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Product Description
In conventional and combined-cycle plants, boiler tube failures (BTFs) have
been the main availability problem for as long as reliable statistics have
been kept for each generating source. The three volumes of the Electric
Power Research Institute (EPRI) report Boiler and Heat Recovery Steam
Generator Tube Failures: Theory and Practice (1012757) present an indepth discussion of the various BTF and degradation mechanisms, providing
plant owners and operators with the technical basis to address tube failures
and create permanent solutions. This field guide is based on the content
of Boiler and Heat Recovery Steam Generator Tube Failures: Theory and
Practice.
Tube failures emanate from poor initial design, poor operation and maintenance,
harsh fireside and cycle chemistry environments, and lack of management
support for comprehensive reduction programs. A total of 35 tube failure
mechanisms affecting conventional fossil plants are described in this field guide.
Most BTFs have been repeat failures, indicating that the return to service of a
unit has historically been more important than understanding the failure. This
field guide provides guidance on identifying and addressing the mechanism
and contributing causes of each tube failure to help eliminate repeat failures.
Tube failures occur in new and old units; in units that cycle and those that
operate under baseload conditions; in supercritical, once-through, and
drum units; and in units burning every sort of combustible material. The
information and comprehensive approach presented will help organizations
to approach and achieve world-class performance.
EPRI Perspective
Approach
This field guide was developed from the content of Boiler and Heat
Recovery Steam Generator Tube Failures: Theory and Practice (1012757).
Keywords
Contributing causes
Failures
Fossil plants
Tubes
vii
Acknowledgments
The technical content of this field guide was obtained in its entirety from
Boiler and Heat Recovery Steam Generator Tube Failures: Theory and
Practice, Volume 1, Fundamentals, Volume 2, Water Touched Tubes, and
Volume 3, Steam Touched Tubes (EPRI report 1012757). The technical staff
at Altran Solutions worked to reorganize the data in these three volumes
and present it in a compact and practical format that would be convenient
for field use.
Most important, this field guide would not be possible without the authors,
editors, and technical contributors of EPRI report 1012757. Their names
are listed as presented in the original document.
viii
Individual
R. Anderson
D. Aspden
W. Bakker
M. Ball
D. Blood
K. Coleman
J. Drennen
D. Gandy
A. Howell
D. Hubbard
P. James
R. Lynch
D. OConnor
J. Parker
S. Paterson
K. Shields
J. Stallings
R. Tilley
S. Walker
I. Wright
Organization
Country
Competitive Power
U.S.A.
Consultant
South Africa
Consultant
U.S.A.
Consultant
U.K.
E-ON UK
U.K.
EPRI
U.S.A.
Drennen Engineering
U.S.A.
EPRI
U.S.A.
Xcel Energy
U.S.A.
AEP
U.S.A.
E-ON UK
U.K.
Detroit Edison
U.S.A.
EPRI
U.S.A.
Structural Integrity
Canada
Aptech Engineering Services U.S.A.
EPRI
U.S.A.
EPRI
U.S.A.
EPRI
U.S.A.
EPRI
U.S.A.
Oak Ridge National Laboratory U.S.A.
Contents
1. Introduction....................................................................... 1
Background............................................................................ 2
Purpose................................................................................. 2
Scope.................................................................................... 2
2. Fundamentals of Field Inspection.......................................... 3
Safety.................................................................................... 4
Tools...................................................................................... 4
Foreign Material Exclusion....................................................... 5
Where to Look........................................................................ 5
What to Look for..................................................................... 5
Documentation........................................................................ 6
Trending................................................................................ 6
Just Look Around..................................................................... 6
3. Tube Failure Mechanisms..................................................... 7
4. Water-Touched Tubes........................................................... 9
Screening Table for Water-Touched Boiler Tube
Failures (Chapter 2).......................................................... 10
Corrosion Fatigue (Chapter 19).............................................. 17
Fly Ash Erosion (Chapter 21).................................................. 26
Hydrogen Damage (Chapter 22)............................................ 35
Acid Phosphate Corrosion (Chapter 23)................................... 45
Caustic Gouging (Chapter 24)............................................... 54
Waterwall Fireside Corrosion (Chapter 25).............................. 64
Thermal Fatigue in Waterwalls (Chapter 26)............................ 77
Thermal Fatigue of Economizer Header Tubes (Chapter 27)....... 87
Thermal-Mechanical and Vibration-Induced Fatigue in
Water-Touched Tubes (Chapter 28)..................................... 90
Thermal Fatigue Caused by Water Blowing (Chapter 29)........... 93
Flow-Accelerated Corrosion in Economizer Inlet Header
Tubing (Chapter 32)......................................................... 96
Sootblower Erosion in Water-Touched Tubes (Chapter 33)........ 103
Short-Term Overheating in Waterwall Or Evaporator
Tubing (Chapter 34)....................................................... 105
ix
1. Introduction
1. INTRODUCTION
Introduction
Background
Relatively simple materials are designed and constructed to function
effectively as boiler tubes under high temperature and high pressure
conditions. The tubes are subject to potential degradation by a variety or
mechanical and thermal stresses and potential environmental attack on both
the fluid- and fire-/gas-side of the tube.
If there are no breakdowns from the original design conditions, watertouched tubes such as waterwall and economizer tubes are designed for
and should have essentially infinite life. The case for steam-touched tubes
such as superheater (SH)and reheater (RH) tubes is somewhat different.
These tubes are affected by the inevitability of creep-limited lifetime,
although lifetimes in excess of 200,000 operating hours are achievable.
Unfortunately, boiler tube failures (BTFs) and cycle chemistry corrosion and
deposition problems in fossil steam plants remain significant and pervasive,
leading causes of availability and performance losses worldwide.
This field guide provides a description of the mechanism producing the
failure, identifies the contributing causes of the degradation, presents
immediate actions that can be taken to remove or reduce the effect of
the contributing causes, and addresses the potential ramifications or
implications to other parts of the boiler unit.
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In no case should the information presented in this field guide be used to the
exclusion of established and applicable codes, standards, plant procedures,
and criteria. This includes the notification of responsible personnel at your
plant for investigation of degradation that may be noted.
Purpose
The purpose of this field guide is to provide a practical and convenient
presentation of information on the degradation mechanisms producing
BTFs, contributing causes of the degradation, appropriate mitigating actions
to remove or reduce the effect of the contributing causes, and possible
ramifications and implications of the degradation or failure on other parts
of the unit.
Scope
This field guide addresses water-touched and steam-touched tubes in
conventional boilers. It presents information that can be used to implement
the following three-step approach to reducing tube failures:
Understand the failure.
Identify the contributing causes.
Develop long-term mitigating actions or solutions.
2. FUNDAMENTALS OF
FIELD INSPECTION
Safety
Typically, tube inspections are conducted when the boiler is shutdown and
cooled. However, safety is still a paramount consideration. Obey your
respective plant safety rules and procedures. Remember that in the field,
so much of your safety depends on awareness of your environment and
common sense. Use both. Comply with the following safety rules:
Wear proper personal protective equipment (PPEs)clothing, hard hats, gloves,
safety boots, eye protection, and filtration masks or breathing equipment.
Hearing protection may be necessary even though the plant is down.
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Make others aware of your intents and whereabouts. Check in with the
control room as required.
Work in teamshave a work buddy or assistant.
Follow confined space protocols for required attendants, ventilation, air
quality, and egress.
Reconnoiter the area in which you will be working for physical hazards
(e.g., energized equipment and shock hazards, hot equipment or
structures, projecting equipment or structures that you might bump into,
operating equipment, potential fall or trip locations).
Use proper climbing equipment (ladders and scaffolds) and safety harnesses.
Tools
Effective and timely inspections require proper tools. Make sure you have
everything you need before starting your walkdown. The following is a list
of tools and equipment to be considered:
Bright flashlight or other light source. Some inspectors combine their use
with helmet-mounted lights.
Camera. LCD cameras with telephoto capabilities are ideal for this use.
Note that most of your photos will require the use of a flashmake sure
your batteries are charged and bring extra batteries if necessary.
Inspection mirrortelescoping handles and pivots are preferred.
Where to Look
Plugging
Pitting
Leaks
Wastage
Cracks
Blisters and bulges
Corrosion
Overheating
Misalignment or displacement (out of position)
Foreign materials left in the boilers by careless inspectors have the potential
to cause more damage faster than degradation itself. Be careful not to lose
equipment that could plug or otherwise damage components. Also remember
that finding and extracting dropped items can be costly and time-consuming.
Bring only the tools that are necessary into the immediate inspection area.
Secure loose items. Use lanyards when necessary.
Make sure equipment caps (e.g., lens caps, battery covers) are secured.
Conduct pre- and post-inspection inventories of equipment.
2. FUNDAMENTALS OF
FIELD INSPECTION
During operation, inspections are typically limited to external areas and review
of operational data including temperatures, flows, and water levels. External
inspections should include, among others, piping arrangements and drains,
supports, boiler walls, access ports, and instrumentation lines. Inspections
during a shutdown should include all areas of the boiler or HRSG including,
among others, crawl spaces, penthouses, access lanes, fire boxes, drums,
headers, tubes, piping, supports, hangers, expansion joints, and ducting.
Documentation
All noteworthy degradation or indications of degradation should be quantified
and mapped. Where photographic or videotape documentation is used, care
should be taken to include a location reference. A tape measure or magnetic ruler
should be included in the visual record for comparison to illustrate relative size.
Locations of cracks and crack tips may be noted with a marking pen in
order to be more visible in the photograph.
Where small samples have been obtained for metallurgical or chemical
analysis, record the locations from where the samples were obtained
and make sure there is a unique corresponding identifier on the sample
container. Photograph the location from which the sample was obtained.
Failed headers or tube sections that have been replaced should be treated
as documentation. Do not throw them away summarily! They provide the
best evidence of the cause of failure or mechanism of degradation.
Records should include the following:
Measurements such as size, location, and population of cracks, pits,
blisters, or other indications of material degradation
Color photographs or videotape of the general condition, observed
degradation indications, and specific degradation
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Trending
Trending of quantitative and qualitative data is a powerful tool in predicting
degradation rates and component service life. It is also very important in
planning repairs, maintenance, and mitigation. Ensure that your inspection
and resulting documentation revisits previously inspected areas in order to
ascertain degradation rates.
Tube failures are produced by a number of degradation mechanisms. The occurrence of one mechanism rather than another is dependent upon a variety
of factors ranging from tube material to operating conditions to time in service. Understanding the degradation mechanism producing a tube failure,
recognizing the contributing causes of the degradation, and implementing appropriate mitigating actions are key steps to developing an effective failure
reduction program.
