3 - Boiler Pressure Parts Failure - Presentation

02-05-2016
Training Workshop
What is our
objective?
Ansuman Sen Sharma

India Boiler dot Com
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 ??
02-05-2016
Various Damage Mechanisms in which Boiler Tube

Fails are:
Damage Mechanisms for

Boiler Tube Failures
Route to Failure
Generation of RC (Root Cause)
Over heating
Stress
Corrosion
Erosion
Fatigue
Stress corrosion
Route from Failures to their Prevention

After each BT Failure
RC develop UC (Undesirable Conditions)
Identification of DM
UC initiate DM
Identification of RCs
DM/s lead to failure
Identification of PMs
RC UC DM Failure
Implementation of PMs
Prevention of similar BT
failure
02-05-2016
DM Irreversible & Accumulative

Almost all DMs i.e. Creep, Fatigue,
Corrosion, Erosion, Embrittlement are
IRREVERSIBLE and ACCUMULATIVE
type damages.
But why wait for

the Boiler Tubes to Fail????
Failure occur whenever there is Total

accumulation of damage/s
Damage Prone Locations
Meaningful
damage
assessment
is
possible if DPL (damage prone locations)
are known.
Each DM may be
different locations.
more
effective
at
Prevention of Boiler Tube

Failures
Awareness and Updating DPL help in

their periodic examination
02-05-2016
We should know
What
adverse
conditions
present in the boiler system?
are
What are the metallurgies of the

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

under which a Boiler operates?
What are the indications which

would suggest that the limitations
could be breached?
Temperature inside the furnace : 1100 -1200oC
02-05-2016
Water Tube Boiler:
Temperature
characteristics
Boiler:
limit
for
Oxidation
of various metal used in
Carbon Steel: 425oC (456oC)

LAS T11: 550oC
LAS T22: 580oC
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
02-05-2016
Development of Creep:
Natural Circulation:
Natural Circulation:
Temperature of steam and Water in
the whole Evaporator system is Ts
Furnace Temperature in the

range of 1100o to 1200oC
Carbon Steel; SA 210 Gr. A/ C1
Mixture of steam
and Water
Water
Creep starts in Carbon Steel at 370oC and it doesnt

have strength against creep
02-05-2016
Nucleate Boiling :
Departure from Nucleate Boiling (DNB):
Film Boiling
Why the bubbles are getting dislodged and

going up?
Is it because of buoyancy since steam
density is less than water density?
Density difference is a factor of pressure;
as the pressure goes up, density difference
goes down
Over Heating Failure
02-05-2016
Nucleate Boiling :
Steam bubbles are coming out in

Nucleate Boiling
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
Nucleate Boiling :
Steam
bubbles
formed
sticking at the bottom
and
This is at Atmospheric pressure where 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
02-05-2016
Natural Circulation
Natural Circulation
P = H g (d r)
P =
H d g -
H
Down comer
Riser
Therefore circulation would be maximum at

MCR
H r g = H g (d r)
Overheating of tube and rapture can be due
500oC
120
120oC
300
High Heat Flux More than Critical Heat

Flux
Poor Circulation Ration
02-05-2016
Natural Circulation
Drum Level
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
= H g (d r)
Disturbance of Water Chemistry due to Steam Blanketing:
What other adverse Conditions?
Increase in concentration of
contaminants
10
02-05-2016
Longitudinal Stress & Hoop

Stress in a cylinder:
L = (P x D) / 4 t
c = (P x D) / 2 t
c = (P x D ) / 2 t
When c exceeds Allowable..Tube fails in the
longitudinal direction
11
02-05-2016
Let us now take a look at the type of

metals, that are being used for Boiler
Pressure parts and their limitations
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.
Sign in front of a Boiler system
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02-05-2016
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%)
Alloy Steels: Alloying

addition to carbon.
element/s
in
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.
Carbon Steel (low carbon)
Tubes
Materials used in Boiler Pressure

Parts
SA179
SA192
SA210GrA1
SA334Gr1
SA334Gr6
Pipes
SA106GrB
SA333Gr1
SA333Gr6
Plates
SA36
SA515Gr55
SA515Gr60
SA515Gr65
SA516Gr55
SA516Gr60
SA516Gr65
Forgings
SA266CL1
SA350LF1
Castings
SA216WCA
SA352LCA
SA352LCB
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02-05-2016
Carbon Steel (medium carbon)

