NACE TM0199-2013

Item No. 21236

Standard Test Method

Standard Test Method for Measuring Deposit Mass

Loading (“Deposit-Weight-Density”) Values for Boiler
Tubes by the Glass-Bead-Blasting Technique
This NACE International standard represents a consensus of those individual members who have
reviewed this document, its scope, and provisions. Its acceptance does not in any respect
preclude anyone, whether he or she has adopted the standard or not, from manufacturing,
marketing, purchasing, or using products, processes, or procedures not in conformance with this
standard. Nothing contained in this NACE International standard is to be construed as granting
any right, by implication or otherwise, to manufacture, sell, or use in connection with any method,
apparatus, or product covered by Letters Patent, or as indemnifying or protecting anyone against
liability for infringement of Letters Patent. This standard represents minimum requirements and
should in no way be interpreted as a restriction on the use of better procedures or materials.
Neither is this standard intended to apply in all cases relating to the subject. Unpredictable
circumstances may negate the usefulness of this standard in specific instances. NACE
International assumes no responsibility for the interpretation or use of this standard by other
parties and accepts responsibility for only those official NACE International interpretations issued
by NACE International in accordance with its governing procedures and policies which preclude
the issuance of interpretations by individual volunteers.

Users of this NACE International standard are responsible for reviewing appropriate health, safety,
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standard prior to its use. This NACE International standard may not necessarily address all
potential health and safety problems or environmental hazards associated with the use of
materials, equipment, and/or operations detailed or referred to within this standard. Users of this
NACE International standard are also responsible for establishing appropriate health, safety, and
environmental protection practices, in consultation with appropriate regulatory authorities if
necessary, to achieve compliance with any existing applicable regulatory requirements prior to the
use of this standard.

CAUTIONARY NOTICE: NACE International standards are subject to periodic review, and may be
revised or withdrawn at any time in accordance with NACE technical committee procedures. NACE
International requires that action be taken to reaffirm, revise, or withdraw this standard no later
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FirstService Department, 1440 South Creek Drive, Houston, Texas 77084-4906 (telephone +1
281-228-6200).

Reaffirmed 2013-05-08
Reaffirmed 2006-03-15
Approved 1999-04-24
NACE International
1440 South Creek Dr.
Houston, Texas 77084-4906
+1 281-228-6200

ISBN 1-57590-082-3
© 2013, NACE International
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Foreword

This standard test method was developed to document the procedures used in determining the
amount of deposit accumulation on a boiler tube surface, commonly expressed as the deposit-
weight-density (DWD) value, via the glass-bead-blasting (GBB) technique. The GBB technique for
determining DWD values is suitable for removing a wide variety of boiler deposit types, but it is
especially useful when deposition is tightly adherent and would be difficult to dislodge completely
via other mechanical or chemical cleaning processes (as specified in Method A and Method B of
(1) 1
ASTM D 3483 ). Typically, the GBB technique allows for complete deposit removal in a very
short time frame, without the risk of error induced by incomplete removal of tightly adherent scale
2
or excessive loss of the metal substrate during the cleaning process.

This standard is for use specifically by those involved in providing technical assessments
concerning boiler cleanliness, such as university/corporate research laboratories, independent
research/engineering consulting firms, or those in the chemical cleaning industry. This standard is
intended to be used to obtain accurate deposit-loading data, which may be pertinent to
establishing the necessity of chemically cleaning boiler systems to avoid boiler tube failure
incidents (such as those related to under-deposit corrosion and tube metal overheating) and to
track the rate of deposit growth over time.

This standard was originally prepared in 1999 by NACE Work Group T-7H-6f, as assigned by the
T-7H-6 Task Group on “Failure Analysis—Boiler Waterside,” which was a component of Unit
Committee T-7H, “Corrosion and Its Control in Steam-Generating Systems.” It was reaffirmed in
2006 and 2012 by Specific Technology Group (STG) 11, “Water Treatment,” and is published by
NACE International under the auspices of STG 11.

In NACE standards, the terms shall, must, should, and may are used in accordance with the
definitions of these terms in the NACE Publications Style Manual. The terms shall and must are used
to state a requirement, and are considered mandatory. The term should is used to state something
good and is recommended, but is not considered mandatory. The term may is used to state
something considered optional.