The information provided in the following sections of the field guide is grouped by water-touched and steam-touched tubes and then organized by the
degradation mechanism within each group. Each degradation mechanism section is organized as follows:
Description of the degradation mechanism supplemented with photographs and/or sketches to illustrate the mechanism
Identification of the contributing causes of the degradation
Discussion of mitigating actions that can be taken to remove or reduce the effect of the contributing causes
Identification of potential ramifications and implications on other unit components
When appropriate, tables and charts are used to present the information.
Chapter numbers provided at the beginning of the description of each degradation mechanism refer to the corresponding chapter in EPRI report 1012757.
The user of this guide is encouraged to review the referenced chapter for additional detailed information.
Various citations are made in this field guide, typically in figure captions, to a reference source. Please refer to the References section in the corresponding
chapter of EPRI report 1012757 for the specifc source reference indicated in the respective citation.
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4. Water-Touched Tubes
4. WATER-TOUCHED TUBES
Water-Touched Tubes
Typical Locations
Possible
Mechanism
Chapter in
Volume 2
Thick-Edged Fracture
Surface
Thick-edged or large window
blowout (pinhole leak or
circular cracking is also
possible)
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10
19
Typical Locations
High heat flux areas; hot side of tube; horizontal or
inclined tubing; pad welds; locations with local flow
disruptions such as upstream of weld, backing ring, or
other discontinuities.
Possible
Mechanism
Chapter in
Volume 2
Hydrogen Damage
22
Thick-edged
26
Thermal Fatigue in
Economizer Inlet Headers
27
4. WATER-TOUCHED TUBES
11
Water-Touched Tubes
Typical Locations
Possible
Mechanism
Chapter in
Volume 2
Thick-edged
35
Thick-edged
Thermal-Mechanical Fatigue
28
Thick-edged
Water Blower
Thermal Fatigue
29
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12
Typical Locations
Possible
Mechanism
Chapter in
Volume 2
Thin-Edged
Fracture Surface
Thin-edged, longitudinal,
cod-or fish-mouth
Polishing of tube outside surface; very localized Near side and rear walls; near economizer banks; near Fly Ash Erosion
damage, wastage flats.
plugged or fouled passages; where previous baffles have
been installed; driven by high local velocities.
21
23
Caustic Gouging
24
25
4. WATER-TOUCHED TUBES
13
Water-Touched Tubes
Typical Locations
Chapter in
Volume 2
Thin-edged rupture
Thin-edged, fish-mouth
Generally thin-edged
Highest heat flux locations above locations such as the Short-Term Overheating
site of a tube or orifice blockage or in horizontal tubing
where a downcomer steam slug can occur.
34
Thin-edged
38
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14
Possible
Mechanism
Flow-Accelerated Corrosion
32
Sootblower Erosion
33
Typical Locations
Possible
Mechanism
Chapter in
Volume 2
Thin-edged
External erosion or mechanical impact damage Sloping wall tubes and/or ash hopper near bottom.
features.
40
Thin-edged
41
36 or 37
Pinhole Damage
Pitting
Internal tube surface damage; distinctive aspect Locations where boiler water can stagnate during unit
ratio of damage - deep relative to area; partial shutdown (pitting).
or total (through-wall) dissolution of the tube
wall metal may be observed.
4. WATER-TOUCHED TUBES
15
Water-Touched Tubes
Typical Locations
Possible
Mechanism
Chapter in
Volume 2
Miscellaneous
Damage Types
Depends on underlying cause Usually obvious from type of damage and
correspondence to past maintenance activity.
Maintenance Damage
Chap. 61,
Volume 3
Depends on defect
Materials Flaws
Chap. 62,
Volume 3
Welding Flaws
Chap. 63,
Volume 3
Usually thick-edged
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16
4. WATER-TOUCHED TUBES
Figure 19-4
Thick-edged failure by corrosion fatigue (Type iii).
Source: TR-100455 V4, 1993
Micro Features
Multiple, transgranular cracks
Cracks usually wide
Cracks usually oxide filled and blunt tipped
Crack profiles usually irregular
Signs of discontinuous growth, re-initiations (beach marking)
17
Water-Touched Tubes
Figure 19-9
Schematic showing the general features of corrosion fatigue cracks.
Source: Moles, 1980
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Figure 19-31
Radiograph clearly showing the presence of corrosion fatigue cracks at a
tube/lower windbox connection.
Source: EPRI TC/Set-Aside Project on Corrosion Fatigue Report
4. WATER-TOUCHED TUBES
19
Water-Touched Tubes
Figure 19-32
Pad weld repair showing renewed
corrosion fatigue crack growth
Source: TR-100455 V4, 1993
20
Table 19-4
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
Excessive strains/stresses
Subcooling (cooling water stratification) in natural
circulation boilers
Perform NDE and selective sampling to see if cracking has Replace damaged tubes in-kind only if a system emergency
initiated at suspect locations and to size cracks.
exists for the unit.
Field test with thermocouples and strain gauges to evaluate Do not pad weld corrosion fatigue leaks (pinholes).
levels of strain developed during all operating regimes,
including all transients.
Perform global and local finite element stress analysis using
as-built configuration and field measured strains and
temperatures.
4. WATER-TOUCHED TUBES
Same as above.
21
Water-Touched Tubes
Actions to Confirm
Environmental Factors
Poor water chemistry
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22
Review water chemistry logs and practices, with particular Same as above.
emphasis on pH reductions during shutdown and early
startup.
Estimate the severity of the environment using the
environmental parameter for the Influence Diagram.
Evaluate timing of environmental contributors at various
strain levels. Use NDE or selectively sample tubes to
determine whether pitting or corrosion fatigue damage has
begun.
Actions to Confirm
4. WATER-TOUCHED TUBES
23
Water-Touched Tubes
Figure 19-34
Influence diagram for corrosion fatigue in waterwall tubes. The lines E1E4
represent the results of the environment parameter evaluation. Line E1 is
approximately equivalent to operating with EPRI guidelines or better.
Decreasing water chemistry is represented by E2E4. Conditions to the right of
a particular environment line indicate a high risk for corrosion fatigue or
confirm that corrosion fatigue has already occurred. Conditions to the left of a
given environment line indicate a lower risk of corrosion fatigue.
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Figure 19-36
Strain gauge and thermocouple monitoring locations on a buckstay
attachment detail.
Source: EPRI TC/Set-Aside Project on Corrosion Fatigue
Table 19-6
Potential Ramifications
Corrosion Fatigue Aspect
4. WATER-TOUCHED TUBES
Potential for boiler tube damage by other mechanisms such as acid phosphate corrosion,
if underlying problem is phosphate hideout, or hydrogen damage such as via condenser
leakage.
Potential for carryover in steam to reheater and turbine.
25
Water-Touched Tubes
26
Figure 21-3
Example of extensive damage to shields caused by fly ash erosion.
Source: J. Drennen
4. WATER-TOUCHED TUBES
27
Water-Touched Tubes
For a constant ash loading, increasing particulate velocity from ~18.3 m/sec (~60 ft/sec) to ~27.4 m/sec (90 ft/sec) can triple the rate of fly ash
erosion.
At a constant velocity, doubling the ash loading will double the erosion rate.
Table 21-3
Fly Ash Composition Affects the Erosion Rate
Controllable* Factors
Constant* Factors
Temperature profile
Ash flux
Mode of operation
Target shape
Angle of impingement
* Controllable factors include those that can be changed during the design process or by operating choices; constant factors are those that are not likely to change without fundamental
modifications once the boiler is built.
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Table 21-1
Typical Locations for Fly Ash Erosion
Economizer / Superheater / Reheater
Leading edges of all tubes
All pendant SH/RH surfaces, especially bottom bends at exit from furnace nose to rear pass
Rear pass RH/SH and economizer; tube bends (all rows) adjacent to back wall of rear pass
Staggered tube bank configurations (economizer); sides of tubes in accessible top rows and
often of tubes in middle of the tube bank.
Staggered tube bank configurations (economizer); sides of tubes in accessible top rows and
often of tubes in middle of the tube bank.
Rear pass SH/RH and economizer; tube bends (all rows) adjacent to back wall of rear pass
Near tube bank stiffeners (wrapper tubes in pendant banks; antivibration bars in horizontal
banks)
4. WATER-TOUCHED TUBES
29
Water-Touched Tubes
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Figure 21-5
Typical boiler locations where fly ash
erosion can occur.
Table 21-4
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
Visual inspection in areas near erosion problem for obvious Repair, replace, align damaged components.
distortions, misalignments, etc.
Apply CAVT.
4. WATER-TOUCHED TUBES
31
Water-Touched Tubes
Actions to Confirm
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32
Actions to Confirm
Review prior maintenance activities to document such palliative Temporary pad weld, spray coating, or shielding may be used.
techniques.
These are not recommended for the long term as they will most
likely lead to continual repairs.
4. WATER-TOUCHED TUBES
33
Water-Touched Tubes
Figure 21-11
Erosion locations on a side elevation
drawing, also showing subsequent
application of distribution and
diffusing screens.
Source: TR-102432, 1994
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34
35
Water-Touched Tubes
Figure 22-8
Hydrogen damage window opening and thick-edged failure. It occurred just
downstream of a butt weld. (Flow is right to left).
Source: D.E. Hendrix
Figure 22-2
Hydrogen damaged tube showing thick-edged final fracture. Note that there
was a tube bend just out of view of the photograph.
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Table 22-2
Contributing Causes/Susceptible Components
Location/Tube Condition
Locations where the water/fluid flow adjacent to the tube wall is disrupted
Welded joints and welding processes
(i) welded joints with backing rings
(ii) poor repair welds including pad welds, canoe pieces, or window welds
(iii) poor weld overlay (penetrating to the inside surface)
(iv) weld overlay on relatively thin wall that, because of high heat input, results in waviness on the tube ID
Locations with existing internal deposits caused by
(i) a deposition mechanism
(ii) deposits left from improper chemical cleaning
(iii) locally high heat flux/transfer
(iv) locally high steam quality
Geometric features
(i) bend around burners or openings
(ii) sharp changes of direction (such as the nose of the furnace)
(iii) tubes bending off lower headers and drums
4. WATER-TOUCHED TUBES
37
Water-Touched Tubes
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4. WATER-TOUCHED TUBES
39
Water-Touched Tubes
40
Table 22-3
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
Flow disruption:
Weld backing bar/ring
Poor weld geometry, pad welds, canoe piece
repairs, etc.
Weld overlay on tube OD
Deposits
Locally high heat flux or steam quality
Bends or sharp changes in tube direction
Horizontal or near horizontal tubing
Local regions of DNB
Fireside conditions:
Flame impingement
Burner misalignment
Change in heat flux patterns following
installation of low NOX burners
Major change in fuel source
4. WATER-TOUCHED TUBES
41
Water-Touched Tubes
Actions to Confirm
Evaluate cation conductivity and/or sodium in the hotwell or at Depending upon severity, initiate established procedures for unit
the condensate pump discharge.
shutdown and chemically clean, as needed.
