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<p>This study investigates the failure of a carbon steel boiler tube (SA210 Grade A1) through a comprehensive metallurgical and mechanical analysis. Visual inspection revealed a localized deformation characterized by a thin lip failure with internal bulging. Sectioned tube samples showed brown and black deposits on the inner diameter (ID), which were confirmed as iron oxide through EDS analysis. Microstructural examination near the damaged region (within 25&#xa0;mm) revealed extensive pearlite disintegration, creep voids, cracks, and carbide precipitates along ferrite grain boundaries, indicating exposure to high temperatures. SEM-EDS analysis further validated the presence of creep-induced damage and precipitate formation. Compared to unaffected regions, a significant reduction (− 18%) in hardness near the failure zone supported the observed microstructural degradation. Beyond 25&#xa0;mm from the damage site, the tube retained its original ferrite–pearlite structure. Chemical composition analysis confirmed conformity with the SA210 Grade A1 specification. The evidence collectively indicates that the tube failure resulted from localized short-term overheating, leading to creep damage, material softening, and eventual rupture. This study highlights the importance of monitoring temperature excursions to prevent premature failures in high-temperature boiler components.</p>

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Root Cause Analysis of a Ruptured Waste Heat Recovery Boiler Tube of Grade SA210 A1

  • 期刊论文

  • 发表日期：

    2025年8月10日

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  • Shiva Bejugama,
  • Raju Vemoori

摘要

This study investigates the failure of a carbon steel boiler tube (SA210 Grade A1) through a comprehensive metallurgical and mechanical analysis. Visual inspection revealed a localized deformation characterized by a thin lip failure with internal bulging. Sectioned tube samples showed brown and black deposits on the inner diameter (ID), which were confirmed as iron oxide through EDS analysis. Microstructural examination near the damaged region (within 25 mm) revealed extensive pearlite disintegration, creep voids, cracks, and carbide precipitates along ferrite grain boundaries, indicating exposure to high temperatures. SEM-EDS analysis further validated the presence of creep-induced damage and precipitate formation. Compared to unaffected regions, a significant reduction (− 18%) in hardness near the failure zone supported the observed microstructural degradation. Beyond 25 mm from the damage site, the tube retained its original ferrite–pearlite structure. Chemical composition analysis confirmed conformity with the SA210 Grade A1 specification. The evidence collectively indicates that the tube failure resulted from localized short-term overheating, leading to creep damage, material softening, and eventual rupture. This study highlights the importance of monitoring temperature excursions to prevent premature failures in high-temperature boiler components.