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(1)
ASTM International, 100 Barr Harbor Dr., West Conshohocken, PA 19428-2959.

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NACE International
Standard Test Method

Standard Test Method for Measuring Deposit Mass Loading

(“Deposit-Weight-Density”) Values for Boiler Tubes by the
Glass-Bead-Blasting Technique

Contents

1. General .......................................................................................................................... 1
2. Test Equipment and Apparatus ..................................................................................... 1
3. Test Specimen Preparation ........................................................................................... 2
4. Test Procedure .............................................................................................................. 2
5 Test Specimen Handling After Cleaning ....................................................................... 3
6. Potential Interferences................................................................................................... 4
References .......................................................................................................................... 4
Appendix A: Sample DWD Report Calculation Sheet (Nonmandatory) ............................. 5

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Section 1: General

1.1 This standard describes a simple test method that employs GBB equipment to remove boiler waterside deposits on a piece
of tubing removed from a representative area of a boiler. The test specimens are cut from a sample tube, weighed before and
after the cleaning process, and the amount of deposit per surface area is estimated by measuring the weight loss of the tube
sample test piece after deposit removal via GBB and dividing by the surface area of the test piece. The DWD value that is
2 2
obtained by this method is typically expressed in mg/cm or g/ft units, and is defined as the weight of the deposit per boiler tube
(2) 2
surface area. Currently, DWD values are commonly expressed in g/ft units. Procedures for test specimen processing,
dimensional analysis techniques, sources of potential interferences, and a sample DWD report calculation sheet are included.

1.2 Measurement of deposit accumulation obtained by this test method should not be the sole source of information used to
decide on the necessity of chemically cleaning a boiler. Although producing an accurate DWD value may be an important factor
3,4,5
to aid in evaluating boiler cleanliness (and there are references in the literature that utilize DWD data to assist in establishing
chemical cleaning guidelines as a function of boiler pressure), other details should be considered. For example, the chemical
composition and relative thickness of the specific waterside scale formed on the heat transfer surface are key parameters that
must be taken into account in the process of making a decision to clean a boiler system to avoid tube failure. In addition, specific
boiler design, heat flux patterns, and operating conditions have significant influence on the amount of deposit loading that can be
sustained prior to the occurrence of overheating and other deposit-related failure processes.

1.3 Caution should be used in the interpretation of high-DWD values obtained from tubes subject to extreme temperature
conditions (beyond the oxidation limit of the steel). This is because the DWD value produced may be unusually high as a result
of the presence of excessive magnetite scale via in situ oxidation. As such, deposit-loading estimates of superheater tubes,
reheater tubes, or water-bearing tubes subject to excessive heat flux may actually reflect the presence of heavy in situ oxides
rather than transported and deposited water-formed scale constituents. No attempt to differentiate between water-formed scale
and in situ oxidation products is made; the overall deposit weight per surface area is estimated with this test method. Other
techniques (such as X-ray diffraction, microchemical analysis of deposit layers, metallography, etc.) may be needed to ascertain
the relative distribution of deposit constituents and the influence of severe oxidation (excessive magnetite) on the DWD value.

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Section 2: Test Equipment and Apparatus

2.1 A commercial GBB cabinet shall be used to perform this test. Various commercial units that have a glass viewing window
incorporated within an enclosed blast cabinet are available. Typical operating requirements are compressed air at 690 kPag (100
3 3
psig) with a minimum 0.34 m /min (12 ft /min) flow rate.

2.2 Medium-size glass beads, 150 to 250 m diameter range (60 to 100 mesh size) shall be used in the blast cabinet.

2.3 A dry-cutting band saw machine, portable band saw, or other appropriate dry-cutting device shall be used to cut the test
specimens from boiler tube sample segments.

2.4 An analytical laboratory balance accurate within a minimum of 0.01 g in the range of 200 to 600 g capacity (or larger
capacity) shall be used.

2.5 A small flexible ruler or measuring tape with gradations of 1.0 mm or 1/16 in shall be used.

2.6 A point micrometer with a 0 to 25 mm (0 to 1.0 in) range, 0.025 mm (0.0010 in) increments, contact points with 15° included
angle, or similar, may be used to estimate deposit thickness (via before/after-cleaning measurements) and on the cleaned
specimens to estimate general corrosion loss and to assess pit depths.

