Engineering Failure Analysis 10 (2003) 645654

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Assessment of service exposed boiler tubes

A.K. Raya,*, S.K. Sahayb, B. Goswamia
a

National Metallurgical Laboratory, Materials Evaluation Division, Jamshedpur, 831007, India

b
Department of Metallurgy, National Institute of Technology, Jamshedpur, 831010, India
Received 7 March 2003; accepted 12 March 2003

Abstract
Boiler tubes in power plants have nite life because of prolonged exposure to high temperature, stress and aggressive
environment. Service-exposed platen superheater and reheater tubes (148,900 h) made of 2.25Cr-1 Mo steels in a 120
MW boiler of a thermal power plant were evaluated for remnant life. The investigation included hot tensile tests, hardness measurement, dimensional measurement, microscopy and creep tests. Experimentally determined yield and ultimate
tensile strength, and estimated 10,000100,000 h rupture strength in the temperature range 520580
C, exhibited a
decreasing trend with increasing temperature. Microstructural study did not reveal any signicant degradation in terms
of creep cavities, cracks, graphitization, etc. Analysis of tensile and stress rupture data revealed that although there was
degradation of the tubes due to prolonged service exposure in terms of the ultimate tensile strength values, stress rupture
plots showed that the service exposed superheater and reheater tubes could remain in service for a length of more than 10
years at the operating hoop stress of 40 MPa/540
C, provided no localised damage in the form of cracks or dents develop.
# 2003 Elsevier Ltd. All rights reserved.
Keywords: Creep; Boiler tube; Residual life; Stress rupture test; Service exposed

1. Introduction
Remaining life assessment (RLA) of aged power plant components in the present highly competitive
industrial scenario has become very popular both for economy and safety reasons. In India there is a great
demand for RLA since some of the 60,000 MW capacity power sectors have become older than 20 years. In
real life both premature retirement and life extension (in relation to design life) can be encountered. The
decision for retiring a component is not purely technical but also one of economics and safety. This has
attracted a few multinationals for RLA studies and the broad purpose is:
 Evaluation of parts for the degree of aging and remaining life.
 Replacement of parts.
 Improvement in the construction of components through material substitution, shape alteration and
reinforcement.
* Corresponding author. Tel.: +91-657-426-091; fax: +91-657-227-0527.
E-mail address: asokroy@nmlindia.org (A.K. Ray).
1350-6307/03/$ - see front matter # 2003 Elsevier Ltd. All rights reserved.
doi:10.1016/S1350-6307(03)00063-3

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A.K. Ray et al. / Engineering Failure Analysis 10 (2003) 645654

 Development of an on-line diagnosis system to monitor aging of components and assure proper
functioning of the unit within a xed period of time.
Boiler components used in power plants have nite life because of prolonged exposure to high temperature, stress and aggressive environment. However, past experience has shown that for a variety of reasons
these may have signicant remaining life beyond the design specication. This is best estimated by conducting a systematic life assessment exercise during a planned shutdown. In most cases damage accumulation starts from the outer surface. It manifests itself as surface cracks. Therefore careful visual
examination and non-destructive tests (e.g. DPI, MPI) carried out on the outer surface can give a fair idea
about the health of the component. In addition use of ultrasonic aw detectors can also detect nucleation
of defects within the material.
It is widely known that carbon and CrMo steels are extensively used as high temperature components in
power plants [111]. Even though most of these components have a specic design life of 20 years, many of
these have been known to have survived much longer. In view of the increasing cost of setting up new
plant, there is now considerable interest in life extension of existing units. In order to arrive at a quantitative estimate of the remaining life of such aging components, it is necessary to have creep and stress rupture
data.
The present work thus incorporates determination of tensile properties in the temperature range of room
temperature (25
C) to 600
C, creep rupture properties in the temperature range of 550700
C and
microstructural study to assess the condition of service-exposed reheater and platen superheater tubes for
their continued service.
1.1. Material and history of the service exposed boiler tubes:
The material specication with service condition and history of operation of the service exposed superheater and reheater tubes of the boiler are given in Table 1.
1.2. Dimension and visual examination of the service exposed tubes
The dimensional measurement (see Table 1) carried out on these tubes did not show any appreciable
change in outer diameter (OD). Wall thickness and the cross sections of the service exposed tubes were
found to be of uniform thickness. Dimensions of the OD were measured at two mutually perpendicular
directions along the length of the tube at intervals of 150 mm. There was no evidence of any localized
attack on the outer and inner surfaces of the tube.

