E2. Boiler Tube Failure Part 2
E2. Boiler Tube Failure Part 2
E2. Boiler Tube Failure Part 2
#6 Hydrogen Damage
Thick Edged
Brittle final fracture
Often window opening
Microstructural decarburization
Source: B. Dooley, PPChem101-Boiler and HRSG Tube Failure: Hydrogen Damage, PP Chem 2010 , 12(2)
Source: B. Dooley, PPChem101-Boiler and HRSG Tube Failure: Hydrogen Damage, PP Chem 2010 , 12(2)
1. Excessive Deposition
2. Acidic Contamination
HP & IP Evaporator
#6 Hydrogen Damages
Root Causes & Action to Confirm
Excessive deposits
High iron in BFW and evaporator increasing potential for concentration
mechanism
- Condenser tube leaks where Cl and SO4 enter the boiler
Flow disruption
Selective tube sampling
#6 Hydrogen Damages
Root Causes & Action to Confirm
H2 Damage
Caustic Gouging
Acid Phosphate
Corrosion
Gouged, thick
deposit
Ductile, thin
edged, pin hole
Gouged, thick
deposit
Ductile, thin
edged, pin hole
Deposit
Metal oxide
Rich in caustic
Na-feroate , Naferoite
Acid PO4
2-3 distinct layer
Maricite
Cycle Chemistry
Source of low pH
exist
Source of high pH
exist
DSP, MSP, or
Na:PO4<3.0
Attack Rate
Very rapid10
mm/year
Rapid up to 2
mm/year
Rapid up to 2
mm/year
10
#7 Oxygen Pitting
11
12
Source: R.Port, The Nalco Guide to Boiler Failure Analysis, Mc Graw Hill, Inc., 1991
13
1. Moisture
2. Oxygen
Source: EPRI, Heat Recovery Steam Generator Tube Failure Manual, 2002
14
Prevalent in economizer
15
#7 Oxygen Pitting
Root Causes & Action to Confirm
17
18
Cracks
Can initiate either inside or outside surfaces
Can be oriented circumferentially or longitudinally
May have significant branching
19
Source: R.Port, The Nalco Guide to Boiler Failure Analysis, Mc Graw Hill, Inc., 1991
21
22
Source: H.G. Seipp, Damage in Water/Steam Cycle-Often Matter of Solubility, PP Chem 2005 (7)
23
24
Carbon Steel
Sodium hydroxide
Copper-based Alloys
Ammonia
25
26
Environmental Effects
Chloride: Condenser in-leakage & chemical cleaning
Caustic: Carry over
Stress Effects
Residual stresses: fabrication/welding/heat treatment/bend
Service stresses: especially at attachment & supports
28
29
30
Source: R.Port, The Nalco Guide to Boiler Failure Analysis, Mc Graw Hill, Inc.,
1991
31
Source: R.Port, The Nalco Guide to Boiler Failure Analysis, Mc Graw Hill, Inc.,
1991
32
Source: R.Port, The Nalco Guide to Boiler Failure Analysis, Mc Graw Hill, Inc.,
1991
33
Source: EPRI, Heat Recovery Steam Generator Tube Failure Manual, 2002
34
Susceptible locations:
Tubing nearest to the gas inlet, especially down stream of supplemental
burner (most common leading row SH)
Tubing down steam of bends;etc- where potential blockage is exit
35
Tube blockage
Oxide from exfoliation tube material, chemical cleaning and /or improper
repair
Videoscope & metallurgical analysis to confirm
37
38
Scale
Internal: Extensive, multilaminated & exfoliating
External: Thick, laminated & often longitudinally cracked
39
Source: R.Port, The Nalco Guide to Boiler Failure Analysis, Mc Graw Hill, Inc.,
1991
40
Source: R.Port, The Nalco Guide to Boiler Failure Analysis, Mc Graw Hill, Inc.,
1991
41
Creep Rupture
Plastic deformation during overheating
Produce thick-lipped rupture
42
Source: EPRI, Heat Recovery Steam Generator Tube Failure Manual, 2002
43
44
Tube blockage
Oxide from exfoliation tube material, chemical cleaning and /or improper
repair
Videoscope & metallurgical analysis to confirm
46
Source: R.Port, The Nalco Guide to Boiler Failure Analysis, Mc Graw Hill, Inc.,
1991
47
48
50
Recommended Test
Corrosion Fatigue
Thermal/Mechanical Fatigue
Deposit
FAC
51
Recommended Test
Radiography
Tube removal
Tube diameter measurement (wall
thickness)
52
Nalco SEA
Recent Case of Boiler Tube Failure
53
54
Condensate polisher: no
Two HRSG HP
Evaporator - tube failure in
1 week!
Important Events
November 2010
and confirmed
Steam Drum
May 11
33 wt%
12 wt%
23 wt%
15 wt%
8 wt%
2wt%
4 wt%
1 wt%
<1 wt%
1 wt%
1 wt%
2 wt%
Magnetite-Fe3O4
Magnesium Iron
Oxide (MgFe2O4)
Steam Drum
Sept 11
22 wt%
8 wt%
32 wt%
26 wt%
6 wt%
1 wt%
1 wt%
<1 wt%
1 wt%
1 wt%
1 wt%
Magnetite-Fe3O4
Ca PhosphateCa3PO4
HP Evap-Sept11
(Sample #1)
50 wt%
15 wt%
14 wt%
8 wt%
5 wt%
2 wt%
1 wt%
1 wt%
<1 wt%
HP Evap-Sept11
(Sample #2)
90 wt%
3 wt%
2 wt%
1 wt%
<1 wt%
1 wt%
Magnetite-Fe3O4
Hematite-Fe2O3
Magnetite-Fe3O4
Iron Oxide - FeO
Hematite-Fe2O3
No tube
bulging
Thick edge
Metal loss
under
deposit
Rectangular
Window
Metal loss
under
deposit
Thick edge
Rectangular
Window
Confirmation
Remarks
Yes.
Yes
Yes.
Yes.
Yes.
May 2011
No.
No.
Root Cause
Condenser in-leakage
Increase chloride and sulfate level in BFW and boiler water
Introduce hardness salts into BFW
Introduce O2 into condensate and BFW
Deposition
Hardness
Iron
Copper
Phosphate
Immediate Solution
Chemical cleaning
Proper chemical cleaning method/procedure.
65
66
July 2011
program
68
Location of BTF:
Water Wall
Radiant heat transfer in
front of buner
Highest temperature areas
73
Confirmation
Remarks
Yes.
Yes
Yes.
?
No
Yes
No.
Immediate Solution
78
THANK YOU!