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Metallurgical Aspects of Boiler Tube Failures A Few Case Studies

Metallurgical analysis
Failure analysis Health/ Condition Assessment Residual Life Assessment Indegenisation / Material Development

Components
Boiler tubes Turbine components High Energy Piping CHP Components Grinding elements Gas Turbine Components

Failure Mechanisms
(Water Touched Tubes)
Corrosion Fatigue Flyash Erosion Hydrogen Damage Acid Phosphate corrosion Caustic Gouging Fireside Corrosion Thermal Fatigue Erosion Corrosion Sootblower Erosion Short Term Overheating Low Temperature Creep Chemical Cleaning Damage Fatigue Pitting Coal Particle Erosion Falling Slag Damage Acid Dew Point Corrosion

Failure Mechanisms
(Steam Touched Tubes)
Long Term Overheating / Creep Fire Side Corrosion Dissimilar Metal Weld Short Term Overheating Stress Corrosion Cracking SH/RH Sootblower Erosion Fatigue Rubbing Tubes / Fretting Pitting Graphitisation SH /RH Chemical Cleaning

Stages in Failure Analysis


Visual Examination. Collection of background data. Identification of sampling locations. Laboratory investigations Analysis of data

Visual examination of damaged parts is the first and most critical step in failure investigation

Case Studies in Failure Investigation

Singarauli STPS
Boiler No.3 Date of Failure: 05/04/2004 Zone: Economiser Lower Bank Location: Coil No.02 Material: SA210 A1 R&D Ref: 2210

Kahalgaon STPS
Boiler No.2 Date of Failure: 28/03/2004 Zone: Convection Pass Wall (RHS) Location: Front Tube-01 (from RHS) Material: C20 R&D Ref: 2209

Ramagundam STPS
Boiler No.1 Date of Failure: 01/03/2004 Zone: Economiser LHS wall Location: Bank no.03 (from rear) Material: SA210 A1 R&D Ref: 2198

Corrosion Fatigue

Ramagundam STPS
Boiler No.2 Date of Failure: 27/02/2004 Zone: Reheater Location: Bank-05, Coil-22, Tube-07 Material: SA213 T22 R&D Ref: 2199

Korba STPS
Boiler No.1 Date of Failure: 09/01/2004 Zone: Reheater Location: Panel-31, 3rd Bend, 2nd Bunch Material: SA213 T11 R&D Ref: 2132

Long Term Overheating

Talcher #2, Stage I


S-Panel Water Wall Tube Failure Dated 09/01/2004 Report: R&D/MET/2130

Pinhole on weld

Vindhyachal #8
S-Panel Water Wall Tube Failure Dated 06/12/2003 Report No R&D/MET/2073

2073

Origin of Leak

Origin of Leak

NCPP Dadri #2
S-Panel Water Wall Tube Failure Dated 05/11/2003 Report No. R&D/MET/R-2118

TANDA Unit #2
Hydrogen Damage Failure in Water Wall

NCPP Dadri Unit #2


Weld Porosity in Economiser Tube

Talcher Thermal Unit #6


Weld Defects in Economiser Tube

Thermal Fatigue

Water wall Tube (near Man hole) Material: SA210 GrA1

Hydrogen Damage

Usefulness of Failure Analysis


Establishing the main reason of failure Taking remedial action to prevent further failures Reduces forced outages Helps in taking decisions for making design modifications, if necessary

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