Creep may be defined as a time-dependent deformation at elevated
temperature and constant stress. It follows, then, that a failure from such a condition is referred to as a creep failure or, occasionally, a stress rupture. The temperature at which creep begins depends on the alloy composition. For the common materials used in superheater and reheater construction, Table I see below! gives the appro"imate temperatures for the onset of creep. It should be pointed out that the actual operating stress will, in part, dictate or determine the temperature at which creep begins. The end of useful service life of the high-temperature components in a boiler the superheater and reheater tubes and headers, for e"ample! is usually a failure by a creep or stress-rupture mechanism. The root cause may not be elevated temperature, as fuel-ash corrosion or erosion may reduce the wall thic#ness so that the onset of creep and creep failures occur sooner than e"pected. $owever, regardless of the cause, the failure will e"hibit the characteristics of a creep or stress rupture. Indeed, the ASME Boiler and Pressure Vessel Code recogni%es creep and creep deformation as high-temperature design limitations and provides allowable stresses for all alloys used in the creep range. &ne of the criteria used in the determination of these allowable stresses is '( creep e"pansion, or deformation, in ')),))) hours of service. Thus, the code recogni%es that over the operating life, some creep deformation is li#ely. *nd creep failures do display some deformation or tube swelling in the immediate region of the rupture.
*t elevated temperatures and stresses, much less than the high-temperature yield stress, metals undergo permanent plastic deformation called creep. Figure ' shows a schematic creep curve for a constant load. a plot of the change in length verses time. The weight or load on the specimen is held constant for the duration of the test. There are four portions of the curve that are of interest/ *n initial steep rate that is at least partly of elastic origin, from point 0)0 to point 0*0 in Figure '.
This is followed by a region in which the elongation or deformation rate decreases with time, the so-called transient or primary creep, from region 0*0 to 0,0 of Figure '. The portion from point 0)0 to point 0,0 occurs fairly 1uic#ly.
The ne"t portion of the creep curve is the area of engineering interest, where the creep rate is almost constant. The portion from 0,0 to 0C0 is nearly linear and predictable. 2epending on the load or stress, the time can be very long. two years in a test and several decades in service.
The fourth portion of the creep curve, beyond the constant-creep-rate or linear region, shows a rapidly increasing creep rate which culminates in failure. 3ven under constant-load test conditions, the effective stress may actually increase due to the damage that forms within the microstructure. Without going into a detailed discussion of the atom movements involved in creep deformation, suffice it to say that creep deformation occurs by grain-boundary sliding. That is, ad4acent grains or crystals move as a unit relative to each other. Thus, one of the microstructural features of a creep failure is little or no obvious deformation to individual grains along the fracture edge. The first two stages will not leave any microstructural evidence of creep damage. +omewhere along the linear portion of Figure ', the first microstructural evidence of damage appears as individual voids or pores. The location of these first voids or holes varies, often noted at the 4unction of three or more grains, occasionally at nonmetallic inclusions. These individual voids grow and lin# to form crac#s several grains long, and finally failure occurs. The ultimate rupture is by a tensile overload when effective wall thic#ness is too thin to contain the steam pressure. +ince creep deformation occurs by grain-boundary sliding, the more grain boundary area, the easier creep deformation will be. Creep deformation and creep strength are a grain-si%e sensitive property. Thus a larger grain si%e improves creep strength. For austenitic stainless steels, +*5'6 T765'$ for e"ample, the code re1uires a grain si%e of 89 or coarser, to assure ade1uate creep strength. The elevated temperatures where creep occurs lead to other microstructural changes. Creep damage and microstructural degradation occur simultaneously. For carbon steels and carbon-':5 molybdenum steels, iron carbide will decompose into graphite. For the low-alloy steels of T-'' and T- 55, the carbide phase spheroidi%es. Thus, creep failures will include the degraded microstructures of graphite or spheroidi%ed carbides along with the grain-boundary voids and crac#s characteristic of these high-temperature, long-time failures. While creep failures are e"pected for superheaters