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Metallurgical Aspects of Boiler Tube

Failures

A Few Case Studies

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Metallurgical analysis

Failure analysis

Health/ Condition Assessment Residual Life Assessment

Indegenisation / Material Development

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Components

Boiler tubes

Turbine components

High Energy Piping

CHP Components

Grinding elements

Gas Turbine Components

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Failure Mechanisms

(Water Touched Tubes)Corrosion Fatigue

Flyash Erosion

Hydrogen DamageAcid Phosphate corrosion

Caustic Gouging

Fireside Corrosion

Thermal FatigueErosion Corrosion

Sootblower Erosion

Short Term Overheating

Low Temperature Creep

Chemical Cleaning DamageFatigue

Pitting

Coal Particle Erosion

Falling Slag DamageAcid Dew Point Corrosion

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Visual examination of damaged parts is the first

and most critical step in failure investigation

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Case Studies in Failure

Investigation

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Singarauli STPS

Boiler No.3

Date of Failure: 05/04/2004

Zone: Economiser Lower Bank

Location: Coil No.02

Material: SA210 A1R&D Ref: 2210

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Ramagundam STPS

Boiler No.1

Date of Failure: 01/03/2004Zone: Economiser LHS wall

Location: Bank no.03 (from rear)

Material: SA210 A1R&D Ref: 2198

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Long Term Overheating

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Talcher #2, StageI

S-Panel Water Wall Tube Failure

Dated 09/01/2004Report:R&D/MET/2130

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Pinhole on weld

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2073

Origin of Leak

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Origin of Leak

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NCPP Dadri #2

S-Panel Water Wall Tube Failure

Dated 05/11/2003

Report No. R&D/MET/R-2118

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TANDA Unit #2

Hydrogen Damage Failure in Water Wall

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Talcher Thermal Unit #6

Weld Defects in Economiser Tube

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Hydrogen Damage

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y g g

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Usefulness of Failure Analysis

Establishing the main reason of failure

Taking remedial action to prevent furtherfailures

Reduces forced outages

Helps in taking decisions for making designmodifications, if necessary

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