Steam Erosion Failure on ASTM A210 Grade A1 Waterwall Tube of Subcritical Boiler

Heny Andya; Abdullah Akmal Ersa Putra; Tio Aditya Maurice; Mas Irfan Purbawanto Hidayat

doi:10.1007/978-981-97-7898-0_46

Steam Erosion Failure on ASTM A210 Grade A1 Waterwall Tube of Subcritical Boiler

Heny Andya^*
, Abdullah Akmal Ersa Putra^*
, Sutarsis^*
, Tio Aditya Maurice
, Mas Irfan Purbawanto Hidayat

^*Corresponding author for this work

PT. Paiton Operation and Maintenance Indonesia
Institut Teknologi Sepuluh Nopember

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

Abstract

This failure analysis investigates tube failures in waterwall components of boilers, crucial for converting water into superheated steam. The study aims to distinguish primary leaks from secondary damage mechanisms, offering insights for power plant OEM safety references. Utilizing visual inspection and validated data collection methods, macrography analysis reveals wall thinning from steam erosion, reducing thickness to a critical 0.085 mm, far below the required 2.8 mm. SEM testing displays dimple rupture patterns, with metallography and hardness tests indicating no microstructural degradation. Chemical composition aligns with ASTM A210 Grade A1. Conclusively, the analysis attributes tube failures to steam erosion, classifying it as a secondary damage mechanism. The results guide the development of mitigation strategies, emphasizing immediate shutdown actions to ensure boiler safety and efficiency. This comprehensive study aids in preventing future tube failures, contributing to the reliability of boiler operations in power plants.

Original language	English
Title of host publication	Smart Innovation in Mechanical Engineering - Select Proceedings of ICOME 2023
Editors	Abdel El Kharbachi, Ika Dewi Wijayanti, Putu Suwarta, Ivan Tolj
Publisher	Springer Science and Business Media Deutschland GmbH
Pages	411-419
Number of pages	9
ISBN (Print)	9789819778973
DOIs	https://doi.org/10.1007/978-981-97-7898-0_46
Publication status	Published - 2025
Event	6th International Conference on Mechanical Engineering, ICOME 2023 - Bali, Indonesia Duration: 30 Aug 2023 → 31 Aug 2023

Publication series

Name	Lecture Notes in Mechanical Engineering
ISSN (Print)	2195-4356
ISSN (Electronic)	2195-4364

Conference

Conference	6th International Conference on Mechanical Engineering, ICOME 2023
Country/Territory	Indonesia
City	Bali
Period	30/08/23 → 31/08/23

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 3 Good Health and Well-being

Keywords

Failure analysis
Leakage
Subcritical
Waterwall tube

Access to Document

10.1007/978-981-97-7898-0_46

Cite this

Andya, H., Putra, A. A. E., Sutarsis, Maurice, T. A., & Hidayat, M. I. P. (2025). Steam Erosion Failure on ASTM A210 Grade A1 Waterwall Tube of Subcritical Boiler. In A. El Kharbachi, I. D. Wijayanti, P. Suwarta, & I. Tolj (Eds.), Smart Innovation in Mechanical Engineering - Select Proceedings of ICOME 2023 (pp. 411-419). (Lecture Notes in Mechanical Engineering). Springer Science and Business Media Deutschland GmbH. https://doi.org/10.1007/978-981-97-7898-0_46

Andya, Heny ; Putra, Abdullah Akmal Ersa ; Sutarsis et al. / Steam Erosion Failure on ASTM A210 Grade A1 Waterwall Tube of Subcritical Boiler. Smart Innovation in Mechanical Engineering - Select Proceedings of ICOME 2023. editor / Abdel El Kharbachi ; Ika Dewi Wijayanti ; Putu Suwarta ; Ivan Tolj. Springer Science and Business Media Deutschland GmbH, 2025. pp. 411-419 (Lecture Notes in Mechanical Engineering).

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title = "Steam Erosion Failure on ASTM A210 Grade A1 Waterwall Tube of Subcritical Boiler",

abstract = "This failure analysis investigates tube failures in waterwall components of boilers, crucial for converting water into superheated steam. The study aims to distinguish primary leaks from secondary damage mechanisms, offering insights for power plant OEM safety references. Utilizing visual inspection and validated data collection methods, macrography analysis reveals wall thinning from steam erosion, reducing thickness to a critical 0.085 mm, far below the required 2.8 mm. SEM testing displays dimple rupture patterns, with metallography and hardness tests indicating no microstructural degradation. Chemical composition aligns with ASTM A210 Grade A1. Conclusively, the analysis attributes tube failures to steam erosion, classifying it as a secondary damage mechanism. The results guide the development of mitigation strategies, emphasizing immediate shutdown actions to ensure boiler safety and efficiency. This comprehensive study aids in preventing future tube failures, contributing to the reliability of boiler operations in power plants.",

keywords = "Failure analysis, Leakage, Subcritical, Waterwall tube",

author = "Heny Andya and Putra, \{Abdullah Akmal Ersa\} and Sutarsis and Maurice, \{Tio Aditya\} and Hidayat, \{Mas Irfan Purbawanto\}",

note = "Publisher Copyright: {\textcopyright} The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2025.; 6th International Conference on Mechanical Engineering, ICOME 2023 ; Conference date: 30-08-2023 Through 31-08-2023",