Table 1
Material specication, dimension and service condition of service exposed tubes
Material

Platen superheater outlet

Reheater outlet

Material specication
Design steam pressure at outlet
Operating steam pressure outlet
Operating temperature
Design temperature
Steam ow
Outer diameter (OD)
Thickness
Service-exposed (running) hours

BS 3059/622/50 SE
151 kg/cm2
133.6 kg/cm2
540
C
570
C
393,000 kg/h
50.8 mm
10.97 mm
148,900 h

BS3059/622 Si
33.044 kg/cm2
28.0 kg/cm2
540
C
570
C
361.400 kg/h
50.8 mm
3.25 mm
148,900 h

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A.K. Ray et al. / Engineering Failure Analysis 10 (2003) 645654

2. Experimental
Chemical analysis (Table 2) shows that the materials under the present investigation are basically
2.25Cr1Mo steels conforming to the grades specied in Table 1.
Optical metallographic examinations (Figs. 1 and 2) were carried out on the service exposed tubes. The
average hardness values (VHN) of these tubes are shown in Table 3.
Tensile tests at room temperature 25, 500, 575 and 600
C of the service exposed tubes were performed
using a digitally controlled 8562 Instron servo-electric testing system, equipped with a three-zone split
furnace with PID control. Standard tensile specimens were made from the service exposed materials as per
Table 2
Chemical analysis of service exposed boiler tubes
SL. No.

1
3
4.

Type of material

Platen superheater outlet

Reheater outlet
BS 3059/622

Wt.% Of elements present

C

Mn

Si

Cr

Mo

0.12
0.15
0.15 max

1.14
0.62
0.6 max

0.08
0.21
0.5 max

0.045
0.034
0.05 max

0.03
0.033
0.03 max

2.23
2.49
2.6 max

0.9
1.05
1.13 max

Fig. 1. Optical microgmph of the service-exposed reheater outlet tube at 500 revealed ferritic and bainitic structure with no evidence
of creep cavitation damage, oxide scale deposition at inner and outer surface or spheroidization of the tube. The ferrite grains are
dispersed with carbides.

Fig. 2. A typical optical micrograph of service exposed platen superheater outlet tube at 500 showing a ferritc bainitic structure with
no evidence of spheroidization and creep cavitation damage. The ferrite grains are dispersed with carbides.

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Table 3
Hardness values of service-exposed reheater and superheater tubes
Sl. No.

Type of material

Hardness value (VHN)

1
3

Platen superheater outlet tube

Reheater outlet tube

168
173

ASTM E8-79 specication. Tensile tests were carried out on the base metal only from the longitudinal direction of the service exposed tubes. During tensile tests, constant test temperature within  2
C and constant
displacement rate of  0.2 mm/min were maintained. The variation of the Yield Strength (0.2% Proof
Stress) and Ultimate Tensile Strength (UTS) with temperature of testing is shown in Fig. 3(a) and (b).
Accelerated stress rupture tests using constant load Mayes creep testing machines were carried out as per
ASTM 139/83 specication with at specimens made from the longitudinal direction of the service-exposed
tubes. These tests were carried out in the temperature range of 550700
C and in the stress range of 36
129 MPa. The stress levels above the operating stress at each temperature were selected in such a way as to
obtain rupture within a reasonable span of time. The hoop stress sh acting on the service exposed tubes
was calculated as  40 MPa.

Fig. 3. (a) Plot of yield strength (0.2% proof stress) with temperature for the service-exposed platen superheater outlet and reheater
outlet tubes. (b) Plot of ultimate tensile strength (UTS) with temperature for the service-exposed platen superheater outlet and
reheater outlet tubes.