Condenser leaks: major ingress, generally one serious Confirm from chemistry control logs, especially the extent and Immediate shutdown of unit, confirm pH depression, and
event
depth of pH depression in boiler water.
chemically clean.
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Figure 22-11
Typical locations of hydrogen damage in conventional
units.
Figure 22-17
Schematic of the ultrasonic velocity change technique to detect hydrogen
damage.
Source: Lamping, 1991
4. WATER-TOUCHED TUBES
43
Water-Touched Tubes
Table 22-5
Potential Ramifications
Hydrogen Damage Aspect
Actions Indicated
Poor feedwater chemistry control (probably iron levels at the Implement stricter cycle chemistry control program, core level of
economizer inlet are > 2 ppb)
instrumentation, etc.
High Cu levels in deposits might indicate Cu deposition in HP turbine Develop monitoring program to optimize feedwater chemistry.
Contaminant ingress
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Appearance
Features of failure
Caustic concentrates at base of deposit and leads to dissolution of protective oxide via
fluxing.
Deposit usually contains distinctive crystals of sodium ferroate and/or sodium ferroite.
Attack rate
4. WATER-TOUCHED TUBES
45
Water-Touched Tubes
Figure 23-1
Example of acid phosphate corrosion showing tube gouging. Tube is from a
400 MW boiler with an 18.2 MPa (2640 psig) drum pressure. The severely
corroded region was approximately 2.5 cm x 10 cm (1 in. x 4 in.) in extent. The
stepped pattern on this ribbed tube is typical of that which occurs by dryout.
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Figure 23-2
Acid phosphate corrosion damage. The railroad track pattern of corrosion is
indicative of local steam blanketing.
Table 23-2
Contributing Causes/Susceptible Components
Location/Tube Condition
Locations where the water/fluid flow adjacent to the tube wall is disrupted
Welded joints and welding processes, such as the following:
(i) welded joints with backing rings
(ii) poor repair welds, including pad welds, canoe pieces, or window welds
(iii) poor weld overlay (penetrating to the inside surface)
(iv) weld overlay on relatively thin wall that, because of high heat input, results in waviness on the tube ID
Locations with existing internal deposits caused by the following:
(i) a deposition mechanism
(ii) deposits left from improper chemical cleaning
(iii) locally high heat flux/transfer
(iv) locally high steam quality
Geometric features, including the following:
(i) bends around burners or openings
(ii) sharp changes of direction (such as the nose of the furnace)
(iii) tubes bending off lower headers and drums
4. WATER-TOUCHED TUBES
47
Water-Touched Tubes
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Figure 23-11
Typical boiler locations where acid phosphate corrosion
can occur in conventional units.
Figure 23-3
Acid phosphate corrosion gouging showing concentric bathtub rings. The fact
that these rings are visible on the sides of the tube up to the mid-diameter
indicates that at some point steam blanketing encompassed the upper half of
the tube. Gouging and a pinhole leak occurred within the concentric rings.
4. WATER-TOUCHED TUBES
49
Water-Touched Tubes
Table 23-3
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
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Actions to Confirm
Phosphate Concentration
Evaluate boiler water; black boiler water samples are an Depending upon severity, initiate established procedures for
indication that severe corrosion is taking place over large
unit shutdown and chemical clean, as needed.
areas of the waterwall.
4. WATER-TOUCHED TUBES
51
Water-Touched Tubes
Table 23-5
Potential Ramifications
Acid Phosphate Corrosion Aspect
Actions Indicated
Excessive deposits
Phosphate hideout
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Poor feedwater chemistry control (probably iron levels at the Implement stricter cycle chemistry control program,
economizer inlet are >2 ppb)
instrumentation, etc.
High Cu levels in deposits might indicate Cu deposition in HP Develop monitoring program to optimize feedwater chemistry.
turbine
Only a control problem by itself; however, chasing the hideout Optimize phosphate treatment without
problem through the use of mono- and/or an excess of di- excessive use of phosphate additions.
sodium phosphate can lead to excess phosphate throughout
the boiler with possible carryover into the turbine.
If associated with pH decreases during a startup, then there is
a possibility of increasing corrosion fatigue.
Table 23-2
Potential Ramifications
Acid Phosphate Corrosion Aspect
Actions Indicated
Figure 23-9
Acid phosphate corrosion damage. The railroad trackpattern of corrosion
is indicative of local steam blanketing.
4. WATER-TOUCHED TUBES
53
Water-Touched Tubes
Appearance
Features of failure
Caustic concentrates at base of deposit and leads to dissolution of protective oxide via
fluxing.
Deposit usually contains distinctive crystals of sodium ferroate and/or sodium ferroite.
Attack rate
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Figure 24-2
Cross-section through the thick, layered deposit shown
in figure at left.
Source: TR-102433, 1993
Figure 24-10
Cross-section through the failed tube showing the internal attack that
occurred. The following figures show detail of the thick deposit and scale at the
failure location.
4. WATER-TOUCHED TUBES
55
Water-Touched Tubes
Table 24-2
Contributing Causes/Susceptible Components
Location/Tube Condition
Locations where the water/fluid flow adjacent to the tube wall is disrupted
Welded joints and welding processes, including the following:
(i) welded joints with backing rings
(ii) poor repair welds, including pad welds, canoe pieces, or window welds
(iii) weld overlay on relatively thin wall that, because of high heat input, results in waviness on the tube ID
Locations with existing internal deposits caused by the following:
(i) a deposition mechanism
(ii) deposits left from improper chemical cleaning
(iii) locally high heat flux/transfer
(iv) locally high steam quality
Geometric features, including the following:
(i) bend around burners or openings
(ii) sharp changes of direction (such as the nose of the furnace)
(iii) tubes bending off lower headers and drums
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4. WATER-TOUCHED TUBES
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Water-Touched Tubes
Figure 24-3
Needle-shaped crystals in the deposits.
Source: TR-102433, 1993
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Figure 24-1
Thick deposits and gouged tube metal on the downstream side of a weld. A
large amount of copper is deposited, and the deposit is laminated.
Source: TR-102433, 1993
Table 24-3
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
4. WATER-TOUCHED TUBES
59
Water-Touched Tubes
Actions to Confirm
Review plant chemistry control logs, on-line cycle chemistry As above, plus reduce levels of NaOH addition to Caustic
records, or instrumentation alarms.
Treatment Guidelines
As above.
As above, plus:
Use blowdown more effectively to minimize NaOH additions.
Investigate the need to use NaOH on startups. The optimum
approach is to remove the reason that NaOH is added
(perhaps air in leakage)
Water treatment plant upset leading to high pH condition Check/confirm operation and records of regeneration of water Shut down unit, remove excess sodium hydroxide, flush unit a
(regeneration of condensate polishers or makeup water treatment plant equipment.
number of times until water is within specification, then
ion exchange resins, for example)
investigate the need to chemically clean unit.
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Figure 24-5
Typical boiler locations where caustic gouging can
occur in conventional units.
Figure 24-8
Schematic of caustic gouging beneath a region of heavy deposition.
Depending on the rate of corrosion, there may be a layer of protective
Fe3O4 beneath the concentrated NaOH.
4. WATER-TOUCHED TUBES
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Water-Touched Tubes
Table 24-5
Potential Ramifications
Caustic Gouging Aspect
Actions Indicated
Excessive deposits.
Potential for carryover into steam; damage to austenitic SHs Consider additional sodium monitoring for feedwater, boiler
and to turbine.
water, and steam.
Ensure that steam limits for sodium (2 ppb) are not exceeded.
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Poor feedwater chemistry control (probably iron levels at the Implement stricter cycle chemistry control program and
economizer inlet are >10 ppb)
instrumentation.
High Cu levels in deposits might indicate Cu deposition in HP Develop monitoring program to optimize feedwater chemistry.
turbine
Actions Indicated
Same as above
Same as above
Same as above
4. WATER-TOUCHED TUBES
63
Water-Touched Tubes
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Figure 25-1
Typical appearance of damage caused by waterwall fireside corrosion.
Figure 25-2
Cross-section through a tube affected by severe fireside corrosion showing
significant wall loss.
4. WATER-TOUCHED TUBES
65
Water-Touched Tubes
Table 25-1
Contributing Causes/Susceptible Components
Summary of Factors Affecting Waterwall Corrosion in Boilers Staged with Low NOx Combustion Systems
Sources: TR-111155, 1998; Bakker, 2004; Bakker, 2003; Kung, 2000; Bakker, 2002
Main factors
FeS and alkali chlorides in deposits and CO and HCl in the flue gas are the main factors increasing waterwall wastage rates.
FeS deposition
FeS deposition increases with increased staging, thus increasing both wastage rates and the area affected by corrosion.
Corrosion rates increase rapidly with increasing FeS content up to 20%; at higher FeS levels, wastage rates increase further, but at a
lower rate.
Effect of amount of Cl
Corrosion rates increase rapidly with increasing chloride content up to 2%. At higher chloride levels, wastage rates increase further,
but at a slower rate.
Effect of stoichiometry
FeS deposits form under reducing conditions but decompose under subsequent oxidizing conditions to produce very corrosive species.
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Sources: TR-111155, 1998; Bakker, 2004; Bakker, 2003; Kung, 2000; Bakker, 2002
Reducing conditions needed
Reducing conditions are needed for FeS and alkali chloride deposition.
Temperature effect
Both FeS and alkali chlorides are less stable at higher temperatures, with little or no deposition occurring above 900C (1652F).
Thus FeS and chloride deposition decrease with increasing deposit thickness. Chlorides, and to a lesser extent FeS, will deposit only on
bare or nearly bare tubes under high heat absorption conditions.
HCl in the flue gas increases corrosion rates. The rate of increase is proportional to the amount of chloride in the deposit. Without
chloride in the deposits, the effect of HCl in the flue gas is minimized.
Role of H2S
Corrosion caused by H2S in the flue gas cannot be neglected, but is generally less than 0.5 mm/yr (20 mils/yr) for supercritical
boilers. Modeling studies have indicated that measures to reduce FeS deposition may also reduce H2S levels near the furnace wall
4. WATER-TOUCHED TUBES
67
Water-Touched Tubes
Figure 25-3
The general structure of the corrosion scale formed
on a furnace waterwall tube under fireside
corrosion conditions, which are usually related to a
reducing environment. Scale thickness is
approximately 0.25 mm (0.01 in.).
Adapted from Cutler, 1978
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Figure 25-4
Grooving of the tubes external surface, known as
alligator hide, associated with oil and coal-ash
corrosion. The fireside oxide scale and ash deposit
were removed by glass bead blasting.
Source: TR-102433, 1993
Figure 25-5
Sample of highly corroded tube showing wall loss
and fireside surface appearance. Note the rounded
pits on the surface.
