Analysis of Steam Superheater Tube Failures of Medium Pressure Boilers

Paper No.
08433
ANALYSIS OF STEAM SUPERHEATER TUBES FAILURES

OF MEDIUM-PRESSURE BOILERS
Veronica A. Dominguez, Roberto Tedesco and Pablo G. Peña

Repsol YPF
Ruta 22 s/n 8318 Plaza Huincul
Neuquen, Argentina.
ABSTRACT
This paper describes the analysis of recurrent failures experienced on 1%Cr – ½%Mo steam
superheater tubes of two boilers at an oil refinery. In all cases, metallurgical analysis of failed tubes
has shown overheating of material, high temperature oxidation, bulging, cracks and creep
degradation as a result of internal deposits on tube wall. Chemical analysis of deposits samples has
determined the presence of sodium sulfate attributable to boiler water carryover to the superheater.
To determine the root cause, a comprehensive assessment of actual boiler conditions was carried
out, considering operation variables and procedures, maintenance and inspection programs,
combustion and control system modifications. On the basis of this assessment, an integral program
was implemented to improve boiler reliability.
Key words: superheater tube, boiler failure, high temperature oxidation, overheating.
INTRODUCTION
The two boilers analyzed, named B-601 and B-602, have thirty years in service and each one
produces 27 ton/h of superheated steam at a temperature of 290°C and pressure of 1.7 MPa. The
equipments are D – type water – tubes boilers. The original fuel oil – gas design combustion
burners have been replaced for new low NOx combustion burners, and are fed with a mixture of
natural gas and oil refinery fuel gas.
The superheater is divided in three passes composed of fifteen 1%Cr – ½%Mo tubes per pass. The
tubes are 50.8 mm in outside diameter and 3.4 mm in thickness, designed to work with steam
temperature up to 340°C. Superheaters are located within the convection zone, surrounded by
carbon steel boiler water tubes. Figure 1 shows the tube’s distribution and the localization of the
superheater inside the boiler.
During the last five years, recurrent failures of superheater tubes were experienced. Bulging, severe
scaling, and overheating were observed in the failed tubes. History of failures is summarized on
table 1.
Boilers are subject to a wide variety of failures involving different mechanisms. Most
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prominent among these mechanisms are corrosion, mechanical environmental processes, fracture
stress rupture, and distortion, especially distortion involving thermal-expansion effects or creep1,2.
Carbon and low- alloy steels are used extensively at elevated temperatures in fossil-fired power
generating plants, chemical processing plants and petroleum processing plants. Low – alloy steels
with 0.5%Mo in combination with 0.5 to 9%Cr are often used at up to about 650°C. The 1Cr-0.5Mo
steel is used for piping, cracking-still tubes and boiler tubes at service temperatures up to 510 or
540°C. The similar 1.25Cr-0.5Mo steel is used at up to 590° and has stress-rupture and creep
properties comparable to those of the 1Cr-0.5Mo alloy3.
Maximum temperature limit for 1Cr-05Mo superheater tube materials is specified at 649°C in
allowable stresses table in ASME Boiler Codes for Section I application. Although stress values at
temperatures of 625°C and above are permissible, use of these materials at these temperatures is
not current practice. In addition, allowable stresses for temperatures of 510°C and above are values
obtained from time-dependent properties4.
Corrosion due to high temperature oxidation occurs at temperatures above about 480°C for carbon
steel and increasing higher temperatures for alloys. The metal loss occurs as a result of the reaction
of metal with oxygen in the environment. Typically, at temperatures just above the temperature
where oxidation begins to occur, a dense comparatively protective oxide forms on the surface that
reduces the metal loss rate. The oxide scale tends to be significantly more protective as the
chromium concentration in the metal increases5. The 1Cr-0.5Mo steel exhibits oxidation rates about
6 mpy at 565°C, increasing up to 13 mpy at 600°C6. The maximum-use temperature based on
oxidation/graphitization criteria is established at 550°C for 0.5Cr-0.5Mo steels and at 565°C for
1.2Cr-0.5Mo steels.
Overheating may be produced either for excessive exposure of tubes to flue gases or for loss of
internal refrigeration. Mild restriction of flow favors a small degree of overheating and failure by
stress rupture; a sudden or severe restriction favors rapid overheating and tensile failure7. Deposits
can cause overheating failures by changing the heat-transfer characteristics of a tube bank or of an
individual tube.
In order to monitor the tube metal temperature, thermocouples were installed on superheater tubes
during the first boiler reparation. The thermocouples registered increasing temperatures up to 600
°C on subsequent failures. The thermocouples were installed on tubes adjacent the ruptured tubes,
so the real maximum temperature reached on failed tubes was certainly above the maximum
temperature registered by the thermocouples.
Table 1. Summary of superheater’s failures
Superheater time Qty. of failed