and reheaters operating at design conditions, deviations from these parameters will promote early failures. The steam temperature always varies some from individual tube to tube, and the design allows for this variability. $owever, when the range of temperatures is larger than accounted for, the hottest tubes fail sooner than e"pected. * more li#ely cause of premature failure is the slow increase in tube-metal temperatures due to the formation of the steam-side scale. +team reacts with steel to form iron o"ide along the I2 surface of the tube. The microstructures themselves will show the grain-boundary sliding and the resultant creep crac#s or voids. For stainless steels, the microstructures are similar in that the failure is by grain-boundary-sliding and crac# formation. In a superheater or reheater tube, often the very first sign of creep damage is longitudinal crac#s in the steam-side scale. *s creep deformation e"pands the tube diameter, the brittle I2 scale cannot follow the e"pansion. Crac#s develop in an a"ial or longitudinal direction which is perpendicular to the principle hoop stress. With time, the tube continues to e"pand, and these crac#s widen. This wide crac# shortens the path from steam to steel. iron o"ide forms preferentially at the tip of the crac#, as there is less o"ide thic#ness to protect the steel. and a cusp forms within the steel tube. The cusp acts as a notch or a stress raiser, reducing the local wall thic#ness. Creep voids form here, often before any other obvious grain-boundary damage appears elsewhere within the microstructure. With continued high-temperature operation, creep crac#s grow from the cusp and ultimately wea#en the cross section to the point where failure occurs. Creep failures are characteri%ed by/ o bulging or blisters in the tube
o thic#-edged fractures often with very little obvious ductility
o longitudinal 0stress crac#s0 in either or both I2 and &2 o"ide scales
o e"ternal or internal o"ide-scale thic#nesses that suggest higher-than- e"pected temperatures
o intergranular voids and crac#s in the microstructure
Editor's note: +ome ASME Boiler and Pressure Vessel Code re1uirements may have changed because of advances in material technology and:or actual e"perience. The reader is cautioned to refer to the latest edition and addenda of the ASME Boiler and Pressure Vessel Code for current re1uirements.
Table I Initial Creep Temperature For superheaters and reheaters, the scale that forms is essentially magnetite alloyed with chromium, molybdenum, manganese, and silicon from the alloy steels of T-'' and T-55. For waterwalls, the iron o"ide may be contaminated with impurities from the boiler water and corrosion debris from the pre-boiler circuits of condenser and feedwater heaters. In any event, the thermal conductivity of the steamside scale is about ;( of the thermal conductivity of the steel tube. Thus, an effective insulating layer forms and prevents proper cooling of the tube metal by the steam. The net effect of the scale is to raise the tubemetal temperature. 2epending on the scale thic#ness, which is dependent on the time and temperature of operation, tube-metal temperature increases of 5; - 9; o F are li#ely. +uch a large increase raises tubemetal temperatures beyond the safe design range. These elevated temperatures result in increased creep deformation rates, more rapid o"idation and corrosion thinner walls and higher stress! and hasten the onset of creep failures. *n increase of <) o F from ')=) o F to '')) o F for e"ample! will decrease creep life by >)(. *n increase of <) o F due to steam-side scale formation in a superheater or reheater is not unusual. Carbon steel....................... ?)) o F Carbon @ ':5 Aolybdenum............ ?;) o F '-':= Chromium-':5 Aolybdenum...... >;) o F 5-' := Chromium-' Aolybdenum....... '))) o F +tainless steel.................... ');) o F 7riority ' items should be considered for inspection with in the ne"t 9,;)) hours or ;) thermal cycles of operation. Bocations with no #nown or documented inspection history and are considered high-ris# areas associated with steam lea#s, crac#s and ruptures. i.e. boiler outlet connection. wye bloc# : lateral fittings. longitudinal seam welds traffic areas!. attemporator spools. drain penetrations Steam Boiler Inspections Using Remote Field Testing )6:)':5)'' By Mynor Celis, 7.3ng, Cussell D23 +ystems Forced outages of steam boilers due to tube lea#ages remain the leading cause of lost production in plants. 