J ES

Mechanical Engineering and Sciences

The International Journal of

http://iptek.its.ac.id/index.php/jmes/index

Failure Analysis of Bend Tube Preheater on Heat Recovery Steam

Generator
R. Sony Endardo Putro1 , Arif Hariyadi2 and Suwarno1,∗
1
Department of Mechanical Engineering, Institut Teknologi Sepuluh Nopember, Surabaya, Indonesia
2
UPHT, PT. Pembangkitan Jawa Bali, Gresik, Indonesia
Received:02 January 2017, Revised:01 February 2017, Accepted:03 March 2017

Abstract
The combined cycle power plant (PLTGU) is the second largest percentage of electrical production
method which is 26% of all electrical production technology in Indonesia. One of the components in
combined cycle power plant is heat recovery steam generator (HRSG), which serves as heat exchanger
between hot gasses from gas turbine cycle and water from steam turbine cycle. There are four stages
on HRSG, preheater, economizer, evaporator, and superheater. In the present work, there is a case
of thinning on a bend tube preheater which exceed the tolerance limits, therefore the purposes of
this research are determine the cause of failure and determine the failure mechanism on bend tube
preheater. Thinning of bend tube preheater occurred due to corrosion from both the inside surface
and outside surface. Corrosion that occurred on the inside surface of bend tube preheater caused by
reaction between water and metal surface of tube. Corrosion on the outside surface could be happen
caused by reaction between hot gas and metal surface of tube. Largest thinning rate occurred on bend
area of bend tube preheater caused by deformation itself, it induces local reduction of breakdown
potential.

Keywords: HRSG; Failure Analysis; Tube thinning; Corrosion

1. Introduction
Combined cycle power plant has both Rankine cycle
by using steam turbine and Brayton cycle by using gas
turbine. One of the components in combined cycle power
plant is heat recovery steam generator (HRSG), which
serves as heat exchanger between hot gasses from gas
turbine cycle and water from steam turbine cycle. There
are four stages on HRSG, preheater, economizer, evapo-
Figure 1. Water and hot gas flow direction on bend tube
rator, and superheater. Preheater serves as preliminary preheater
stage to heat water up to 50◦ C (Figure 1). Bend tube
preheater use Grade ST37.8 from DIN 17177-79 standard
as material specification with dimension specification can
be seen on Figure 2. The initial thickness of bend tube
preheater is 2.9 mm, where the critical thickness is 60%
of initial thickness. After being used for 23 years (1992
- 2015) with standard working condition and operation,
there is a case of thinning on bend tube preheater which
exceed the tolerance limits and have to be replaced. Then,
the purposes of this research are determining the cause
of failure and determine the failure mechanism on bend
tube preheater. Where each of specimen pipes have equal
chemical composition taken as initial condition.

Figure 2. Bend tube preheater dimension specification

∗ Email:[email protected]

Phone/Fax:+62(31)5922941

The International Journal of Mechanical Engineering and Sciences; Vol.1, No. 1 (2017):37-41
 Putro et al./The International Journal of Mechanical Engineering and Sciences/1/1(2017)

