ADVANCED EROSION PROTECTION TECHNOLOGY FOR STEAM BOILER SUPERHEATED TUBES

CHAPTER 1

INTRODUCTION

1.1GENERAL INTRODUCTION

Understanding Wear, and the Material Characteristics Critical to

Preventing It
Wear is the damaging, gradual removal or deformation of material at solid surfaces. Causes of
wear can be mechanical (e.g., erosion) or chemical (e.g., corrosion) . It is important to
differentiate between various modes of wear, and to understand which mode is the primary
driver for tube failures in a given location. Under nominal operation conditions, the wear rate
normally changes in three different stages:

 Primary stage or early run-in period, where surfaces adapt to each other and the wear-
rate might vary between high and low.
 Secondary stage or mid-age process, where steady wear can be observed. Most of the
component's operational life is spent in this stage.
 Tertiary stage or old-age period, where surfaces are subjected to rapid failure due to a
high rate of wear.

A material that withstands corrosive attack in a waterwall application may be a poor choice
for protecting super-heater tubes against fly ash entrained flue gas erosion. For example, 316
Stainless Steel may perform reasonably well at protecting against Nitric Acid attack, but does
not provide notable protection against high velocity fly ash erosion. The same can be said for
most weld overlay materials, which typically do not have a sufficient density of hard particles
to qualify them as high performance erosion resistant materials.
Extreme temperatures, thermal shock, and the possibility of impact from clinkers are all
factors confronting wear protection methods in a power generation steam boiler. A material
must possess the following characteristics to defend against high velocity fly ash erosion in
this severe environment:
1. Ultra high density of hard particles to withstand extreme ash particle impingement
energies;
2. Extreme interparticle bond strength to ensure that the hard particles remain in place, even in
the presence of corrosive agents;
3. Toughness to withstand large particle impact and extreme thermal shock;
4. Minimal impact on desired tube heat transfer characteristic.

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ADVANCED EROSION PROTECTION TECHNOLOGY FOR STEAM BOILER SUPERHEATED TUBES

EROSION
Erosion is caused by the impact, cutting action or abrasive wear of small solid particles freely
immersed in the direction of fluid flow that frequently undercut portions of the material they
strike. Erosion is the progressive loss of original material from a solid surface due to
mechanical interaction between that surface and the impinging fluid or solid particles. If high
erosion-resistant particles such as Tungsten carbide exist in low erosion resistant or soft
matrix, the impacting Particles can undercut and remove portions of the material. However, if
the high erosion resistant particles are densely packed in a matrix material that causes the
impacting particles to impinge on a greater percent of the hard particle, the erosion resistance
increases dramatically.Solid particle erosion (SPE) is the progressive loss of original material
from a solid surface due to mechanical interaction between that surface and solid particles.

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ADVANCED EROSION PROTECTION TECHNOLOGY FOR STEAM BOILER SUPERHEATED TUBES

CHAPTER 2

METHODS OF WEAR PROTECTION

Several methods for protecting boiler tubes from the severe wear environment in a power
generation steam boiler have been employed, with varying degrees of success. Each method
offers certain benefits, but may add additional risks to asset availability.

2.1Tube Shields
Virtually every boiler maintenance team is familiar with the use of shields for the
protection of boiler tubes. Shields may be as simple as a sacrificial contoured plate of carbon
steel welded in place, or as complex as a “hand-cuffed” superalloy with sophisticated spray
coatings. While tube shields may reduce the frequency of tube leaks and the opportunity for
collateral damage caused by high-velocity steam cutting, there are multiple issues that make
tube shields a poor performing, if not risky, solution.
The objective of tube shields, to prevent hot gas from contacting the heat exchanger
tubes of the boiler, it significantly reduces the efficiency of the unit by impeding heat transfer.
This heat transfer degradation is caused not only by the increased material of the shield, but
also by the shield’s tendency to entrap “dead” air between itself and the tube that it is
protecting.

2.2 Spray Coatings

Protective spray coatings, including HVOF, plasma spray, laser, and others, have
become very popular over the past two decades. While spray coatings have provided good
wear resistance in some applications, their popularity has been primarily driven by the
mystique of the technology, along with considerable marketing investments by OEMs and
other large coating manufacturers. Though direct application of spray coatings alleviates some
of the issues that plague tube shields, sprays have experienced limited success in protecting
boiler tubes from fly ash erosion in severe environments.
The spray coating process, which typically utilizes a hot molten carrier material to move
hard particles into place, tends to produce limited hard particle density in the resulting coating
layer. The higher the density of hard particles, the more difficult it is to make and keep the
carrier material fluid.

