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Boiler tube failures (BTFs) in natural circulation high pressure drum boiler of a
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Journal of Scientific & Industrial Research
SOHAIL et al: BOILER TUBE FAILURES IN NATURAL CIRCULATION HIGH PRESSURE DRUM BOILER
Vol. 68, January 2009, pp. 61-65
61

Boiler tube failures (BTFs) in natural circulation high pressure drum boiler of a
power station
M Azad Sohail1*, A Ismail Mustafa2 and M Abdul Gafur3
1
Central Chemical Research Laboratory, Ghorasal Thermal Power Station, BPDB, Narsingdi 1610, Bangladesh
2
Department of Applied Chemistry and Chemical Technology, University of Dhaka, Dhaka 1000, Bangladesh
3
Pilot Plant and Process Development Centre, Bangladesh Council of Scientific and Industrial Research, Dhaka 1205, Bangladesh

Received 18 July 2007; revised 13 October 2008; accepted 25 November 2008

This paper assesses boiler tube failures (BTFs), especially in boiler water wall tubes (BWWTs) for a natural circulation
high-pressure fossil (natural gas) drum boiler unit (TIME-COB-206, Russia). Metallographic (micro and macrostructural)
examinations of BWWTs materials (carbon steel, Russia) were carried out extensively. Analyses of carbon (mild) steels (0.22%
C) revealed distinctive changes in ferrite-pearlite distribution, might be due to decarburization. Huge pits, few grooves followed
by flow lines were observed on internal surfaces of BWWTs with respect to length of power plant operation. Corrosions or
scaling in BWWTs depicted one of the major causes of BTFs in fossil units with drum boilers usually treated by coordinated
phosphates.

Keywords: BTFs, Boiler, Hydrogen damage, Regime, Water wall tubes

Introduction 206, Russia), at unit No.4 Ghorasal Thermal Power Station

Boiler tube failures (BTFs), due to corrosion, scale
formation and materials degradations, are major
problems in thermal power plants. Dooley 1,2
investigated tubes failures in conventional fossil fired
boiler as well as in combined cycle power plant, besides
BFTs in all volatile treaded (AVT) fossil drum boiler
unit. Bursik3 found that under-deposit mechanism
continue unabated with hydrogen damage occurring in
drum boiler unit (60%) due to deficiencies in cycle
chemistry. Hirano4 investigated corrosion behavior of
boiler materials during long-term lay up of a fossil unit.
Kohler5 studied corrosion damage in copper alloyed
power cycle components of thermal power plant.
Hickling6 identified environmentally assisted cracking
(EAC) of carbon steel and low-alloy steels pressure
vessels and pipelines for steam generating system of
nuclear power plants. Prisyazhniuk 7 simplified a
technique for calculating index of corrosion and scale
forming properties of boiler water.
This study presents cause failures in boiler water
wall tubes (BWWTs) materials (carbon steel, st.- 20,
Russia) for a natural circulation water wall tubes high
pressure (158 kgfcm-2) drum boiler unit (TIME-COB-
*Author for correspondence
E-mail: masohail2004@yahoo.com
(GTPS), Bangladesh.
Experimental Procedure
Using a Metallurgical Microscope (Japan), micro and
macro structural investigations of BWWTs materials were
carried out. During analyses of microstructures,
hydrochloric acid, nitric acid and water were employed
for etching of sample materials. Analyses of the
composition of BWWTs materials, deposits attained and
operational chemical parameters of boiler water were
carried out by using an Atomic Absorption
Spectrophotometer (AAS), model: AA6650, Shimadzu
(Japan) and a Photo-electric colorimeter, model: KFK-2
(Russia).
Measurement of Deposits
Quantity of deposits on inside surface of BWWTs at
different period of time was determined8 by rubbing out
deposits from a definite surface area (3 cm × 3 cm) of
WWTs followed by weighing. Composition of deposits
(as oxide) was determined by gravimetric8, titrimetric,
AAS and colourimetric8-10 techniques.
Results and Discussion
Coordinated phosphate treated natural circulation water
wall tubes high pressure drum boiler unit No.4, at GTPS,
Bangladesh, is operated with maintaining chemical
 62 J SCI IND RES VOL 68 JANUARY 2009

parameters as supplied by the Russian plant

manufacturers (Table 1). Chemical analyses of BWWTs

3.0-6.0

Up to
P043-
materials (carbon steel, st.-20, Russia) collected from

30
-

-
boiler unit No.4 revealed slight changes in constituents
in BWWTs. (Table 2). Steel BWWTs contained (average

≤0.005
values): C, 0.22; Si, 0.21; Mn, 0.47; S, 0.02; and P,

0.010
0.015%.
Na

-
During last overhauling of unit, hard, irregular, dark
brown to black, tenacious deposits have covered internal
0.010

0.020
DO

surfaces of BWWTs after 96000 h of boiler operation.