2.7 An instant-film copy camera, 35 mm or digital image camera, or other photographic system may be used to record deposit
appearance and other features.

2.8 Engineering graph paper may be utilized to estimate surface area of the test specimen.

(2)
1 g/ft2 is equivalent to 1.075 mg/cm2.

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Section 3: Test Specimen Preparation

3.1 Test Specimen

3.1.1 The optimal length of tubing cut from the boiler for evaluation is 0.6 to 0.9 m (2 to 3 ft). However, it is not uncommon
to receive tube sections/samples that are very short in length or cut out in rectangular or circular shapes. Modification to the
following steps may be required to determine the DWD value for unusually shaped or undersized test pieces. Comments
should be added to the report (see Appendix A [Nonmandatory]) when unusual conditions are observed.

3.1.2 With this method, straight-bored cylindrical tube samples from a boiler should be cut lengthwise in half, and the
deposit accumulation on each half should be measured individually on test specimens that are cut to approximately 76 mm
2 2
(3.0 in) in length. This produces a standard test specimen with a surface area of about 6,000 to 6,500 mm (9 to 10 in ).
Longer test specimens may be processed, but this may be limited by the capacity of the analytical balance being used. Test
specimens less than 76 mm (3.0 in) long may be processed if necessary, but the deposit-loading result may not be as
representative if deposits are not homogeneous (see Paragraph 6.1).

3.2 Test Specimen Preparation: The following procedure shall be used in test specimen preparation.

3.2.1 Visually inspect the length of tubing cut from the boiler to assess the nature of the internal deposit. For tubes exposed
to a differential heat flux (waterwall, screen, etc.), identify the hot and cold sides of the tube for test specimen removal from
both sides, and locate areas of the heaviest deposit accumulation. In the case of tubes exposed to a more uniform heat flux
pattern around the tube circumference (economizer, superheater, etc.), removal of a test specimen from one side of the tube
may be adequate. If one side appears more heavily deposited, it should be used for the test specimen.

3.2.2 Inspect the internal surface to ensure that no cutting debris or weld spatter (from torch cutting) is present in the region
to be tested. By visual inspection, select a region containing a representative sample of the internal surface deposits
(typically a 76 mm [3.0 in] length in the center of the tube sample). Avoid sampling at previously torch-cut ends where
contamination or deposit loss could have occurred.

3.2.3 If necessary, clean the external surface of the test specimen(s) by using the glass-bead blaster. This step must be
taken if loosely adherent external scale is present on the tube sample and could possibly spall off in subsequent processing.
During external scale cleaning, care must be taken to avoid any inadvertent removal of internal deposit. This external
cleaning step may be considered optional if the external surface’s oxide layer is very thin and tightly adherent (i.e., no risk of
inadvertent deposit spalling of the external surface during handling of the test specimen [see Paragraph 6.3]). To avoid
sample mix-up, write the test specimen identification information on the external surface (or on the cut tube edges)
immediately after removing any external scale.

3.2.4 With a dry-cutting saw, complete transverse cuts to produce a test specimen that is preferably 76 mm (3.0 in) long in a
representative region, then split the test specimen lengthwise to create two half-pieces (hot-side/cold-side). After cutting, re-
inspect the surface for artifacts from the cutting process and carefully remove any debris and/or metal fines. Deburr rough-
cut edges as necessary with a metal file. Using a felt-tip marker, paint pen, or vibratory engraver, identify the test specimens
(i.e., specimen number, hot, cold, etc.) by marking on the external surface or the saw-cut end of the section.

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Section 4: Test Procedure

4.1 Photography of an area of the internal surface exhibiting deposits representative of the test specimen may be desirable, but
is not mandatory.

4.2 The test specimen shall be weighed on an analytical balance with a minimum accuracy of 0.01 g. The weight measurements
(and optional micrometer measurements [see Paragraph 4.4]) will provide the “before-cleaning” data for the test specimens.

4.3 All measurement data (i.e., weight, lengths, thicknesses, and depths) should be recorded on a standardized laboratory
calculation data sheet (see Appendix A).