1 Cr Mo
Tubes
SA210GrC
Pipes
SA106GrC
Plates
SA515Gr70
SA516Gr70
SA299
Forgings
Castings
SA105
SA216WCB
SA266CL2SS SA216WCC
A350LF2
SA352LCC
Tubes
SA213T11
Pipes
2Cr 1Mo
Tubes
SA213T22
Pipes
SA335P22
Plates
SA387Gr22
Plates
SA335P11
SA387Gr11
Forgings
Castings
SA182F11
9Cr 1Mo V
Forgings
SA182F22
Castings
SA217WC9
Tubes
SA213T91
SA199T91
Pipes
SA335P91
Plates
SA387Gr91
Forgings
Castings
SA182F91
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02-05-2016
Material specifications for Heat Exchanging Elements
18Cr 8Ni
Sr.
No.
Heat Exchanging Elements
ECONOMISER
Economiser Coils
Tubes
Pipes
Plates
Forgings
SA213TP304
SA213TP304H
SA213TP316
SA213TP321
SA213TP347
SA213TP347H
SA376TP304
SA376TP304H
SA376TP316
SA376TP321
SA376TP347
SA376TP347H
SA240TP304
SA240TP321
SA240TP347
SA182F304
SA182F321
SA182F347
SA336F304
SA336F321
SA336F347
Castings
SA351CF3
SA351CF8
SA351CF3M
SA351CF8M
SA351CF10
SA351CF10M
II
SA 210 Gr. A1
WATERWALL
1. Wall Panels
2. Platen assemblies
III
SA 210 Gr. A1
SA 210 Gr. A1
SUPERHEATER
1.
2.
3.
4.
5.
Radiant roof Panel

SCW side walls
SCW front wall panel
SCW Roof & rear wall panel
LTSH (Low temp.) Assembly
6. Platen S.H. Vertical assembly

7. Final S.H. Vertical assembly
IV
Specification
REHEATER
Reheater coils
SA 210
SA 210
-do-doSA 210
SA 213
SA 213
SA 213
SA 213
Gr. A1, SA 209 T1

Gr. A1
Gr. A1, SA 209 T1,

T11
T11, SA 213 T22,
TP 347 H
T22
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
Temperature Sensitivity:
55F (30.5oC) rise >>> 90% Creep life loss
10F (5.5oC) rise >>> 60% Creep life loss
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)
Example: T 22 LAS,
1000F (538C) 3,47,520 hrs.- 40 yrs.
1050F (567C) 49,573 hrs.- 5.7 yrs.
And.when the temperature is about 1235 (668C)
only 100 hrs, i.e.
4 days!!!!!!
15
02-05-2016
Stress Sensitivity:
with stress rise of 10%, i.e. working
pressure rise 10%, or thickness
reduction 10%......
>>>>>>>>> 50% Creep life loss
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
Damage Mechanisms
is Justified & Necessary
16
02-05-2016
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
Creep Regime.
are
called
The Larson-Miller Parameter (LMP) can be used

to determine the expected life of a component.
LMP = (F + 460) (C + Log10t) (10-3)
C is a constant taken as
20 for CS and LAS
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)
17
02-05-2016
Commonly Large bulge and thin lip

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

of LTOH in general.
Short Time Over Heating
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02-05-2016
Long Time Over Heating
Generally, as per prevailing avg.

metal temp., ECO, WW, and SCW-SH
systems are below creep regime.
Long Time Over Heating
Case Study (STOH):

120 MW PF Thermal Plant Boiler
Location: Final SH
LTOH is almost rare ( except in partial

chocking cases) in these systems.
In WW, with some abnormalities,
STOH failures are common.
19
02-05-2016
Case Study:
Location: Final SH
Occurrence: R&M completed on 22nd Mayand
1st Failure: 31st May
2nd Failure: 7th June
3rd Failure: 13th June
Replaced tube failed
4th Failure: 19th June
5th Failure: 26th June
6th Failure: 27th July
7th Failure: 9th August
8th Failure: 18th August
Visual Inspection
Microstructure
20
02-05-2016
Metal Temperature was persistently on the higher side

(~ 550-590oC)
Flue gas to inlet of FSH was recorded more than
1000oC
Case Study (LTOH):

Location: Hot Reheat
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
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 )
21
02-05-2016
Initial two occurances believed to be isolated

cases of partial chocking
Few more
chocking
occurances
ruled
out
partial
All boiler parameters within limit. Hence

reason for overheating not apparent
Failure at HRH
Steam temperature was remaining around

550 - 560oC instead of 540oC even after full
attemperation
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
Damage Mechanisms - Fatigue
22
02-05-2016
DM - Fatigue
MECHANICAL FATIGUE :
If fluctuating stress is only mechanical
than fatigue is called mechanical fatigue
Case Study (Mechanical Fatigue):

