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03491 PREMATURE FAILURE OF A 9 CHROMIUM VANADIUM-MODIFIED SUPERHEATER TUBE

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Product Number: 51300-03491-SG
ISBN: 03491 2003 CP
Author: Gordon P. Kallenberg
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The failure of a 9 Chromium Vanadium-Modified superheater tube in a Heat Recovery Steam Generation (HRSG) boiler at a Co-Generation (Co-Gen) plant took place only 20 hours after the plant was brought on-line. Final failure of the tubing occurred due to tensile overload in the presence of preexisting cracks that were concluded to have been introduced during hydro-testing and a total of 3 startup cycles that took place within the first 20 hours of operation. The cracks were a consequence of brittle crack initiation that occurred in a low-toughness, high hardness region in a heat-affected zone (HAZ) at the tube-to-stub end weld at the discharge header. The high hardness was attributed to a line of arc strikes and weld spatter along the HAZ on the tube side of the weld joint. The weld spatter was found to have a composition of 73 percent nickel and 12 percent chromium. HAZ hardness under the line of arc strikes/weld spatter reached a maximum of 303 Brinell, while the hardness of the HAZ away from the failure, and the tube base metal, were 210-220 Brinell and 150-170 Brinell, respectively. The HAZ hardness within the failure region supported the conclusion that the weld spatter most likely originated from an event external to the fabrication of the superheater coil that took place after welding and Post Weld Heat Treatment (PWHT) of the tube/discharge header had been completed. Keywords: brittle fracture, weld spatter, arc strikes, superheater tubing, 9 Chromium Vanadium- Modified alloy steel, hydro-test, tensile overload, HRSG, Co-Gen plant.
The failure of a 9 Chromium Vanadium-Modified superheater tube in a Heat Recovery Steam Generation (HRSG) boiler at a Co-Generation (Co-Gen) plant took place only 20 hours after the plant was brought on-line. Final failure of the tubing occurred due to tensile overload in the presence of preexisting cracks that were concluded to have been introduced during hydro-testing and a total of 3 startup cycles that took place within the first 20 hours of operation. The cracks were a consequence of brittle crack initiation that occurred in a low-toughness, high hardness region in a heat-affected zone (HAZ) at the tube-to-stub end weld at the discharge header. The high hardness was attributed to a line of arc strikes and weld spatter along the HAZ on the tube side of the weld joint. The weld spatter was found to have a composition of 73 percent nickel and 12 percent chromium. HAZ hardness under the line of arc strikes/weld spatter reached a maximum of 303 Brinell, while the hardness of the HAZ away from the failure, and the tube base metal, were 210-220 Brinell and 150-170 Brinell, respectively. The HAZ hardness within the failure region supported the conclusion that the weld spatter most likely originated from an event external to the fabrication of the superheater coil that took place after welding and Post Weld Heat Treatment (PWHT) of the tube/discharge header had been completed. Keywords: brittle fracture, weld spatter, arc strikes, superheater tubing, 9 Chromium Vanadium- Modified alloy steel, hydro-test, tensile overload, HRSG, Co-Gen plant.
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