Failure Boiler Reparation
in service Tubes
1 B-602 25 years 2 Replacement of superheater assembly
2 B-601 25 years 3 Replacement of superheater assembly
3 B-601 8 months 2 Plugging of tubes
4 B-602 12 months 2 Replacement of tubes
5 B-602 30 months 2 Replacement of superheater assembly
Collection and careful consideration of the evidence will often identify the root cause of the failure,
which can be related to design, installation, operation, chemistry, or even repairs¡Error! No se encuentra el
origen de la referencia.
. The main purpose of this work is to make a thorough analysis to determine the root
cause of the superheater tubes failures and establish the corrective action to improve the boilers
reliability.
EXPERIMENTAL PROCEDURE
Microstructural analysis of failed tubes was made by optical microscopy. Sixteen metallographic
samples were extracted from diverse sections along the tubes. Sample preparation was made
according to standard ASTM E 3-80. Etching method use is contemplated on standard ASTM E
407-93. Both external and internal faces were evaluated by scanning electron microscopy (SEM)
and energy-dispersive X-ray microanalysis (EDAX).
Chemical analysis by spark metal analyzer was use to verify the tube material specification.
Characterization of deposits was made according to AWWA - APHA - WEF Standard Methods for
the Examination of Water and Wastewater.
Hardness test was made according to standard ASTM E10 on the extracted samples.
RESULTS AND DISCUSSION

Chemical analysis confirmed in all cases that the tube’s material was in accordance with
specification ASTM A - 213 Gr. T129 (Table 2).
Visual inspection of tubes surfaces revealed major scaling, attributable to high-temperature
oxidation and slight bulging in the section of fracture (Fig. 2 and 3). Cracks were observed along the
longitudinal axis of the tubes. Damage was initiated on the external surface where dark gray
deposits were observed. The high temperature oxidation damage was more significant on the
fireside of the tubes and nearly the complete thickness was consumed in the sector with cracks (Fig.
4 and 5). SEM – EDAX analysis of external scale determined that ferrous oxide was the essential
constituent of the deposits. The external damage can be seen on microstructural examination in Fig.
6.
In addition, the microstructure in the bulk material exhibited spheroidization and carbides
coalescence (Fig. 7); this indicates that the material was overheated at temperatures above 540°C.
The observed decomposition of pearlite into ferrite and spheroidal carbides weakens tube materials,
and may result in a loss in strength and/or creep resistance10. Hardness measurements obtained on
this area are between 130 – 140 HB; which is significantly lower to values obtained on non affected
zones where hardness resulted to be about 160 – 165 HB. Typical microstructure for 1%Cr –
½%Mo steel was observed in non-affected tube material (Fig 8), which indicates that overheating
was originated during the service of the component.
The major thickness decrease by high-temperature oxidation in combination with the deterioration of
the mechanical properties by overheating, are the probably causes that lead to the stress-rupture of
the tubes.
Table 2. Chemical Analysis of tubes material
Sample C Si Mn Cr Ni Mo P S
1 0.06 0.66 0.67 1.01 0.03 0.46 0.02 0.02