2. Experimental Procedures 3. Results and Discussion

Research started with field observation to find out 3.1. Bend Tube Preheater
bend tube preheater location, working condition, and
Bend tube preheater uses DIN 17177-79 with ST
environment condition, and then we took maintenance
37.8 as a material grade, the material grade equivalent
schedule for bend tube preheater. After that, we did visual
with ASTM A178 Grade A. Based on DIN standard, chem-
inspection on inner and outer surface of each specimens
ical composition of specimens stated in Table 1. Based
to find out any cracks or failure condition, and followed by
on DIN 17177-79 standard, the material itself is belong
3D scanning. Then, we took samples from specimens by
to heat resistant low alloy steel which frequently used on
cutting them two-centimeter length and measuring each
heat exchanger tubes with low pressure condition, and so
sample with 12 measuring points on front-side and 12
material is suitable to use as bend tube preheater. From
measuring points on back-side (Figure 3) to find out local
field observation, we got bend tube preheater maintenance
thickness reduction rate. In the end, we did X-Ray Diffrac-
schedule, working condition and environment data stated
tion (XRD) test on inner and outer surface of bend tube
in Table 2. Based on operational data history we conclude
preheater to get chemical compound of corrosion prod-
that specimens working condition within material limits.
uct, and also metallography test to saw corrosion product
Based on working condition and material specifica-
formed on pipe surface. We got 60 cutting samples form
tion we can find critical thickness of bend tube preheater
total 4 specimens, where divided by 15 samples from spec-
with ASME B31.3. From ASME standard calculation, the
imen 1A, 14 samples from specimen 1B, 15 samples from
critical thickness of bend tube preheater is 1.778 mm. So,
specimen 2A, and 16 samples from specimen 2B. From
the standard that company set for material rejection if
total 60 samples we got 1440 measuring points to locate
exceeds 60% was suitable.
local thinning rate on 3D images.

Table 1. Chemical composition and mechanical properties of the failed tube

Grade St 37.8
Chemical Composition (%) C 0,17 max
Si 0,1 – 0,35
Mn 0,4 – 0,8
P 0,04 max
S 0,04 max
Tensile Test (MPa) Min Yield Point 235
Tensile Strength 360 – 480
Elongation in 50 mm (%) 35

Table 2. Material and data operation

Information Data
Material Type Welded Boiler Tube (DIN 17177-79 ST 37.8)
Tensile Strength (MPa) 325
Using Period 23 years (1992 – 2015)
Outside Diameter (mm) 38
Thickness (mm) 2.9
Working Temperature Limit (oC) 180
Pressure Limit (bar) 5.4
Mass Flow Rate (ton/h) 1500
Pressure Limit High (bar) 75.5
Pressure Limit Low (bar) 5.4
Maintenance Schedule Every 8000 Operating Hours

37
 Putro et al./The International Journal of Mechanical Engineering and Sciences/1/1(2017)

3.2. Visual Inspection

Visual inspection carried out on inner and outer sur-
face of bend tube preheater was to find damage such as
holes and cracks, forming of corrosion product, and color
changes that occurs on the surface [1]. Visual inspection
on inner surface of bend tube preheater showed that the
entire surface covered with thin red-brick layer and dis-
tributed evenly along the surface pipe (Figure 4). It shows
that corrosion processes associated with water as corrosive
media occurred. There are not any visible damage such as
cracks on the inner surface of bend tube preheater. So we Figure 3. Outer surface condition of bend tube preheater
concluded that the corrosion process occurred on the inner
surface belong to the type of uniform corrosion[2]. On From the visual inspection on inner and outer sur-
outer surface of bend tube preheater, there is a brownish- face of bend tube preheater, there are many indications
black layer that covered along surface pipe with even that lead to thinning due to corrosion process. There-
distributed (Figure 3). It shows that corrosion processes fore, it is necessary to doing measurement on each sample.
occurred on outer surface of bend tube preheater. There First, each sample cut into two parts, thus forming into a
are not any visible damage such as cracks on the outer cross-section A and B. Then we measured on 12 measur-
surface of bend tube preheater. ing points on front side of sample (marked with X1) and
another 12 measuring points on the back side of sample
(marked with X2), with a 10 mm distance of X1 and X2 as
seen on Figure 4.

Figure 4. Measuring points on every sample

After measurement on each sample, the result of critical thickness (1.778 m). The combined 3D images
measurement is combined with 3D file of specimens from results can be seen on Figure 5.
3D scanning. Then, a codification was given to the com-
bined 3D file to show the local thickness of pipes. The red
color in 3D image shows if the location thickness is below
the critical thickness (< 1.778 m), while the green color
in 3D image shows the location thickness is still above the