4.4 An estimate of the waterside deposit thickness may be very useful. To obtain this value, the combined thickness of the tube
wall and waterside deposit prior to cleaning should be carefully measured using a point micrometer, after external surface deposit
removal has been achieved. Three or more locations on the cleaned external surface where the thickness readings were

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obtained should be marked and recorded. Three data points are normally sufficient. These marked sites should be re-measured
after cleaning to obtain approximate deposit thickness values.

4.5 The internal surface of the test specimens may now be cleaned using the glass-bead blaster. A typical pressure setting is
550 kPag (80 psig), and the usual duration of blasting is about 30 seconds with an appropriately sized gun nozzle tip and
sufficient air flow volume. In any event, the surface should be blast cleaned, be completely free of deposit, and any adherent
magnetite layer be removed (blasted down to a shiny metal condition). Assuming optimal equipment settings, blast times
exceeding one minute are not typical at these prescribed operating conditions and should not be necessary. Tests on clean
carbon steel coupons or cleaned tube specimens are recommended to evaluate the potential risk (if any) of excessively long blast
times (see Paragraph 6.5).

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Section 5: Test Specimen Handling After Cleaning

5.1 Following cleaning, the test specimens shall be reweighed to the nearest 0.01 g, and the tube wall re-measured at the
marked sites for thickness to provide the “after-cleaning” measurements.

5.2 The surface area of each test specimen shall then be measured. If the specimen shape is regular (i.e., a standard test
specimen) a flexible ruler may be used. Measurements should be within the nearest 1.0 mm or 1/16 in. For a standard, regular-
shaped test sample, the longitudinal dimension should simply be multiplied by the actual circumferential length of the cut test
specimen to yield the total internal surface test area (see Appendix A). (For a standard sample size, this is typically around 6,000
2 2
to 6,500 mm (9 to 10 in ).

5.2.1 If the surface dimensions of the test specimens are irregular, engineering graph paper or a paper-pattern technique
may be used. If a paper sheet is trimmed to fit the irregular shape, the approximate surface area of the region cleaned may
be estimated by comparing the weight of the paper pattern to the known weight of a sheet of paper that has a specific square
area. The size may thus be determined by proportional analysis.

5.3 Determination of the DWD value

5.3.1 Subtracting the “after-cleaning” data from the “before-cleaning” data provides the weight loss (i.e., the deposit weight)
and thickness of the internal deposit that was removed.

5.3.2 A DWD value is determined by dividing the weight of the internal deposit by the surface area. The overall expression
to determine the DWD value shall be calculated using Equation (1) or (2):

2 initial weight (mg) - final weight (mg)

DWD (mg/cm ) = (1)
2 2 2
area (mm )  (1 cm /100 mm )

2 initial weight (g) - final weight (g)

DWD (g/ft ) = 2 2 2 (2)
area (in ) x (1 ft /144 in )

2 2
Note: DWD (g/ft ) = DWD (mg/cm ) x 0.929.

5.4 The DWD value should be reported to the nearest integer value, unless higher precision is required.

5.5. Photography of the internal surface in a representative area after cleaning of the test specimen may be desirable, but is not
mandatory.

5.6 The employment of a pin-type micrometer to measure pit depths or the extent of other corrosion loss on the cleaned test
specimen may be desirable, but is not mandatory.

5.7 The cleaned test specimen may be sprayed with clear acrylic coating to avoid flash rusting after evaluation. A fume hood
should be used as necessary to avoid overspray and odor.

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Section 6: Potential Interferences

6.1 Test Specimen Size: With the GBB method, excellent data repeatability can be achieved regardless of test sample size.
However, there are circumstances in which a too-small test specimen may provide a potential interference in determining a
representative DWD value. Specifically, if the deposit being removed from the boiler tube is not homogeneous (i.e., thick, uneven
deposits that may tend to spall off when the tube test specimen is cut out), processing of small test specimens (less than the 76
mm [3.0 in] standard test length) should be avoided. In addition, slight measurement errors that are inherently a problem with
processing of small test specimens can be easily avoided by processing a larger, standard-size test specimen.

