Paper No.

06465

BOILER INSPECTION TECHNIQUES:

Tools and Degradation Identification
Eric P. Thurston
David N. French Metallurgists
1345 Old Preston Highway N.
Louisville, KY 40229
ethurston@davidnfrench.com

ABSTRACT
The unavailability of coal fired electrical generating capacity when needed is often
attributable to corrosion in steam generators. Such problems are becoming more widespread
as electricity demand grows faster than new plants come online, forcing greater use of old
plants. Identifying such corrosion problems before they force boiler shutdowns requires proper
inspection tools and techniques. These enable inspectors to take the guesswork out of
whether boiler tubes should be repaired or replaced.
Keywords: boiler inspection tools, boiler inspection techniques, NDE, corrosion, boiler tubes,
steam generators.
INTRODUCTION
Thegoaloft
oday

sboi
l
eri
ns
pec
t
ion programs is to increase the availability, efficiency,
and reliability of the existing power plants and ensure safe and cost effective operation. Power
generators are extending the time period between unit shutdowns which makes scheduled
outages even more important to completely examine the boiler in order to operate until the
next scheduled outage. As the United States utility boiler fleet ages, and the time periods
between shutdowns increase, the proper inspection tools and techniques needed to find,
observe, and document current and possible failures are paramount. Before large and
cumbersome inspection rigs are assembled for inspecting large areas in the firebox, it is the
job of the inspectors to inspect all surfaces and focus the inspection rigs on the degraded
areas. The following paper outlines the tools and techniques needed for properly conducting
Copyright
2006 NACE International. Requests for permission to publish this manuscript in any form, in part or in whole must be in writing to NACE International,
Conferences Division, 1440 South Creek Drive, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of
the author(s) and are not necessarily endorsed by the Association. Printed in the U.S.A.

and documenting a boiler inspection. The degradation mechanisms will first be introduced, and
then the techniques and tools used to find each mechanism will be discussed.
Degradation Mechanisms Observed Using the Proper Inspection Techniques in Utility Boilers
Long Term Overheating: The steam temperature always varies some from individual tube
to tube, and the boiler design allows for this variability. However, when the range of
temperatures is larger than anticipated, the hottest tubes fail sooner than expected. A more
likely cause of premature failure is the slow increase in tube-metal temperatures due to the
formation of the steam-side scale. Steam reacts with steel to form iron oxide along the ID
surface of the tube. In any event, the thermal conductivity of the steam side scale is about 5%
of the thermal conductivity of the steel tube. Thus, an effective insulating layer forms and
prevents proper cooling of the tube metal by the steam. The net effect of the scale is to raise
the tube metal temperature. Depending on the scale thickness, which is dependent on the
time and temperature of operation, tube-metal temperature increases of 25 to 75oF (14 to
42oC) are likely. The presence of scale can increase tube metal temperatures beyond the safe
design range. These elevated temperatures result in increased creep deformation rates, more
rapid oxidation and corrosion (thinner walls and higher stress) and hasten the onset of creep
failures.
Creep failures are characterized by:
1.
2.
3.
4.

Bulging or blisters in the tube.

Thick-edged fractures often with very little obvious ductility.
Longitudinal "stress cracks" in either or both ID and OD oxide scales.
External or internal oxide-scale thicknesses that suggest higher-than expectedtemperatures.
5. Microstructure has intergranular voids and cracks.
In steam touched tubes, often the very first sign of creep damage is longitudinal cracks in
the steam-side scale. As creep deformation expands the tube diameter, the brittle ID scale
cannot follow the expansion. Cracks develop in the direction, which is perpendicular to the
principle hoop stress. With time, the tube continues to expand, and these cracks widen. This
wide crack shortens the path from steam to steel; iron oxide forms preferentially at the tip of
the crack, as there is less oxide thickness to protect the steel; and a cusp forms within the
steel tube. The cusp acts as a notch or a stress riser, reducing the local wall thickness. Creep
voids form here, often before any other obvious grain-boundary damage appears elsewhere
within the microstructure. With continued high-temperature operation, creep cracks grow from
the cusp and ultimately weaken the cross section to the point where failure occurs.
Ash Corrosion (oil, coal, refuse): Carbon and alloy steels develop corrosion resistance
from the formation of protective oxide scales. The denser and more tightly bound the oxides
are, the more corrosion resistant the material will be. Any process that removes protective
oxides will promote more rapid corrosion wastage. Any process that prevents the formation of
these oxides will also promote more rapid corrosion.