38
 Putro et al./The International Journal of Mechanical Engineering and Sciences/1/1(2017)

be resistant of corrosion. XRD or X-Ray Diffraction can be

used to obtain chemical compound contained in corrosion
product (rust). XRD test result will be used to perform
advanced analysis related to corrosion process occurred
on inner and outer surface of bend tube preheater. con-
taminants or abrasive particles, so the corrosion occurs in
inner surface is pure due to direct contact between metal
surface and water.
XRD test result on inner surface of bend tube pre-
heater (Figure 6) showed, that red-brick layer is detected
as hematite or Fe2 O3 . Hematite formed by direct contact
between metal surface with water continuously. Hematite
in inner surface of sample test formed with a thickness
below 1 mm. Corrosion process occurs continuously due
Figure 5. Combined 3D image for specimen 1B
to the direct contact between metal surface and water, so
that reduction of thickness also occurs continuously. From
The result of visual inspection and measurement on Figure 6 we also conclude that the inner surface of bend
inner and outer surface of each specimens showed that tube preheater undefiled from contaminants or abrasive
bend tube preheater is in critical condition and should be particles, so the corrosion occurs in inner surface is pure
replaced, although there are not any signs of damaged due to direct contact between metal surface and water.
such as leaking or crack on four specimens. However, XRD test result on outer surface of bend tube pre-
corrosion process happens on every specimen based on heater (Figure 7) showed, that brownish-black layer is de-
color changes, reduction in thickness, and forming of ox- tected as magnetite or Fe3O4 and sodium aluminum phos-
ide layer on specimen surface. Combined 3D image for phate. Corrosion process that occurs on outer surface is
other specimens can be seen on additional information different from inner surface due to the difference between
chapter. corrosive media. A direct contact between metal surface
and hot gasses from gas turbine combustion formed mag-
3.3. Corrosion Analysis netite and chemical compound. The chemical compound
Pourbaix diagram explain forming of Fe2 O3 as oxide can be different on every sample due to difference of con-
layer causes the metal surface to be passive. A metal sur- taminants in natural gas compound as gas turbine fuel
face with Fe2 O3 still undergo a corrosion process, but with and gas turbine working conditions. Magnetite in outer
a lower rate. But, the forming ofFe2 O4 oxide layer causes surface of sample test formed with a thickness below 1
the metal surface to be more passive or allow the metal to mm.

Figure 6. XRD test result on inner surface of bend tube preheater

39
 Putro et al./The International Journal of Mechanical Engineering and Sciences/1/1(2017)

Figure 7. XRD test result from the outer surface of bend tube preheater

The bend-side of pipe is designed to flow the water a temperature up to 50◦ C. Sample that being used in
from the preheater drum to economizer drum. However, microstructure test is sample number 1 from specimen 2A.
the deformation of bend-side itself causes the pipe to be
more susceptible locally to corrosion. The deformation
on bend-side lower the breakdown potential locally, thus
the bend-side of pipe more susceptible to corrosion rather
than straight-side of pipe [3, 4, 5, 6].
Breakdown potential is electrical potential value on
the surface of metals that is needed to determine the state
of corrosion of the metal. By having smaller breakdown
potential locally on bend-side, so that the area is easier to
get into transpassive state and has greater corrosion rate.
Figure 8. Microstructure analysis with 50x magnification
When the oxide layer breakdown, the surface is in direct
contact with water. The potential difference occurs on
the surface of specimen at bend-side area, causing pitting Microstructure test done with 3% Nital as etching
corrosion occurs. Where the surface of metal as anode reagent according to ASTM E407 [7]. The result of mi-
and the metal oxide layer as cathode, so the thinning rate crostructure analysis with 50x magnification (Figure 8)
due to corrosion was greater at bend-side area. showed a formed layer on inner and outer surface of bend
The corrosion rate of a pipe can be determined by tube preheater. The formation of red-brick hematite that
calculating the difference of the thickness at a certain of occurred on inner surface of pipe marked by yellow circle
measured time interval. Corrosion rate can be formulated on figure 8 with a thickness of about 7 micrometer or
as the initial Thickness-Actual Thickness)/(Time Interval). 0.007 millimeter. On the outer surface of pipe formed
By using the corrosion rate formula, we obtained local brownish-black that marked by red circle on figure 8 with
corrosion rate data on each sample. The highest corro- a thickness of about 25 micrometer or 0.025 millimeter.
sion rate occurs on specimen 1B sample 7 with 0.0956 With 50x magnification we can see oxide layer formed
mm/year. Sample 7 is located in bend-side of specimen 1B. on inner and outer surface of bend tube preheater due to
After measuring the inside and outside diameter of each reaction of the specimens with working environment.
sample, we can obtain the comparison of largest thinning With 500x magnification on Figure 9a showed the
due to corrosion that occurred on inner and outer surface establishment of hematite on inner surface with detailed
of bend tube preheater as stated in table 3. From Table image as marked with blue circle, there are not any indi-
3, we know that the largest thinning due to corrosion cation that another oxide layer formed on inner surface.
occurred on the outer surface of bend tube preheater. Figure 9b showed the establishment of magnetite on outer
Microstructure analysis conducted to determine phe- surface with detailed image as marked with green cir-
nomena that occur on specimens due to working condition cle, there are not any indication that another oxide layer
and environment. Material used in bend tube preheater formed on outer surface. With 1000x magnification as
is ST 37.8 with a maximum carbon content 0.17%. The seen on Figure 10, we can conclude that working condi-
outer surface of specimen contact with hot gases from the tion and environment did not change any microstructural
turbine gas combustion with a temperature up to 150◦ element of specimen. So we concluded that there are not
C and the inner surface contact with flowing water with any failure from working condition and operation. The

