TYPICAL BOILER TUBE FAILURE

ANALYSIS
Tube failures occur due to the ‘Overheating’ and the ‘Plastic Flow’ conditions associated with
restricted flow of water in side of the particular tube facing failure.

Such failures are generally of two types:

(i) Overheating in ‘Short Duration’
(ii) Overheating over a ‘Long Period’

Careful examination of the failed tube section reveals whether the failure is on account of rapid
acceleration in the tube wall temperature or it is on account of a long term gradual build up/
accumulation of the cause of failure.

(a) Short Duration Over-Heating: -

When conditions causing a rapid metal temperature elevation at local spot occur, a violent rupture
results. The ‘Plastic – Flow’ phenomena of ‘Carbon Steel’ materials at temperatures between: 700 0C
– 800 0C is the cause of such occurrences.

PHOTOGRAPH 1

Interruption/ Restriction, in the water circulation by some blockage in tube leads to such failures, as
the tube metal gets exposed to direct flames in such cases.

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(b) Long Duration Over-Heating: -
‘Long Term’ conditions finally lead to a tube leak; wrinkled or bulged external surfaces are observed
in such cases. Such appearance is caused by long term ‘Creep Failure’ causing by repetitive scale
formation, which leads to ‘Overheating’, thus ‘Swelling’ the surface, forming a Bulge or Blister,
visually observable minor fissures, etc. on external surfaces. Photograph 2 given hereunder
illustrates the same.

PHOTOGRAPH 2

(c) Some Suggestions for Avoiding Such Failures: -

It is recommended that the quality of the ‘Boiler Feed Water’ for boilers operating at 21 Kg/ cm2 (g)
should be as per the annexure ‘A’ attached herewith.

It is also recommended that the ‘Blow Down Time’ & duration should be observed as per the
annexure ‘B’ attached herewith.

Blow Down must also be conducted on regular basis (When Boiler is in Low Steaming Stage) from
side wall, rear & front wall headers; so that sludge accumulation in these headers may be avoided;
which otherwise would rise in furnace tubes creating conditions for circulation restrictions/
blockage, thus overheating at local spots.

At times, foreign matters get left behind during the erection. Such happenings may be avoided by
carefully examining tubes/ headers after fitting the same by a suitable method, such as, ball test/
by passing water & observing flow at the other end (where possible). Anyhow, these precautions
should be taken before the firing of the Boiler.

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 ANNEXURE ‘A’

Sr. Feed Water

1 Hardness, Max. (as Ca CO3) mg/L : 10

2 pH at 25 0C : 8.8 to 9.2

3 Oxygen, Max. mg/L : 0.1

4 Total Iron mg/L : 0.100

5 Copper, Max. mg/L : 0.05

6 Total Dissolved Solids, Max. mg/L : 200

Sr. Boiler Water

1 pH at 25 0C : 9.8 to 10.8

2 Phosphate Residual (as PO4) : 20 to 40 (If Added)

3 Total Dissolved Solids, Max. (T.D.S.) mg/L : 3500

Specified Electrical Conductivity at 25 0C, Max.

4 : 7000
Microsiemens/ cm

5 Total Alkalinity mg/L : 700

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