Tube Failures In High Pressure Boilers

Dr V T Sathyanathan M.E., Ph.D

Dr V T Sathyanathan, M.E., Ph.D.

 Defects and Failures
• Defects and their significance with respect to
failures is a complex subject.

• Brittle Failures - Crack propagation

without appreciable plastic deformation

• Ductile Failures - Plastic deformation

with gradual propagation of cracks

Dr V T Sathyanathan, M.E., Ph.D.

 Classification of Service Failures

• Design (structural, design notches, joint

location or welding configuration) related
• Materials (selection and handling) related
• Base Metal Defects (introduced during
raw material manufacture and shaping)
• Fabrication Defects
• In - service Defects
Dr V T Sathyanathan, M.E., Ph.D.
 Design Considerations

• Flexibility for Thermal Fatigue Cracking

Resistance
• Avoid sharp corners and notches for Fatigue
Resistance and gradual taper (4 : 1)
• Proper Stress Concentration factors
• Proper Weld Joint design

Dr V T Sathyanathan, M.E., Ph.D.

Material Selection & Handling Considerations
• Graphitisation and Embrittlement
• Proper choice of steels especially stainless steels
• Proper choice of welding consumable
• Minimise abrupt material transitions (DMW)
• Choice against temper embrittlement
• J-Factor = (Si + Mn)x(P + Sn)x 104 (to be less than 160,
elements in weight %)
• X-Factor = ( 10P + 5 Sb + 4 Sn + As) (to be less than 15, elements
in ppm)
• Step Cooling Cycle, Impact test at sub-zero temperatures
• Combination Heat Treatment Feasibility
• Material Handling and surface protection in storage
• Hydrogen Induced Cracking and Sulphide Stress Cracking
Resistance for sour service applications

Dr V T Sathyanathan, M.E., Ph.D.

 Base Metal Defects
In Wrought and forged Products
• Mechanical Notches :
– Laminations - Severe inclusions aligned parallel to surface
– Laps - Surface defect in rolling, parallel to length, at an angle
– Scabs - Scale rolled into surface
– Slivers - Metal surface ruptures, rolled into the surface
– Bark - Intergranular penetration of oxides and scale
– Seams - Surface defect, parallel to rolling, linear fissures
• Metallurgical Notches :
– Hot Shortness
– Surface Carburisation / Decarburisation

Dr V T Sathyanathan, M.E., Ph.D.

 Casting Defects

• Mechanical Notches
• Hot Tears and Cracking
• Gas and Blow Holes
• Unfused chaplets
• Inclusions
• Internal Shrinkage
• Metallurgical Notches
• Hot Shortness

Dr V T Sathyanathan, M.E., Ph.D.

 Fabrication Defects
• Cold Bending (Excessive Thinning,
Ovality)
• Hot Bending (Reduced Hot Ductility
problem)
• Weld Defects
• Improper Heat Treatment
• Surface Cleanliness (for SS, for welds
before welding etc.)

Dr V T Sathyanathan, M.E., Ph.D.

 Weld Defects
• Improper Fit up
• Root Oxidation in SS welds
• Burn Through & Porosity
• Hot Cracks & Cold Cracks
• Concavity
• Slag Inclusions
• Crater Cracking
• Undercut
• Lack of Fusion
• Stray Arcing

Dr V T Sathyanathan, M.E., Ph.D.

In-service Defects

Boiler Tube Failures

Will be covered
as
Failure Analysis

Dr V T Sathyanathan, M.E., Ph.D.

 Boiler Tube Failures

• Boiler Tube Failures - main cause of

forced outages in electric utility steam
generating boilers
• Single tube Failure in a 500 MW ⇒ Rs. 5
to 6 Crores (replacement power charges
for 3-4 days to repair) besides affecting
Plant Morale.

Dr V T Sathyanathan, M.E., Ph.D.

