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Boiler Super Heater Tube Failure Analysis

A boiler tube in the fourth stage super heater outlet header ruptured during routine patrol, and further inspection found another nozzle had also ruptured. The cause was determined to be that some tubes near the nozzles were overheated during fabrication, changing the local metal structure and reducing creep strength enough for early rupture. To prevent recurrence, the failed and distorted tubes found by inspection were replaced, and tube soundness will be confirmed during future turnarounds.

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Eslam Khamis
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331 views5 pages

Boiler Super Heater Tube Failure Analysis

A boiler tube in the fourth stage super heater outlet header ruptured during routine patrol, and further inspection found another nozzle had also ruptured. The cause was determined to be that some tubes near the nozzles were overheated during fabrication, changing the local metal structure and reducing creep strength enough for early rupture. To prevent recurrence, the failed and distorted tubes found by inspection were replaced, and tube soundness will be confirmed during future turnarounds.

Uploaded by

Eslam Khamis
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Boiler super heater tube failure

(Reference: Japan METI report)

Summary -One through water tube boiler -Fuel: only coal combustion -MCR 2,120t/h

-The leakage of steam was found during operators patrolling.


-One stub of 4th stage super heater outlet header was ruptured -As the result of extensive inspection, further one nozzle were found to be ruptured

4th S.H. inlet tube header

4th S.H. outlet tube header


Non-heating zone

Rapture

4th S.H. tubes Heating zone

4th S.H. outlet tubes header cross-section

Cause of failure
-When the header was fabricated in the factory, some tubes were heated to rectify the pitch of nozzles.
-The heating temperature was over phase transformation point, so locally metal structure changed and creep strength was down. So creep rupture occurred at short time which was expected.

Countermeasure to recurrence
-Failed tube and other distorted tubes found by extensive inspection (Total 29 tubes) were replaced to new ones.
-Soundness of the tubes were confirmed every turnaround

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