Skip to main content
SpringerLink
Log in

Water Wall Tube Cracking in an Ultra-Supercritical Boiler Caused by Deep Peaking

  • Original Article
  • Published:
Transactions of the Indian Institute of Metals Aims and scope Submit manuscript

Abstract

After running for about 59 000 h, the tubes at the intermediate mixing header of the furnace water wall leaked in an ultra-supercritical boiler. Preliminary analyses show that the primary crack may be initiated from two kinds of crack. One kind of crack is the dense transverse cracks in the external walls of the fireside, and the other one is the crack in adjacent H-shaped fin fillet weld. In order to figure out the initiation of the primary crack, the macroscopic morphology, chemical composition, microstructure, Vickers hardness and fracture morphology observation were conducted on the sample tube. The oriented dimples in the primary crack indicate that the crack propagates from the external side to the inner side. The erosive metal loss at fireside surfaces of tubes adjacent to the initial cracking shows significant differences. It is indicated that the primary crack is initiated from one side connected with the H-shape fin fillet weld crack. Based on comprehensive analyses of material quality of the sample tube and boiler operation data, it can be concluded that the wall temperature of water wall tubes changes with the frequent and large fluctuation of boiler load due to peak regulation operation, which is the root cause of fatigue cracking of H-shape fin fillet weld.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig.3
Fig. 4
Fig.5
Fig.6
Fig.7
Fig.8
Fig.9
Fig.10

Similar content being viewed by others

References

  1. James J. Dillon, Paul B. Desch, Tammy S. Lai, et al. Nalco Guide to Boiler Failure Analysis, Second Edition[M]. McGraw-Hil, in U.S.A, 2011.

  2. Ji L, Zhi C, Liying T, et al. Microstructure investigation on S30432 steel used for heating surface tubes of a double reheat boiler[J]. Therm Power Gener. 2017; (8):72–76. (In Chinese).

    Google Scholar 

  3. Liu, S.W.,Wang, W.Z, et al. Failure analysis of the boiler water-wall tube[J]. Case Stud in Eng Failure Analy. 2017, 9: 35-39.

    Article  Google Scholar 

  4. Duarte, C. A., Espejo, Edgar, et al. Failure analysis of the wall tubes of a water-tube boiler. Eng Failure Analy. 2017, 79: 704–713.

  5. Jeff Henry, Gang Zhou, Ted Ward. Lessons from the past: materials-related issues in an ultra-supercritical boiler at Eddystone plant[J]. High Temp Technol, 2014, 24(4):249-258.

    Google Scholar 

  6. S. Srikanth, K. Gopalakrishna, S. K. Das, et al. Phosphate induced stress corrosion cracking in a water wall tube from a coal fired boiler[J]. Eng Failure Analy, 2003, 10(4):491-501.

    Article  CAS  Google Scholar 

  7. Neal Hanke. Evaluation of a Failed Water Wall Boiler Tube[J]. J Failure Analy Prevent, 12(1):11–15.

  8. Zheng, Xiang Feng, Jiang, Yun Jian, Xue, Rong Gang,et al. Failure Analysis and Welding Repair for Water Wall Tube Crack of Supercritical Boiler[J]. Adv Mater Res, 1004–1005:1410–1414.

  9. ZHANG Guangcai, ZHOU Ke, LU Fen, et al. Discussions on deep peaking technology of coal-fired power plants [J].Therm Power Generat, 2017,(9):17–23. (In Chinese.)

  10. Ding N , Duan J , Xue S , et al. Overall review of peaking power in China: Status quo, barriers and solutions[J]. RenewSustain Energy Rev, 2015, 42:503-516.

    Article  Google Scholar 

  11. Ruppert, H. Barriers to Increased Flexibility of Thermal Power Plants. 2015,1–10. (https://www.researchgate.net/publication/309476773_Barriers_to_Increased_Flexibility_of_Thermal_Power_Plants)

  12. FAN Zhidong, MA Yichao, ZHANG Zhibo, et al. Failure Analysis of Water Wall Tubes' Leakage in (Ultra) Super-critical Boiler. Hot Work Technol, 2017, 46(23): 254–258,253. (In Chinese)

  13. ZHANG Jia-wei, ZHANG Zhong-hua, ZHANG Zhen-jie, et al. Reason Analysis and Process on Vertical Rising Rifled Tube Transverse Crack of Ultra-supercritical Boiler. Northeast Electric Power Technol, 2013, 34(10): 24–30. (In Chinese)

  14. National standardization administration of China. Seamless steel tubes and pipes for high pressure boiler [S]. GB/T 5310, 2018.

  15. YANG Jian-ju,ZHANG Dong-wen,FENG Yan-ting,et al.Preliminary analysis of ribben structure in high quality carbon steel [J].Therm Power Generat ,2009,(12):98–101. (In Chinese)

  16. ZHONG Qun-peng, ZHAO Zi-hua. Fractography[M], Higher Education Press, in BeiJing, 2005: 149–153. (In Chinese)

  17. Gu Y, Xu J, Chen D, et al. Overall review of peak shaving for coal-fired power units in China. Renew Sustain Energy Rev, 2016, 54:723-731.

    Article  Google Scholar 

  18. Yadav S D, Sonderegger B, Sartory B, et al. Characterisation and quantification of cavities in 9Cr martensitic steel for power plants. Mater ence Technol, 2015, 31(5):554-564.

    Article  CAS  Google Scholar 

  19. Kassner M E , Hayes T A . Creep cavitation in metals. Int J Plast, 2003, 19(10):1715-1748.

    Article  Google Scholar 

  20. S. K. Dhua, Atul Saxena, B. K. Jha. Failure Analysis of Boiler Tubes Used in a Thermal Power Plant [J]. Trans Indian Inst Metals. 2016, 69(2):653–657.

  21. Testing of metallic materials - Conversion of hardness values [S]. DIN 50150,1999.

Download references

Acknowledgement

This work was financially supported by the Science and Technology Project of China Huaneng Group [grant number HNKJ18-H45]. The authors are grateful for this support.

Author information

Authors and Affiliations

  1. Xi’an Thermal Power Research Institute Co., Ltd, Xi’an , 710054, China

    Zhidong Fan, Kun Niu, Zhibo Zhang, Yichao Ma, Chengxin Liu & Hongnian Dong

  2. Huaneng Shandong Shidao Bay Nuclear Power Co. Ltd, Weihai, 264312, China

    Qingwu Wang, Jingjing Jia, An Xu & Yingjie Zhan

Authors
  1. Zhidong Fan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Qingwu Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Kun Niu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jingjing Jia
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Zhibo Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. An Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Yichao Ma
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Yingjie Zhan
    View author publications

    You can also search for this author in PubMed Google Scholar

  9. Chengxin Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  10. Hongnian Dong
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Zhidong Fan.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Fan, Z., Wang, Q., Niu, K. et al. Water Wall Tube Cracking in an Ultra-Supercritical Boiler Caused by Deep Peaking. Trans Indian Inst Met 75, 183–191 (2022). https://doi.org/10.1007/s12666-021-02243-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12666-021-02243-4

Keywords

Search

Navigation