Failure Analysis

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Tube shows bulging and cracked with thick lip on Boiler Primary Super Heater Outlet Tube is attributed to (Creep) Long term overheating during service to above design temperature for a long time.
The Economiser tube bend shows failure with thin lips, Erosion on fireside surface and some reddish brown deposit on the water surface is attributed to fire side corrosion and erosion.
The Boiler bed coil tube showing severe external metal wastage (Erosion), Wall thinning and Pinhole failure on the fireside surface is caused by the movement of the bed materials / hard material in the coal.
Tube showing heavy deposits and pits on the water side of Economiser tube The failure is attributed to water side pitting corrosion.
Micro examination reveals several rounded Pits filled with Oxides & Heavy deposits on steam side surface of Re-Heater coil is due to Corrosion / Excess oxygen in the steam.
Tube shows bulging and burst opened with thin lips on Water wall tube is due to short term overheating to above design temperature.

 
Tube shows bulging near the burst and oxide scales on both the fireside and steam side surfaces of Boiler Final Re-Heater inlet coil the failure is attributed to (Creep) long term overheating during service to above design temperature for a long time.
The Boiler economizer tube showing the Failure, Erosion on fireside surface & Reddish brown deposits on waterside surface the failure of the tube is attributed to Water side corrosion.
Hydrogen Damage detected in water wall tube. The ID of the tube shows acidic deposit.

 

 
Tube shows bulging and burst opened with thin lips & Oxide scales on both the fireside and steam side surfaces the failure is attributed to short term overheating during service to above design temperature of the tube to below AC1 temperature for the steel.
Tube shows burst opening with thin lips and also mild erosion along the axis of burst and corrosion on Boiler Bank tube ID the failure of the tube may be attributed to waterside corrosion and erosion
The Severe external wastage / erosion of the Boiler bed coil tube is caused by high velocity movement of bed materials / hard faces in the coal.

 

 
Bed coil shows pinhole failures on the tension axis of bend, severe erosion around the failure on fireside surface and reddish brown deposit on waterside surfaces. The non- uniform erosion on OD is due to water impingement from the nearby failures (secondary) and not due to bed materials. The pinhole failures of the tube are attributed to a higher level of Oxygen content in the feed water.
Tube shows metal wastage, wall thinning and a small fine crack like failure near the fin weld and consequent failures is attributed to severe external metal wastage (Erosion) on Water wall tube.
The wide and deep pits and pitting corrosion observed on the waterside surface of the Boiler front water wall tube may be attributed to waterside corrosion.