6.2 Contamination of Test Surfaces: Another potential interference is the presence of surface contaminants such as weld
spatter, abrasive cut-off wheel residue, or oils that could influence the test specimen weight and condition during its removal from
the boiler (as discussed in Paragraph 3.2.2). Thus, torch-cut ends, etc., should be avoided during selection of a representative
region for cutting out the test specimen.

6.3 External Scale: To avoid interference with external scale, the tube outer surface should be cleaned as described in
Paragraph 3.2.3. Failure to do so may result in an erroneous DWD value because external scale could spall off the external
surface during sample handling after the initial weight has been recorded, which would introduce error into the weight-loss
calculation. However, if the oxide layer on the external surface is very thin and tightly adherent (i.e., little to no risk of external
deposit interference), cleaning the external surface may not be strictly necessary as a procedural step.

6.4 Glass Bead Condition: The glass beads in the bead-blast unit should be in good condition with minimal contamination.
Scheduling routine dumping and replacement of the glass bead charge at a specific time interval (i.e., once every 30 days)
should avoid accumulation of scale (which could act as a more aggressive abrasive than the glass beads), and excessive
breakdown of glass beads into fine dust. Simple visual inspection of the glass beads should provide sufficient indication of
whether the charge has become contaminated or has reduced cleaning effectiveness as a result of excessive breakdown (via
long-duration use).

6.5 Tenacious Scale: During a typical cleaning cycle, most adherent boiler tube deposits may be removed in less than 30
seconds with optimal equipment performance and settings. In this time frame, loss of the metal substrate is relatively insignificant
2 6
(around 0.20 mg/cm , which is negligible). However, long-duration blasting with glass beads to dislodge tenacious scale (silica-
based scale, thick metal oxides formed via tube overheating, etc.) should not be used because of the risk of excessive metal
substrate loss. For tubes with such tenacious scale, ASTM D3483, Method A (bending/scraping method) is preferable. ASTM
D3483, Method B (acid solvent method) may also be considered.

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References

1. ASTM D3483 (latest revision), “Standard Test Methods for Accumulated Deposition in a Steam Generator Tube” (West
Conshohocken, PA: ASTM).

2. M.J. Esmacher, J.M. Jevec, T.M. Laronge, K.A. Selby, D.A. Shifler, “Evaluation of Boiler Tube Deposit Weight Density
Methodology,” CORROSION/97, paper no. 454 (Houston, TX: NACE, 1997).
(3)
3. EPRI TR-10241, “Guidelines for Chemical Cleaning of Fossil-Fueled Steam Generating Equipment,” (Palo Alto, CA: EPRI,
June 1993).

4. J.G. Singer, ed., Combustion: Fossil Power, A Reference Book on Fuel Burning and Steam Generation, 4th ed. (Windsor,
CT: Combustion Engineering Inc., ABB, 1991), p. 18.

5. Babcock & Wilcox Plant Service Bulletin PSB-44-3M-N-6/91, Chemical Cleaning Guide, June 1991.

6. M.J. Esmacher, “Deposit Weight Density Methodology for Industrial Boilers,” Materials Performance 28, 1 (1988): pp. 74-78.

(3)
Electric Power Research Institute (EPRI), 3420 Hillview Ave., Palo Alto, CA 94304-1395.

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Appendix A
Sample DWD Report Calculation Sheet
(Nonmandatory)

This appendix is considered nonmandatory, although it may contain mandatory language. It is intended only to provide
supplementary information or guidance. The user of this standard is not required to follow, but may choose to follow, any or all of
the provisions herein.

Lab Number ________________

(Optional)
Deposit/Wall Thickness Measurements
Region 1 Region 2 Region 3
Weight:
Before Cleaning: __________ Before Cleaning: ______ ______ ______

After Cleaning: __________ After Cleaning: ______ ______ ______

Deposit
Test Sample Weight Loss: __________ Thickness: ______ ______ ______

Tube Measurements

Longitudinal Axis (L):

Circumferential Axis (C):

Calculated Test Area (L x C):

2 weight loss (mg) 2

DWD (mg/cm ) = 2
= mg/cm
test area (cm )

or

2 weight loss (g) 2

DWD (g/ft ) = 2 2 2
= g/ft
test area (in ) x (1 ft /144 in )

[ ] See attached Comments (if applicable)

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NACE International