Whether the fuel burned is oil or coal, and whether the corrosion location is in the furnace
at temperatures of 500 to 700oF (260 to 371oC) or the high-temperature components at a metal
temperature above 1,000oF (538oC), the corrosion mechanisms are similar. Constituents within
the ash form a low-melting-point species or a mixture of several compounds that has the
required low melting point. These low-melting-point species dissolve the protective iron oxide
on the surface of the boiler tube and bring the bare metal in contact with oxygen. Two
observations: a) the melting point discussed here is not the ash fusion temperature, and b) the
action of these liquids is like a brazing flux; it dissolves and prevents the formation of a
protective oxide film.
In the case of furnace-wall corrosion, mixtures of sodium and potassium pyrosulfates are
the suspected liquid species. Melting points between 635oF (336oC) and 770oF (410oC) have
been reported for ash constituents on furnace walls under severe coal-ash corrosion. For
corrosion of steam cooled tubes at temperatures above 1000oF (538 oC) in coal-fired boilers,
sodium and potassium-iron trisulfates are the culprits. The exact melting point depends on the
relative amounts of sodium and potassium, but the minimum melting point can be as low as
1030oF (554oC)1. In oil-fired boilers, mixtures of vanadium pentoxide and sodium oxide or
vanadium pentoxide and sodium sulfate are the problem. Again, the precise composition will
dictate the particular melting point, but these compounds can melt at temperatures as low as
950oF (510 oC). In municipal-refuse burners where appreciable chlorine, from polyvinyl
chloride, is part of the fuel, various chlorides or mixtures of chlorides will serve the same
purpose. Mixtures of iron, sodium, zinc, lead, and perhaps calcium chlorides will form lowmelting-point species2. There are many combinations of chlorides that have melting points
below 600oF (315 oC) and some less than 350oF (177 oC).
The morphology or appearance of fuel-ash corrosion is variable. For steam cooled tubes
in an oil-fired boiler, the corrosion pattern depends on the volume of liquid and the
aerodynamics of the flue-gas flow over the tube. In coal-fired boilers, the appearance takes the
form of a series of grooves and is sometimes referred to as "alligator hide"3. For water wall
tubes, especially in super-critical units burning coal, the appearance is a series of
circumferential grooves or cracks. In cross section, again, the appearance is a series of
shallow grooves. A micrometer measurement would show that the gross fire-side wall
thickness is not substantially different from the cold or casing side. The wall thickness at the tip
of the crack can, of course, be thin enough to form a steam leak. In the case of a refuse
burner, the appearance is one of a smooth and uniform wastage that reduces the wall
thickness. Corrosion rates can be exceedingly high. Carbon-steel wastage rates of about 1/2
inch per year (1.27 cm per year) (failure in less than 2,000 hours of operation) are known.
Thermal Fatigue: Fatigue results from reversed plastic strain in metallic crystals. If plastic
straining is confined to microscopic or submicroscopic regions in an otherwise elastically
stressed component, it is likely that a single crack will occur, originating at the point of
maximum local stress and minimum local strength in the entire structure. Thermal fatigue may
result in either low-cycle or high-cycle failure. Cracking that occurs after many cycles of loading
is high-cycle fatigue and has no macroscopic evidence of plastic flow. On the other hand,
when plastic straining is more extensive, there is a greater likelihood that cracks will initiate at
many discontinuities after fewer cycles of loading (low-cycle fatigue) and that there will be
macroscopic evidence of plastic flow. The fracture surfaces exhibit some plastic flow which is
indicative of low-cycle fatigue. Low-cycle thermal fatigue is usually associated with large

