Journal of Failure Analysis and Prevention

, Volume 16, Issue 5, pp 703–711 | Cite as

Feed Water Chemistry-Related Corrosion Failures in Subcritical 250 MW Coal-Fired Boiler

  • Amrita Kumari
  • S. K. Das
  • P. K. Srivastava
Case History---Peer-Reviewed


This paper emphasis on the study of typical premature failure of water wall tubes of two thermal power plant boiler of same capacity (250 MW) and same operational parameter but with different boiler water chemistry. The investigation concludes on the water-side corrosion in both of the cases. One boiler is running with coordinated phosphate treatment (CPT) and another with all volatile treatment (AVT). The causes of corrosion were discovered and proposed measures for their elimination were given. Visual examination, chemical analysis of deposits, oxide scale thickness measurement, and microstructural examination were carried to ascertain the probable cause/causes of failure. From the investigation, it was finally concluded that the combination of localized high tube metal temperature and wall thinning due to under deposit corrosion led to the premature tube failure in boiler running with CPT and localized pitting corrosion in boiler running with AVT. Based on the results and discussions, a possible way to combat the corrosion was proposed.


Boiler tube failure All volatile treatment Caustic gouging Oxygen corrosion Scale deposition 



Authors are thankful to the Director of Birla Institute of Technology (BIT)-Deoghar-India, for giving support and permission to prepare and publish this paper. The necessary funding required is also supported by the management of Birla Institute of Technology (BIT)-Deoghar-India.


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© ASM International 2016

Authors and Affiliations

  1. 1.Department of Applied ChemistryBirla Institute of TechnologyRanchiIndia
  2. 2.Department of Mathematical Modelling and SimulationCSIR-National Metallurgical LaboratoryJamshedpurIndia

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