In this study Cr3C2-25%NiCr powder was deposited on the ASME SA213 T-91 boiler tube steel substrate by HVOF thermal spray process in order to combat erosion problems. Structural and mechanical properties are evaluated and it was also found that cracks failure initiated in the boiler tubes at the localized areas due to long term over-heating. Bend test was performed to evaluate the peel off behaviour of Cr3C2-25%NiCr coating. Air-jet erosion test was conducted as per ASTM G-76. The investigation provided key results like the maximum depth of erosion along with cumulative weight loss (mg) of the coated sample with respect to time (minutes). Ductile mode of erosion leaving behind the erosion scars in bulging form along with an increase in the time period was exhibited. The diameter (D) of the air-jet erodent scar has increased with time for 12 numbers of cycles. An attempt has been made to achieve a better erosion resistance. The coating has shown a drastic improvement in the erosion resistance which reduces the failures in the boiler tube systems. Microstructural, cracks failure analysis and mechanical properties are discussed in detail.