Table 25-2
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
Collect and evaluate samples of fireside scale/ash to determine Choose repair strategy based on the severity of the corrosion
concentration, patterns, and melting points of elements and rate and extent.
compounds n present.
Use corrosion probes to monitor wastage.
Substoichiometric (reducing)
EnvironmentAll Causes
Monitor for levels of O2, CO, H2S, and HCl along damaged or As above.
susceptible locations.
Field testing to detect combustion conditions in susceptible areas
with waterwall deposition probes to collect deposits.
Establish a combustion fluid dynamics model and use the
model to evaluate potential improvements in combustion
parameters.
4. WATER-TOUCHED TUBES
69
Water-Touched Tubes
Actions to Confirm
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Use visual and metallographic analysis to determine whether As above, plus adjust mill classification.
carbon particle impingement is occurring.
Analyze coal fineness.
Actions to Confirm
Flame impingement
Excessive buildup of waterside deposits, such as ripple magnetite Chemically clean waterwalls.
(this should occur only on boilers where the feedwater treatment
has not been changed to oxidizing AVT (O) or oxygenated
treatment).
4. WATER-TOUCHED TUBES
71
Water-Touched Tubes
Actions to Confirm
Excessive sootblowing
Review of the coal and coal ash chemistry (proximate and Adjust mills to decrease grind size.
ultimate analyses and ash chemistry) for the coals currently
being used and that were used prior to the occurrence of
the fireside corrosion.
Perform an analysis of the scales being formed.
Determine coal fineness.
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Actions to Confirm
Monitor for levels O2, CO, H2S, and HCl along damaged or
susceptible locations as a function of various load conditions.
Establish a combustion fluid dynamics model and use the
model to evaluate various operating regimes.
4. WATER-TOUCHED TUBES
73
Water-Touched Tubes
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Figure 25-6
Typical boiler locations where fireside corrosion can occur.
Table 25-4
Potential Ramifications
Waterwalls Fireside
Corrosion Aspect
Actions Indicated
Overheating in tubes.
Alert of poor feedwater treatment or controls.
4. WATER-TOUCHED TUBES
75
Water-Touched Tubes
Figure 25-7
Strategies for preventing repeat failures by waterwall fireside corrosion in
coal-fired plants.
Note: The circled numbers are used to identify options for the discussions
presented in EPRI report 1012757, and no ranking of the possible solutions is
thus implied.
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4. WATER-TOUCHED TUBES
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Water-Touched Tubes
Figure 26-1
Circumferentially cracked waterwall tubes from an 800 MW supercritical boiler.
Source: TR-104442, 1995
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Figure 26-2
Thermal fatigue cracking through a 622 weld overlay and into the base tube
(T11).
Figure 26-4
Cross-section showing the
typical appearance of
cracking: sharp-pointed
features and the oxide (dark)
and sulfide (light) corrosion
products.
Figure 26-7
Appearance of thick internal oxide common in recent cases of thermal
fatigue. The left hand photograph shows the ID of the tube on the
furnace side, and the arrows indicate the extent of oxide was 0.14 mm
(5.5 mils). The right hand photograph shows the ID of the tube on the
casing side with an oxide layer (shown by the arrows) of 0.25 mm
(1 mil) thickness.
Figure 26-5
Closeup of typical cracking indicating the
appearance at the crack tip and presence of a minor
amount of intergranular sulfidation at the tip. The
right of the two photographs is of etched material.
Source: TR-104442, 1995
4. WATER-TOUCHED TUBES
79
Water-Touched Tubes
Figure 26-10
Location of thermal fatigue cracking relative to the
position of the fireball.
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Figure 26-9
Typical areas of supercritical
waterwall thermal fatigue.
Source: Plumley, 1991
Table 26-1
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
All causes
Measure total tube metal thickness, including weld overlay, Apply thinner layers of protection or alternates.
and correlate to locations of thermal fatigue damage.
Measure tube temperatures at susceptible locations using
chordal thermocouples.
4. WATER-TOUCHED TUBES
81
Water-Touched Tubes
Actions to Confirm
Inspect furnace waterwall slag patterns for evidence of flame Adjust burners, etc.
impingement.
Compare heat flux patterns.
Monitor the flame profile and extent of flame impingement.
Install a number of heat flux meters at representative
locations and compare results with CFD heat flux map of
waterwalls.
Analyze tube samples and deposits, specifically to determine Perform chemical cleaning if indicated by level of deposits that
the presence of rippled magnetite, thick oxide layers, or has formed. Plot pressure drop before and after.
corrosion products. This should include chemical and Perform chemical cleaning of thick (steamlike) oxides.
metallurgical examination.
Evaluate unit pressure drop.
Evaluate unit chemical cleaning frequency and records.
Evaluate cycle chemistry, including monitoring records, to
determine the cause of ripple magnetite or feedwater
corrosion product deposits.
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Actions to Confirm
Analyze tube and fluid temperature transients to determine Monitoring of temperature and heat flux to identify time in
effective midwall and tube crown temperatures.
operating space when thermal transients occur.
Review plant records for indications of the source of the
problem.
4. WATER-TOUCHED TUBES
83
Water-Touched Tubes
Actions to Confirm
Use instrumented tube/panel and measured thermal transients Perform periodic testing of sootblowers to ensure proper function
along with thermal analysis to estimate local stresses created of the water removal system.
within the wall and at the crown. With the predicted
local stresses and frequency of blowing operations, the life of
the tubes can be predicted by fatigue analysis.
Perform visual examination to detect extent of problem and
identify any obvious deficiencies in the operation or
maintenance of the equipment.
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Actions to Confirm
Flame instabilities
Monitor the flame profile and extent of flame impingement Adjust burners, etc.
using a tube/instrumented panel.
Compare heat flux patterns.
Review unit operating records for conditions outlined above to Modify operating regimes in conjunction with results from
identify potential sources of excessive cyclic stresses.
instrumented tube/panel.
Monitor temperatures and strains during all unit transients
using instrumentation.
Fireside Environment
4. WATER-TOUCHED TUBES
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Water-Touched Tubes
Table 26-2
Potential Ramifications
Waterwalls Thermal Fatigue Aspect
High levels of feedwater corrosion products
Actions Indicated
Figure 26-19
Close-up view of cleaned area of a tube with thermal fatigue cracks showing the
radiographic crack indications, their visual crack mouth appearance, and the
measured crack depth. Note that a longitudinal saw cut was made through the
tube.
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Figure 27-2
Damage developed from a tube penetration in an economizer inlet header.
4. WATER-TOUCHED TUBES
Micro Features
Straight transgranular cracks filled with oxides
Longitudinal cracking propagating radially from ID to OD of stub tube
Figure 27-1
Cross-section through economizer inlet header and tubes showing stub tube
leak location and typical longitudinal pattern of cracking in the tube and
header bore.
Source: Dooley, 1981
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Water-Touched Tubes
Table 27-2
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
Stress concentrations
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Confirm mechanism.
Inspect to determine the extent of damage (fiber
optic is the usual first approach).
For minor damage, replace tube, modify operating
procedures, and institute long-term monitoring.
For major damage, replace header, modify
operating procedures, and institute long-term
monitoring.
Possible header redesign to lower stress
concentrations and stress levels caused by
temperature differentials (when replacing
header).
Figure 27-3
Typical thermal fatigue cracking morphology.
Note regular spacing of cracks and that they
become thinner and straighter with
propagation.
Potential Ramifications
Figure 27-7
Inspection methods and areas
to be inspected. (MP)
magnetic particle inspection,
(DP) dye penetrant inspection.
Source: GS-5949, 1989
Figure 27-6
Schematic of typical thermocouple locations on the economizer inlet header.
Thermocouple locations are designated by a letter (S, F, R) followed by an
identifying number.
Source: GS-5949
4. WATER-TOUCHED TUBES
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Water-Touched Tubes
Thick-edged failures.
Circumferential cracking initiated on OD.
Appearance of beach marks is typical, but they may be obliterated by oxidation.
Figure 28-1
Fatigue failure of a wall tube from a once-through boiler. The tube is a finned
tube and forms part of a manhole door opening. The failure initiated on the OD
of the tube at the toe of the fin/tube weld. The tube is shown here with the fin
removed by mechanical grinding to allow removal from the boiler.
Source: J. Hickey, Irish Electricity Supply Board
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Figure 28-2
Micrograph taken through the crack showing transgranular cracking typical of
fatigue.
Source: J. Hickey, Irish Electricity Supply Board
Figure 28-4
Three possible locations for tubing-related fatigue
failures in tight 180 bends.
Figure 28-3
Typical spacers or sliding supports where fatigue in
water-touched tubing can occur.
4. WATER-TOUCHED TUBES
Figure 28-5
Schematic illustrating failures caused by inflexibility
to the movement between header and waterwall.
91
Water-Touched Tubes
Table 28-2
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
Visual examination for distortion or bending in adjacent tubes. Identify similar damaged locations.
Strain gauging of suspect locations to evaluate strains during unit Repair/replace affected tubes.
starts and cycling operation.
LVDT measurements to monitor the relative movement of the
header/tube during transients.
Potential Ramifications
None for this mechanism
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As above.
Figure 29-1
Typical appearance of the
waterwall tube thermal
fatigue cracks caused by
water blowing.
4. WATER-TOUCHED TUBES
93
Water-Touched Tubes
Damage is usually found in waterwall tubes cleaned with water blowers. Carbon steel tubes (e.g., SA 21- A1) are much more susceptible than low
chromium alloy (e.g., SA 213 T-2).
Figure 29-2
Close-up of damage showing portions with exclusively water cannon damage
and portions of the tube that were affected by normal circumferential thermal
fatigue and water-cannon-induced thermal fatigue.
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Figure 29-3
Surface appearance of cracking (right hand portion of tube shown in figure to
left).
Table 29-1
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Excessive Operation of Water Blowers
Operation is too frequent.
Progression velocities are too slow.
Flow volumes too large.
Maintenance or blower problems.
Actions to Confirm
Figure 29-4
Microscopic view of typical
water-cannon-induced thermal
fatigue cracks. Features
indicated include surface
initiation, circumferential
orientation, narrow v-shape,
oxide-coated, and generally
straight- sided cracks with some
minor side branching in the
deeper cracks.
[1 mil = 0.0254 mm].
4. WATER-TOUCHED TUBES
Potential Ramifications
None for this mechanism
95
Water-Touched Tubes
96
Table 32-2
Distinguishing Features of the Common Damage Mechanisms in Economizer Inlet Headers
Characteristic
Flow-Accelerated Corrosion
Location on header
Long-term monitoring and alarm of through-Anywhere along the first 10-12 cm (4-5 in.) from
the header inlet.