2ue to hundreds, if not thousands of linear feet of pipe, there is a high potential for failure without notice. &ne of the biggest challenges for maintenance and operations personnel is the prevention of tube failures in boilers and heat e"changers without causing significant loss to the company. When e"cursions from normal operating conditions occur, the 1uestion must be raised, Eif our boiler tubes were damaged by the e"cursion for e"ample, overheating, or a condenser tube lea#!, how do we find out if we have a problem that could lead to failure?F ,oiler operation always involves harsh wor#ing conditions. &n the fuel side of tubes, high operating temperatures and corrosive by-products from burning fossil fuels or solid waste can seriously degrade the life-e"pectancy of the boiler tubes. &n the water:steam side, there is a high potential for o"idi%ation of boiler tubes due to high temperature steam and the corrosive action of chemicals in the water supply. These conditions may cause metal to overheat, corrosive wall thinning, and locali%ed pitting, any or all of which can lead to premature failure of the tubes, possible in4uries to personnel, damage to ad4acent tubes and a forced outage. In spite of these adverse operating conditions, boilers have a life e"pectancy upwards of 6) years and most premature failures are due to conditions that ma#e operational variables deviate from e"pected parameters. Industrial best practice is to inspect all tubes periodically, chec#ing to ensure that mechanical properties of the materials are intact and that material thic#ness is within normal e"pectations. * proper and rigorous inspection regimen will go a long way to reduce the probability of premature boiler failures. Thomas C. +chmidt of +hell &il headed the initial development of the remote field testing CFT! techni1ue for measuring oil well casings. *fter that, several tools have entered the mar#et using CFT for multiple speciali%ed applications. The primary benefit of this techni1ue is that it does not re1uire contact with the ob4ect under test to measure material thic#ness and condition. *dditionally, a high-1uality inspection can be assured without re1uiring couplant and with minimal surface preparation. CFT also shows high sensitivity to detection of defects on the I2 or &2 of the tube in 1uestion and can measure through non-ferromagnetic coatings, linings and scale. There are two approaches to doing maintenance of any #ind/ a preventative approach or a corrective approach pro-active or reactive!. This holds true with boiler inspections. * preventative approach see#s to loo# at the long-term wear-and-tear tendencies on the e1uipment, with an eye towards improving operations through improvements to the fuel- air mi"ture, flow balancing and the creation of a maintenance specification for tube repair or replacement. Gnderta#ing a corrective approach loo#s to inspect the boiler after a failure to loo# for collateral damage and to ensure that the failure mechanism has not affected other areas in the boiler. &f the two, the former is more advantageous from the perspective of being performed before failure, within the conte"t of the firmHs long-range operational plan, resulting in a reduced effect to the operations budget and significantly reduced time lost due to une"pected outages. Longterm o!er"eating #creep$: This type of failure occurs when the operating temperature of the boiler tubes e"ceeds the operational limits for an e"tended period of time. These limits are variable based on the tube si%e and thic#ness, operating pressures, as well as the tube locations in the boiler and construction materials. &verheating leading to creep damage can be caused by internal deposits, which reduce flow through the tubes or, more commonly, sudden spi#es in operating temperature due to increasing load or issues with the temperature control. These reduce the resistance of the tubes. Figure % Longterm o!er"eating #creep$ How to detect creep damage: 2uring the period of long-term overheating, the surface of the tube will develop blisters at the locations sub4ect to the highest temperature and will develop elongated a"ial crac#s. ,oth of these failures will reduce overall tube thic#ness and material properties of the tube. *dditionally, thic#, dar#, brittle o"ides will appear on the internal and e"ternal surfaces of the tube. *ll of these conditions can be detected through CFT as the changes in the tubes electrical permeability can be easily measured. How to prevent creep damage: &ften, when boilers are operating outside of standard operational parameters, it goes unrecorded or unnoticed by the operator. 3ither of these issues can lead to premature failure, as the degradation of the tubeHs material properties is not being accurately recorded. *s such, it is necessary to run periodic performance evaluations on the boiler. 