J Fail. Anal. and Preven.
(2009) 9:365–369
DOI 10.1007/s11668-009-9250-1
TECHNICAL ARTICLE—PEER-REVIEWED
Failure Investigation on Reheater Tube Due to Deposit and Wall
Thinning
J. Purbolaksono Æ F. Tarlochan Æ M. M. Rahman Æ
N. F. Nordin Æ B. Ahmad
Submitted: 16 October 2008 / in revised form: 4 April 2009 / Published online: 29 April 2009
Ó ASM International 2009
Abstract Failure analysis of a reheater tube showed that
the failure was caused by overheating and wall thinning.
Finite element modeling, dimensional measurements, and
microscopic examinations were performed to investigate
the root cause of the failure. Wall thinning, due to exces-
sive coal-ash corrosion, and overheating, due to scale
buildup on the tube were measured, and estimations, the
average corrosion and scale growth rates, were made. The
combination of excessive scale formation on the inner tube
surfaces and wall thinning due to coal-ash corrosion on the
outer tube surfaces combined to cause the failure of the
reheater tube.
Keywords Boiler material
Deposits
Failure analysis

Tube burst
Thinning
High temperature
Introduction
The thermal efficiency of a boiler depends on the heat
transfer process across the tube wall. With prolonged
exposure at elevated temperature, boiler tubes may
develop scales on the internal and/or external surfaces [1]
which will retard heat transfer and reduce the thermal
J. Purbolaksono (&)
F. Tarlochan
M. M. Rahman
Department of Mechanical Engineering,
Universiti Tenaga Nasional, Km 7 Jalan Kajang-Puchong,
Kajang 43009, Selangor, Malaysia
e-mail: Judha@uniten.edu.my
N. F. Nordin
B. Ahmad
TNB Research Sdn Bhd, No. 1 Lorong Air Hitam,
Kajang 43000, Selangor, Malaysia
efficiency. Additionally, the growing scales may cause the
tube temperatures to be higher than those originally
specified. High temperatures and scale formation may
cause degradation of the tube material and eventually will
lead to tube rupture. Tube rupture may also be caused by
reduction in tube wall thickness as the alloy is consumed
by scale formation and corrosion processes. It is estimated
that 10% of all power-plant breakdowns are caused by
creep fractures of boiler tubes due to the scale formation
and 30% of all tube failures in boilers and reformers are
caused by creep [2].
As reported in Ref. [3], coal-ash corrosion is caused
by the formation of complex alkali sulfates such as
K3Fe(SO4)3 and Na3Fe(SO4)3 at the scale/metal interface
when the tube metal temperature is in the range of 566–
732 °C. Coal-ash corrosion may be accelerated when the
fuel supply or fuel type is changed and the new heat source
results in the production of an aggressive ash. Certain coals
contain constituents which form ash deposits that are
molten at typical operating temperatures and can cause
extensive corrosion. The corrosion may lead to a significant
concern if the wall thickness is reducing at rate of 8 mils/
year or greater [4].
In this study, dimensional measurements of the failed
tube sample were made to obtain data of the wall thinning
and scale thickness of the tube. Average rates of the scale
formation on the inner surface and tube thinning due to
corrosion on the external surface were then estimated.
Finite element models, conducted using software package
of ANSYS [5], for heat transfer analysis are developed
according to the data obtained from visual inspection and
dimensional measurements. Microscopic examination was
also carried to show any microstructure changes. The
maximum allowable stresses of SA-213-T22 for different
temperatures [6] are also presented.
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Visual Inspection

The boiler/reheater tube data can be seen in Table 1. Visual

inspection of the failed tube sample shown in Fig. 1a and b
revealed the following features:
1 Significant wall thinning was found. The tube metal
thickness at the distance of 30 cm and 2 m away from
the failure region were in the average of 2.5 and 5 mm,
respectively.
2 Scale thickness on the inner surface at the distance of
30 cm and 2 m away from the failure region were in
the average of 2.2 and 0.4 mm, respectively.
3 According to data from Table 1, it can be estimated
that the amount of wall thinning was approximately
1.8 mm (30 cm away from rupture region) and 1.1 mm
(2 m away from rupture region).
4 The tube was failed with wide opened (fish mouth)
burst having dimension of the rupture of 2.8 cm in
width and 5.5 mm in length.