2 0.07 0.62 0.65 1.05 0.01 0.47 0.02 0.02
3 0.12 0.49 0.40 1.10 0.03 0.57 0.02 0.02
4 0.12 0.48 0.43 1.07 0.01 0.55 0.02 0.02
5 0.13 0.80 0.45 0.95 0.03 0.45 0.02 0.02
6 0.12 0.79 0.44 0.94 0.01 0.46 0.02 0.02
ASTM A213 T12 0.05 – 0.15 0.5 0.30 – 0.61 0.80–1.25 … 0.44–0.65 0.025 0.025
Except on the first superheater failure, deposits were also observed on internal surfaces of tubes
(Fig. 9 and 10). In the case of second and third failures, SEM – EDAX analysis determined that the
majority constituent was iron oxide, with peaks of sodium, silicon, calcium and sulfur. In the case of
fourth and fifth failures, internal components mainly detected were sulfates and chlorides. Table 3
resumes the internal deposits characterization.
The deposits observed inside of the superheater tubes indicate that water boiler entered the
superheater. Phosphate treatment is used for boiler water; thus salts such as sulfates, chlorides,
silicates and phosphate are present in the solution. These salts are removed by the continuous
purging of the steam drum, and salt deposits on the bottom drum are eliminated by batch purge.
When boiler water gets into the superheater tubes, it vaporizes accumulating salt deposits on the
tube’s internal wall.
Table 3. Internal deposits analysis
Composition, % wt
Component
Failure #2 Failure #3 Failure #4 and #5
-
Cl 7 - 21.4
=
CO3 - 0.67 4.8
=
SO4 2.3 1.4 25.4
Na 26 - 35
Ca - - 3.2
Mg 0.03 - 0.4
Silicates 2.8 10.3 6.4
Total Fe 63 87 0.9
Boiler water carry over may be produced by different causes such as excessive high water level,
foam formation, or incorrect steam drum internals assembly.
Visual examination of the steam drum interior revealed an uneven water level mark (Fig. 10). On the
superheater end of the drum, where hot flue gases leave the furnace, the water level was observed
to be significantly higher than the normal operation water level mark on the opposite end of the
drum (Fig.12). The excessive level at the end of the drum could not be detected by the level
indicator and it was probably causing boiler water carry over to the superheater.
After consulting to the boilers designer, it was established that the uneven level could be produced
by excessive exposure of the bottom of the steam drum to hot flue gases leaving the furnace.
Normally, the under side of the steam drum is covered by refractory where it is exposed just above
the superheater (Fig. 13), even so the refractory insulation was not specified on the boilers original
drawings. During inspection, no refractory insulation was observed on the bottom of the steam
drum.
Low NOx combustion burners were installed in year 2000, replacing the original fuel oil - gas
combustion burners. The flame was observed to be longer and unstable, reaching almost the front
wall of the furnace; but no flame impingement was detected on radiant zone tubes. Flue gases
temperature registered a rise of about 100°C comparative with the original burner’s performance.
The increased flue gas temperature, in combination with the lack of refractory insulation of the
steam drum bottom, was the most likely cause of the irregular water level and the consequent boiler
water carry over to the superheater.
Refractory insulation, 50 mm in thickness, was installed on the steam drum underside (Fig. 14).
After this, a straight water level mark was observed all along the steam drum.
Nevertheless, boiler water entering the superheater was still been observed. This was evidenced by
high water levels registered in the steam drum, followed by abrupt decrease indicated on
thermocouple’s temperature of the superheater tubes. The excessive high water level events were
registered when rapid load swings from 50% to 90% were experienced. In these cases, the steam
drum level was extremely difficult to control.
The components of the drum level control system were analyzed. Correction on the level indication
was made, verifying correspondence with the plant visual indicator. The flow regulator control valves
(FRCV) of boiler feed water had poor response under sudden load changes. Figure 15 shows the
corrosion products found on internals of valves during maintenance; the stems normal travel was
probably affected by the scaling causing the valves not to operate correctly. Preventive
maintenance frequencies of valves and instruments were increased in order to assure the reliability
of the drum’s level control system components. However, the bad response of the control system
was still an issue.
The original operative condition of the plant established that the two boilers were operated in
automatic. Thus, in the case of sudden load change, the control system can reply with both boilers
at the same time. Nowadays, the boilers are operated one in automatic and the other one in
manual; hence, there is only one boiler available to respond in case of abrupt changes on steam’s
demand. The control system is too slow to regulate the FRCV of boiler feed water and level of
steam drum is exceed.
The drum level control configuration is according to the standard one used in similar boilers, so the
poor respond is probably related to a tuning problem of the control system. A specialist in boiler
instrumentation and control should evaluate the system for enhancement.
As internal deposits in tubes were proved to be water soluble salts, counter flow cleaning of the
superheater was implemented after steam drum high level detection. Unfortunately, no satisfactory
results were obtained as enough recirculation flow rate was not achieved.
The boilers’ start up procedure was modified; continuous venting of the superheater, until the
production condition is reached, was put into practice. This operation facilitates the removal of solids
present in the tubes.
Boilers operator’s training was carried out to incorporate the procedures changes.
CONCLUSIONS
According to the analysis, the tubes stress-rupture was caused by overheating and high
temperature oxidation. The tubes worked at high temperature as a result of internal deposits that
affected the heat transfer characteristics.
The internal deposits were originated by boiler water carry over to the superheater tubes due to
steam drum high water level. This was a consequence of two main combined factors:
1 – Excessive exposure of the underside of the steam drum to flue gases as a result of increased
temperature after the burner’s design changed.
2 – System failing to control the steam drum level.
The installation of a 50 mm in thickness of refractory insulation avoid the excessive exposure of

