Abstract
A failure analysis was carried out on an A213 T91 secondary superheater tube after 4 months of overhaul. The failure caused the 600-MW coal power plant was shut down. The investigation consisted of visual inspections, microstructure analysis, Vickers hardness test, x-ray diffraction, and ash fusion temperature test and ash content analysis. The failed tube had a thin-lip rupture with sharp edges and experienced a decrease in hardness in the area of lip rupture. The microstructure analysis shows the coarse carbide and some isolated voids. Corrosion products were detected in slag deposits, and nonuniform thin oxide layer in the inner wall of the tube was observed. It is concluded that the main failure of the failed tube was due to the formation of slag deposits on the outer surface of the tube wall. This formation has resulted in simultaneously occurring phenomena, which was the localized flue gas erosion followed by the rapid overheating of the tube. The formation of slag deposits was in consequence of the use of coal with lower ash fusion temperature than required coal ash fusion temperature for the power plant.
Similar content being viewed by others
References
G.K. Gupta, S. Chattopadhyaya, Critical failure analysis of superheater tubes of coal-based boiler. Strojniški vestnik J. Mech. Eng. 63(5), 287–299 (2017)
D.R.H. Jones, Creep failures of overheated boiler, superheater and reformer tubes. Eng. Fail. Anal. 11(6), 873–893 (2014)
A. Saha, H. Roy, Failure investigation of a secondary super heater tube in a 140MW thermal power plant. Case Stud. Eng. Fail Anal. 8, 57–60 (2017)
A.K. Pramanick et al., Failure investigation of super heater tubes of coal fired power plant. Case Stud. Eng. Fail. Anal. 9, 17–26 (2017)
G.A. Lamping, R.M.J. Arrowood, Manual for investigation and correction of boiler tube failures. Final report. Southwest Research Institute, San Antonio, USA, 331 (1985)
Z.-F. Hu, D.-H. He, X.-M. Wu, Failure analysis of T12 boiler re-heater tubes during short-term service. J. Fail. Anal. Prev. 14(5), 637–644 (2014)
S. Srikanth et al., Analysis of failures in boiler tubes due to fireside corrosion in a waste heat recovery boiler. Eng. Fail. Anal. 10(1), 59–66 (2003)
S. Chaudhuri, Some aspects of metallurgical assessment of boiler tubes-Basic principles and case studies. Mater. Sci. Eng. A 432(1–2), 90–99 (2006)
F. Masuyama, Creep rupture life and design factors for high-strength ferritic steels. Int. J. Press. Vessels Pip. 84(1), 53–61 (2007)
I.J. Perrin, J.D. Fishburn, A perspective on the design of high-temperature boiler components. Int. J. Press. Vessels Pip. 85(1), 14–21 (2008)
R.K. Roy et al., Analysis of superheater boiler tubes failed through non-linear heating. Procedia Eng. 86, 926–932 (2014)
R.W. Bryers, Fireside slagging, fouling and high temperature corrosion of heat transfer surface due to impurities in steam-raising fuels. Prog. Energy Combust. Sci. 22(1), 29–120 (1996)
A. Movahedi-Rad, S.S. Plasseyed, M. Attarian, Failure analysis of superheater tube. Eng. Fail. Anal. 48, 94–104 (2015)
S. Chaudhuri, R. Singh, High temperature boiler tube failures, Case studies, in Proceeding: COFA. 1997 (Jamshedpur, India), pp. 107–120
J.H. Swisher, S. Shankarnarayan, Inhibiting vanadium induced corrosion. Mater. Perform. 33(9), 49 (1994)
D. Young, High Temperature Oxidation and Corrosion of Metals, 2nd edn. (Elsevier, Amsterdam, 2016)
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Nurbanasari, M., Abdurrachim, H. & Prihadi, M.M. Failure Analysis of Secondary Superheater Tube in a 600-MW Coal Power Plant. J Fail. Anal. and Preven. 19, 453–460 (2019). https://doi.org/10.1007/s11668-019-00619-9
Received:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11668-019-00619-9