Location: Rear Water Wall
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.
Rear
Front
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!!
Tubes were fractured transversely!!!
23
02-05-2016
No signs of plastic deformation at edges of

fracture
It should be noted that the wall construction

was not of Membrane type but of Tangent
type
No signs of corrosion
No signs of over heating
These indicated Brittle
Mechanical Fatigue
failure
due
to
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
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
24
02-05-2016
.. After a closer inspection of one of

the failed pieces..
Contradiction: location was not erosion

prone!!!!!
Crack: Fatigue due to restriction to thermal

expansion & contraction at welded clit
All other failures were due to secondary
erosion damage
Usually Creep / Overheating DM

result into longitudinal cracking and
Fatigue DM result into transverse
cracking.
Transverse fatigue cracking usually
occur at HAZ of WJs.
Clits of similar locations cut

Mechanical anchoring provided during next
AOH
This failure occur after many starts

and stops. Regular NDT checks may
detect initiation of this type of
cracking.
25
02-05-2016
Corrosion Fatigue Failure
Damage Mechanisms - Erosion
Corrosion Fatigue
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
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)
26
02-05-2016
CAE (Coal air erosion)

SAE (Secondary air erosion)
Case Study (FGE):

Location: Final RH Rear Assy. No 24
Tube No 2 bend
Occurrence: after 1,60,000Hrs.
FSE (Falling slag erosion), and

Air ingress assisted ash erosion.
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
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
27
02-05-2016
Damage Mechanisms - Corrosion
Soot Blower Erosion
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
28
02-05-2016
FIRE SIDE CORROSION
FIRE SIDE CORROSION
Low Temperature / Cold End 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
FUEL ASH CORROSION
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
FUEL ASH CORROSION

REASONS:
CLOSE-UP VIEW OF TUBE PIT FIRE SIDE CORROSION
Presence of sodium and Vanadium in fuel

Boiler
operation
under
oxidizing
atmosphere
Formation of low melting (995F)
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
29
02-05-2016
Damage Mechanisms Contributed by

Water Quality
What makes Boiler Water Chemistry

Critical for the O&M Engineers?
3 + 2OH
10Ca2+ + 6PO
$
+
4
[Ca3(PO4)2]3Ca(OH)2
Water Flow diagram in Boiler
30
02-05-2016
Power Boiler Flow Diagram

HP
Water Analysis:
What do we check in the Feed Water, Boiler Water & Steam?
IP / LP
GEN
Analysis
CRH
HRH
SH-1
SH-2
Down
comer
LP Heater
HP Heater
Economizer
Condenser
Deaerator
Boiler Feed Pump
APH
PA / FD Fan
Cond. Extraction Pump
FROM FUEL HANDLING SYSTEM

ID Fan
Feed Water
Boiler Water
Steam
Cond.
pH
Conductivity
Silica
Residual
Hydrazine
Residual
Phosphate
P Alkalinity
M Alkalinity
Chloride
Iron & Copper
Residual
Ammonia
ESP
Scale
What are the consequences of faulty
Water Chemistry in Boiler?
Corrosion
Carry Over
31
02-05-2016
Scale and Corrosion :
Carry Over :
Carry Over :
Impurities in Water
32
02-05-2016
Source of Water:
Surface Water - River, Canal, Reservoir, etc.

Ground Water
Water has been

universal solvent
Sea Water
IMPURITIES
called
SOLID IMPURITIES:
The natural surface water picks up:

Minerals and salts
dissolved condition
from
the
earthen
layer
Suspended (> 1 micron)

Dissolved (< 0.001 micron)
Organic and inorganic impurities
Increases Turbidity
Increases Conductivity
Colloidal (< 0.5 micron)
Decayed vegetation and marine lives

Coarse and un-dissolvable substances in suspended
form, mainly silt and clay matters - turbidity
Siliceous matters,
colloidal forms
in
dissolved
as
well
as
in
Various gases, mainly Oxygen, and others like

Carbon dioxide etc.
33
02-05-2016
Dissolved Solids:
Suspended (> 1 micron)
Non Reactive
Dissolved (< 0.001 micron)

Colloidal (< 0.5 micron)
Ionization of dissolved NaCl
Reactive
Non Reactive
Na+ + Cl-
Scale Formation
Dissolved Ions in Natural Water:
Mainly mineral salts
CATION (Basic Radical) ANION (Acidic Radical)
Ca++ (Calcium)
HCO3
(Bicarbonate)
Mg++ (Magnesium)
CO3
(Carbonate)
Na+
SO4
(Sulphate)
Cl
(Chloride)
(Sodium)
NO3
(Nitrate)
PO4 (Phosphate)
HSiO3 (Bisilicate)
t2 = t4 + (1/ + D/ k2) x Q
Where,
t2 = inner skin temperature of tube (C)
t4 = boiler water temperature (bulk) (C)
= heat transfer coefficient of boiling surface
(kcal/ m2hC)
D = scale thickness (m)
k2 = thermal conductivity of scale (kcal/ mhC)
Q = heat flux (kcal/m2h)
34
02-05-2016
Most deposits can be classified as one of two types