plastic strains and is most often caused by large changes in temperature or large differences in
thermal expansion between two structural members.
Pressure and thermal cycling during start-up and shutdown are the most common causes
of low-cycle fatigue failures. Design factors that concentrate strain influence low-cycle fatigue
as well as high-cycle fatigue; however, the effect is not quite the same. When service stresses
are high enough to be conducive to low-cycle fatigue, the presence of a severe stress riser will
often cause complete fracture to occur on the first load cycle. Mild stress risers usually do not
lead to fracture on the first cycle, but only induce localized yielding, and multiple crack
initiation. Water in soot blowers, water lances, and water cannons may lead to a crazing
pattern. The predominant cracks will be circumferential and the minor cracks will be axial4.
Dissimilar Metal Weld Failures: Dissimilar metal weld (DMW) cracking is caused by the
application of temperatures and stresses that increase oxide wedge formation and accelerate
the creep process. The total stress applied to the joint includes stresses that arise from
differences in the coefficient of thermal expansion; from internal steam pressure, tube dead
weight, and through wall thermal gradients; and from constraints to thermal expansion due to
tube support malfunction. Dissimilar metal weld cracking produces a circumferential fracture in
the joint. Cracks typically form at the toe of the weld in the heat-affected zone of the ferritic
alloy. Poor geometry of the weld, excessive undercut, and other stress factors will aggravate
the crack formation. A brittle, thick edged fracture results from the linking up of creep voids
adjacent to carbide precipitates along the grain boundaries.
The key factors affecting DMW cracking are the magnitude of the temperature swing and
the frequency (number of cycles). The likelihood of initiating damage and the extent of
damage increase with wider temperature swings and an increasing number of cycles. Startup
and shutdown of equipment can cause thermal fatigue. There is no set limit on temperature
swings; however, as a practical rule, cracking may be suspected if the temperature swing
exceeds about 200F (111oC) 5. Damage is also promoted by rapid changes in surface
temperature that result in a varied temperature through the thickness or along the length of a
component. Time to failure is a function of stress and the number of cycles.
Erosion (fly ash, corrosion, soot blower): Erosion involves impact of large numbers of
small solid particles against a surface. Erosion by solid particles is a form of abrasive wear.
Erosion-corrosion is a description for the damage that occurs when corrosion contributes to
erosion by removing protective films or scales, or by exposing the metal surface to further
corrosion under the combined action of erosion and corrosion6. Abrasive erosion of
superheater tubes results from impact by particles of fly ash entrained in the flue gases.
Erosion is enhanced by high flow velocities; thus, partial fouling of gas passages in tube bands
by deposition of fly ash can lead to erosion by forcing the flue gases to flow through smaller
passages at higher velocity. This effect, sometimes called laning, exposes tube surfaces to a
greater probability of impact by particles having higher kinetic energy, thus increasing the rate
of damage. Erosion by fly ash causes polishing, flat spots, wall thinning, and eventual tube
rupture.

Fly ash erosion can occur at locations that:

1. Have gaps between the tube bank and the duct walls.
2. Have gas bypass channels where the velocity of the flue gas can be much higher than
that of the main flow.
3. Have protrusions or misalignment of tubing rows.
4. Are adjacent to areas with large accumulations of ash.
Reducing Conditions: Reducing conditions will increase corrosion rates. The presence of
carbon monoxide and/or unburned carbon and hydrogen sulfide promote the formation of
metallic sulfides. Iron sulfide, for example, is inherently less protective than iron oxide. Sulfides
tend to be less protective because they are porous and less firmly attached to the steel.
Alternate oxidizing and reducing conditions are no help either. The oxide that forms during
oxygen-rich cycles is reduced or made less sound during the reducing part of the cycle. In fact,
it is not unusual in municipal-refuse burners to find a strong smell of hydrogen sulfide (a rottenegg aroma) on a freshly broken ash sample. The presence of hydrogen sulfide is positive proof
of a reducing furnace atmosphere.
Tube Misalignment: Tube misalignment is common in boilers. Alignment spacers, buck
stays or attachment welds break, and due to the thermodynamics of the water-cooled or steam
cooled tube, the tube bends in the path of least resistance which can misalign the tube. This
misalignment can increase erosion due to impingement into the fly ash path, or soot blower, or
water lance path. Corrosion can also be exacerbated by tube misalignment due to
encroachment into the burner path or fly ash path.
Slag Crushes: Falling slag damage results from impacts by fused coal ash deposits or resolidified molten material that detach from furnace walls and superheater pendants. The slag is
directed towards the ash hopper by the furnace lower sloping wall. Damage can occur from
either erosion or mechanical impact results to water tubing in either sloping wall tubes and/or
the ash hopper. Slag crushes are due to mechanical impact.
Acid dew-point corrosion: In boiler terminology, "acid dew-point" refers to the sulfuric-acid
dew-point, as this is the highest dew-point temperature. Both sulfurous acid and hydrochloric
acid condense at lower temperatures. For hydrochloric acid, the dew-point may be as low as
130oF (54oC). While the precise dew-point for sulfuric acid depends on the sulfur-trioxide
concentration, at 10 parts per million (ppm), or 0.001 wt%, of sulfur trioxide in the flue gas the
dew-point is 280oF (138oC). The exact dew-point depends on the concentration of these
gaseous species, but it is around 300oF (149 oC). Surfaces that are cooler than 300oF (149 oC)
are likely locations for dew-point corrosion. Any point along the flue-gas path, from combustion
in the furnace to the top of the chimney, is a possible site. Any flue-gas leak can also cause
this type of corrosion. The obvious locations are openings to the furnace, support penetrations
through the roof, leaks around superheater, reheater and economizer penetrations, and the air
pre-heater. Load, oxygen levels, sulfur in fuel, moisture content of the fuel and boiler
cleanliness are also parameters that will affect the acid dew-point temperature. Since these
are difficult to measure, and correlate, on a continuous basis, it can be difficult to understand
the effects of each parameter on the dew-point temperature. This dew-point temperature
variation, when uncontrolled, could result in the condensation of the sulfuric acid on the metal
walls, economizer sections, and stack linings resulting acid dew-point corrosion.