40
 Putro et al./The International Journal of Mechanical Engineering and Sciences/1/1(2017)

result of microstructural test on sample is also suitable 4. Conclusion

based on DIN 17177-79 chemical composition standard. Failure that occurs on bend tube preheater is not
caused by heat recovery steam generator design and work-
ing operation, but due to the thinning of the pipe due to
the corrosion process that are continuously occurred on
the surface of bend tube preheater. However, the corrosion
rate on each sample is different, but the largest thinning
occurs at bend-side of bend tube preheater due to the
deformation. The deformation caused a local decrease
in the breakdown potential, the reduction of breakdown
potential induces local corrosion process occur faster.
There is formation of oxide layer on inner and outer
surface of bend tube preheater. Fe2 O3 or hematite formed
on the inner surface due to the reaction between metal sur-
face of specimen and flowing water in bend tube preheater.
Fe3 O4 or magnetite formed on the outer surface of bend
tube preheater due to the reaction between metal surface
of specimen and hot gases from gas turbine combustion.
References
[1] W. T. Becker, R. J. Shipley, S. Lampman, B. R. Sanders,
S. D. Henry, G. J. Anton, N. Hrivnak, J. Kinson, and
C. Terman. ASM Handbook: Failure Analysis and Pre-
vention. ASM International, 2002.

[2] M. G. Fontana. Corrosion engineering. Tata McGraw-

Hill Education, 2005.

Figure 9. Microstructure analysis with 500x magnification [3] Z. Foroulis and H. Uhlig. Effect of cold-work on corro-
(a) inner surface (b) outer surface of bend tube preheater sion of iron and steel in hydrochloric acid. Journal of
the Electrochemical Society, 111(5):522–528, 1964.

[4] W. France Jr. Effects of stress and plastic deformation

on the corrosion of steel. Corrosion, 26(5):189–199,
1970.

[5] I. Ghayad, A. Hamada, N. Girgis, and W. Ghanem.

Effect of cold working on the aging and corrosion
behaviour of fe-mn-al stainless steel. Steel Grips,
4(2):133–137, 2006.

[6] H. Huang and W. Shaw. Cold work effects on sul-

fide stress cracking of pipeline steel exposed to sour
environments. Corrosion science, 34(1):61–78, 1993.
Figure 10. Microstructure analysis with 1000x magnifica-
tion [7] A. Standard et al. Standard practice for microetching
metals and alloys. 2007.

41