Thermal Conductivity of various scales
Substance
Thermal conductivity
(kcal/m2hC)
Silica scale
0.20.4
Calcium carbonate scale
0.40.6
Calcium sulfate scale
0.52.0
Calcium phosphate scale
0.50.7
Iron oxide (hematite)

scale
35
Iron oxide (magnetite)

scale
Carbon steel
4060
scale that crystallized directly onto tube surfaces

sludge deposits that precipitated elsewhere and were
transported to the metal surface by the flowing water
Dissolved Ions in Natural Water:

CATION (Basic Radical) ANION (Acidic Radical)
What is Hard Water?
Ca++ (Calcium)
HCO3
(Bicarbonate)
Mg++ (Magnesium)
CO3
(Carbonate)
Na+
SO4
(Sulphate)
Cl
(Chloride)
(Sodium)
NO3
(Nitrate)
PO4 (Phosphate)
HSiO3 (Bisilicate)
35
02-05-2016
Scale formation is a function of two

criteria
Carry Over
1. The concentration and solubility limits of the

dissolved salt
A. Chemical Carry Over
2. The
retrograde
solubility
(inversely
proportional to temperature) characteristic
of some salts
B. Mechanical Carry Over
The principal scaling and fouling ions are:

Calcium,
carbonate
Silica
Magnesium,
Iron
and
bicarbonate
and
Factors that make Managing Silica difficult

Distribution Ratio (DR) =
mass dissolved in steam

mass dissolved in water
Above 28 kg/ cm2 pressure, silica DR starts increasing

almost logarithmically
Silica DR starts decreasing above 9 pH
ms
mw
DR P
For most solids, P >> 221 bar; DR >> 1
But not for silica

Boiler Water pH > 9.2
36
02-05-2016

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
The need of Managing Silica

Total accumulation can happen very fast
Stage pressure increased by 5% after 15 months
37
02-05-2016

Super heater
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
temperature in the drum
reactive
silica
at
high
MS
Economizer
BW
FW
Colloidal Silica in the system
Managing Silica
Managing Silica
Silica < 0.01 - 0.02 ppm
ms
mw
SiO22 in steam in ppm
SiO2 in boiler (mg/L)
MS
Boiler Water pH 9.2 to 9.8

BW
Silica < 0.5 ppm
FW
Pressure in bar
38
02-05-2016
Managing Silica
Managing Silica
EPRI recommended Guideline for Boiler Water
Managing Silica
EPRI recommended Guideline for steam
Managing Silica
Silica Control:
Clariflocculator
Strong Based Anion
Silica < 0.01 ppm
ms
mw
MS
Boiler Water pH 9.2 to 9.6
Mix Bed
Ultra Filtration
BW
Silica < 0.3 ppm
FW
Silica < 0.01 ppm
Reverse Osmosis
Drum Separator
Unwanted intrusion
39
02-05-2016
Managing Silica
Managing Silica
Membrane treatment can remove virtually all

colloidal silica. Both reverse osmosis and ultrafiltration are effective in this respect. Reverse
osmosis offers the additional advantage of
significant reduction (98%+) of reactive silica as
well.
Unwanted intrusion
GEN
H
P
CR
H
HR
H
SH1
LP
IP
AP
H
SH2
Down
comer
LP
Heater
Condens
er
MWCO (Molecular Weight Cut-off = 10,000 D )
HP
Heater
Deaerator
Economi
zer
Using Ultra Filter at MB outlet
Boiler Feed
Pump
Cond. Extraction
Pump
Managing Silica
Managing Silica
150 MW unit, silica went sky high during

commissioning
Date : 03.8.11 To 19.08.11 (Day Average data)
Boiler Feed water
Boiler Drum
Main Steam
Mine water was being used