Fretting: Fretting corrosion occurs when there is slight relative motion, as caused by
vibration, of two metals in contact with each other. The relative motion destroys the protective
oxide film so that clean metal is in contact with the corroding media. An example of this may be
the more rapid attack of superheater or reheater tube ties or supports as they rub7.
Common Utility Boiler Inspection Techniques for Degradation Mechanisms
Proper inspection techniques will help minimize downtime by identifying degradation
before failures occur to power generation utility boilers. Most of these inspections are visual,
however, inspectors are always recommended to have electronic verification if applicable to
the degradation mechanism. The scope of this paper is to document generalized inspection
techniques and may not fully address the particular corrosion/degradation mechanism in all
parts of the boiler system. The typical water wall tube numbering system in a boiler consists of
the front and rear wall tubes numbered from left to right while the sidewall tubes are labeled
front to rear.
Figures 1 and 2 document long term overheat failures as observed in a utility boiler.
Three indicators used for inspection of overheating in the firebox of a boiler. These are:
darkening or discoloring of the tube, an elephant hide appearance, and if bulging or warping
are observed8. If overheating is evident using the above visual criteria, inspectors should
record the wall and tube number on the suspect wall, the length of indication on the tube, and
elevation of the suspect tube. This will allow the boiler inspectors to accurately explain the
location and size of the failure for the boiler repairmen, or boilermakers to remove the tube for
replacement.
Tubing may overheat if:
1. Tube is the wrong material for the location in the boiler.
2. Over-firing or uneven-firing of the burners cause a higher surface heat flux than the
tube was designed for.
3. Fouling or deposits are observed on the inside of the tube.
4. Loss of boiler coolant or low water level occurs.
Determine if the factors above play a role in the overheating of the damage tube and
rectify the issue. Figure 3 presents microstructure of a typical creep failure. Numerous creep
voids are observed in the overheated tube metal. Microstructures consisting of spheroidized
carbides in a ferrite matrix confirm elevated temperatures were experienced by the overheated
tube.
Figures 4 and 5 depict coal ash corrosion inside the boiler on superheater pendants. Coal
ash corrosion is easier to visually observe than oil or refuse ash corrosion due to the typical
buildup of coal ash deposits. Sandblasting of the chosen inspection surfaces is recommended
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enough surfaces for ultrasonic wall thickness testing (UT) to be performed across the crown of
the tube. Figure 6 exhibits the OD surface of a superheater tube suffering from coal ash
corrosion.

