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Failure Analysis and Magnetic Evaluation of Tertiary Superheater Tube Used in Gas-Fired Boiler

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Abstract

Failure analysis was carried out on a prematurely failed tertiary superheater tube used in gas-fired boiler. The analysis includes a comparative study of visual examination, chemical composition, hardness and microstructure at failed region, adjacent and far to failure as well as on fresh tube. The chemistry was found matching to the standard specification, whereas the hardness was low in failed tube compared to the fish mouth opening region and the fresh tube. Microscopic examination of failed sample revealed the presence of spheroidal carbides of Cr and Mo predominantly along the grain boundaries. The primary cause of failure is found to be localized heating. Magnetic hysteresis loop (MHL) measurements were carried out to correlate the magnetic parameters with microstructure and mechanical properties to establish a possible non-destructive evaluation (NDE) for health monitoring of the tubes. The coercivity of the MHL showed a very good correlation with microstructure and mechanical properties deterioration enabling a possible NDE technique for the health monitoring of the tubes.

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Author notes

  1. Sujay Patil, formerly of JSW Steel Ltd, Bellary, India, is now deceased.

Authors and Affiliations

  1. JSW Steel Ltd, Toranagallu, Bellary, Karnataka, 583275, India

    J. N. Mohapatra, Sujay Patil & Rameshwar Sah

  2. JSW Energy Ltd, Toranagallu, Bellary, Karnataka, 583275, India

    P. C. Krishna & B. Eswarappa

Authors
  1. J. N. Mohapatra
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  2. Sujay Patil
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  3. Rameshwar Sah
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  4. P. C. Krishna
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  5. B. Eswarappa
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Correspondence to J. N. Mohapatra.

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Mohapatra, J.N., Patil, S., Sah, R. et al. Failure Analysis and Magnetic Evaluation of Tertiary Superheater Tube Used in Gas-Fired Boiler. J. of Materi Eng and Perform 27, 580–589 (2018). https://doi.org/10.1007/s11665-018-3171-7

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  • DOI: https://doi.org/10.1007/s11665-018-3171-7

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