Treatment :
RO
DM
MB
Condensate Water
Date
pH
Silica
Iron
pH
Control Limits
8.8-9.5
Unit
< 0.02
0.01
9.4-9.7
ppm
ppm
03.08.11
05.08.11
07.08.11
9.43
0.21
0.16
9.43
0.24
0.13
9.39
0.18
0.11
08.08.11
9.45
0.19
10.08.11
9.46
15.08.11
9.40
16.08.11
17.08.11
Cond
Silica
< 80
Iron
Po4
pH
Silica
Iron
pH
Silica
Iron
Boiler Pr.
Load
DM water analysis
< 0.5
5 to 10
8.8-9.5
< 0.02
< 0.02
8.8-9.5
< 0.02
mS/cm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
Kg/Cm2
MW
9.68
31
3.44
0.03
2.6
9.52
0.08
0.02
9.44
0.10
0.14
9.55
32
4.41
0.05
2.1
9.44
0.07
0.01
9.50
0.13
0.08
9.51
32
2.96
0.04
3.3
9.33
0.06
0.02
9.38
0.13
0.09
0.09
9.69
31
2.88
0.07
3.1
9.46
0.04
0.02
9.39
0.11
0.09
0.17
0.09
9.62
34
2.08
0.07
4.6
9.39
0.06
0.03
9.38
0.10
0.13
0.12
0.10
9.66
34
1.89
0.09
5.4
9.45
0.06
0.05
9.39
0.08
0.09
9.44
0.09
0.07
9.68
40
1.83
0.03
5.7
9.46
0.04
0.02
9.48
0.05
0.05
9.54
0.08
0.04
9.70
42
1.45
0.03
4.4
9.53
0.04
0.02
9.54
0.04
0.04
112
107
18.08.11
9.43
0.08
0.07
9.62
38
1.97
0.04
5.0
9.45
0.05
0.01
9.49
0.05
0.05
109
75
19.08.11
9.41
0.06
0.03
9.64
34
0.95
0.02
6.0
9.42
0.03
0.01
9.43
0.03
0.02
139
97
Average
9.44
0.14
0.09
9.64
35
2.39
0.05
4.2
9.44
0.05
0.02
9.44
0.08
0.08
120
93
S.No
Description
Unit
Design value
Actual value
RO water
ppm
<3
< 0.4
MB outlet
ppm
< 0.02
< 0.02
Condensate
ppm
< 0.02
0.04
They were operating with lower drum level to

avoid mechanical carry over !!!!
40
02-05-2016
Managing Silica
strongly advise against operating with lower drum level
as mechanical Silica carry over is not indicative. It also
doesn't appear to be Colloidal Silica Problem, but rather
physical Silica intrusion from some point, so don't go for
that test immediately. First rule out silica intrusion from LP
dozing / HP dozing, Deaerator and CST. better clean all of
them. Covering the area is a good idea
Managing Silica
A gunny bag was found in Deaerator storage tank
CONCLUSION:
Mass can not be created, neither can it be destroyed
An analytical investigation is likely to lead you to the

problem
B. Mechanical Carry Over:

Factors related to Operating control,
causing Priming:
Checking of Drum
mechanical carry over
Separators
to
avoid
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
41
02-05-2016
Corrosion
Corrosion
Oxidation of Fe in Boiler water:
Mainly due to Dissolved Oxygen
Fe + O2 + H2O Fe(OH)2
4Fe2 + 3O2 + 6H2O 2Fe2O3 6H2O
The degree of oxygen attack depends on

The concentration of dissolved oxygen
The pH and
3Fe + 4H2O = Fe3O4 + 4H2
Magnetite
The temperature of the water
Corrosion
Formation of Magnetite:
N2H4 + 6Fe2O3 4Fe3O4 + N2 + 2H2O
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)
Boiler internals with stable magnetite

layer
Without stable magnetite layer
42
02-05-2016
LOW pH CORROSION AND OXYGEN PITTINGS
LP Heater
Courtesy..TAQA Neyveli Power Company Pvt.Ltd.,
Galvanic Corrosion:
Galvanic Corrosion:
Anode:
Fe Fe2+ + 2e
Cathode:
O2 + H2O + 2e 2OH
Overall:
Fe + O2 + H2O Fe(OH)2
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
43
02-05-2016
Effect of Temperature:
Influence of temperature on carbon steel
corrosion in water including dissolved oxygen
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.
In a closed system like boiler feed water degree of
corrosion is directly proportional to temperature
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.
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.
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 1014 at
25C; [H+] x [OH] = 1 X 1014
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 107 and
this water is said to be neutral.
44
02-05-2016
Alkalinity
Effect of pH:
The corrosion rate of copper is low in the
condensate of the pH 6 to 9 as shown in Figure
below.
The three basic sources of alkalinity in water are: alkalinity

resulting from
the bicarbonate ion (HCO3-),
the carbonate ion (CO32-), and
the hydroxyl ion (OH-).
HCO3-
Heat
CO32- + H2O CO2 + OH-
The amount of each of these in water can be determined by

titrating with an acid to certain pH levels (end points) using
phenolphthalein (P alkalinity) and a methyl orange (M
alkalinity).
Alkalinity
Alkalinity
"P" alkalinity: It is the measure half of the carbonate ion (CO32-)

and Hydroxyl ion content and is expressed in ppm of calcium
carbonate.
M" alkalinity: It is the measure of carbonate ion content,
bicarbonate ion (HCO3-) and hydroxide content.
1. At the P endpoint, all OH and 1/2CO 3
would be reacted.
2. At the M endpoint, all OH and all CO3
would be reacted, or,
P = 1/2CO3 + OH; 2P = CO3 + 2OH
M = CO3 + OH + HCO3
When HCO3 is absent;
Subtracting, 2P M = OH
and
CO3 = (M OH) = [M (2P M)]
= 2 (M P)
EXAMPLE :
If P = 86 ppm as CaCO3, and if M = 118 ppm as CaCO3
Then, situation 2 exists (P > M)
Hydroxyl = 2P - M = (2 x 86) - 118 = 54 ppm as CaCO3
Carbonate = 2(M - P) = 2 x (118 - 86) = 64 ppm as CaCO3
Bicarbonate = 118 54 64 = 0 ppm as CaCO3
Neutralization of alkaline water with H2SO4