For oil and refuse ash corrosion, UT testing is recommended. The smooth uniform
wastage produced by both types of fuel can mislead an inspector into a false sense that the
tube meets minimum tube wall thickness criteria.
Thermal fatigue is observed in Figures 7 and 8. Typically, circumferential cracking
indicates thermal fatigue, however, if a unit is known to use water cannons or water lances,
t
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ed.In visual field observations,
inspectors use judgment calls to base the severity of the cracking observed. Thermal fatigue
cracking correlates to the corrosion potential of the material experiencing thermal fatigue. For
example, thermal fatigue cracks on carbon steel water wall tubes will tend to be wider than the
same crack observed on a stainless steel superheater tube. Corrosion of the material plays a
part in the width of the crack, while the thermal shock determines the depth of the crack.
Location of these cracks should be noted in reference to soot blowers, water cannons, etc. for
future monitoring for leaks. Primary sources for the craze cracking in a boiler are water
splashing from the bottom ash hopper, and condensate from the soot blower systems9.
Historical information plays a large role in determining the probability of failure for fatigue
cracks. Sand blast the tube metal surfaces to create grid locations in the suspected areas for
UT and dye penetrant (DT) testing. Welds should be removed from locations where craze
cracking is observed to minimize failures due to stress risers caused by welding. Figure 9
documents typical thermal fatigue cracking on the crown of the tube.
Figures 10 and 11 exhibit dissimilar metal weld (DMW) failures. DMW failures occur due
to different thermal expansion coefficients of the joined materials. In the high temperature
10
superheater and reheater s
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,i
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. Focus the
area of inspection on the magnetic or ferritic steel side of the weld, which tends to be the
weaker material. Figure 12 illustrates a typical DMW failure. This particular failure shows a
stainless steel weld overlay which has exacerbated the failure.
Figure 13 depicts multiple tubes that have experienced erosion. Some of the tubes show
shields on the tube surfaces which help protect against solid particle erosion. Figure 14
presents clogged gas lanes observed during a dirty inspection. The clogging will increase fly
ash velocity, increasing the fly ash erosion potential. Figure 15 documents typical fly ash
erosion across the crown of the ring sample. UT testing is the recommended inspection tool for
erosion. Ideal areas to inspect for erosion is in the back pass region of the boiler in the
economizer section. Shields and baffles are a couple of ways to combat erosion. Furthermore,
areas of refractory should be inspected for soundness. Refractory is another tool used to slow
erosion.
Figures 16 and 17 document wall wastage due to reducing conditions in the boiler firebox.
Reducing conditions are usually localized around the burner elevation and should be regularly
inspected. Multiple mils per year of wall wastage can occur in these localized areas of
corrosion. UT testing is the recommended inspection tool for wall wastage due to reducing
conditions. Inspection should be across the crown of the tube.
Tube misalignment is observed in Figures 18 and 19. When tube misalignment is
observed, inspect for previous repairs that may have been made, materials with different
thermal expansion coefficients, and broken hardware11. These areas should be repaired or
replaced, otherwise future issues could arise due to current missed steps.

Figures 20 and 21 shows slag fall damage to ash slope boiler tubes. As ash/slag builds
up on the pendant components of the boiler, these masses exfoliate and fall to the ash hopper
for removal. Some of these masses are as large as small cars. Inspection of the lower slope
portion of the boilers may reveal slag fall damage that may need replaced. Rule of thumb is if
15% reduction in the ID cross section of the tube is observed, replacement is recommended.
Further inspection is recommended up the slag fall damaged circuit(s) in order to identify future
possible failures caused by the restricted coolant flow.
An economizer tube experiencing acid dew-point corrosion is observed in Figures 22 and
23. Inspectors should observe the surface of the suspected acid dew-point corrosion. White or
yellowish deposits will be observed on the surface of the tube. Furthermore, iron oxides (rust)
may be observed in piles underneath the tubing experiencing acid dew-point corrosion.
Inspectorsmays
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ddew-point corrosion
is active in a region of the boiler. Final verification of the particular species of active acid
should be sent to a laboratory for analysis. If possible, stack temperatures should be increased
to prevent this type of corrosion.
Figure 24 clearly exhibits signs of fretting corrosion. Inspect areas where contact may
happen particularly when the boiler is operating at normal operating temperatures. The
materials will expand, thus increasing the opportunity for fretting to take place. The use of an
extendable mirror to observe behind areas normal vision is unable to see is very useful in
identifying fretting corrosion12.
Recommended Inspection Tools/Accessories to be used for Utility Boiler Inspection
This section will identify the recommended inspection tools used by inspectors to
thoroughly inspect utility boilers. Table 1 identifies the inspection tools coupled with the above
techniques that will detect the particular degradation mechanism that could cause a failure and
downtime of a utility boiler to occur.
Figure 25 documents the hard cased box suggested for transporting boiler inspection
tools to the worksite. Plant sites can be harsh environments and a solid-cased inspection box
will protect the equipment, especially electronic equipment, from being damaged. Figure 26
documents the satchel pack carried by boiler inspectors to easily tote the needed tools into the
boiler. Important digital documentation devices such as a digital voice recorder and a digital
camera help inspectors when communicating a possible safety or loss of life issue or a
situation that will cause a forced outage before the next planned outage. Figure 27 exhibits an
extremely important tool in an inspectors satchel; the ultrasonic thickness test gauge. This tool
allows the inspector to give accurate and precise wall thickness readings in areas of interest
and removes all guesswork from the inspection process. This tool works best on a smooth
sand-blasted OD surfaces, so proper preparation of the boiler tube surface is essential for
accurate readings. Figure 28 presents vernier calipers useful for determining the outer
diameter of a tube surface. Figure 29 documents a fillet weld gauge. This tool is excellent for
measuring the depth of crushes and nicks found on the fireside surfaces of tubes. Figure 30
exhibits a tube wall thickness conversion calculator. The reference page allows the inspector
to quickly determine what course of action is needed for a wall thickness below specified
minimum wall thickness. Figure 31 presents an angle locator. The angle locator is used to