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doi = "10.1007/978-981-97-7898-0\_46",

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Andya, H, Putra, AAE, Sutarsis, Maurice, TA & Hidayat, MIP 2025, Steam Erosion Failure on ASTM A210 Grade A1 Waterwall Tube of Subcritical Boiler. in A El Kharbachi, ID Wijayanti, P Suwarta & I Tolj (eds), Smart Innovation in Mechanical Engineering - Select Proceedings of ICOME 2023. Lecture Notes in Mechanical Engineering, Springer Science and Business Media Deutschland GmbH, pp. 411-419, 6th International Conference on Mechanical Engineering, ICOME 2023, Bali, Indonesia, 30/08/23. https://doi.org/10.1007/978-981-97-7898-0_46

Steam Erosion Failure on ASTM A210 Grade A1 Waterwall Tube of Subcritical Boiler. / Andya, Heny; Putra, Abdullah Akmal Ersa; Sutarsis et al.
Smart Innovation in Mechanical Engineering - Select Proceedings of ICOME 2023. ed. / Abdel El Kharbachi; Ika Dewi Wijayanti; Putu Suwarta; Ivan Tolj. Springer Science and Business Media Deutschland GmbH, 2025. p. 411-419 (Lecture Notes in Mechanical Engineering).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

TY - GEN

T1 - Steam Erosion Failure on ASTM A210 Grade A1 Waterwall Tube of Subcritical Boiler

AU - Andya, Heny

AU - Putra, Abdullah Akmal Ersa

AU - Sutarsis,

AU - Maurice, Tio Aditya

AU - Hidayat, Mas Irfan Purbawanto

N1 - Publisher Copyright: © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2025.

PY - 2025

Y1 - 2025

N2 - This failure analysis investigates tube failures in waterwall components of boilers, crucial for converting water into superheated steam. The study aims to distinguish primary leaks from secondary damage mechanisms, offering insights for power plant OEM safety references. Utilizing visual inspection and validated data collection methods, macrography analysis reveals wall thinning from steam erosion, reducing thickness to a critical 0.085 mm, far below the required 2.8 mm. SEM testing displays dimple rupture patterns, with metallography and hardness tests indicating no microstructural degradation. Chemical composition aligns with ASTM A210 Grade A1. Conclusively, the analysis attributes tube failures to steam erosion, classifying it as a secondary damage mechanism. The results guide the development of mitigation strategies, emphasizing immediate shutdown actions to ensure boiler safety and efficiency. This comprehensive study aids in preventing future tube failures, contributing to the reliability of boiler operations in power plants.

AB - This failure analysis investigates tube failures in waterwall components of boilers, crucial for converting water into superheated steam. The study aims to distinguish primary leaks from secondary damage mechanisms, offering insights for power plant OEM safety references. Utilizing visual inspection and validated data collection methods, macrography analysis reveals wall thinning from steam erosion, reducing thickness to a critical 0.085 mm, far below the required 2.8 mm. SEM testing displays dimple rupture patterns, with metallography and hardness tests indicating no microstructural degradation. Chemical composition aligns with ASTM A210 Grade A1. Conclusively, the analysis attributes tube failures to steam erosion, classifying it as a secondary damage mechanism. The results guide the development of mitigation strategies, emphasizing immediate shutdown actions to ensure boiler safety and efficiency. This comprehensive study aids in preventing future tube failures, contributing to the reliability of boiler operations in power plants.

KW - Failure analysis

KW - Leakage

KW - Subcritical

KW - Waterwall tube

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BT - Smart Innovation in Mechanical Engineering - Select Proceedings of ICOME 2023

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A2 - Wijayanti, Ika Dewi

A2 - Suwarta, Putu

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PB - Springer Science and Business Media Deutschland GmbH

T2 - 6th International Conference on Mechanical Engineering, ICOME 2023

Y2 - 30 August 2023 through 31 August 2023

ER -

Andya H, Putra AAE, Sutarsis, Maurice TA, Hidayat MIP. Steam Erosion Failure on ASTM A210 Grade A1 Waterwall Tube of Subcritical Boiler. In El Kharbachi A, Wijayanti ID, Suwarta P, Tolj I, editors, Smart Innovation in Mechanical Engineering - Select Proceedings of ICOME 2023. Springer Science and Business Media Deutschland GmbH. 2025. p. 411-419. (Lecture Notes in Mechanical Engineering). doi: 10.1007/978-981-97-7898-0_46

Steam Erosion Failure on ASTM A210 Grade A1 Waterwall Tube of Subcritical Boiler

Abstract

Publication series

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UN SDGs

Keywords

Access to Document

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