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ADVANCED EROSION PROTECTION TECHNOLOGY FOR STEAM BOILER SUPERHEATED TUBES

2.3 Weld Overlays

Weld overlay materials are available in a variety of compositions, including chrome

carbide, vanadium carbide, tungsten carbide, Inconel’s, stainless steel, and other exotic
materials. All weld overlays generally utilize the same approach to inhibiting wear, with
varying compositions selected depending upon environmental variables. In an environment
where corrosion is a significant factor, a stainless steel overlay might provide adequate
protection. Whereas, a tungsten carbide weld overlay may perform better when corrosion is
nominal and the primary wear mode is erosion.
Due to the relatively “low tech” nature of welding, many of the constraints related to
spray coatings are even more relevant to weld overlays. Weld overlay procedures do not
typically achieve the same temperatures or particle movement velocities as those attained with
spray coating processes. This significantly limits the amount of hard particles that can be
deposited for a given amount of carrier material. Typical hard particle volumetric densities for
weld overlay materials rarely exceed 28% by volume, the remainder consisting of relatively
soft carrier material. While there are many corrosion resistant carrier materials that can be
used in the weld overlay process, the nature of such materials (which makes them useful as a
carrier in the weld process) precludes them from withstanding high velocity particle erosion.
Erosion resistance is directly proportional to the density of the material’s hard particles (see
Figures 3 and 4). High localized heating in the weld overlay process typically causes
absorption of substrate carbon, known as “carbon dilution”, into the weld overlay material.
This dilution of carbon causes a reduction in the material’s ability to withstand high velocity
erosive attack. This extreme localized heating, combined with the difficulty in controlling
cooling rates, also results in check cracking of the weld overlay material. This check cracking
may propagate into the base tube material, leading to premature tube failure. Check cracking
at the weld surface offers a path for high velocity erosive material to penetrate into the
protective layer; a phenomenon known as “channeling”.

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ADVANCED EROSION PROTECTION TECHNOLOGY FOR STEAM BOILER SUPERHEATED TUBES

Fig 2.1
Typical weld overlay Fig 2.2 comparison mosaic

2.4 Infiltration Brazed Tungsten Carbide Cladding

Infiltration brazed tungsten carbide cladding overcomes the constraints of tube shields, spray
coatings, and weld overlay materials, as described below.
 Infiltration brazing does not require the movement of hard particles. Therefore, hard
particle densities of more than 70%, by volume, can be achieved (see
photomicrograph figure 2.2).
 Infiltration brazing creates a metallurgical bond between the hard particles, the carrier
material, and the boiler tube to be protected, thus keeping the particles in place.
 Brazing precludes the introduction of contaminants and the development of oxides in
the protective layer, ensuring consistent cladding integrity.
 Infiltration brazing does not allow for significant carbon dilution into the protective
layer, ensuring uniform wear resistance from top to bottom.
 Infiltration brazing allows for a deposition thickness as high as 120 mils, providing
extreme life extension when required.
 The metallurgical bond and high toughness of the carrier material enables infiltration
brazed cladding to withstand extreme thermal shock and impact.
 Infiltration brazed tungsten carbide has a heat transfer coefficient similar in magnitude
to common tube steels (~30 W/ (m-ºK)), and the metallurgical bond ensures that there
is no significant heat transfer impediment at the bond surface.
 Controlled application and cooling during infiltration brazing ensures that protection is
virtually crack-free.

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ADVANCED EROSION PROTECTION TECHNOLOGY FOR STEAM BOILER SUPERHEATED TUBES

Fig 2.3 Infiltration brazed tungsten carbide cladding

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CHAPTER 3

PERFORMANCE COMPARISONS

3.1High Temperature Erosion Comparisons

Multiple lab comparisons of infiltration brazed tungsten carbide cladding have been
performed in order to benchmark its erosion protection capabilities against other, more
commonly known, materials. In December 2003, the Electric Power Research Institute (EPRI)
completed a hot erosion comparison utilizing ASTM G73 test methodology. The test, which
used fluidized boiler bed ash as the erodent material, compared the following commonly
accepted erosion “resistant” materials:
 SA387 steel
 Inconel 52 weld overlay
 Inconel 72 weld overlay
 Inconel 622 weld overlay
 Inconel 625 weld overlay
 312 SS weld overlay
 309L weld overlay

Table 3.1 EPRI HOT EROSION COMPARISON RESULT

3.2 Corrosion Resistance Comparisons

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ADVANCED EROSION PROTECTION TECHNOLOGY FOR STEAM BOILER SUPERHEATED TUBES