verify header location and on some vintages of boilers, the tilt of the burners. Figure 32
presents a flexible Pi tape. Pi tapes are used to measure the diameters of headers to
determine if they have swelled, for example, due to creep. Figure 33 exhibits one portion of
replication kit used to non-destructively analyze microstructure on high energy piping, typically
headers. Replication tools typically consist of a polishing tools kit and a chemical etchant kit
that are transported separately. Another tool that should not be discounted is boiler inspection
software. Figure 34 exhibits an example of a boiler software package system used for
maintenance tracking and asset management for both fossil fueled and alternative fueled
boilers. These systems enable the user to identify potential tube failures before occurrence
and aid in the development of maintenance strategies for through life management. Improving
availability, extending unit life, and optimizing capital expenditures are the three core
objectives of these types of systems. Furthermore, this software also aids management with a
foundation for easier and more accurate budgeting and maintenance repair planning.

CONCLUSIONS
Proper inspection tools and techniques can help minimize downtime by identifying
degradation before tube failures occur within power generation utility boilers. Furthermore,
these tools can help identify problem areas of the boiler to observe during subsequent
outages. Corrosion and erosion mechanisms active in certain locations of power utility boilers
can be easily and routinely detected by a boiler inspector using the general tools and
techniques outlined in this paper.

ACKNOWLEDGEMENTS
The author would like to express specific appreciation to Dr. David N. French who shares
his knowledge and insight regarding metallurgical failures in fossil fired boilers with us each
day. In addition, the authors express gratitude to the owners and management of David N.
French Metallurgists, in supporting the contribution of this paper to NACE and the utility power
industry.

10

REFERENCES
1.

D.N. French, Metallurgical Failures in Fossil Fired Boilers, Second Edition; John Wiley
& Sons, 1993. p 351

2.

Ibid, p 364

3.

Ibid, p 348

4.

J.D. Dobis and D.N. French, Damage Mechanisms Affecting Fixed Equipment in the
Fossil Electric Power Industry, WRC Bulletin 490 April 2004, p 21.

5.

Ibid, p 19

6.

Ibid, p 29

7.

French, op. cit., p 330

8.

Boiler Inspection Techniques Manual. Uni

t
ed Dy
nami
c
s
Adv
anc
ed Tec
hnol
ogi
es

Corporation, Louisville, KY, USA. p 176.

9.

Ibid, p 114

10.

Ibid, p 183

11.

Ibid, p 195

12.

Ibid, p 172

11

APPENDIX

Inspection Tools/Degradation Mechanisms Matrix for Utility Boilers

Wall wastage due to

reducing conditions

Tube Misalignment

Slag Crushes

Acid Dew-point
Corrosion

Fretting Corrosion

x
x
x
x
x

Erosion (Fly Ash, Soot

blower)

x
x
x
x
x

Dissimilar Metal Weld

Failures

x
x
x
x

Thermal Fatigue

Digital voice recorder

Paint markers
Digital camera
Flashlight, extra bright
Extension mirror
Extension magnet
Vernier calipers
Fillet Weld gauge
Paintbrush
UT thickness tester
Tube thickness calculator
Tape measure
Angle locator
Slag pick
Magnifying glass
Binoculars
Pi tape
Replication kit

Ash Corrosion (Coal,

Oil, Refuse)

Long Term Overheating

Table 1
Inspection Tool/Degradation Mechanism Matrix

x
x
x
x
x
x

x
x
x
x

x
x
x
x

x
x
x
x

x
x
x
x

x
x
x
x
x

x
x
x
x
x

x
x

x
x
x

x
x
x

x
x
x

x
x
x
x

x
x
x

x
x

x
x

12

x
x

FIGURE 1. Long term overheat failure observed in superheat pendant. A bulging, thicklipped semi-ductile failure is observed.