3nsuring fre1uent calibration of the thermostats is the best way to prevent une"pected temperature spi#es and to help ensure that the unit is warmed up in accordance with the manufacturerHs recommended specifications. Fre1uent sampling of the unitHs feed water supplyIideally once per shiftIwill help to ensure that the feed water 1uality is within the manufacturerHs recommended parameters. Cegular internal flushing of the boiler tubes will ensure removal of any material deposits clogging the tubes. *ny deposits must be measured fre1uently, and chemical cleaning is recommended when the deposit density e"ceeds '; g:s1.ft. Cleaning becomes mandatory as the density reaches 6) g:s1:ft. Fre1uent drum inspections are mandatory according to the maintenance manual of the manufacturer. 2epending on the hours of service, it is necessary to determine how well the e1uipment is wor#ing, the effectiveness of the water treatment and that there are no failure mechanisms affecting the internal surface, mainly in the area of water-steam interface line. Bastly, it is necessary that all spare parts used in maintenance or repairs are correct to the manufacturerHs specifications. It should be noted that when any tube fails as a result of creep damage, there will be a rupture with slightly rounded edges and 4agged edges with crac#s or brea#s in the vicinity of the rupture. * thic#, fragile layer of magnetite will appear near the failure, indicative of long-term overheating. S"ort Term &!er"eating: Aost often, these failures occur when the tubes are left without sufficient cooling and occur in short order. Failures caused by short-term overheating fre1uently occur at the top of the tubes or close to the steam collector. If the failure occurs in a single tube and if surrounding tubes have no appearance of alteration, it suggests that the failed tube was at least partially obstructed, causing the temperature to rapidly e"ceed material limits, causing an e"plosion or lea# in the tube. Figure ' S"ortterm o!er"eating How to detect short-term overheating: *s these failures occur rapidly, it is recommended that the tubes be inspected visually through the inspection ports during start-up. If red spots suddenly appear on a tube, it is a signal that the tube may be plugged. This type of inspection is necessary after chemical cleaning, tube replacement or re- commissioning after a long period of dormancy. How to prevent short-term overheating: *s a result of the rapid occurrence of this type of failure, it is not readily detectable through non-destructive testing methods. The best way to prevent it is to flush the tubes with water to ensure all obstructions are removed prior to startup and by ensuring that the purge and bottom headers are open as the pressure is increased. This type of failure can be recogni%ed by the longitudinal rupture, smooth edges and no loss of wall thic#ness as the rupture. &(ygen Corrosion: &"ygen corrosion occurs in a boiler due to small corroded regions which acts as an anode to the rest of the boiler, causing further corrosion. This process is e"acerbated by the presence of dissolved o"ygen in the boiler system. Ideally, the boiler surface would be covered with a protective layer of iron o"ide, preventing the attac# of free o"ygen in the water supply. The small pits that result from o"ygen corrosion can cause significant stress, and will result in the formation of crac#s in the region Figure ) &(ygen corrosion How to detect oxgen corrosion: CFT is one of the most effective methods used to detect o"ygen corrosion if it is located at the fire side. $igh tool sensitivity and accuracy J':?F diam.! allows for the early detection of initial defects, providing data necessary to determine a repair or replacement protocol before the tube fails. Gltrasonic testing GT! can also be used, but is limited by significantly slower inspection time and the fact that ')) percent coverage is impossible. The latter increases the ris# that serious damage to tubes could go unnoticed. How to prevent oxgen corrosion: The most effective way to prevent o"ygen corrosion in boiler tubes is to prevent o"ygen from entering the system in the first place. &"ygen enters a boiler system primarily through three means/ air can be trapped during normal operation when internal pressure is less than the ambient atmospheric pressure. when the system is left open for maintenance. and as a result of molecular dissociation of water in the system. &ther critical factors are the presence of ambient moisture in the system and, the loss of a passivation layer after chemical cleaning. 