Nature of damage
Damage morphology
Initiation site
ID initiated.
4. WATER-TOUCHED TUBES
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Water-Touched Tubes
Figure 32-4
Cross-section through the economizer inlet header and tubes showing locations of FAC in the
tubes. The tube bore shows the orange peel appearance. This FAC peaks after a distance of about
2.55 cm (~12 in.) into the tube.
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Table
Contributing Causes/Susceptible Components
Factor
Generally, a higher pH will reduce FAC; an alkaline pH with a positive ORD will minimize FAC.
Temperature
FAC occurs over range of 100C to 250C (212F to 482F) but tends to peak in the range of
150C to 180C (300F to 350F).
Velocity
Under laminar flow, magnetite growth at the oxide/steel interface matches the dissolution
rate, and the corrosion rate is stable. Under turbulent and higher velocity conditions, the flow
disrupts the boundary layer and the magnetite growth cannot match the flow- accelerated
dissolution, exfoliation, and spallation, and FAC occurs.
Mass transfer
Local mass transfer coefficient addresses transport of material (essentially magnetite) from
surface to bulk flow and is dependent in a complex manner on fluid velocity and viscosity, flow
geometry, temperature, and tube surface roughness. Mass transfer is a strong factor with an
exponent of approximately 3.
Geometry
Alloy composition
Even trace amounts of chromium (and copper and molybdenum) can significantly reduce the
solubility of magnetite and therefore FAC. A chromium concentration as low as 0.1 weight
percent in carbon steel can significantly reduce FAC.
4. WATER-TOUCHED TUBES
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Water-Touched Tubes
Table 32-1
Survey Results of FAC Incidents in Fossil Plants in 2006 (2003, 2000, and 1997)
Locations of FAC
FAC any location
Economizer inlet tubing*
Percentage Reporting
70% (60%, 60%, 40%)
23% (25%, 22%)
Tubesheet/tubes in HP heaters*
Deaerator shell*
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13% (7%)
Figure 32-3
Cross-section of the failed tube shown in figure on left. Note the almost
complete absence of protective magnetite on the inside surface.
Table 32-3
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
Review chemistry records and monitoring systems for (i) ORP Visual examination and UT thickness measurements in
<-300 mV or (ii) dissolved oxygen levels approaching 1 ppb susceptible areas.
or less and the presence of a reducing agent.
Replace severely thinned tubes with 1.25% Cr material.
Figure 32-1
Appearance of an economizer inlet tube that failed by FAC. The weld is the
header nipple weld about 5 cm (~2 in.) from the header. The orange peel
appearance of FAC is clearly visible.
4. WATER-TOUCHED TUBES
Figure 32-11
Economizer inlet tube removed from a conventional fossil unit that had
previously experienced FAC damage. This drum unit was converted from
reducing AVT (with a reducing agent) to an oxidizing AVT. As a result, and as
can be seen here, the protective magnetite, previously lacking, has been
restored. Importantly, no further loss of wall thickness occurred after operating
on the oxidizing AVT for a year.
101
Water-Touched Tubes
Figure 32-12
Road map of activities for
controlling FAC.
Source: 1008082,
2005
Table 32-4
FAC Resistance of Commonly Used Replacement Alloys Compiled in
(TR-106611 R1, 1998) based on (Ducreux, 1982; ANSI B31.1, 1990)
Alloy
Rate (Carbon
Steel)/Rate (Alloy)
Nominal Composition
(Chromium and
Molybdenum only)
0; 0
39 *
76 *
2.25% Cr; 1% Mo
Type 304 **
> 250
18% C
Carbon Steel
Notes:
* These values were determined using the nominal alloy content. ** Type 304 not permitted
in water-wetted applications for an ASME Section I design.
Potential Ramifications
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FAC is a unit-wide problem. Discovery of a problem in one part of the unit must
trigger the initiation of a unit-wide program.
High iron levels in the fluid caused by FAC can cause deposition in HP evaporator
tubes that act as centers for under-deposit corrosion.
4. WATER-TOUCHED TUBES
Potential Ramifications
None for this mechanism.
103
Water-Touched Tubes
Table 33-1
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
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Temperature Range
Fracture Surface
> Design
< Lower critical temperature, A1
Thin-lipped, fish-mouth
Considerable
Thin-lipped, fish-mouth
Considerable
Thick-lipped, fish-mouth
Little
4. WATER-TOUCHED TUBES
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Water-Touched Tubes
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Figure 34-2
Typical locations in conventional
boilers where short-term overheating
in waterwalls can occur.
Table 34-4
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
Inspect orifices in other lower waterwall areas for evidence of Clean orifices.
blockage.
Institute repair and replacement as required.
Check records of pressure drop across boiler circulation
pumps.
4. WATER-TOUCHED TUBES
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Water-Touched Tubes
Table 34-5
Potential Ramifications
Water-Touched Tube ShortTerm Overheating Aspect
Excessive deposits.
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Actions Indicated
Thick-edged failure.
Tend to tunnel inside the tube wall, i.e., their true size will be larger than
inferred by the exposed length on the tube surface.
Description
Micro Features
Macro Features
Typically initiates in high stress locations, notably the outside surface of
tube bends.
Circumferential cracks are common, but longitudinal cracks also have
been observed on economizer bends in conventional units.
Figure 35-1
Low temperature creep in the 135 bend of a
reheater tube.
Source: Hickey, 1995
4. WATER-TOUCHED TUBES
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Water-Touched Tubes
Figure 35-3
Cross-section through a failed reheater tube showing ovality in excess of 8%.
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Table
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
High residual stress
High service stress
High metal hardness
Actions to Confirm
Potential Ramifications
None for this mechanism
4. WATER-TOUCHED TUBES
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Water-Touched Tubes
Figure 36-1
Internal surface of a failed tube exhibiting a rough pitted and scalloped
appearance typical of acid cleaning corrosion. (MAG: 1.2X)
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4. WATER-TOUCHED TUBES
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Water-Touched Tubes
Potential Ramifications
There is a concern for volatile carryover. In conventional units, the chemical carries over and inadvertently cleans the superheater. These steam circuits are
not rinsed; therefore, the material removed by the inadvertent chemical cleaning remains in the tubes and can cause deposits and blockage that result in
short-term overheating and tube failure.
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Table
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
4. WATER-TOUCHED TUBES
115
Water-Touched Tubes
Pitting is associated with exposure to stagnant, oxygensaturated water formed during shutdown.
Pits can be numerous and closely spaced or isolated.
Pits usually covered with caps of corrosion product
(tubercles or nodules).
Pits may undercut the tube surface.
Figure 37-1
Pitting in a carbon steel economizer tube. Pits are covered with caps of
corrosion products (arrow). (MAG: 1.6X)
Source: TR-102433, 1993
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Figure 37-2
Cross-section through a pit showing corrosion product cap and corrosion
products in the pit.
Figure 37-9
Pitting on waterwall tube hot side caused by acid phosphate corrosion.
4. WATER-TOUCHED TUBES
117
Water-Touched Tubes
In conventional units, pitting typically occurs where boiler waste stagnates in the tubes during shutdown and/or layup.
In HRSG units, pitting occurs in any component that is intentionally maintained wet during idle periods or that is intended to be dry but is subject to
incomplete draining or condensation accumulation. Horizontal tubes are particularly susceptible.
Potential Ramifications
Improper shutdown/layup procedures also can lead to problems in other areas, such as feed water heaters, condenser, and turbine.
Table 37-1
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Accumulation of stagnant, oxygenated water with no
protective environment during shutdown
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Actions to Confirm
Analyze corrosion products in and around pits, specifically looking Identify damaged locations.
for presence of hematite.
Replace affected tubes.
Perform critical evaluation of shutdownprocedures and of unit Revise shutdown/layup procedures.
condition during shutdown.
Wear of surfaces where resistant liners or refractory coatings no longer perform their function.
Failure occurs where the remaining tube wall is insufficient to withstand the normal operating stresses.
Features include wall thinning, external wastage flats, little or no surface ash, a shallow layer of surface hardening caused by the particle impact, and in
some case, grooving of the tube surface.
In cyclone burners, impact of the coal particles entrained in the high velocity combustion air can wear out resistant liners and refractory coatings and
erode the subsequently exposed tube surfaces.
Particularly in front- or rear-fired burners, impact of the coal stream, before ignition, erodes the tubes in the throat or quarl region.
Potential Ramifications
4. WATER-TOUCHED TUBES
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Water-Touched Tubes
Table
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
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Actions to Confirm
Visual examination of refractory coatings and wear-resistant Periodic program of inspection and replacement of wear-
liners
resistant liners and refractory coatings
Adjustment of secondary and tertiary air dampers
4. WATER-TOUCHED TUBES
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Water-Touched Tubes
Table 40-1
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
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Perform visual inspection of superheater pendents and boiler Lower boiler load to cause partial freezing and shedding of slag
waterwalls. Determine location of damage on slope tubes and or deposits.
ash hopper.
Correlate extent of damage with variations in coal quality and
boiler operating conditions.
Obtain coal and slag samples for testing.
Perform probe studies to determine the slag potential as a
function of time.
Actions to Confirm
Potential Ramifications
None for this mechanism.
4. WATER-TOUCHED TUBES
123
Water-Touched Tubes
The normal fireside oxide scale will typically be thin or absent in the
affected regions.
The corroded surface of the tube, after removing fire-side deposits, if any,
will have a gouged or orange peel appearance.
The final failure will be over pressurization caused be wall thinning; the
fracture will appear thin-edged, transgranular, and ductile.
The presence of sulfur in ash deposits remaining on the tube is likely
because the attack is typically by sulfuric acid. A white layer of iron
sulfate may be present at the tube to deposit interface.
Figure 41-2
Influence of fuel type and sulfur in fuel on the minimum design tube metal
temperatures to avoid dewpoint corrosion.
Source: Steam, 1972
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Table 41-1
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
Potential Ramifications
All downstream components such as ductwork, air heaters, flue gas cleaning equipment, and stack are at risk for extensive corrosion damage.
4. WATER-TOUCHED TUBES
125
5. Steam-Touched Tubes
5. STEAM-TOUCHED TUBES
127
Steam-Touched Tubes
Typical Locations
Possible
Mechanism
Chapter in
Volume 2
Thick-Edged Fracture
Surface
Thick-edged
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Chap. 35 Volume 2
Typical Locations
Highest temperature locations: near material transitions,
where there is a variation in gas-touched length, in or just
beyond cavities, in the final leg of tubing just prior to the
outlet header.
Possible
Mechanism
Long-term Overheating
(Creep)
Chapter in
Volume 2
44
47
49
5. STEAM-TOUCHED TUBES
129
Steam-Touched Tubes
Typical Locations
Possible
Mechanism
Chapter in
Volume 2
Thick-edged
Fatigue
52
Thick-edged, leak
May have helical fracture path; most commonly Low temperature regions of the SH/RH; adjacent to
in HAZ of C or C-Mo steel tubes, although may weld fusion line at heat- affected zone most common
also be remote from weld; key is microstructure
appearance of graphite particles or nodules.