FIGURE 2. Exfoliated tubing in the penthouse on the outlet terminal tubes is observed; further
signs of long term overheating.

13

FIGURE 3. ID microstructure is completely spheroidized with creep voids and crack near the
rupture location. Material is SA-213-T22, 200x, nital etchant.

FIGURE 4. Coal ash buildup on superheater pendants is observed.

14

FIGURE 5. Superheater tube metal surface after coal ash has been shed. Typical

al
l
i
gat
orhi
demor
phol
ogyi
sobs
er
v
ed.

FIGURE 6. Coal ash corrosion is observed on the OD surface of the leading edge superheater
tube. Material is SA-213-T11, 100x, nital etchant.

15

FIGURE 7. Circumferential thermal fatigue cracks are observed on the fireside crown of the
tube.

FIGURE 8.Ther
mal
f
at
i
gue
c
r
az
ecr
ac
k
i
ngi
sobs
er
v
edont
heODs
ur
f
ac
eofa tube due to
over-use of a water cannon used to clean slag off tube surfaces.

16

FIGURE 9. Multiple, dagger-shaped, thermal fatigue cracks are observed on the surface of
the tube. Material is SA-192, 200x, nital etchant.

FIGURE 10. Failed dissimilar metal weld (DMW) is observed.

17

SA-213-T304

SA-213-T22

FIGURE 11. Macroscopic view of photomicrograph samples indicate transgranular cracking in

the heat affected zone (HAZ) of the SA-213-T22 material. This is a typical failure of DMW.
Material is SA-213-T22 to SA-213-304H DMW, 10x, nital etchant.

SA-213-T22

FIGURE 12. Oxide filled transgranular crack is observed in HAZ of weld. Creep is also
observed parallel to weld repair. Material is SA-213-T22 to SA-213-304H DMW, 100x, nital
etchant.

18

FIGURE 13. Polished surfaces due to fly ash erosion are observed deep into the superheater
bundle.

FIGURE 14. Ash deposits, which clog the gas lanes, are observed during a dirty inspection.
This in turn increases the fly ash velocity through the boiler increasing the fly ash erosion
potential.

19

FIGURE 15.Fl
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FIGURE 16. Wall wastage due to reducing conditions at the burner elevation is observed.

FIGURE 17. Uniform OD surface wastage is observed due to reducing conditions at burner
elevation in the water wall tubes. Material is SA-210-A1, 200x. nital etchant.

20

FIGURE 18. Leading tubes of superheater pendant are bent to the right into the gas path.

FIGURE 19. Tube has pulled away from alignment bar into the gas path.

21

FIGURE 20. Depression in ash slope region of boiler due to slag fall damage is detected.

FIGURE 21. Slag fall damage to ash slope boiler tubes.

22

FIGURE 22. Finned economizer tube experiencing acid dew-point corrosion is shown.
White/yellowish deposits are observed on tube fins.

FIGURE 23. OD intergranular corrosion is observed. ICP analysis confirmed acid dew-point
corrosion. Material is SA-178-A, 800x. nital etchant.

23

FIGURE 24. Fretting corrosion observed on OD surface of tube due to perpendicular crossing
tube.

FIGURE 25 Hard case box for transporting boiler inspection tools.

24

FIGURE 26 - Inspection satchel bag used while in the boiler with exploded view of the tools
used during the inspection.

25

FIGURE 27 - Ultrasonic thickness tester with ultrasonic coupling medium. Thickness tester
documents hard data using ultrasonic technology to determine actual wall thickness of
suspected tube.

26

FIGURE 28 - Vernier calipers for verifying outer diameter of boiler tubes.

FIGURE 29 - Fillet weld gauge used to measure depths of crushes, and nicks.

27

FIGURE 30 - Tube wall thickness conversion calculator quick reference sheet for ultrasonic
thickness reading determinations.

28

FIGURE 31 - Angle locator to check header location and burner tilt.

FIGURE 32 - Pi tape used to measure diameter of headers to determine if creep is present.

29

FIGURE 33 Part of a replication kit used to non-destructively evaluate microstructural

degradation on large high energy headers.

30

FIGURE 34. Software system used to track repairs/replacements throughout the utility boiler
system.

31