Boiler and Turbine operation chapter 5

Chapter 5
Boiler Failure Case Studies
AF1 BOILER

Due to repeated accidents in boiler of AF1, I was invited to study this

phenomenon and recommend appropriate solutions to ensure the safe operation.

Accident:

Steam generator is a water tube boiler 129.6 bar with 6 burners front firing, and
consists of Generating tubes 53 & membrane tubes & front wall tubes beside the
burners (14+14 tubes). The three major accidents that the boiler was subjected
to was in the generating tubes; In direct exposure to the burners.

Present investigated Accident

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One tube ruptured No 42 (27/9/2010) in the front of burner no. 5 .

One tube ruptured No 18 (1/10/2010) in front of the burner no. 6 .
One multi crack No 27 (1/10/2010).
Two tubes with cracks No 21&38 (1/10/2010).
One tube rupture NO 24 (1/12/2010) in front of Burner No 6

Previous Accident
One tube ruptured No 8 (22/8/2002). The failure was 4 m height from bottom and
facing burner no. 4.
One tube ruptured No 14 (26/8/2002). The failure was 5.5 m height from bottom
and facing burner No. 6.

Materials

All generating tubes was originally St 35.8, however after the first accident 1st
row completely of generating tubes was changed 53 tubes as follows:
1. 52 tubes from the modified material 15MO3
2. 1 tube from St 35.8.
The length changed in all tubes was 6 meter length only .

Failure indications

Tube No 42 Tube No 18

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Tube No 21 Crack in new material No 27

Damage of boiler AF1, 2010

The defected tube NO 24 From right in the 1st Raw of Generating Tubes ( in
front of Burner No 6 ) in the old material 1/12/2010

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Accident Progress

A well-designed steam generator achieves satisfying lifetime only if the boiler

steel is able to develop and to maintain a thin protective layer of iron oxides with
its main constituent magnetite (Fe3O4), a real protective magnetite layer must be
compact, nearly free of pores and adherent to the metal surface.
The thickness of a protective magnetite layer depends on the material, operation
temperature and operation time .For carbon steel St. 35.8 this layer is about 100
- 300 μm. A thin magnetite protection layer with low porosity is an urgent
necessary “scale” but must not be mixed up with deposit formation due to
precipitates from the BW.

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The few hours of interrupted water quality specifically at 11/9/2010 the pH

values reached 6 for about 3 hours (the normal value of pH for this high pressure
boiler is 9.79.

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Corrosion rate versus Ph

Note that the corrosion rate increased 100 times the corresponding higher value
as indicated by the following diagram.
Having established the increase in corrosive activity of water the overheating of
the boiler tubes even further increased the chemical reaction. For every 10
degrees increase in water temperature the chemical reaction rate doubled as
indicated by the following diagram.

Corrosion rate versus temperature

Accident Hypothesis

The acidity of water and the high heat flux destroyed the thin protective layers.
Acid attack is characterized by general thinning and severe deposition which
result in visually irregular surface appearance. Indeed in our present investigated
case there was a reduction of thickness of about 0.4 mm in the test piece as
indicated in the Report of GERMANISHER LLOYD PRUFLABOR GMBH. This
was also confirmed by AF Inspection report which indicated that measurements
of tube thickness also indicated up to 0.6 mm thickness reduction in some tubes.
Also the LLOYD report referred to scaly oxide in the sectioned tube in the hot
side.

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In addition, the acid attack of the steel generates hydrogen which saturate the
metal structure and reacts with the carbon content causing the metal to rupture
along the crystalline boundaries. The cracking that develops is primarily
intergranular in nature which is also indicated by the findings of GERMANISHER
LLOYD PRUFLABOR GMBH microsection “Starting from pipe’s interior side
along the flank of the main fracture/crack, pronounced separation of grain
boundaries exist”, the metallic area affected becoming decarburized in the
process. Failure occurs when the ruptured section can no longer withstand the
internal pressure.

