Failure analysis of SG # 8 boiler super heater tubes

Super heater coils

Total nos. of coil - 10 nos.
Size & Material : 2 OD x 10 SWG ASTM A 192
Last replacement : 100% super heater coil replacement in April 2000.
4 coils were leaked in service .

CAUSES OF DETERIORATION IN FIRED BOILERS

OVERHEATING

Overheating is one of the most serious causes of deterioration of boilers.

Overheating of the boiler tubes and other pressure parts may result in oxidation,
accelerated corrosion, or failure due to stress rupture. Overheating develops from
abnormal conditions, including loss of coolant flow or excessive boiler gas
temperatures. These abnormal conditions may be caused by inherently faulty
circulation or obstructed circulation resulting from water tubes partly or wholly
plugged by sludge or dislodged scale particles. Overfiring or uneven firing of
boiler burners may cause flame impingement, short-term overheating and
subsequent tube failure. The results may be oxidation of the metal, deformation of
the pressure parts, and rupture of the parts, allowing steam and water to escape.
Boiler tubes may be damaged by poor circulation. Under certain conditions of
load and circulation, a tube can become steam-bound long enough to overheat
locally and fail. If circulation is periodically reestablished, the hot portion of the
tube is quenched by relatively cool water. This often causes thermal fatigue
cracks, which may eventually result in tube failure. This condition can also result
in caustic or chelate corrosion.
Steam binding may be caused by the insulation effect of slag deposits on the outside of the lower
part of the tube. This demonstrates the importance of avoiding, as much as possible, nonuniform
slagging of waterwalls. Steam superheaters can become overheated and severely damaged
during start-up if cold boilers are fired at an excessive rate before a sufficient flow of steam is
established to keep the superheaters cool. They can also become overheated if the steam vented

from the superheater outlet is not sufficient top provide steam flow through the superheater
during warmpup of lowload operations. The overheating results in warped tubes and oxidation
of the tube metal, leading to early tube failure.
The faulty operation of steam-separating devices may result in deposition of boiler water
solids in the superheater tubes, with subsequent damage to the tubes from overheating.
Nonpressure parts, including refractory linings of furnaces, burners, supporting structures
and casings, may also be damaged from overheating. Usually, such overheating is caused
by improper operating conditions or is a result of deterioration of other protective parts.
For example, if the refractory lining of a furnace is permitted to deteriorate from normal
wear, erosion, spalling or mechanical damage, it will no longer protect the outer furnace
casing and structural supports adequately and such parts may in turn being to deteriorate
rapidly.

GENERAL CAUSES OF SUPERHEATER TUBE FAILURES

The superheater tubes in a boiler can fail due to some of the following reasons :
a)
b)
c)

Tube overheating
Internal / external corrosion
Erosion

a)

TUBE OVERHEATING

One of the major reasons of superheater tube failures in boilers is

overheating. The localised overheating can take place either due to flame
impingement or due to reduced heat transfer caused by solid water deposits.
This localised overheating of the pipe reduces the high temperature strength
and finally results in either Thick lip or Thin lip rupture. Tube ruptures
due to overheating can be easily identified by the presence of oxide scales
and microstructure variations.
b)

INTERNAL / EXTERNAL CORROSION

The internal corrosion of the superheater tubes is generally caused by the

presence of the moisture film and oxygen during startup, shutdown and idle
periods. These conditions will finally lead to pitting type corrosion.
C)

EROSION

Failure due to internal steam impingement or external flue gas particles impingement is
not uncommon in superheaters. Abrasive erosion of superheater tubes on the external
surface results from impact by particles of fly ash entrained in the flue gas. Erosion is
enhanced by high flow velocities; thus partial fouling of gas passages in tube banks by
deposition of fly ash can lead to erosion by forcing the flue gas to flow through smaller
passages at higher velocities. Erosion by fly ash causes external tube polishing, flat spots
and wall thinning beginning from the external surface of tubes and result in tube rupture.
The internal tube erosion due to steam impingement occurs chiefly due to high velocity
flow of steam. The high steam velocities in superheater tubes can result either due to
partial blockage of tubes by deposits or due to reduced cross-section of the tube.
Improper fabrication techniques result in denting of the U-bends thereby reducing the
cross-section of the tube.
Failures due to internal steam impingement can be easily identified by internal thinning
of the bend and thin lip rupture.

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