Graphitization
59
Thick-edged
51
Chap. 21 Volume 2
Thin-Edged Fracture
Surface
Thin-edged (unless creepassisted)
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Typical Locations
Possible
Mechanism
Chapter in
Volume 2
Thin-edged
45
(Coal-fired
units)
46
(Oil-fired units)
Thin-edged
Short-Term Overheating
48
Sootblower Erosion
50
Thin-edged
Rubbing/Fretting
57
5. STEAM-TOUCHED TUBES
131
Steam-Touched Tubes
Typical Locations
Possible
Mechanism
Chapter in
Volume 2
Pinhole Damage
Pitting
Internal tube surface damage; distinctive aspect For pitting: Tubes where condensate can form and
Chemical Cleaning Damage
ratio of damage - deep relative to area; partial or remain during shutdown: bottoms of pendant loops on or Pitting
total (through-wall) dissolution of the tube wall metal either SH or RH, low points in sagging horizontal tubes
may be observed.
58 or 60
61
Various Other
Damage Types
Depends on the underlying
cause
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Maintenance Damage
Typical Locations
Depends on defect
Usually thick-edged or
pinholes
Possible
Mechanism
Chapter in
Volume 2
Materials Flaws
62
Welding Flaws
63
Chap. 21 Volume 2
Thin-Edged Fracture
Thin-edged (unless creepassisted)
5. STEAM-TOUCHED TUBES
133
Steam-Touched Tubes
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Figure 44-1
Typical appearance of a tube failure by LTOC with axially oriented thick-edged
crack.
5. STEAM-TOUCHED TUBES
Figure 44-2
Typical appearance of an LTOC failure in a reheat tube.
135
Water-Touched Tubes
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Figure 44-4
Example of alligator hide appearance of a tube subject to LTOC.
Figure 44-5
Example of wastage flats on a tube subject to LTOC.
Figure 44-6
Example of spheroidized microstructure and creep
cavitation associated with a long-term overheating/
creep failure in 2 Cr - 1 Mo material (MAG: 500X,
Nital etch).
Figure 44-8
Typical grain boundary creep cavitation/
microcracking at and adjacent to a crack.
Source: J. Hickey, Irish Electricity Supply Board
5. STEAM-TOUCHED TUBES
137
Steam-Touched Tubes
Table 44-4
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
All causes of overheating
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Actions to Confirm
Actions to Confirm
5. STEAM-TOUCHED TUBES
139
Steam-Touched Tubes
Actions to Confirm
Selective sampling of suspect locations to verify whether local Clean out tubes and remove source of blockages.
blockage is leading to excessive temperatures.
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As above.
Actions to Confirm
Combustion conditions
Excessive flue gas temperature
Displaced fireball
Delayed combustion
Periodic overfiring or uneven firing of fuel burners
Metallographic analysis.
Monitor gas temperatures with pyrometers or infrared
instruments.
5. STEAM-TOUCHED TUBES
141
Steam-Touched Tubes
Table 44-6
Potential Ramifications
Long-Term Overheating
Aspect
SH/RH tubes are more susceptible to damage from fireside Correct cause of overheating if possible; upgrade to more
corrosion if coal is corrosive.
resistance materials as required.
May change absorption patterns through the SH/RH sections Check temperatures in the redesigned section and other
and may increase temperatures in other circuits.
sections.
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Actions Indicated
Figure 44-9
Schematic representation of steamside oxide thickness versus tube wastage
(wall loss). Such a plot can be used to distinguish between long-term
overheating/creep and fireside corrosion mechanisms. [1 in. = 25.4 mm].
Source: TR-102433, 1993
5. STEAM-TOUCHED TUBES
143
Steam-Touched Tubes
Typically, multilayered fireside scale and ash deposits that are generally tightly bound to tubes at room temperatures and will typically consist of three
layers
1. A hard, brittle, and porous outer layer, which makes up the bulk of the deposit and has a composition similar to that of boiler fly ash.
2. A white intermediate layer consisting of compounds of complex alkali sulfates, including alkali iron trisulfates. When this layer has a chalky
consistency, corrosion has been found to be mild or nonexistent; when fused and semi-glossy, corrosion has been found to be severe.
3. A black, glossy inner layer, composed primarily of oxides, sulfates, and sulfides of iron.
Tube wastage will often be evident and manifested as flat spots on the tube at the 10 oclock and 2 oclock positions (12 oclock is the upstream
position).
Fireside corrosion damage will be primarily distinguished from long-term overheating by the presence of low melting point ash compounds.
Greatest wall loss will generally be seen in tubes that have been operated at the highest temperatures over a period of time.
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Figure 45-1
Schematic representation of fireside corrosion development for superheaters
and reheaters involving a molten intermediate layer (alkalis, sulfates). This case
shows maximum wastage at the 10 and 2 oclock positions.
5. STEAM-TOUCHED TUBES
Figure 45-2
Tube sample exhibiting fireside corrosion. Note the presence of multilayered
scale along with wastage flats at the 10 and 2 oclock positions of the tubes
circumference.
Source: TR-102433, 1993
145
Steam-Touched Tubes
Corrosion will generally be the worst in the highest temperature locations. Parts at highest risk therefore include the following:
Leading sides of all tubes in pendant platens, especially hottest (leading) tubes and steam outlet tubes.
Tubes out of alignment that act as leading tubes.
Tubes in the outlet (final) sections towards the header, because these are at the highest temperatures.
Just prior to a change of material, e.g., in T22 just prior to the austenitic material, as the lower Cr content. material may be operating above its design point.
Wrapper tubes.
Tubes that surround a radiant cavity (i.e., they may pick up more heat).
At bottom bends of platens, especially those facing the fireball.
Tubes with a longer GTL. (GTL is the distance measured along the tube circuit from the inlet header to the point of corrosion. See long-term overheating,
Chapter 44.)
Spacers and uncooled hangers and the fins and studs on tubes.
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Figure 45-6
Typical locations where fireside corrosion can
occur.
Figure 45-3
Two tube sample segments showing fireside corrosion. The left shows the ash
pattern as removed; the right shows the tube with the ash removed. On this
segment, the 12 oclock position shows a smooth contour typical of a fluxing
fireside corrosion reaction, and the 10 and 2 oclock positions show alligator
hide, here indicative of long-term overheating/creep.
5. STEAM-TOUCHED TUBES
147
Steam-Touched Tubes
Table 45-2
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
Collect and evaluate ash and deposits to identify presence of Choose repair strategy based on severity of corrosion rate.
low melting point constituents, particularly alkali iron trisulfates.
Implement long-term actions in conjunction with on-going
Use corrosion probes to monitor deposit compositions and program of remaining life assessment and monitoring.
wastage.
Use NDE measures (typically UT) to identify wall thinning.
Evaluate temperatures across the element (via thermocouple As above; primary emphasis on upgrading to a more resistant
or steamside oxide measurements) to determine if sections material.
particularly near material changes are running too hot.
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Actions to Confirm
Measure oxide scale thickness and use selective sampling to c As in primary list above (repairs followed by long-term strategy)
onfirm the results.
plus chemical cleaning of steamside scale.
Visual examination.
Monitor temperatures.
Consider the use of the cold air velocity technique. See
Chapter 21, Volume 2, on fly
ash erosion for a discussion of the technique.
Check startup probe and that initial gas is limited to 1000F Modify startup procedures if feasible.
(538C) prior to RH flow.
5. STEAM-TOUCHED TUBES
149
Steam-Touched Tubes
Actions to Confirm
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Monitor for levels of O2, CO, H2S, and HCl along damaged or As above, plus:
susceptible locations.
Increase combustion air to avoid reducing conditions (however
Establish a combustion fluid dynamics model and use the model to
may increase corrosion by other mechanisms, and may
evaluate potential improvements in combustion parameters.
adversely affect NOX control).
Actions to Confirm
Perform metallurgical
examination, including
evaluating carbides, and
check for phase
transformations.
Perform microhardness t
traverses.
Evaluate carbon profile
if necessary.
Check for ferromagnetic
response.
F = (C x 1.8) + 32)
1nm = 0.00004mils
1mil = 0.025nm
Figure 45-11
The linear dependence of corrosion rate on coal chlorine content for UK coals
and austenitic steels. 50 nm/hr is approximately 18 mils/yr. Superheater
corrosion as a function of coal chlorine content.
Source: Gibb, 1983
5. STEAM-TOUCHED TUBES
151
Steam-Touched Tubes
Table 45-2
Potential Ramifications
Aspect of SH/RH
Fireside Corrosion
Corrosive coal
Poor combustion
conditions
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Actions Indicated
Combustion adjustments to
improve unit efficiency. See
guidance in (CS-5552, 1988).
Correct mill performance.
Figure 45-4
Grooving of the tubes external surface, known as alligator hide, here associated
with coal ash corrosion. The fireside oxide scale and ash deposit have been
removed by glass bead blasting.
Source: TR-102433, 1993
The tube will usually be coated with multilayered fireside scale and ash
deposits that typically consist of two layers:
1. A hard, brittle, and porous outer layer, which may have alternating
dark/black/blue and light bands
2.
Figure 46-1
General appearance of a 9% Cr final superheater tube containing fireside
corrosion deposits (top of the figure) in an oil-fired boiler after 50,000 hours of
service. The bottom of the figure shows a section of tubing having been acid
cleaned to remove the deposits, and the ring section taken through the
cleaned section shows the general appearance of tube wastage on the outside
surface.
Source: J. Hickey, Irish Electricity Supply Board
5. STEAM-TOUCHED TUBES
153
Steam-Touched Tubes
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Figure 46-4
Typical boiler locations where oil ash fireside
corrosion can occur.
Table 46-5
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
Ash and deposit analysis to identify presence of low melting Choose repair strategy based on severity of corrosion rate.
point constituents, particularly vanadium/vanadium- Implement long-term actions in conjunction with ongoing
sodium and sodium sulfate complexes.
program of remaining life assessment and monitoring.
NDE measures (typically UT) to identify wall thinning and
steamside oxide scale buildup.
Oil Composition
Overheating of Tube
Excessive temperatures caused by steamside oxide
buildup
5. STEAM-TOUCHED TUBES
155
Steam-Touched Tubes
Actions to Confirm
For high temperature laning: monitor temperatures as in (g) Modify operation to correct the specific problem.
above and consider the use of the cold air velocity technique Implement long-term strategy in conjunction with ongoing
(CAVT). Details of the latter can be found in Chapter 21, program of remaining life assessment and monitoring.
Volume 1 on fly ash erosion.