Finite Element Models

Data obtained from dimensional measurements for the

inner scale and outer wall thinning of the tube sample was
used to estimate the average scale growth and wall thinning
rates. The average scale growth and wall thinning rates are
shown in Table 2. These data are based on the measure-
ments and the report that the tube failed after 99,083 h. Fig. 1 (a) Cross section of the as-received tube at 30 cm away from
rupture region. (b) Rupture region with opened wide burst (Courtesy:
Table 1 Boiler data and properties of fluid and solid materials Kapar Power Station, Malaysia)
Boiler
Fuel Pulverized coal
Load capacity 300 MW
Flue gas properties Table 2 Estimations of scale growth and wall thinning rates
Flue gas temperature 800 °C Scale growth
2
Convection coefficient 109.44 W/m C Scale thickness at 99,083 h
Inlet steam properties - Rupture region: 2.2 mm
Inlet temperature 541 °C - 2 m away from rupture region: 0.4 mm
Thermal conductivity 0.0604 W/m C Average scale growth rate:
Specific heat 2161 J/kg C - Rupture region: 2.2 mm/99,083 h = 2.22036 9 105 mm/h
Density 0.2697 kg/m3 - 2 m away from rupture region
Dynamic viscosity 0.00002834 N s/m2 0.4 mm/99,083 h = 4.03702 9 106 mm/h
Mass flow rate 18,000 kg/h Wall thinning
Water wall properties Wall thinning at 99,083 h
Tube material SA-213-T22 - Rupture region: 1.80 mm
Thermal conductivity [3] 34.606 W/m C - 2 m away from rupture region: 1.10 mm
Inner radius 0.0189 m Average scale growth rate
Outer radius 0.0254 m - Rupture region: 1.80 mm/ 99,083 h = 1.81666 9 105 mm/h
Fe3O4 iron oxide (magnetite) - 2 m away from rupture region:
Thermal conductivity [3] 0.592 W/m C 1.10 mm/ 99,083 h = 1.11018 9 105 mm/h

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J Fail. Anal. and Preven. (2009) 9:365–369 367

1/2 expansion model of 2D-axisymmetric solid

hot gas
oxide
100 mm scale tube metal

scale/metal interface

549.757 563.619 577.481 591.343 605.204

steam remaining tube 542.826 556.688 570.550 584.412 598.273

X
metal thickness
hollow
radius initial tube metal thickness
Fig. 2 Model of the reheater tube with inner scale on the surface
Finite element analyses are conducted in order to
determine the temperature distribution at the final stage of
rupture and simulate some configurations at different times
prior to rupture. In order to represent the actual geometry
of the tube and by considering the ratio of the length to
radius of the tube, the model used is 100 mm in length (see
Fig. 2).
In modeling of the steady state heat transfer for the
problem using ANSYS, the area of the model is divided
into two regions, i.e., scale region and tube region. Data for
the steam region is used to determine the convection
coefficient of steam film for fully developed turbulent flow
in circular tube. Steam flows through the internal of tube
with an inlet temperature of 541 °C and a mass flow rate of
18,000 kg/h. The flue gas temperature is 800 °C, and the
heat transfer along the external surface between the flue gas
and the tube wall is considered as free convection heat
transfer. The scale is magnetite (Fe3O4 iron oxide) and
detailed material properties of steam, scale, tube, and flue
gas used are shown in Table 1. Some parameters shown in
Table 1 are taken from the actual data by courtesy of Kapar
Power Plant, Malaysia. It was reported that the operational
pressure of the reheater tubes is around 40 bar or 4 MPa.
The scale and tube are modeled as two-dimensional
axisymmetric solids. In order to ensure the models have a
good meshing connectivity, the meshing size control of
0.0001 is used to generate the triangular elements. Steady
state analyses of heat transfer are carried out in order to
show the influence of different scale thickness and wall
thinning to the temperature distribution developed in the
tube wall. Phenomenon of heat transfer inside the boiler
tube is considered as forced convection with turbulent flow,
while the outer surface is experiencing free convection.
Fig. 3 Estimated temperature (°C) distribution of the tube at 60,000
service hours
Convective coefficient of steam film for fully developed
turbulent flow in circular tube is expressed as [7]:
k
hs ¼ 0:023 ðReÞ0:8 ðPrÞ0:4 ðEq 1Þ
d
where Re is Reynolds number; Pr is Prandtl number; k is
fluid conductivity; and d is the inner diameter of the tube.
The maximum elastic hoop stress in the tube wall [4] is
used in order to provide a conservative estimation as
ðb2 þ a2 Þ
rh ¼ P ðEq 2Þ
ðb2  a2 Þ
where P is operational pressure; a and b are inner and outer
radius, respectively.
Microscopic Examination
The microscopic examination for the specimens taken from
the rupture region of the failed tube was carried out to reveal
any change of microstructure. Locations of the specimens
are indicated at A and B in Fig. 1b. The locations chosen are
expected to obtain sufficient information in order to support
the analysis pertaining to the tube rupture.
Results and Discussion
Estimated temperature distribution at the rupture region of
the tube at 60,000 service hours obtained from the finite
element analysis is shown in Fig. 3. It can be seen that the
metal temperature already relatively high. The average
tube temperatures for different regions of the tube are
plotted in Fig. 4. The temperatures are taken from of the
average of the temperatures at oxide scale/metal interface