—
Table 1Supplied (Russian) parameters for natural circulation high -pressure (158 kgf.cm-2) drum boiler unit

-
Witch often indicates that deposition11 has been occurring
for a long time at high metal temperature. Maximum
0.040
0.02

0.02

0.60 deposits were observed on fireside internal surface (388

Fe

-
gM-2) and on insulation side of internal surfaces (290
gM-2). Extensively immaculate chemical compositions
∠0.005

∠0.005

(as oxides) of deposits collected (by rubbing out) from

TIME-206-COB (Russia) of Ghorasal Power Station, Bangladesh

Cu

internal surfaces of BWWTs after three different periods

(21900 h, 43800 h and 96000 h) contained maximum (%)
0.002

0.004

0.004

amount of Fe2O3, followed by SiO2, CaO, MgO, P2O5,

Cl-

Al2O3 and CuO (Table 3). As such a types of hard

deposition on BWWTs, essentially due to excessive
0.5-1.0

0.5-1.0
NH 3

fireside heat input, uncontrolled chemical dosing as well

-

as administration of contaminated makeup (feed) water

into boiler water chemical regime (BWCR) due to
0.02-0.06

condenser leakage.
Trace
N 2H 4

Microstructure images of internal BWWTs materials

-

(carbon steel, st-20, Russia) of unit No.4 after 43800h

(Fig. 1) and 96000 h (Fig. 2) of power plant operation
0.02-0.04

0.02-0.04

0.50-1.50
0.02-0.1

depicted distinctive changes (spreading trends) in ferrite

2.0-6.0

≤0.015

(white) and pearlite (lamellar, black, i.e. γ→∝+ Fe3C)

SiO2

distributions with respect to plant operating period.

Microstructural change in carbon mild steel also indicates
0.1-0.2
∠0.05

∠0.05

∠0.05

∠0.05

decarburization, initially around pearlite and then gradually

H2

spreading, may be due to long term high rate of heat

flow through BWWTs. Macrostructure images of the
0.35-0.40

30.0-45.0
Alk. p/m

0.50-1.0

0.50-1.0

0.50-1.0

internal BWWTs materials of unit No.4, after 96000 h of

2.0-3.0

2.0-3.5

1.5-2.0
4.5-6.0

1.5-2.5

2.0-3.0

plant operation revealed huge pits and very few numbers

00

of grooves on internal surfaces of BWWTs in transverse

section (Fig. 3) and while irregular parallel flow lines
Up to 40
0.3-1.5

9.1±0.1 0.8-4.0

9.1±0.1 0.8-4.0

4.0-8.0

were observed on inside surfaces of BWWTs at

EC*-µ Scm-1, Other units-mgl-1
EC*

longitudinal direction (Fig. 4).

9.1±0.1 -

Oxygen pitting was present along waterline throughout

6.5-6.8

internal surfaces of BWWTs due to improper hydrazine

pH

9.3

9.5

dosing. While grooves might be resulted from

accumulation of highly concentrated NaOH in BWWTs
(blow down)
Condensate

Salt section
Boilerdrum
DemiWater
Parameters

Feedwater

as well as erosion loss due to long time high rated

(clean)

circulation of water-steam system as well as excessive

Steam

boiler blow down. Close macrostructure images show

finely spaced, wave lines, parallel undulation on eroded
 SOHAIL et al: BOILER TUBE FAILURES IN NATURAL CIRCULATION HIGH PRESSURE DRUM BOILER 63

Fig. 1—Microstructure of ∅ 60 × 6 Carbon Steel, Water Wall Fig. 2—Microstructure of (∅ 60 × 6 Carbon Steel, Water Wall
tube showing ferrite and pearlite × 600 (after 43800 h) tube) unit No. 4 showing ferrite and pearlite × 600 (after 96000 h)

Fig. 3—Macrostructure of (∅ 60 × 6 Carbon Steel, Water Wall

Fig. 4—Macrostructure of (∅ 60 × 6 Carbon Steel, Water Wall
tube, internal) unit No. 4, showing etch pits, × 60, in the
tube) unit No. 4, showing flow lines in the longitudinal directions,
transverse section (after 96000 h)
× 60 (after 96000 h)

45 0

40 0

35 0

30 0
D e pos it gM-2

25 0

20 0

15 0
F ire s ide (15 8 k gfc m -2)
10 0 in sula tio n s ide (158 k gfc m -2)
F ire s ide (10 0 k gfc m -2)
50 in sula tio n s ide (100 k gfc m -2)