This type of attack may develop very quickly , the boiler pressure is 130 bar
which means a high pressure boiler and under high heat rates “the boiler is fired
110% capacity”. Such harsh operation requires continues monitoring of
temperature and pH values. Therefore, constant surveillance of water purity and
temperature is required. Furthermore, it is to be noted that since start up of the
plant 1979 the boiler was in continuous operation without major problems until 8/
2002 , 27/9/2010,1/10/2010 & 1/12/2010 where failure of tubes occurred.
It is expected that these accidents will not stop until major interventions will take
place.
Conclusion of this study

 The accident of boiler: Internal tube Corrosive attack at overheated

portion of the tubes which resulted in an irregular cracks due to
uncontrolled upset in water quality for few hours. Water excursions
influence both initiation and propagation of corrosion . Explosion of tubes
was affected when sufficient cracks accumulated over a piece of tube
material. Other unexploded but cracked tubes was due to the same
phenomenon but there was not enough accumulation of cracks for the
explosion process to occur.

Recommendations:
1. Change all length of front two rows of Generating Tubes to 15Mo3.
2. Implement Trip control strategy on feed water pH; boiler pH, and exit
steam pH when pH values out of accepted range for 30 minutes .
3. Check the burner orifice whether it was eroded from continuous
operation which may contribute to the failure.
4. Use thermograph inspection to measure the tubes temperature on a
regular intervals.

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Case study 2
Repeated accidents in boiler

Failed tube No 25 Failed tube No 27

leaked tube No 23 crack with length 7 cm and crack tube

No 26 with length 4 mm

Introduction

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The failure is not caused by general deposits on the inner side of the tubes such
deposits will lead to long term overheating rupture with known bulges. The failure
is also not caused by sudden interruption of the circulation by blockage or by
circulation failure caused by low water levels such interruptions cause short term
overheating and is indicated as violent bursts. Also a rapid firing rate during
boiler start-up can lead to the same failure shape.

Depending on the metal temperature reached, the tube can be damaged by

corrosive mechanisms over a long period of time before bulges or blisters or
outright failures develop. In such instances, a metallurgical examination in
addition to an examination of the contributing mechanical factors can be helpful
in identifying the source of the problem. Indeed, proper investigative procedures
requires macroscopic examination combined with chemical analysis and
microscopic analysis of the metal.

The failed tubes have the following characteristics

1- All damaged tubes are only one side of walls; south side wall tubes
2- longitudinal fracture and no indications for external corrosion damage

3- Heavy scales were observed in the exploded tube from the side of burner.

4- There was no visible reduction in wall thickness at or away from fracture

(fire) zone.

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5- The fracture location are all on the vertical part and it is close to the I -beam
supported sections of the side tubes.

Water chemistry

There was no recorded changes in the water chemistry in these accidents

Accident Progress

The use of carbon steel or low-alloyed steel for boiler components exposed to
high temperatures and pressures is only possible because a protective oxide
layer is formed on the waterside surface of the tube. These materials are
thermodynamically instable in water at operating temperatures. The protective
layer consists mainly of magnetite Fe3O4. When the imposed strain is greater

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than the fracture strain of the oxide (magnetite), the oxide will crack in a regular
array. This cracking then allows boiler water to come in touch with the tube
surface. This then causes more magnetite to grow on this exposed surface at a
relatively fast rate (parabolic growth law). This oxide will remain in place until the
next application of strain greater than the fracture strain. This will crack the newly
formed magnetite at the bottom of the corrosion fatigue crack. The cracks grow
by a repetition of this process (called repetitive crack initiation): Rupture of the
magnetite film acts as a stress concentrator. Generally, it is recommended to
keep the strain level in the magnetite layer below, 02 % in tension to avoid film
rupture.

The breakdown of the magnetite layer is probable at locations at which excessive

strains may be developed. In waterwalls, the predominant locations are those at
which large stresses develop during transient operating conditions as thermal
expansion is constrained by tube attachments. Typical locations include scallop
bar attachments. Indeed, in this investigation (AF3) all the failed tubes are within
this area. This is called Corrosion Fatigue damage which occurs in general
when a boiler tube is subject to repeat cyclic or fluctuating loading although the
stress produced is below the material yield strength.

Intensive heating from the fire side and constrained expansion in regions of I
beam caused cyclic stresses; fracture location are all on the vertical part and it is
close to the I -beam supported sections of the side tubes. This distorted the thin
protective oxide layer. The normal reaction between iron and water is sufficient to
cause pitting at freshly exposed surfaces. Intensive boiling from one side of the
tubes contributed to scale deposition in this side. Thus the mechanism of failure
is corrosion fatigue. Corrosion fatigue is caused by a combination of a corrosive
mechanism and fatigue generated by mechanical or thermal stresses. Corrosion
fatigue is also known by a number of other names designating basically the same
mechanism, for example , stress-assisted cracking and stress-assisted pitting.