steam drum’s underside to flue gases.
A revision of the control system’s tuning may possibly solve the problem with the poor system
response on drum level control. In addition, the control system should be evaluated by a boiler
instrumentation specialist for enhancement.
Thermocouples installed on the tubes were proved to be useful to detect either boiler water entering
the superheater and excessive tube metal temperature.
Reviewing of the maintenance and inspection program, in combination with revision of operational
procedures and training of personnel, was required in order to achieve an improvement in the
boiler’s reliability.
REFERENCES
1. ASM International Handbook Vol. 11. “Failure Analysis and Prevention”. p. 602.
2. D.L. Cypriano Nevesa, J.R. Carvalho Seixasa, E.B. Tinocob, A. da Cunha Rochac, I. de
Cerqueira Abudc “Stress and Integrity Analysis of Steam Superheater Tubes of a High
Pressure Boiler”. Materials Research, Vol. 7, N° 1, 155-161, 2004.
3. ASM international Specialty Handbook. “Heat-Resistant Materials” p. 89.
4. 2004 ASME Boiler & Pressure Vessel Code. Section II Part D.
5. API Publication 581” Risk – Based Inspection, Base Resource Document.”. First Edition.
2000.
6. George Y. Lai. “High-Temperature Corrosion of Engineering Alloys”. ASM International.
1990
7. ASM International Handbook Vol. 11 “Failure Analysis and Prevention”, p. 609.
8. P.B. Desch and J.J. Dillon. “The metal doesn’t lie – Investigative boiler failure analysis”
NACE Annual conference & Exposition. 2006
9. ASTM A 213/A 213M – 07 “Standard Specification for Seamless Ferritic and Austenitic Alloy-
Steel Boiler, Superheater, and Heat-Exchanger Tubes”.
10. API Recommended Practice 571”Damage Mechanisms Affecting Fixed Equipment in the
Refining Industry”. First edition, 2003.
Figure 1. Superheater location.
Figure 2. Failed tubes on superheater (white scale was verified to be salt deposits).
Figure 3. Swell on failed tube.
Figure 4. External view of failed tube. Overheating and high

temperature oxidation is observed.
Figure 5. Failed tube with evidence of overheating.
Figure 6. External surface 800X. External high temperature oxidation (top)

and spheroidization carbide is observed.
Figure 7. Bulk material micrograph 800X. Carbides spheroidization is observed.
Figure 8. Micrograph of non-affected tube 800X. Typical microstructure is observed.
10
Figure 9. Internal deposits on failed tube.
Figure 10. Internal deposits on failed tube.
11
Figure 11. Uneven level observed on steam drum.
Figure 12. Steam drum level mark on superheater area.

Connecting tubes and dry box opened on the left.
12
Figure 13. Superheater lateral view
Figure 14. Refractory lining installed on bottom of steam drum.
13
Figure 15. Feedwater control valve. Corrosion deposits were observed on
bonnet flanged joint during maintenance
14

Analysis of Steam Superheater Tube Failures of Medium Pressure Boilers

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Paper No.

ANALYSIS OF STEAM SUPERHEATER TUBES FAILURES

Veronica A. Dominguez, Roberto Tedesco and Pablo G. Peña

Table 1. Summary of superheater’s failures

Superheater time Qty. of failed

RESULTS AND DISCUSSION

1 0.06 0.66 0.67 1.01 0.03 0.46 0.02 0.02

The installation of a 50 mm in thickness of refractory insulation avoid the excessive exposure of

Figure 4. External view of failed tube. Overheating and high

Figure 6. External surface 800X. External high temperature oxidation (top)

Figure 8. Micrograph of non-affected tube 800X. Typical microstructure is observed.

Figure 10. Internal deposits on failed tube.

Figure 12. Steam drum level mark on superheater area.

Figure 14. Refractory lining installed on bottom of steam drum.

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