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A.K. Ray et al. / Engineering Failure Analysis 10 (2003) 645654

The stress rupture data have been plotted in terms of stress vs LMP (LarsonMiller Parameter) along
with the ASME (minimum) data line [12] for a similar grade of steel, for the purpose of comparison (Fig. 4).
For the grade of steel under investigation [12], the LarsonMiller Parameter LMP T20 log tr ,
where T=Temperature in K and tr=Rupture time in hours. The life of the tube in hours was then estimated at various temperatures from the LMP value read from Fig. 5.
Regression analysis of stress rupture data for service-exposed reheater and superheater tubes has been
carried out using a standard software package, in order to evaluate the long-term rupture strength of the
tubes over the range of temperature presently investigated.
LMP T20 log tr ao a1 log S a2 log S2 . . . . . . . . . . . . am log Sm ;

where S=Rupture strength in Mpa, m=Order of polynomial, ao, a1, a2 and am polynomial constants
(Table 4). Table 5, and Figs. 6 and 7 reveal the variation of rupture strength, S of the service exposed tubes
with temperature, in the temperature range of 520580
C, for various rupture times and at m=1.

Fig. 4. Plot of stress versus LMP (LarsonMiller Parameter) for the service-exposed tubes.

Table 4
Polynomial constants from regression analysis
Type of material

Order of polynomial

Average sum square error

a0

a1

Platen superheater outlet tube

Reheater outlet tube

m=1, C=20
m=1, C=20

0.537610
2
0.6762610
2

0.23631856105
0.22533105

46.68142

21.746043

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3. Results and discussion

3.1. Visual observation and metallography
Dimensional measurement revealed that the tubes have not undergone any appreciable deformation
during actual operating conditions. The hardness level of service exposed tubes revealed (see Table 3) no
signicant variation in hardness values with exposure lives.

Fig. 5. Plot of temperature versus balance life of the service-exposed platen superheater outlet and reheater outlet tubes.

Table 5
Estimated rupture strength in MPa
Type of material

Temp.
C

Order of polynomial

Time (tr) in h
10,000

30,000

100,000

Reheater outlet tube

520
540
550
560
570
580

m=1,
m=1,
m=1,
m=1,
m=1,
m=1,

C=20
C=20
C=20
C=20
C=20
C=20

161.0
138.9
127.9
116.9
105.8
94.8

143.6
121.1
109.9
98.6
87.3
76.1

124.6
101.6
90.1
78.6
67.1
55.6

Platen superheateroutlettube

520
540
550
560
570
580

m=1,
m=1,
m=1,
m=1,
m=1,
m=1,

C=20
C=20
C=20
C=20
C=20
C=20

98.5
88.3
83.1
77.8
72.8
67.7

94.3
79.9
74.7
69.5
64.2
59

81.6
70.8
65.5
60.1
54.8
49.4

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651

The microstructure of the service exposed reheater and platen outlet tubes mainly consisted of a ferritic
bainitic structure (Figs. 1 and 2). The ferrite grains are dispersed with carbides. Evidence of graphitization
and creep damage in the form of cavitation and decarburization was not observed in any of the service
exposed tubes. Therefore, it is clear that the service exposed reheater and platen superheater outlet tubes
have had hardly any appreciable degradation from the microstructural point of view.

Fig. 6. Plot of rupture strength versus temperature for the service-exposed reheater outlet tube.

Fig. 7. Plot of rupture strength versus temperature for the service-exposed platen superheater outlet tube.

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3.2. Mechanical properties

Room temperature as well as high temperature tensile properties as obtained from experiments are
reported (Fig. 3). It is evident from the results that 0.2% proof stress (yield strength) and the UTS (ultimate tensile strength) values for the service exposed tubes showed a decreasing trend with increasing temperature. This is the common trend observed for materials tested at elevated temperature [1217]. Analysis
of tensile data revealed that there is some deterioration in ultimate tensile strength [see Fig. 3(b)] compared
to ASTM 213-T22 grade of steel due to service exposures. However, these variations fall within the specied limits for similar grades of steels, e.g. 2.25Cr1Mo steels [12].
In the absence of discernible cavitation or aws, stress rupture tests can be selectively used to assess the
condition of components. One of the most widely used techniques for life assessment of components
involves removal of samples and conducting accelerated tests at temperatures above the service temperature [8]. An estimate of the remaining life is then made by extrapolation of the results to the service temperature. Several uncertainties relating to the validity and application of the technique have been resolved
in recent research projects [8].
In the present investigation, long term rupture strengths were estimated with best tted curves to a third
order polynomial. For dierent orders of the polynomial, the average sum square error (ASSE) was estimated from the following equation:

2
ASSE  Yexperimental
Yestimated =n;
2
where n is the number of data points. The rst order polynomial was selected for estimation of rupture
strength as there was no signicant change in the average sum square error for higher orders.
Since microstructural examination did not show any major degradation it is expected than the mechanical properties will be within expected limits which is also revealed from the experimental data.
Short-term stress rupture tests were also carried out on standard test specimens made from platen
superheater outlet and reheater outlet coils. The data obtained have been compared with the reported data
on 2.25Cr1Mo steel (Fig. 4). The lines in the gure represent the minimum and mean rupture strengths for
2.25Cr1Mo steels from the literature (the ASME minimum data line). It is clear that barring one point all
the data fall on or above the minimum and mean ASME data lines. It is noteworthy that at low stress
levels the stress rupture data merged with the minimum and mean ASME data lines which is the common
trend observed in such steels. It is also interesting to note that most of the data seemed to fall on or above
the ASME minimum and well within the scatter band of the ASME mean data line (see Fig. 4). Therefore,
as far as creep strength is concerned there is no appreciable degradation due to service exposure. This is
also consistent with the information collected from other destructive and non-destructive tests conducted
on boiler components.
When the steam temperature is 540
C, the metal wall temperature is usually around 570
C. Therefore
to estimate remaining life it will be more appropriate to use the actual operating design temperature which
is 570
C. Fig. 5 represents the variation of temperature with the balance life in hours for the service
exposed platen superheater and reheater outlet tubes. It is evident that at 540 and 570
C, all these service
exposed tubes have a remaining life of more than 100,000 h, provided there are no defects in the materials
due to long term service exposure. However, a similar health check is recommended after 5 years of service
exposure.
It is clear from Figs. 6 and 7, and from Table 5 that the estimated 10,000100,000 h rupture strengths at
various temperatures showed a decreasing trend with increasing temperature. This is the general trend
observed in service-exposed materials [1417].
The hardness values of the service-exposed platen superheater and reheater tubes have been superimposed on the mean data line in the hardness versus LMP plot (see Fig. 8), thus enabling us to justify that

A.K. Ray et al. / Engineering Failure Analysis 10 (2003) 645654

653

Fig. 8. Plot of hardness versus LMP (LarsonMiller Parameter) for the service-exposed platen superheater outlet and reheater outlet tubes.

that the hardness data lie on or above the mean data line for 2.25Cr1Mo steels as reported in the literature
[18,19]. A similar behaviour was also observed from the stress versus LMP plot (Fig. 4), where most of the
data lie on or above the minimum and mean data line for 2.25Cr1Mo steel. Since there was not any
appreciable change in the hardness values of such steels even due to prolonged service exposure, it justies
that the temperature of the metal wall was not less than the steam temperature.
So far as the remaining life at 540
C/40 MPa is concerned, it is possible to obtain a minimum life of
> 100,000 h for the service-exposed reheater and platen superheater outlet tubes provided there is no evidence of localised damage. Another check for safety of the service exposed pipes in terms of residual life is
recommended to be carried out after 50,000 h of service life from the view of economic and safety reasons.
Also during shut down of the plant, NDT tests may be carried out to assess the condition of the materials
for their future serviceability.

4. Conclusions
The study leads to the following conclusions:
1. So far as the residual life at 540
C/40 MPa is concerned, it is possible to obtain a minimum life of
about 100,000 h for the service-exposed reheater and platen superheater outlet tubes provided there
is no evidence of localised damage in the form of surface cracks, cavitation or dents.
2. Analysis of tensile data revealed that there is some deterioration in ultimate tensile strength of the
service-exposed reheater and platen superheater outlet tubes compared with those of the virgin tube
reported in the literature, but these variations are within the specied limits for similar grade of steels.
3. The service-exposed reheater and platen superheater outlet tubes appear to be in a reasonably good
state of health. Another check for safety is recommended after 50,000 h of service. Also during shut
down of the plant, NDT tests, viz. dimensional (thickness and diameter) measurements, hardness
measurement and insitu metallography may be carried out to assess the condition of the materials.

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A.K. Ray et al. / Engineering Failure Analysis 10 (2003) 645654

Acknowledgements
The authors are thankful to Mr. Santokh Singh, Mr. Hira Lal and Mr. Sashi Bhushan Singh for their
assistance in the stress rupture tests. The authors are grateful to the Director, National Metallurgical
Laboratory, Jamshedpur and the Department of Metallurgy, NIT Jamshedpur, for their kind permission
to publish this paper.

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