of the main flow have protrusions or misalignment of tubing rows. are adjacent to areas with large accumulations of ash. PROBABLE ROOT CAUSES. Fly ash erosion is caused by non-uniform or excessive gas flow which accelerates a large volume of fly ash particles and directs them onto the tube surface. Tube erosion is enhanced by distortion or misalignment of tubing rows; fouling or plugging of gas passages by ash buildups, which forces the flue gas to flow through smaller passages at higher velocities. Changing fuel to one with higher ash contents can result in more erosion and failures.

VIBRATION FATIGUE
TYPICAL LOCATIONS. Vibration fatigue can occur at locations that: have welded tie type spacers between vertical water wall. have welded or fixed attachment on horizontal steam cooled tubes. PROBABLE ROOT CAUSES. Vibration fatigue is caused by tube vibration produced by gas-flow induced forces. The vibration may be produced directly by the energy in the energy in the flue gas or indirectly by vortex.

CORROSION FATIGUE
TYPICAL LOCATIONS. Corrosion fatigue cracking can occur at locations that: have difference in thermal expansion rates and directions between joining boiler components. Cracking originates on the external surface of steam-cooled terminal tubes at headers. have corrosion activity and strain from cyclic stresses or residual stresses. Cracking originates on the internal surface of water-cooled tubes at welded attachments to structural supports. PROBABLE ROOT CAUSES. Corrosion fatigue cracking is caused by cyclic stresses and corrosive environmental conditions. Stresses may be due to differences in thermal expansion between two joining components or to concentration of stress from the formation of pits, notches, or other surface irregularities.

MAINTENANCE CLEARING DAMAGE

TYPICAL LOCATIONS Maintenance clearing damage can occur at any locations that: Requires hammering and chipping Requires dynamiting Requires vacuum clearing Requires high pressure grit or water blasting Requires shotgum blasting.

PROBABLE ROOT CAUSES Maintenance cleaning damage is caused by lack of quality control during furnace cleaning. Maintenance clearing damage results when excessive forces are applied during the process of removing ash accumulations from the boiler. Heavy equipment and powerful tools are employed to clean the furnace side of a boiler. Tube damage results when the clearing equipment and tools are mishandled to improperly applied.

CHEMICAL EXCURSION DAMAGE

TYPICAL LOCATIONS. Chemical excursion damage can occur at locations that: have been inadvertently exposed to chemical cleaning solutions. have been inadvertently exposed to chemical clearing solutions. have been inadvertently exposed to corrosive chemicals present in pant for normal water chemistry control. PROBABLE ROOT CAUSES Chemical excursion damage is caused lack of quality control when using corrosive chemicals. Chemical damage results when chemical cleaning agents are not adequately neutralized prior to operation or are inadvertently injected into some portion of the boiler by equipment malfunction or operator error. Acid or caustic excursions during normal boiler operation can also cause general corrosion attack and are the result of malfunction of water chemistry controls and water treatment equipment.

MATERIAL DEFECTS
TYPICAL LOCATIONS. Material defects can occur at any location in the boiler but are more likely to lead to failure at high temperature locations due to interaction with the stress rupture failure mechanism. PROBABLE ROOT CAUSES. Material defects are caused by lack of quality control during tube manufacture, fabrication, storage, and installation. Material defects can be introduced during the making of the steel, fabrication of the tube and tube panels, erection of the boiler, or replacement of the tube.

WELDING DEFECTS
TYPICAL LOCATIONS Welding defects can occur at any location where tubing is joined together or to structural members by the welding process. PROABLE ROOT CAUSE. Welding defects are caused by lack of quality control during the welding process. Various type of welding defects can be introduced due to deficiencies in the welding method. The most common types of defects are excess penetration, porosity, inclusions, incomplete fusion, undercut, and inadequate joint penetration. Defects result from poor welding practice, improper joint preparation, improper electrode, inadequate preheat, or rapid cooling.

HIGH TEMPERATURE CREEP FACTORS

TEMPERATURE TIME STRESS

ACCELERATED CREEP RUPTURE TEST

FAILURE MECHANISM OF WATERWALL TUBES (LOCATION AND POSITION) Water Wall Tube Locations And Typical Positions
Failure Mechanism Short-term overheating Below Burner Level At Burner Level X Above Burner Level X Typical Positions

Horizontal or slightly inclined tubes. Downstream from flow disturbance, tube blockage, or tube leak. High heat flux areas. Horizontal tubes. Down stream of weld, bend, or flow disturbance. High heat flux areas. Horizontal tubes. . Down stream of weld, bend, or flow disturbance. Tube that experience flame impingement or have the highest heat flux. Tubes in walls close to burners. Tubes on sloping walls about 0.9 to 1.2m from bottom opening.

Caustic Corrosion

Hydrogen damage

Water wall Fire-side Corrosion

Falling Slag Erosion

Soot blower Erosion

Near furnace corners where direct impingement can occur. At soot blowers where nozzles have been damaged. Vertical screen tubes at welded tie type spacers or at welded attachments to tubes or supperts.

Vibration Fatigue

FAILURE MECHANISM OF ECONOMISER TUBES (LOCATION AND POSITION) Economiser Tube Locations And Typical Positions
Failure Mechanism Feed Water Inlet X Bends Fuel Gas Inlet X Typical Positions

Pitting (Localised Corrosion)

Horizontal tubing where water can accumulate during shutdowns. Feed water inlet where oxygenated water first enters tubing. At tubes containing water or exposed to flue gas that has a temperature below the acid dew point.

Low temperature Corrosion

Fly Ash Erosion

Leading tube or protruding tube. Tubes adjacent to walls or large accumulations of fly ash. At tube connections to feed water inlet headers.

Thermal Fatigue Corrosion Fatigue

Horizontal or slightly inclind tubes. Downstream from flow disturbance, tube blockage, or tube leak.

FAILURE MECHANISM OF SUPERHEATER AND REHEATER TUBES (LOCATION AND POSITION) Superheater or Reheater Locations And Typical Positions
Failure Mechanism Radiant Circuits X Convection Circuits X Typical Positions

Pitting (Localised Corrosion)

Low bends in pendant loops where pluggage from scale, debris, or condensate causes low coolant flow. Upstream of Transition to higher grade of tube material. Leading tubes or outlet tubes. Local areas or outlet tubes. Local areas of higher temperatures. Bottom of pendant loops and low points of sagging horizontal tubes. At protrusions or misalignment of tubing rows. At walls or gas bypass channels. Adjacent to large ash accumulations. At header-to-terminal tube welds, especially at both ends of header where expansion is greatest.

High Temperature Corrosion

Pitting (Localised Corrosion) Fly Ash Corrosion

Corrosion Fatigue