The hypothesis of failure of the present investigation which include the initiation
of corrosion pits and later cracks is supported by the micro examinations of other
consultants although their hypothesis is different. The microscopic examination
by CMRDI and NALCO report showed pits

Also cracks was reported by Babcock Borsig, NALCO, and CMRDI

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The deterioration of mechanical properties that occurred during corrosion fatigue

can be demonstrated by hardness measurement. Indeed, hardness test carried
by AbUQIR Fertilizer inspection team indicated that hardness beside the cracks
varied from 50% to 65% the equivalent value far from the crack which represent
a significant reduction in strength . This is attributed to the corrosion pits present,
in fact these pits later developed to cracks from the internal surface which
contributed to the weakness of the tubes and the ultimate fracture since the
strength was not capable of maintaining the pressure.

Conclusion: The boiler side suffered corrosion fatigue damage at the supported
section of the vertical waterwalls of the south side of the furnace. It is believed that
overheating developed large stresses during transient operating conditions as
thermal expansion is constrained by tube attachments in this section which
contributed in cracking the protective oxide layer. Pits which was developed in the
internal surfaces of the portion facing inside later developed to longitudinal cracks.
This mechanically weakened the tubes to the limit it could not maintain the pressure
at this elevated temperature and thus burst or cracked.

Comparison of views

Babcock Borsig NALCO CMRDI Present

service Investigation
Damag

hypoth

Alternating Stress corrosion Corrosion – Corrosion –

esis

stresses cracking Fatigue damage Fatigue damage

e

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1-An assessment of To prevent stress 1- Chemical 1-Redesigning

the affected boiler corrosion cracking cleaning to remove tube attachments
area by an it is essential to internal porous in order to
experienced maintain accepted oxide layer and increase the
commissioning water chemistry at then to avoid flexibility at the
Recommendations

engineer and all time. Excursions pitting corrosion . 2- connection and/or

request a long time in pH can produce maintain operation improvement of
operating data for lasting damage in within design weld profiles by
further evaluation short period and specifications and grinding may be
2- non-destructive therefore require proper start up and important
examination should that the boiler is shutdown 2- Check
be integrated in the stopped when the procedures to orientations of
current boiler pH drops minimize thermal close burners
maintenance below 8 and mechanical which may be
Program stresses influential in
reducing the
fatigue.
1- 1-Hypothesis not 1-Accepted .
Not conclusive supported by hypothesis which
hypothesis operating data ; no agrees with the
excursions of pH present
reported . investigation but
2- Fatigue corrosion is
3- 2- Stress corrosion known to be due to
cracking is not different reasons
common in lower and geographic
My Comments

strength carbon or places in the boiler.

low alloy steel 2-lacks pin pointing
4- the root cause of
failure
2- Generalized
recommendations

References.
1- Boiler and HRSG Tube Failure, corrosion fatigue, R. Barry. Dooley and
Albert. Bursik, Power plant chemistry ,586- 591, 2009,11 (10).
2- B&W power generation group , PSB-55 5MU2D , Corrosion fatigue
failure of riser tube bends , plant service bulletin , 2002 The Babcock &
Wilcox Company.
3- Thermal fatigue and corrosion fatigue in heat recovery area wall side
tubes. J. Ahmad a, J. Purbolaksono b, L.C. Beng , Engineering Failure
Analysis 17 334–343, (2010)
4- Corrosion fatigue failure of tubes in water tube boilers, HSG, Guidance,
Topics, COMAH, Safety alerts, Mar 2010

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Report No 3
INTRODUCTION

This report covers the failure analysis in Egyptian Methanex Methanol compay in
Damiatta. Two consecutive accidents occurred in Auxiliary boiler B within the
period between the end of December 2010 and 15 th February 2011within nearly
one year from start up on January 2010. The investigation included sight visit,
and microscopic and macroscopic analysis of damaged tube. The investigation
also studied and used some of the photographs and reports by the inspection
team and engineers of the company.

Location

Fig 1: Damaged Roof Tubes

Present Investigation Examination of the cracked pipe

The surface of the pipe was cover with an oxide layer. The pipe has an ID of 3.9
cm and OD of 5.3 cm. The thickness of the pipe wall is 7 mm. The pipe has a
fracture that extends parallel to its axis with a length approximately 3.8 cm. And
also a small crack was seen on the outer surface that extends to below the oxide
layer, while the oxide layer itself was cracked in the surrounding of the fracture.