Corrosion is not typically the primary driver for failure of steam boiler tubes in the flue
gas stream, such as primary super heater tubes. However, corrosion can play some role in
accelerating other modes of failure, such as high velocity ash erosion. Therefore, corrosion
resistance characteristics are of some interest.
ASTM specifies a standardized corrosion resistance test methodology referred to as G31.
G31testing exposes a material sample to a 10%, by weight, concentration of boiling corrosive
material. ASTM classifies any material as a CLASS A corrosion resistant material if the
amount of material lost over the period of one year is less than 0.002″. Figure 3.2 is a
graphical representation of the ASTM G31 test results, illustrating that all three primary
formulations(WC200, WC210, WC219) of infiltration brazed tungsten carbide cladding are
CLASS A corrosion resistant materials in Nitric and Sulphuric Acid environments. All
infiltration brazed tungsten carbide claddings, except WC200, are CLASS A resistant to
Hydrochloric Acid.

Table 3.2 ASTM G31CORROSION RESISTANCE RESULT

CHAPTER 4

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ADVANCED EROSION PROTECTION TECHNOLOGY FOR STEAM BOILER SUPERHEATED TUBES

CASE STUDY

In an effort to reduce the risk of boiler tube leaks and increase unit availability,
American
Electric Power Company elected to perform a major redubbing project on its Philip spurn
Unit number one. In order to achieve maximum predicted availability in its super heater tube
sections, AEP elected to upgrade the protection of its primary super heater tube legs with
infiltration brazed tungsten carbide cladding.
Philip Spurn unit 1 is a Babcock and Wilcox front-fired boiler with a nameplate rating of
153 MW, burning Bituminous coal. The unit, which went online in 1950, utilizes two
elevations of burners supplied by five B&W E70 coal pulverizes. High velocity fly ash
entrained in the flue gas causes severe erosive attack in several areas of the furnace. The
erosive attack is exacerbated by increased fly ash concentration during periods of soot
blowing activity. The flue gas temperature, in the area of primary superheat tubes, is
approximately 700 degrees Fahrenheit during full-load operation. The steam conditions inside
these tubes are 2450 PSIG and 550º F.
The primary superheat tube legs, made of SA210 Grade A-1 material, have an outside
diameter (OD) of 2 ¾″, with a 0.280″ wall thickness. Tube sections have an “S” shaped
double bend (see Figure 9), and are approximately 60″ in length.
Due to frequent tube leaks, and the need for repeated patch weld repairs, the primary
super heater tube inlet section in unit 1 was replaced with tube sections protected with
infiltration brazed tungsten carbide cladding. Prior to this upgrade, the tube areas required pad
weld repairs on an average of every two to four years.
Conforma Clad Inc. received tube sections from AEP, and applied a 0.030″ thick layer of
its WC219 cladding formulation along an approximately 40 section, centered along the length
of the overall tube. It was determined that a thickness of 0.030 provided sufficient protection
for the application. Greater thicknesses were evaluated and deemed unnecessary. The cladding
layer covered only 200 degrees around the circumference of the pipe, on the upstream side
facing the flue gas flow. Coverage on the downstream face was deemed unnecessary.

4.1 High Temperature Oxidation Test Results

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ADVANCED EROSION PROTECTION TECHNOLOGY FOR STEAM BOILER SUPERHEATED TUBES

Operating temperatures for this application were significantly below the oxidation onset
temperature of infiltration brazed tungsten carbide cladding (1,922º F).

4.2 Structural Integrity of Tube Materials

Infiltration brazing is a relatively high temperature process, which may have an

annealing effect on some materials. Depending upon the material being brazed, this may
affect the yield strength of the material. In many applications, a moderate reduction of a
material’s baseline yield strength is insignificant. However, for boiler tube applications, it is
critical that a complete quantitative evaluation of mechanical integrity be performed to ensure
the reliability and safety of the application.
ASTM material specifications require that SA 210 Class A-1 meets the following minimum
criteria:
Tensile Strength: 60 ksi
Yield Strength: 37 ksi
Elongation: 30%
ASTM A 520 specifies that hydrostatic burst pressure shall be no less than 1.5 times design
pressure; in this application 3,675 PSIG.

CHAPTER 5

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ADVANCED EROSION PROTECTION TECHNOLOGY FOR STEAM BOILER SUPERHEATED TUBES

DESTRUCTIVE TESTING PROCEDURE

A twenty foot section of a SA 210 Class A-1 seamless boiler tube, with a 2 ¾ ″ OD was
procured from an approved supplier. A wall thickness of 0.280″ was not readily available;
therefore, a 0.240″ minimum wall thickness tube was used. Several 12″ and 18″ test samples
were cut from this single tube length.