3liminating these factors can successfully prevent o"ygen corrosion. It is recommended that all metal surfaces be #ept dry using positive-pressure inert gas, moisture-absorbing materials, or a continuous flow of dry, dehumidified K6) percent! air. Caustic Corrosion: Caustic corrosion refers to the corrosive action of sodium hydro"ide with a metal and is restricted to/ water-cooled tubes in regions of high heat fluctuation. regions with heat transfer in welding rings or other devices that disrupt flow. hori%ontal or inclined tubes. places with thic# internal deposits reducing flow rates. This penetration may be filled with dense corrosion products which sometimes contain magnetite crystals. Aost often, the metal surface has a smooth contour and laminations. +odium hydro"ide is added to boiler water in non-corrosive concentrations. however other physical factors tend to concentrate it further, leading to the production of corrosive al#aline in the boiler. Figure * Caustic corrosion *d by websave L Close This *d How to detect caustic corrosion: Caustic corrosion is easily detected using non- destructive testing methods, because the affected area is found with reduced wall thic#ness. If this is in its early stage there may not be any blister, but if the thic#ness is reduced there is li#ely to be a blister or deformation in the tube. Cemote field testing is the most suitable method. These tools have high sensitivity and inspection speed, allowing for rapid detection of corrosive damage. GT can also be used, once the affected region has been located. How to prevent caustic corrosion: When sodium hydro"ide is presentIeither by itself, or as a salt-producing al#alineIwith a concentration mechanism, there e"ists the possibility of caustic corrosion. To reduce the li#elihood of caustic corrosion damage in a boiler, the amount of free sodium hydro"ide available to produce al#aline salts in the condenser water must be controlled at the purification stage. This will prevent nucleate boiling, and the formations of water-level lines. 7roper purging will prevent the formation of sludge deposits. +cidic Corrosion: There are two necessary conditions for this type of failure to occur/ the boiler must be operated with a p$ below normal parameters, and there must be a means to concentrate the acid-producing salts that are responsible for the low-p$ environment. If both of these conditions are met, then the protective layer of iron o"ide is dissolved, and the bare metal is left unprotected. Figure , +cidic corrosion How to detect acidic corrosion: Corrosion of this type primarily results in metal loss on the interior surface of the tube. +imilar to caustic corrosion, areas affected by a low p$ environment tend to have smooth edges and lamination. The difference between the two is that the region affected by acidic corrosion is often covered with iron o"ide. Cemote field testing has high sensitivity, and can detect minimal corrosion accurately from ':?F diameter, ma#ing it one of the most effective ways to detect acidic corrosion. The Gltrasonic testing to determine the e"tent of wall loss however this can only be effectively utili%ed once the affected region is #nown. How to prevent acidic corrosion: Two ways e"ist to reduce the probability of acidic corrosion in the boiler. The first involves reducing the availability of free acid, or acid producing salts in the boiler, avoiding ma#e up water with Bow 7h. The second involves eliminating the means to concentrate the acid in the boiler, such as bubble formations, water-side deposits, and water-level lines. This can be achieved through regular, proper purging of the boiler. Stress Corrosion: +tress corrosion is caused by a combination of two separate factors/ tensile stresses on the pipe caused by internal pressure, or residual stresses induced by improperly-applied heat treatment, or tube bending. and a corrosive material such as sodium hydro"ide or chlorine. This combination results in crac#ing near the stressed region. +tress corrosion usually occurs near welds, or tube bends. Figure - Stress corrosion How to detect stress corrosion: +tress corrosion displays as crac#ing near welds sub4ect to tensile stresses. While stress corrosion crac#ing can be difficult to see, it can be detected visually. Bi1uid penetrant inspection provides a surer means of detection. *dditionally, ultrasonic testing or radiographic testing can detect stress corrosion crac#ing. How to prevent stress corrosion: *nnealing will relieve residual stresses from welding or bending. *dding phosphates to the operating environment will help prevent the formation of free sodium, reducing the concentration of corrosion products. .ydrogen /amage: When chemicals are added to boiler water to balance p$, an electrochemical reaction can occur, releasing free hydrogen atoms into the environment. This can cause decarburi%ation, embrittlement and the formation of molecular hydrogen and methane in the steel. $ydrogen damage is restricted to evaporator tubes with pre-e"isting corrosion problems. $ydrogen atoms diffuse into the steel of the boiler tubes. +ome of these atoms bond with either each other, or the carbon in the steel, forming molecular hydrogen or methane. These gasses accumulate until the pressure causes the separation of the metal along the granular borders, producing inter-granular micro-crac#s. This in turn reduces the mechanical strength of the tube, which causes it to burst. *ny tubes suspected of failing due to hydrogen damage should have samples ta#en and sent for metallographic analysis in a lab. Figure 0 .ydrogen damage How to detect hdrogen damage: $ydrogen damage is hard to detect visually, e"cept in the advanced stages when the pipe has visible crac#s. Cemote field testing is highly effective in detecting hydrogen damage because the changes in the electrical properties of the material due to hydrogen damage are readily detected. How to prevent hdrogen damage: The two critical factors in reducing a boilerHs susceptibility to hydrogen damage are the amount of hydrogen available, and the means to increase its concentration. 