(assume 50 ppm M alkalinity)
45
02-05-2016
Caustic Corrosion (Gouging ):
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
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.
UNDER DEPOSIT BOILING
Water and Steam
Porous Oxide
Protective
Protective
Oxide Oxide
Fe3O4
Tube metal wall

Wick Boiling
Na3PO4 + H2O Na2HPO4 + NaOH
46
02-05-2016
Tube Location
Case study:
30 MW BFB Boiler
Location: Bed Coil Tubes
Size & Spec : 51 x 6.35 mm & SA 210
Gr.A1
Bed Temperature: 905C
Service: less than 1 year
Bed Coil Tube
BFB Boiler
Failed Tube
Failed Tube
Failed Bed Coil Tube
Damage at 12 O Clock position
47
02-05-2016
Failed Tube
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.
Deposits near damage
Acid Phosphate Corrosion:
Thick corrosion product and deposit layers covering

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

within a narrow zone where phosphate corrosion occurred
48
02-05-2016

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

Acid Phosphate reaction mechanism:
2Na2HPO4 + Fe3O4 NaFePO4 + Na3PO4 + Fe2O3
+ H2O
2Na2HPO4 + Fe + O2 NaFePO4 + Na3PO4
+ H2O
3NaH2PO4 + Fe3O4 3NaFePO4 + O2 + H2O
The presence of maricite (NaFePO4) and/or
iron phosphate on a corroded surface is
strong evidence that phosphate corrosion
has occurred
Metallographic cross section of corroded surface may show

Dense, stratified corrosion product layers
SEM examination may reveal Needle like material covering

corroded surfaces.
49
02-05-2016

Acid Attack:
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.
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
Stress Corrosion
FeCl2 + H2
50
02-05-2016
HYDROGEN DAMAGE (EMBRITTLEMENT)

Mechanism:
4NaOH + Fe3O4 2NaFeO2 + Na2FeO2 + 2H2O
Fe + 2NaOH Na2FeO2 + 2H
4H+ + Fe3C CH4 + 3Fe
MgCl2 + H2O MgO + 2HCl
Fe3O4 +HCl FeCl2 + FeCl +H2O
Thick Lip Brittle Appearance
Fe + 2HCl FeCl2 + 2H
Violent rupture Hydrogen Damage
4H+ + Fe3C CH4 + 3Fe

Decarburization weakens tube
Gas generated collects in grain boundaries
and form fissures as pressure builds up
which eventually grow
Case Study:
120 MW Oil Fired Boiler
Location: Goose Neck Rear Water Wall
Size : 76.1 x 5.5 mm
Specification: SA210 GR A1
Working Temp. & Pressure: 350C & 90
kg/cm
Service: 250000 Hrs
Failure occurs when the ruptured section can no longer

withstand the internal pressure. Ruptures are violent
sudden, and can be disastrous
and
51
02-05-2016
Dimensional Measurement (mm):

Tube location
Outside Diameter
0-180 90-270
Near failed lip

Ring section
74.15
The middle tube has burst opened with thick

lips
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
78.73
0
4.08
3.97
Thickness
90 180
6.12
5.60 5.78
270
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.
Opposite
the failed
region, the
On a ring to
section
a littleaway
from the failed
microstructure
of is
polygonal
grains
region,
a similarconsists
structure
observed
of ferrite and pearlite
Decarburization is observed near the crack

edges throughout this region.
52
02-05-2016
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.
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 embrittlementproducing 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
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.
53
02-05-2016
Case study:
Heat Recovery Steam (HRSG)
A thick-walled, circumferential fracture occurred

along a circumferential weld joining sections of T22
and T91 low-alloy steel tubing
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
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
Microscopic examinations revealed that tight, highly

branched, inter-granular cracks originated from the
internal surface within the fusion zone of the
circumferential weld
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
54
02-05-2016
Conclusion:
The cracks were possibly caused by caustic
stress corrosion cracking due to boiler water
carryover.
CAUSTIC EMBRITTLEMENT
REMEDIAL ACTION
Residual stresses from welding most likely

contributed significantly to the formation of
stress corrosion cracks.
Proper stress relieving of all welded or
Applied bending stresses due to thermal

expansion and contraction may have also
contributed since it was near a dissimilar
weld joint
Application of a coordinated pH/phosphate
Stress Corrosion Cracking (SCC)

Cases of chloride stress
corrosion
cracking
of
austenitic stainless steel
have
occurred
in
deaerators, superheaters,
and, in rare cases, highpressure
utility
boiler
feedwater heaters
rolled section
control
Chloride stress corrosion cracking in austenitic

stainless steels is usually characterized by branched,
trans-granular cracks
Chloride stress corrosion cracking in austenitic

stainless steel does not necessarily require a high
chloride concentration
Sensitization a high temperature (above 550oC) may
also lead to SCC
55
02-05-2016
Damage Mechanism: Flow Accelerated

Corrosion

Corrosion
Flow-accelerated corrosion (FAC) is a wellknown 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.
HP Economizer drain
tube
Feed Pipe
Feed Pipe

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

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.
entry path and where orifices are installed.