0
0 20 00 0 40 00 0 60 00 0 80 00 0 10 00 00 12 00 00
O pe ratin g p eriod , h

d
-2
m d.
Fig. 5— Macrostructure of (∅ 60 × 6 Carbon Steel, Water Wall -2
Fig. 6—Amount of deposit (gm ) built up on boiler water wall
tube, external fire side) unit No.4, showing flow lines and groove tubes of 158 and 100 kgf cm-2 boilers with respect to operating
in the longitudinal directions, × 60, (after 96000 h). period
64 J SCI IND RES VOL 68 JANUARY 2009

fireside external surfaces of boiler WWTs followed by
distinctive hemispherical pits adjacent to a distinct
groove after 96000 h of plant operation (Fig. 5). It
happened possible due to erosion of tube materials by
highly heated fuel flow containing trace amount of
sulphur in the fuel. Corroded regions of fireside boiler
WWTs were covered with a thin but soft layer of brown
corrosion product, which contained: iron, 93.4; silica,
3.3; carbonates, 1.7; and sulpher, 1.1%.
Scale layer thickness as well as deposits quantity
(gM-2) in BWWTs increases with increase in boiler
pressure followed by length of plant operation (Fig. 6).
Moreover, burner position and excessive steam
production contributed significantly to deposition and
eventual overheating. So far, in one of the fireside tube
(No.10, panel No.13), slight rupture and fissuring, might
be caused by very long -term expose of metal to high
temperature. Deposits contained high level of silica
(10.7% SiO2) in its constituent. Therefore, silica-
containing deposits have very low 12 thermal
conductively (0.2-0.6 Kcal.m-1.h.°C). Even a relatively
small amount of such a type of deposit can cause rise
in wall temperatures considerably, and hence results in
boiler tube overheating followed by bulging, rupture,
and bursting of BWWTs..
Grooving on internal surfaces of boiler, WWTs might
be resulted from caustic accumulation from excessive
phosphates dosing into BWCR. Phosphates dosing
parameters in BWCR of such a high-pressure drum
boiler is found to be very high in comparison to
Japanese13 practices of similar capacity. Actually,
phosphates in BWCR produce NaOH and apparently
concentrated to corrosive level beneath porous iron
oxide deposits. Presence of hard magnetite deposits
indicates exposure to concentrated NaOH 14
adminstration in BWCR, which may finally cause in
hydrogen damage9 that is almost always associated with
BWWTs metal gouging followed by thick-walled
ruptures. Robin15 depicted that employing steel alloy 600
(USA) tubes in re-circulating steam generators (RSGs),
which chemically treated with phosphates, produces
excessive corrosive thinning (waste) followed by stress
corrosion cracking (SCC) on internal tubes materials.
After completion of overhauling the unit No.4, boiler
was acid cleaned carefully and boiler chemical
parameters were re-evaluated, especially phosphates
parameter has been minimized. Now, unit has been
operated at or slight below the designed loads and
ensuring that all boiler components are working
effectively. Procedure has minimized solid deposition
on internal surfaces of BWWTs tube.

Table 2—Chemical composition (%) of boiler WWTs (158 kgf.cm-2 boiler) materials (carbon steel,
st.-20, Russia) with respect to operating period

Location Operating Chemical composition, %

period, h Carbon Silicon Manganese Sulphur Phosphorus

Right wall 0 0.24 0.18 0.55 0.03 0.03

Left wall 21900 0.22 0.21 0.50 0.02 0.01
Front wall 43800 0.21 0.22 0.48 0.02 0.02
Back wall 96000 0.18 0.23 0.44 0.03 0.02

Table-3—Chemical composition (average) of deposits attained on internal surfaces of boiler WWTs (158 kgf.cm-2 boiler) as a function of
plant operation at GTPS, Bangladesh (maintaining chemical parameters as Table 1)

Operating Oxide, %
period, h
Fe2O3 SiO2 CaO MgO Al2O3 P 2O 5 CuO

21900 82.4 6.20 3.88 2.27 0.71 2.90 0.82

43800 72.3 8.2 6.20 3.80 1.9 4.8 1.02
96000 63.2 10.7 8.38 5.84 2.8 5.6 1.78
 SOHAIL et al: BOILER TUBE FAILURES IN NATURAL CIRCULATION HIGH PRESSURE DRUM BOILER
Conclusions
Administration of contaminated feed water (due to
condenser leakage), excessive dosing of phosphates in
BWCR, non-uniform practices of boiler blow down as
well as over firing during startup are major causes of
hard deposition on BWWTs, in such a type of high
pressure drum boiler with respect to length of plant
operation. Long term overheating of BWWTs caused
distinctive microstructure changes in BWWTs materials
(carbon steel, st.-20, Russia) due to carburization,
initially around pearlite and then gradually spreading
and causeing micro fissuring, leading to inter-granular
cracking followed by hydrogen damages. Thermal
stresses during startup, shutdown, load changes as well
as faulty boiler firing and fuel adjustment may also be
reason for scaling followed by metallographic change
in BWWTs materials.
Acknowledgement
Authors thank Head, Department of Materials and
Metallurgical Engineering, Bangladesh University of
Engineering Technology (BUET), Dhaka 1000,
Bangladesh for help in micro and macro examination.
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