Boiler Tube Failures (22 Primary Mechanisms)
Stress Rupture Fatigue
• Short Term Overheating • Vibration
• High Temperature Creep • Thermal
• Dissimilar Metal Welds • Corrosion
Water-side Corrosion Erosion
• Caustic Corrosion • Fly Ash
• Hydrogen Damage • Falling Slag
• Pitting • Soot Blower
• Stress Corrosion Cracking • Coal Particle
Fire-side Corrosion Lack of Quality Control
• Low Temperature • Maintenance cleaning
• Waterwall -  damage
• Coal Ash -  • Chemical Excursion damage
• Oil Ash • Material Defects
• Welding Defects
 - indicates that such problems have not been reported in India
Dr V T Sathyanathan, M.E., Ph.D.
 Short Term Overheating
Steam / Water cooled Corrective Action
tubes • Prevent Blockage
• Plugged by debris, • Maintain Drum level
scale etc.
• Assure Coolant flow
• High Heat Transfer /
• Reduce over firing
Improper firing
• Redesign tubing to
• Low water/steam
promote flow
flow due to poor
circulation / • Relocation of horiz. /
upstream leak inclined tubes to
avoid film boiling
Dr V T Sathyanathan, M.E., Ph.D.
Dr V T Sathyanathan, M.E., Ph.D.
Dr V T Sathyanathan, M.E., Ph.D.
SHORT TERM OVERHEATING

Dr V T Sathyanathan, M.E., Ph.D.

SHORT TERM OVERHEATING TRANSFORMED MARTENSITE
SHORT TERM OVERHEATING ORIGINAL STRUCTURE

Dr V T Sathyanathan, M.E., Ph.D.

 High Temperature Creep
Typical Locations Corrective Action
• Steam cooled Tubes • RLA
– Partially choked • Fluid flushing
– Radiant Heat Zone • Material up-grades
– Gas Blockage
• Tube shielding
– Incorrect Material
– Material Transition
– Higher stress due to
– weld attachment

Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.
 LONG TERM OVERHEATING RANDOM GRAPHITISATION
LONG TERM OVERHEATING OXIDE NOTCHES
LONG TERM OVERHEATING EYEBROW GRAPHITISATION
LONG TERM OVERHEATING CREEP MICROCRACKS

Dr V T Sathyanathan, M.E., Ph.D.

 LONG TERM OVERHEATING
OVERHEATING, CREEP –INCORRECT MATERIAL
OVERHEATING – BULGING, SATELLITE SCALE CRACKING
OVERHEATING – WATERSIDE DEPOSITS

Dr V T Sathyanathan, M.E., Ph.D.

 LONG TERM OVERHEATING
WATERSIDE DEPOSTS &

DAMAGE DUE TO TUBE INSIDE TUBE

Dr V T Sathyanathan, M.E., Ph.D.

Dr V T Sathyanathan, M.E., Ph.D.
Dr V T Sathyanathan, M.E., Ph.D.
Dr V T Sathyanathan, M.E., Ph.D.
 Dissimilar Metal Welds
Typical Locations Corrective Action
• At SH / RH dissimilar • Repair/Replacement
weld joints : • Relocating the weld
• Temperature / Stress • Use of Ni-base filler
excursions • Frequent inspection
Mechanism : 1. The formation of carbon depleted zone on the ferritic side of the
transition from the ferritic to austenitic structure is the initial step and any
treatment which enhances the formation of this zone will enhance the failure
probability.
2. The carbon depleted soft feerritic zone is constrained by the sorrounding harder
and stronger material and is subjected to strains induced by thermal expansion
mismatch, bending, vibration and pressure.
3. The strain accumulation in the carbon-depleted zone is relieved by creep at
elevated temperature.
4. Creep damage in the form of cavitation, grain boundary sliding and tearing
results in cracking in the carbon depleted zone along and adjacent to the weld
interface Dr V T Sathyanathan, M.E., Ph.D.
Dr V T Sathyanathan, M.E., Ph.D.
DISSIMILAR METAL WELD FAILURE

Dr V T Sathyanathan, M.E., Ph.D.

Cont to Tube Fail2

Dr V T Sathyanathan, M.E., Ph.D.