LP riser tubes/pipes to the LP drum.
LP evaporator transition headers.
Feed Water Line.
56
02-05-2016
FLOW ASSISTED CORROSION

FAC
affectedthinning
by:
Localized
Dissolution
Temperature
of protective
oxide and base metal
pH
Occurs in single or two
O2 concentration
phase water
Mass flow rate
Low pressure system bends
in
Geometry
evaporators,

Effect of temperature on normalized
wear rate of various metallurgies
Risers
Qualityand
of fluid
economizer
tubes
Alloys of construction
Feed water cycle
Greatest potential for FAC occurs around 150 C

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

pH 8.6 and 9.4

Dissolved oxygen has direct impact
FAC minimized above 30 ppb O2

FAC increases exponentially below 30 ppb O2
57
02-05-2016
Effect of Velocity
Location
Normalized wear rate minimal below 10 ft/sec
Geometry affects location of FAC, regardless of

Reynolds Number
Rate increases by 2.8 times at 100 ft/sec
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)
Dissolution of Magnetite
58
02-05-2016

Corrosion
Precaution:
For HRSG and fossil fired boiler plants with
all-ferrous feedwater systems the feedwater
chemistry should be AVT(O) to avoid singlephase 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.
Effect of Temperature and Ammonia on
iron dissolution

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
Effect of pH on FAC
Regular inspection of susceptible components

by ultrasonic (UT) examination needs to be
undertaken to prevent any catastrophic
failure
59
02-05-2016

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.

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.
Disturbing Findings by EPRI :
11 fossil plants with ACCs were visited during the

project.
80% of the plants practiced ammonia dosing to control
pH while 20% utilized neutralizing amine products.
CORROSION IN ACC
80% of the plants had performed at least a partial

inspection of their ACCs
Duct damage had been observed in all plants where this
area of the cycle had been inspected
70% of the plants confirmed damage in the distribution
headers and tubes of the ACC
20% of the plants reported development of through-wall
tube leaks
60
02-05-2016
Flow
Flow
DHACI for Lower

Tube Inlets
Ducts
DHACI: (Dooley Howel Air Cooled Condenser

Corrosion Index)
ACC Corrosion Index to Categorize Corrosion and Track

Improvements
DHACI for Tube Inlets
1. Tube entries in relatively good shape (maybe
some dark deposited areas)
2. Various black/grey deposits on tube entries as
well as flash rust areas, but no white bare metal
areas
A. Ducting shows no general signs of two-phase

4. Serious white bare metal areas on/at numerous
damage
tube entries. Lots of black areas of deposition
adjacent
B.
Minor white
to white
areas
areas
on generally grey ducting.
Maybe some tiger striping with darker
5. Most
grey/black
serious.
areas
Holes
of in
two-phase
the tubing
damage
or welding.
Obvious corrosion on many tube entries
C. Serious white bare metal areas in the hot box
and at numerous changes of direction (eg. at
intersections of exhaust ducting to vertical
riser). White areas are obvious regions of lost
metal.
3. Few white bare metal areas on a number of

tube entries. Some black areas of deposit
61
02-05-2016
Mechanism of metal loss:

2-phase Flow Accelerated Corrosion
62
02-05-2016
Chemistry optimization:
Elevate pH in early condensate; 9.8
10 as per EPRI Guideline.
Feed alternative less-volatile chemical (e.g.
Amine)
Alternative material to carbon steel
Use of CPU or Condensate Filter to restrict
Iron transport
Reliability Issues of HRSG
Common damage mechanisms:

Low Cycle Thermo-mechanical Fatigue
Flow Accelerated Corrosion
Cold end gas-side corrosion
63
02-05-2016
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
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
High efficiency has driven rapid increases in GT

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

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
Damage Mechanism: Thermo-mechanical

Low Cycle Fatigue
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
64
02-05-2016

Low Cycle Fatigue

Low Cycle Fatigue
HP Superheater and outlet manifold
Location:

HP Steam Drum and Evaporator circuit
Economizer
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

Low Cycle Fatigue
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
65
02-05-2016

Low Cycle Fatigue

Low Cycle Fatigue
Precaution:
Care to be taken both for ramp up and
coasting down rate
ETM to be used for 9FA machines
Precaution:
Hold the GT load at
load until steam flow
the superheater
a nominal block
is established in
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

Low Cycle Fatigue

Low Cycle Fatigue
Precaution:
Condensate quenching 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 headers through-wall
temperature gradient equalize before shutting
down the GT
Low-point drains are open during startup to

purge water/conden-sate 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
66
02-05-2016

Low Cycle Fatigue

Low Cycle Fatigue
Condensate quenching precaution:
Over spraying of attemperation; reasons:
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
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
turbines performance at startup or low load.