For reheater overtemperature during start sequences: check
the startup probe and limit temperatures to 538C (1000F)
prior to RH flow.
Visual inspection can be used to detect tube misalignments.
Operating Factors
Operation with high levels of excess oxygen and/or
periods of very low excess oxygen
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Actions to Confirm
Excess of unburnt or partially burnt Particles leading to Perform metallurgical examination, including evaluating carbides,
an increase in carburization
and check for phase transformations.
Perform microhardness traverses.
If necessary, evaluate carbon profile.
Check for ferromagnetic response.
5. STEAM-TOUCHED TUBES
157
Steam-Touched Tubes
Table 46-8
Potential Ramifications
SH/RH Fireside Corrosion Aspect
Actions Indicated
Use of additives
Mg-based additives can coat the waterwalls of the furnace and Monitor unit for signs of detrimental effects of additives.
cause a reflection of heat into the convective passes. This could
lead in turn to higher temperatures for SH and/or RH tubes
and an increase in boiler tube failures by long-term
overheating (see Chapter 44).
Additives can also cause increased erosion of burner
components and additive transport lines.
Potential for additional tube failures by longterm overheating Chemically clean unit if necessary
mechanism.
Exfoliation of scale with subsequent carryover into turbine
could lead to solid particle erosion.
Exfoliation could lead to tube blockage and additional SH/RH
failures by a short-term overheating mechanism (Chapter 48).
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Figure 47-1
Typical appearance of a cracked dissimilar metal weld.
5. STEAM-TOUCHED TUBES
159
Steam-Touched Tubes
Table 47-2
Distinguishing Features (Microscopic) of Failures in Fe-Based Stainless Steel and Ni-Base Filler Metals of DMW
Characteristic
Along prior austenite grain boundaries approximately 12 Immediately along weld interface associated with carbide
grain diameters from fusion line
precipitation and creep cavitation
Carbide morphology
Generally Type II
Generally Type I
Nature of carbide
No
Yes
No
Yes
Along prior austenite grain boundaries approximately 12 Immediately along weld interface associated with carbide
grain diameters from fusion line
precipitation and creep cavitation
Generally Type II
Note: Induction-welded DMW will have similar properties to those listed for Fe-based fusion welds above.
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Generally Type I
Figure 47-2
Typical cross-sectional appearance of a dissimilar
metal weld failure after longtime boiler service. This
example is a DMW with stainless steel filler metal.
Note the oxide notch on the OD and the
intergranular cracking adjacent to the weld line.
Source: TR-102433, 1993
Figure 47-3
Further detail of the intergranular creep cracking
adjacent to a pressure weld. Note that the cracking
is oriented normal to the hoop stress.
Figure 47-4
Detailed metallographic appearance of cracking
along the weld fusion line associated with a line of
carbides. This is typically observed in dissimilar
metal welds made with nickel-base filler metals.
Source: D. French
5. STEAM-TOUCHED TUBES
161
Steam-Touched Tubes
Dissimilar metal welds (DMW) between ferritic steels and austenitic stainless steels.
Welds made by induction process have properties similar to those for fusion welding with austenitic filler.
DMW are more suceptible to failure than like material welds due to the following differences:
Thermal expansion
Creep behavior of the joined materials
Local metallurgical cchanges at the low alloy to weld metal interface
DMW are located in the superheater, reheater, vestibule, and penthouse regions of the boiler.
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Table 47-4
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
5. STEAM-TOUCHED TUBES
163
Steam-Touched Tubes
Actions to Confirm
Table 47-5
Potential Ramifications
DMW Aspect
Actions Indicated
Tubes are being subjected to temperatures in excess of Possibility of additional tube failures by mechanisms such as
Evaluate sources of overheating and determine what control
those that were expected by the design.
long-term overheating/creep (Chapter 44) or fireside measures are possible to prevent future failures.
corrosion (Chapter 45 or 46)
Consider installation of additional thermocouples or instituting
periodic oxide scale surveys via UT to monitor tube
temperature progression.
Redesign of SH/RH has changed absorption pattern
within convective pass.
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Ensure that the locations of DMW are known and that the
ramifications to them by any redesign of an adjacent SH/RH
section are known.
5. STEAM-TOUCHED TUBES
165
Steam-Touched Tubes
Figure 48-2
Fish-mouth appearance typical of failures by short-term overheating.
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Table 48-2
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
5. STEAM-TOUCHED TUBES
167
Steam-Touched Tubes
Actions to Confirm
Review repair records and correlate to locations of failures.
Operation-Induced Short-Term
Overheating in SH or RH
Improper shutdown and startup of unit (condensate
collection in SH/RH bends
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Figure 48-4
Bottom bend and debris causing blockage in a conventional unit.
Source: Austra Electric, Australia
5. STEAM-TOUCHED TUBES
169
Steam-Touched Tubes
Table 48-3
Potential Ramifications
Short-Term Overheating Aspect
Presence of thick and exfoliating oxide
Actions Indicated
Potential for solid particle erosion damage to begin in turbine Chemical cleaning of boiler. See Chapter 9, Volume 1.
components.
Remnant life assessment using oxide technique.
Potential for long-term overheating of SH/RH tubes and loss of
tube life.
Figure 48-10
Appearance of thick-section fish-mouth failure in Type 304 superheater tube.
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Micro Features
Crack propagation can be transgranular or intergranular.
Transgranular cracking often exhibits branching.
5. STEAM-TOUCHED TUBES
171
Steam-Touched Tubes
Figure 49-1
Cracking of SA-213 Type 304H base material near the edge of a weld backing
bar in a dissimilar metal weld joint. This tube contained through-wall cracks
after a few weeks of service. The corrodent causing the cracking was suspected
to be a petroleum-based preservative which was not effectively flushed from
the weld backing rings prior to service.
Source: TR-102433, 1993
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Figure 49-2
Intergranular stress corrosion cracking (IGSCC) of an SA-213 Type 304H reheater
tube. Away from the rupture, the IGSCC was limited to the tubes inside surface.
Carryover of chlorides was believed to have been the corrodent responsible for
the cracking.
Source: TR-102433, 1993
Table 49-1
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
5. STEAM-TOUCHED TUBES
173
Steam-Touched Tubes
Actions to Confirm
Visual examination for signs of obvious distress, such as broken or Repair any obvious contributors to excess stress levels.
missing attachments or supports, etc.
Ensure that any redesign of supports, etc. will actually lower the
Review manufacturing process details to evaluate whether imposed stress.
proper heat treatment/annealing procedures were used.
Review field welding procedures for details of post-weld heat
treatment.
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Potential Ramifications
Contamination that has caused SCC in the SH or RH tubes may cause significant damage to other parts of the unit, especially the steam turbine
Figure 49-3
View of the top tubes on the upper bank of the reheater showing the failure,
which was located in an area away from stress concentrations (such as welds or
bends).
5. STEAM-TOUCHED TUBES
Figure 49-4
Closeup view of the damaged location indicating the window-type blowout of
a section of tube.
175
Steam-Touched Tubes
Potential Ramifications
None for this mechanism
Description
Typical failure locations for sootblower erosion in the SH/RH include those
that:
Are the first tubes in from the wall entrance of the retractable blowers.
Are in the direct path of the retractable blowers.
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Figure 50-1
Superheater tube that failed because of sootblower erosion. Note wastage flats
and absence of ash deposits.
Source: TR-102433, 1993
Table 50-2
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
5. STEAM-TOUCHED TUBES
177
Steam-Touched Tubes
Explosive cleaning used in cases of extreme ash deposition on the gas passages of superheater pendent sections.
Explosive impact can induce high strains in the metal leading to immediate brittle fracture failure or to progressive degradation of the base metal
resulting in failure during subsequent cleaning.
May cause exfoliation of tube ID scales that could lead to short-term overheating (Chapter 48).
Recommended that ash deposition problems be resolved prior to reaching point at which explosive cleaning is required.
As a minimum, utilities using explosive cleaning processes need to have specifications in place to detail the allowable practices.
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Figure 51-1
Longitudinal split in the superheat pendent tube.
Figure 51-2
Closeup of the split showing the thick-edged
fracture surface.
Figure 51-3
Cross-section through the leak. No significant wall
thinning or tube deformation was present.
5. STEAM-TOUCHED TUBES
179
Steam-Touched Tubes
Macro Features
Thick-edged failures.
Circumferential cracking initiated on OD.
Appearance of beach marks is typical, but they may be obliterated by oxidation.
Micro Features
Predominately straight transgranular cracks.
Cracking may be intergranular when occurring in creep-damaged materials.
Depending on service conditions, the cracks may be filled with oxides.
180
Figure 52-1
Thermal-mechanical fatigue failure of an SA 213 Type 304H superheater tube.
The portion of the rupture that is missing was believed to have contained a
welded attachment clip.
Source: TR-102433, 1993
Table 52-1
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
Visual examination for distortion or bending in adjacent tubes. Identify similar damaged locations.
Strain gauging of suspect locations to evaluate strains during Repair/replace affected tubes.
unit starts and cycling operation.
LVDT measurements to monitor the relative movement of the
header/tube during transients.
As above
As above
Potential Ramifications
None for this mechanism.
5. STEAM-TOUCHED TUBES
181
Steam-Touched Tubes
Figure 52-3
Three possible locations for tubing-related fatigue failures in tight 180 bends.
Figure 52-2
Schematic showing typical locations of fatigue failures in steam-touched
tubing.
Source: Dooley, 1983
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Figure 52-5
Schematic illustrating failures due to inflexibility of movement between steam
header and waterwall.
Figure 52-4
Fatigue tube failures caused by differential thermal expansion of element
transfer tubes on a header.
Source: Sylvester, 1978
5. STEAM-TOUCHED TUBES
183
Steam-Touched Tubes
Smooth wastage flats on the fireside of the tube; ash and fireside oxide scale may be missing.
Rubbed area may exhibit a concave shape that matches the profile of the adjacent tube.
Occurs where adjacent tubes come into direct metal-to-metal contact. Metal loss results from rubbing/fretting and be accelerated oxidation of the tube
surface where the protective iron oxide is removed by the rubbing/fretting.
Root causes may include (i) misaligned, nonfucntioning, broken, or inadequate tube supports or (ii) misaligned rubbing.
Repair or replace damaged tube.
Repair or replace defective or inadequate supports and correction misalignment.
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Figure 57-1
Region of a tube surface where rubbing occurred (arrow). Note the smooth
appearance and absence of a fireside scale in this region. (MAG: 1.3X)
Source: TR-102433, 1993
5. STEAM-TOUCHED TUBES
Figure 57-2
Side view of the rubbed area. Note the concave surface formed as a result of
the rubbing. (MAG: 1.3X)
Source: TR-102433, 1993
185
Steam-Touched Tubes
Pitting is associated with exposure to stagnant, oxygen-saturated water formed during shutdown.