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368 J Fail. Anal. and Preven. (2009) 9:365–369

640

630
Average metal temperature °C

620

610

600

590 Rupture region

2 m away from rupture region
580
Oxidation might become excessive [1]
570

560

550
50,000 60,000 70,000 80,000 90,000 100,000
Service hours

Fig. 4 The average tube temperatures for different regions of the

tube at the corresponding service hours

30
Rupture region

25 Maximum allowable stress [6]

Hoop Stress, MPa

20

15
Hoop stress start
exceeding the
10 allowable stress
at about 85,000
service hours
5

Fig. 6 (a) Photomicrograph of the tube metal at location of A (see

0
590 600 610 620 630 640 650 Fig. 1b). (b) Photomicrograph of the tube metal at location of B
(Courtesy: Kapar Power Station, Malaysia)
Average Metal Temperature °C

Fig. 5 Hoop stresses in service at rupture region of the tube and the
allowable stresses for SA-213-T22 tube at the corresponding average
tube temperatures
and outer surface of the tube. It can be seen from Fig. 4 that
at 60,000 h the average tube temperature at rupture region
has already exceeded 600 °C. At this temperature, thermal
oxidation may become excessive. At the higher metal tube
temperature ash deposits might also become corrosive as a
result of the molten fly ash deposits. It can be seen from
Fig. 5 that the hoop stress at the rupture region start
exceeding the maximum allowable stress values for
SA-213-T22 tube for the last 14,000 h. The interaction
between the significant outer wall thinning due to coal-ash
corrosion and scale formation on the inner surface in the
metal tube is identified as the governing factor for the
failure problem. The interaction leads to the overheating
and excessive stresses in the tube and eventually results in
the tube rupture.
The microscopic examinations were carried out in order
to support the findings obtained from finite element analyses.
The results of the microscopic examinations as shown in
Fig. 6a and b indicated that the tube metal at locations of A
and B (see Fig. 1b) shows complete spheroidization with
uniform dispersion of carbide particles. It is clear that the
failed tube had operated at high temperature for a long time
as shown by the change of microstructure.
It is obvious that a severe condition had been occurred
in the tube over a prolonged period of time due to scale
formation on the inner surface which results in temperature
increase, and outer wall thinning which increases the hoop
stress. Additionally the metal is weakened by microstruc-
ture deterioration (Fig. 6a and b). Results obtained from
the finite element analysis are well supported by the find-
ings from the microscopic examinations.
Conclusions
Finite element modeling supported by dimensional mea-
surements and microscopic examinations for investigating

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J Fail. Anal. and Preven. (2009) 9:365–369
the failed reheater tube due to overheating and wall thin-
ning were presented. It was found that the major
contributor which resulted in the failure of the reheater tube
was interaction between the excessive scale formation on
the inner surface and outer wall thinning due to coal-ash
corrosion. The tube had consequently operated at higher
temperature and had operational stress exceeding the
maximum allowable stress values for a prolonged period
of time.
Acknowledgments The authors wish to thank the Ministry of Sci-
ence Technology and Innovation, Malaysia for financial supports
through the research project of IRPA 09-99-03-0033 EA001 and
Sciencefund 04-02-03-SF0003. The authors would also like to thank
Universiti Tenaga Nasional, TNB Research Sdn. Bhd and Kapar
Power Station Malaysia for permission of utilizing all the facilities
during conducting this study.
369
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