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

probe/nozzle damage or partial plugging
Improper piping designin 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.
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
67
02-05-2016

Low Cycle Fatigue
Economizer:

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 nexta 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:
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.
Economizer tube leak at weld caused by thermal shock

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
When HP drum level finally starts to drop, the

feedwater control valve opens and cold water
shocks the economizer.
68
02-05-2016
Case 1:
Location: Primary SH Coil
Failures Case Studies
Size : 57.15 x 4.2 mm

kg/cm
Service: 243000 Hrs
Dimensional Measurement (mm):

Tube location
Outside Diameter
0-180
90-270
Thickness
90
180
270
Near failed lip

Ring section
little away
-59.21
-61.81
3.03
3.35
-3.68
4.27
-3.93 3.82
Burst section is having thick lip
The tube shows bulging (OD=61.5 mm) and burst

opened like a fish mouth
69
02-05-2016
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.
Conclusion:
Micro examination indicates several rounded
pits filled with oxides on the ID surface of
the tube.
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.
However, take the case of a similar failure

in the same Boiler
The failure is attributed to waterside

corrosion.
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.
70
02-05-2016
Some rounded pits filled with oxides are

observed on the ID surface tube in all the
three sections examined.
Transverse section of the burst lip shows oxidation of

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

grains of ferrite and pearlite.
Above observations suggests that the tube has been

overheated to above AC3 temperature for the steel
for a short period of time.
71
02-05-2016
Case 2:
Location: LHS Water Wall
Size : 76.1 x 5.5 mm
Specification: SA210 GR A1
kg/cm
Service: 254378 Hrs
The tube shows blisters at four locations (OD = 80
to 82 mm) in the spool piece between two weld
joints.
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
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.
72
02-05-2016
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
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
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
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
73
02-05-2016
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.
74

3 - Boiler Pressure Parts Failure - Presentation

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3 - Boiler Pressure Parts Failure - Presentation

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02-05-2016

Ansuman Sen Sharma

To Understand Analytically How &

Why & How Boiler Tubes Get Damaged

Various Damage Mechanisms in which Boiler Tube

Damage Mechanisms for

Generation of RC (Root Cause)

Route from Failures to their Prevention

RC develop UC (Undesirable Conditions)

DM/s lead to failure

DM Irreversible & Accumulative

But why wait for

Failure occur whenever there is Total

Damage Prone Locations

Prevention of Boiler Tube

Awareness and Updating DPL help in

What are the metallurgies of the

What are the adverse Conditions

What are the indications which

Temperature inside the furnace : 1100 -1200oC

Water Tube Boiler:

Carbon Steel: 425oC (456oC)

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

For Carbon Steel, creep begins at about 370oC

Furnace Temperature in the

Carbon Steel; SA 210 Gr. A/ C1

Creep starts in Carbon Steel at 370oC and it doesnt

Departure from Nucleate Boiling (DNB):

Why the bubbles are getting dislodged and

Steam bubbles are coming out in

At Atmospheric pressure the difference is

This is at Atmospheric pressure where the

It is the flow in the water due to natural

Therefore circulation would be maximum at

Overheating of tube and rapture can be due

High Heat Flux More than Critical Heat

Factors inducing DNB and tube

Obstruction due to foreign object fouling

Disturbance of Water Chemistry due to Steam Blanketing:

What other adverse Conditions?

Longitudinal Stress & Hoop

Let us now take a look at the type of

Basic MET of Fe family

IRONS: Irons without any alloying

Alloy Steels: Alloying

Low Alloy Steels: If total alloying less

Carbon Steel (low carbon)

Materials used in Boiler Pressure

Carbon Steel (medium carbon)

Material specifications for Heat Exchanging Elements

Heat Exchanging Elements

Radiant roof Panel

6. Platen S.H. Vertical assembly

Gr. A1, SA 209 T1

Gr. A1, SA 209 T1,

SA 209, T1, SA 213 T11,

And is highly sensitive to even little deviation

only 100 hrs, i.e.

Flue Gas Velocity Sensitivity:

is Justified & Necessary

The Larson-Miller Parameter (LMP) can be used

With Over heating (actual temp. more

Commonly Large bulge and thin lip