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Fracture

Crack

Cracks in
the oxide
layer

Figure 2: View of the fractured tube.

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Figure 3 A close up of the oxidized layer

Cutting the samples around the fracture showed that the pipe thickness in this
place was reduced to 3 mm. The inner side of the pipe showed multiple cracks
that were visible to the naked eye and were perpendicular to the original fracture
(i.e. perpendicular to the pipe axis).
The two sides of the fracture were separated. One of them, was cleaned with
inhibited acid (Ethyl Alcohol and 5% Nitric Acid) for 120 seconds since the oxide
layer was very thick and adherent (Part 1), the other half was cleaned but for only
20 seconds (Part 2) . They were washed by running water and then in acetone.
The samples were examined under the SEM directly.

Transverse
Cracks

Part (1) after cleaning.

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Part (2) after cleaning

Figure 1: Fracture surface

SEM examination of the these parts

Figure 2: Transverse cracks in the inner side of the tube for part (2).

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Figure 3: Magnification of the inside of these cracks showing intergranular

cracks and separation between the grains (part 2)

Figure 4: Magnification of the inside of another crack showing intergranular

cracks and cavities between the grains (part 2)

Figure 5: Cracks in the inner side of the pipe of part (1)

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Figure 6: Magnification of these cracks showing the intergranular cracks

and cavities. (part 1)

The examination of the fracture surface

Figure 7: Fracture surface, near the inner side of the pipe.

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Figure 8: Fracture surface, near the outer side of the pipe.

The increased roughness in the crack surface near the inner side of the tube
than near the outer side of the tube indicated that the crack started from the inner
side and proceeded to the outer surface.
The presence of these microcracks and cavities in the inner side of the tube
suggests a failure resulting from creep. The plastic deformation resulted in the
cracking of the oxide layer, the formation of these cavities. The growth of these
multiple cracks, which joined together and caused this longitudinal fracture
according to the stress release distribution in the pipe.

Creep rupture is a time dependent failure that results when a metal is subjected
to stress for extended periods of time at elevated temperature. There are more
than one type of creep rapture, but the present investigation findings indicate
intergranular creep and not transgranular creep. Furthermore, it is a wedge
cracks rather than cavitation crack . These are known to occur under relatively
high strain rates and intermediate temperatures which is typical for long term
overheating than short term overheating which is due to operation disorder.

Macro-examination and Evidence

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Figure 12: Bulged overheated leaking tubes with fishmouth feature

Figure 13: Bulged overheated tube

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Causes of Overheating

Although there are many reasons for long term overheating of boiler tubes, this
specific accident was due to undesired channeling of fireside gases when
failure of a carbons steel plate occur . This failure changed the pass of the gases
and induced hot flue gases to the top wall water tubes especially in the
superheater area number 3. This carbon steel plate was covering the upper
header connected to the failed tubes. This plate was covered by refractory and
the area between this plate and the header was filled by thermal insulation
packing.

Figure 14: Damaged carbon steel plate for the upper header

Temperature limits for Tubes

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Figure 15: Recommended Maximum Temperature of tube material, F

This figure indicate the difference in recommended maximum temperature of

tube material between tube top roof walls SA210Gr.A1 and superheater SA213
Gr T91 walls .

Figure 16 : Allowable Stresses for Design (ASME B&PV CODE)

It can be seen from the figure the degradation of material of roof tubes with
higher temperatures which permitted the formation of bulges and then rapture.

Conclusion

This report conclude that the damage of the roof tubes was creep rupture long
term overheating due to undesired channeling of fireside gases when failure of a
carbons steel plate occur . The evidence was concluded from:

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a- The SEM (Scanning Electron Microscopy) examination indicated wedge

intergranular cracks which is known to occur at relatively high strain rates
and intermediate temperatures, this cracks ultimately burst when the tube
could not contain the applied pressure .
b- Oxidized internal and external surface of the sample segments which is
indicative of long term overheating
c- The macrostructure examination illustrated the initial bulging of tube prior
to explosion a common feature of long term overheating.
d- Our measurements and others indicated thinning of the tubes in the
overheated and exploded areas which is typical of long term overheating.

References:
ASM Handbook; Volume 11; Failure Analysis and Prevention
ASM Handbook; Volume 12; Fractography

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