5.1 Tensile Testing.

Two 12-inch sections were processed through a typical infiltration brazing furnace cycle
without the application of cladding material. One sample was subsequently Figure 9. Clad
Superheater Tube Leg normalized at 1,675º F and rapidly cooled (specific rates are
proprietary). A third 12-inch control sample was cut and left in its original state. All three 12-
inch tube sections were then sent to an independent laboratory for ASTM E8 tensile testing.
Three samples from each of the three 12-inch sections, for a total of nine samples, were
tensile tested. The results are tabulated in Table 6.

5.2 Hydrostatic Burst Testing.

Two 18-inch sections were clad with 0.030″ WC 219 on the OD of 180 degrees
circumference and processed through a typical infiltration brazing cycle. One sample was
subsequently normalized at 1,675º F and rapidly cooled. A third 18-inch control sample was
cut and left in its original state. All three 18-inch sections were sealed using a robotic welder,
with plugs machined in-house, and were sent to an independent facility for hydrostatic burst
testing. The results are reported in Table 2

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ADVANCED EROSION PROTECTION TECHNOLOGY FOR STEAM BOILER SUPERHEATED TUBES

Table 5.1 Result of hydrostatic burst testing.

Data in Table 5.1 indicates that actual burst pressure, following normalization heat treatment,
exceeds the minimum allowable 3,675 PSIG by a factor 3.5X. The ruptured pipes are
illustrated in Figure 5.1. Both of the clad specimens had axial cracks running the length of the
cladding, and burst within the cladding.

Fig : 5.1 Boiler tube section ofter hydrostatic burst test

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ADVANCED EROSION PROTECTION TECHNOLOGY FOR STEAM BOILER SUPERHEATED TUBES

CHAPTER 6

DESTRUCTIVE TESTING RESULTS

Tensile Testing
Results of Tensile Testing and calculated Yield Strength are tabulated below.

Table 6.1 testing result

Results shown in the center section of the table indicate that subjecting the tubes to a
typical brazing cycle reduced the tensile strength of the material to its minimum allowable
level of 60 ksi, and reduced the material yield strength to below its minimum allowable level
of 37 ksi. The normalization heat treatment process, as shown in the bottom section of the
table, increased the material yield strength to the minimum allowable level of 37 ksi.

CHAPTER 7
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ADVANCED EROSION PROTECTION TECHNOLOGY FOR STEAM BOILER SUPERHEATED TUBES

RESULT

Laboratory testing and the destructive evaluation of tubes indicates that the infiltration
brazing of tungsten carbide cladding to boiler tubes, under high temperature and pressure, will
not significantly alter the mechanical characteristics of the material. Proven erosion
characteristics of this cladding indicate that this protective upgrade will provide significant
reduction in the risk of tube failures.
The cladding application has performed as expected, after approximately 14 months of
operation. Actual performance data has not been collected, due to the absence of an
appropriate unit shutdown.
Conforma Clad Engineers will travel to AEP, equipped with portable eddy current
cladding thickness gauges, and map the superheater tube inlet leg cladding thickness layers.
Based upon the known initial cladding thickness and the fact that the cladding wears at a
linear rate from top to- bottom, Conforma Clad will provide a comprehensive report
identifying the location of the most severe wear and extrapolating remaining life.

CONCLUSION

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ADVANCED EROSION PROTECTION TECHNOLOGY FOR STEAM BOILER SUPERHEATED TUBES

Power generation plant owners and maintenance teams are expected to use innovative
methods to increase the availability and productivity of their steam boilers and other large
capital assets. Infiltration brazed tungsten carbide is a proven technology available to provide
substantial protection against the most common causes of aggressive equipment wear.
Infiltration brazed tungsten carbide, while not as well-known as spray coatings and other
older technologies, has proven its ability to simultaneously withstand extremes of thermal
shock, erosion, abrasion, corrosion, and impact. Through the use of this ultra-high
performance protection material, plant operators can significantly reduce the risk of boiler
tube leaks, greatly increasing levels of unit availability and overall capital asset productivity.

REFERENCE

1. P. hulsizer, corrosion/91, paper no 246 NACE , Houston, TX, 1991.

2. G. Lai and P. Hulsizar, corrosion/2000 paper no 258, NACE, Houston, TX, 2000.

3. D. Bowers, Pulp and paper, 61(7), (1987), P.118

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