7roper chemical treatment of feed water, combined with a stringent p$ control system is the best way to prevent hydrogen damage. 1rap"iti2ation: Mraphiti%ation is caused by small structural changes of low-carbon steels at moderate temperatures over e"tended periods of time. Mraphiti%ation causes the decomposition of pearlite in ferrite, wea#ening the steel. The e"tent of the decomposition is dependent on the temperature. This phenomenon generally occurs due to long-term overheating, during which, the graphite nodules are lin#ed to each other, reducing the resistance to internal pressure, causing the metal to tear. Figure 3 1rap"iti2ation How to detect graphiti!ation: Mraphiti%ation occurs internally, with the graphite detaching from the steel reducing the total wall thic#ness. *s with hydrogen damage, the electrical properties of the material changes when graphiti%ation is present. For this reason, remote field testing is the most effective means of detection. How to prevent graphiti!ation: The primary concern with respect to the susceptibility to embrittlement due to graphiti%ation is tube 1uality. Bow carbon content steel is more susceptible to graphiti%ation and long-term overheating is liable to e"acerbate the problem. * good metal passivation program and treating the boiler feed water with phosphate will reduce the probability of graphiti%ation. Fire Side Corrosion: Aost fuel components can cause corrosion on boiler tubes. 2ue to incomplete combustion, deposits of combustion residue can change the heat transfer characteristics with potentially severe effects on system efficiency. Aost solid fuels contain ') to 5) percent ash that remains in the boiler after combustion, leading to lost heat transfer and corrosion. While li1uid fuels do not e"ceed 5 percent ash, they do contain elements such as vanadium and sodium. Figure 4 Fireside corrosion How to detect "ire side corrosion: When the surface of the boiler tubes are e"posed to combustion gases, the damaged area of the surface will change color. Bong-term corrosion of this type affects the permeability and conductivity of boiler tubes, as well as causing pitting. How to prevent "ire side corrosion: Fuel selection is of primary concern in addressing the issue of fire-side corrosion. Fuels should be selected containing minimal corrosive agents such as sulfur, sodium and calcium. +econd, optimi%ing the combustion 1uality through control of temperature, fuel-air mi"ture, and air balancing will reduce the ash deposits in tubes. Thermocouples should be installed throughout the boiler to indicate when heat transfer is outside optimal operating range, which could be indicative of ash deposits on the tubes. Third, continuous cleaning programs should be implemented in the boiler. The probability of steam boiler failure is dependent on numerous operational and maintenance factors. The implementation of preventative inspection and tube profile measurements will help to ensure that boilers are active for their e"pected 6)-year average operational lives. *n active regime of preventative maintenance will be effective at reducing the financial impact of une"pected shut-downs due to boiler tube failures. &perations staff need to be trained in preventative maintenance procedures and processes. &ften, when boiler tubes undergo catastrophic failure, ad4acent tubes are often damaged as well, increasing the outage time. 7eriodic inspections and follow-up preventative maintenance is necessary to ensure the boiler system remains in good repair, and potentially e"tend its life-e"pectancy. With this in mind, we can conclude that periodic boiler inspection is a vital part of any maintenance regime, and that remote field testing is the optimal means for early detection of most causes of boiler tube failure. *uthor/ Aynor Celis, currently is Aar#eting Aanager for Batin *merica for Cussell D23 +ystems, 3dmonton, *,. Canada, $e has previous e"perience as operation manager in a coal-fired power plant, having responsibility for the operation of the boiler, water and wastewater systems, high and low boiler steam pressure. $e is a mechanical and electrical engineer with A,* speciali%ation.