Pits can be numerous and closely spaced or isolated.
Pits usually covered with caps of corrosion product (tubercles or nodules).
Pits may undercut the tube surface.
Figure 58-1, Figure 58-2
Superheater inlet heater drain with a failure at the neutral
axis. The tube was resting flat on a horizontal support at
this location resulting in oxygen-saturated water remaining
in the tube during shutdown periods of the unit. Typical
pitting on the ID surface of the tube is shown at the right.
Source: J. Hickey, Irish Electricity Supply Board
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Pitting occurs in any component that is intended to be dry but is subject to incomplete draining or condensation accumulation, such as the bottoms of
pendent loops.
Potential Ramifications
Improper shutdown/layup procedures also can lead to problems in other areas, such as feedwater heaters, condenser, and turbine.
Table 58-2
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
Actions to Confirm
Analyze corrosion products in and around pitting, specifically Identify damaged locations.
looking for presence of hematite.
Replace affected tubes.
Perform critical evaluation of shutdown procedures and of unit Revise shutdown/layup procedures.
condition during shutdown. Check logs of chemistry monitoring
during shutdown.
5. STEAM-TOUCHED TUBES
187
Steam-Touched Tubes
Occurs most commonly in the heat affected zones (HAZ) of welds in carbon or carbon molydenum low alloy steel.
Microscopically, the damage is manisfested by brittle fracture along a line of graphite nodules (often termed chain graphitization) that forms along the
HAZ.
Failure is usually circumferential and parallel to the weld, but it can folllow any line of graphite formation.
Thick-edged, brittle failure.
Most prevalent in the low temperature portions of the superheater and reheater
Can occur over long periods of exposure to temperatures in the range of 450700C (~8401290F)
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Figure 59-2
Closeup of graphitization damage.
Figure 59-1
Failures of tubes by graphitization. Note the almost helical nature of the
fractures.
5. STEAM-TOUCHED TUBES
189
Steam-Touched Tubes
Table
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
All causes
Potential Ramifications
None for this mechanism.
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Actions to Confirm
Metallurgical examination on samples removed from service to Replace or repair damaged tubes.
characterize the appearance of graphitization.
Identify those similar locations or welds that may also be at risk
Bend testing of removed samples. Since graphitization results given the failures experienced.
in embrittled material, a bend specimen can be used to
determine qualitatively whether significant damage has
accumulated. A 45 bend at failure is taken as indicative of
severe graphitization damage and a 90 bend of mild
damage.
Fracture toughness testing on miniature specimens removed
from suspect locations. A method to remove small
samples from components for fracture testing using miniature
specimens has been developed (McMinn, 1988). These tests
are harder to apply and interpret than bend testing
but provide a more quantitative approach to flaw tolerance.
Potential Ramifications
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Steam-Touched Tubes
Table
Actions to Confirm and Immediate Actions and Solutions
Major Root Causes
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Actions to Confirm
Review of chemical cleaning procedures,chemical pumping Repairing or replacing the damaged tubes
systems, and chemical control logs. Items of particular concern Immediate chemical cleaning followed by proper neutralizing
are those listed above, which would lead to significant and rinsing
damage.
Review of cycle chemistry monitoring records to detect a
pH depression on startup of the unit after cleaning, indicating
improper rinsing of acid from the unit.
Sampling of affected tubes to allow examination of the inside
surface for evidence of generalized corrosion. Part of an
optimized procedure for chemical cleaning will be sampling
of selected tubes to confirm the efficacy of the cleaning
process. These samples can be used to determine whether
excessive damage has accumulated. Wall thickness
measurements can provide a quick screening as to whether
excessive tube corrosion has occurred.
Figure 61-1
Cross-section of a tube near a rupture; deformation was caused by the impact
of an explosive charge.
Source: TR-102433, 1993
193
Steam-Touched Tubes
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Figure 62-5
Materials flaws can be introduced by the original fabrication process. Here an
electric resistance weld used to join a tube to a membrane results in a lack of
fusion region. Subsequent handling during manufacture can introduce cracks
in the weld heat-affected zone (HAZ), which has a martensitic zone.
Source: Flatley, 1995
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Steam-Touched Tubes
Weld spatter or cutting debris left in tubes; improperly executed weld repairs that leave
material in tubes.
Tube blockage leading to short-term overheating failures in SH/RH tubes (Chapter 48)
Stress riser caused by the toe of a fillet weld or improper geometry to a weld repair.
Mechanical fatigue failures near tubing attachments in SH/RH tubes (Chapter 52)
Weld and attachment design can lead to constraint of thermal stresses and is a contributor to
tube failure.
Contributor to excessive stresses that can cause mehanical fatigue (Chapter 52)
Welding procedures can lead to sensitization of material, or weld defects act as an initiation
site for stress corrosion cracking
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Generally, planar or sharp defects such as cracks, lamellar tears, lack-of-fusion, and lack-of-penetration are the most likely to grow into cracks and propagate to
final failure, particularly in the high residual stress fields that remain after the welding process.
Often, metallurgical analysis is needed to determine whether a welding problem has been at the root cause of a tube failure. A review of the welding
process, welder qualification records, inspection records, and weld material control reports may also provide an indication about whether a weld process
error is responsible for an observed failure.
Detection of a weld shortcoming, once the joint has been placed in service, is difficult. Avoiding weld failures is therefore mostly preventive.
Solution of welding-defect-induced tube failures will consist of removing the problem areas and re-welding with proper techniques. References for welding
in conventional units (1004701, 2003) have been developed.
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Steam-Touched Tubes
Figure 63-2
Example of a poorly
executed pad weld, which
led to tube failure.
Figure 63-1
Example of a pad weld made on a tube with corrosion fatigue; the process
extended the corrosion fatigue crack.
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Prevalence to Date
Fretting
Corrosion fatigue
A few incidences known in non-coal-fired (agricultural waste) units. Fly ash erosion (Chapter 21, Volume 2).
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Steam-Touched Tubes
Figure 64-1
Schematic of a bubbling-bed boiler.
Source: J. Makansi, Special Report: Fluidized Bed Boilers, Power,
March 1991. Reproduced with permission.
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Figure 64-2
A horizontal bottom tube from an atmospheric fluidized bed. The tube
experienced caustic corrosion at the 12 oclock position due to steam
blanketing and additional heat transfer through the top rib. Tube leaks occurred
after only 500 hours of operation.
Table 64-2
Actions to Confirm and Immediate Actions and Solutions
Mechanism: In-Bed Wastage of FBC Tubes
Major Root Causes
Actions to Confirm
Susceptible material
Fuel factors
Excessively hard particles
Excessively angular or sharp-edged
particles
High chlorine content
High alkali contents
Evaluate ash and erosive/abrasive content of fuel. Compare to Determine quartz content and assess fuels erosive/abrasive
design coal.
potential.
Metallographic analysis of tube deposits and bed materials
may provide indicators of key contaminants.
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Steam-Touched Tubes
Table 64-3
Actions to Confirm and Immediate Actions and Solutions
Mechanism: Underdeposit Corrosion in the In-Bed Tubes of FBC Units
Major Root Causes
Excessive deposits due to steam blanketing
Potential Ramifications
Actions to Confirm
Analysis of results from chemistry monitors, mainly for levels of Chemically clean to remove excessive levels of deposits. See
Fe and Cu.
guidance in (1003994, 2001) and summary in Chapter 9,
NDE examination and selective sampling of tubes for deposit Volume 1.
measurements.
Check efficacy of chemical cleaning.
Check circulation ratio and confirm that tube flows are outside
regime of DNB.
Perform metallurgical analysis of tube samples to determine
nature and extent of tube deposits.
Perform metallurgical examination of damaged tubes,
As above, plus:
particularly to determine composition of deposits.
- Move to optimum cycle chemistry as detailed in (1004187,
Analyze cycle chemistry data: plant chemistry control logs,
2002; 1004188, 2004)
on-line cycle chemistry records, chemical additions to boiler,
and instrumentation alarms.
See appropriate chapters; otherwise there are none for these mechanisms.
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Prevalence to Date
Underdeposit corrosion in horizontal tubes of external Some occurrences in external heat exchangers
heat exchangers or cyclone separators in some
designs
Corrosion fatigue
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Steam-Touched Tubes
Two problems have been found in CFB units that are somewhat different from those in conventional plants:
Erosion/abrasion on waterwall tubes, particularly at the interface between the refractory lining on the lower portions of the bed and the waterwall tube
panels
Wear has, in some cases, been extremely rapid, e.g., maximum loss rates up to 1800 mils per year (5200 nm/hr).
Because the problem is not uniform around the walls, inspections to determine the extent of damage must be as comprehensive as possible.
Corrective/preventive acitons have included (i) applying proprietary coatings, (ii) installing shelves above the refractory interface, (iii) reducing the
angle of the tapered region, and (iv) routing the affected tubes outside of the bed.
Potential for damage to external heat exchangers or in the cyclone separator by mechanisms such as wastage, fretting, and fatigue; a particular concern
is waterside corrosion in CFB units with horizontal tubes in these areas.
The potential for horizontal tubing to develop excessive deposits and for concentration of control chemicals (caustic or phosphates) within the deposits
has been extensively discussed in Chapter 64 on BFB. The mechanism, root causes and actions for preventing the development of underdeposit
corrosion in susceptible CFB locations are identical.
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Figure 65-2
Typical wear pattern on the waterwall
above the refractory lining in
circulating fluidized-bed units.
Source: Stringer, 1991
Figure 65-1
General schematic of a circulating fluidized bed.
Adapted from E. Bretz, Power, 133, No. 3, 1989, p. W-8. Reproduced
with permission.
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Steam-Touched Tubes
Fireside corrosion caused by low-melting-point chlorides and sulfates*
Fireside corrosion by combustion gases*
Erosion from excessive sootblowing required by slagging of superheater
tubes*
Fouling that results in flow-channeling, high local velocities, and
subsequently to excessive erosion rates*
Flame impingement from furnace in older units with short furnace zones
Pitting (external) from aqueous corrosion during unit downtime
Notes:
1. * Indicates mechanisms that are specifically discussed in Chapter 66.
2. Not all designs have all these problems; some of the problems are also
specific to older designs, and prevention has been achieved by various
approaches
Figure 66-3
Failure in a 57 mm (2.25 in.) O.D. furnace wall tube
from an RDF-fired boiler showing localized thinning
caused by fireside corrosion.
Source: TR-103658, 1994
Figure 66-1
Schematic of a waste-to-energy combustor
illustrating the typical areas that experience boiler
tube failures.
Source: Wright, 1995
Figure 66-2
Waterwall tubes from a waste-fired boiler showing
thinning from fireside corrosion.
Source: TR-103658, 1994
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