Failure Analysis of Water-Wall Tubes in the High-Pressure Boiler

2014 ◽  
Vol 912-914 ◽  
pp. 456-459
Author(s):  
Na Xu ◽  
Jun Bo Shi ◽  
Yong De Li ◽  
Wei Min Guo ◽  
Xiao Feng Wu ◽  
...  
Keyword(s):  
High Pressure ◽  
Failure Analysis ◽  
Pitting Corrosion ◽  
Failure Process ◽  
Surface Damage ◽  
Metallographic Examination ◽  
Boiler Water ◽  
Corrosion Failure ◽  
Water Wall ◽  
Sulfide Corrosion

In this case study, the corrosion failure analysis of high-pressure boiler water-wall tubes in a power plant was investigated by means of the chemical analysis, metallographic examination and scanning electron microscope (SEM) observation. Energy dispersive spectroscopy (EDS) was used to examine the changes of test materials and corrosion products. Based on the failure process of the boiler water-wall tubes and the experimental results, a conclusion was drawn that the failure of water-wall tubes was mainly caused by pitting corrosion. Sulfide and chloride attack was the major cause of localized pitting corrosion on the inner surface, and the outer surface damage was mainly due to the synergism of high temperature sulfide corrosion and flue gas erosion.

Pitting Corrosion Failure Analysis of a Produced Oil/Water Fluid Pipeline

2019 ◽  
Vol 953 ◽  
pp. 39-44 ◽  
Author(s):  
Yun Ma ◽  
Zi Long Guo ◽  
Jiu Chun Qiao ◽  
Hai Tao Bai
Keyword(s):  
Failure Analysis ◽  
Pitting Corrosion ◽  
Corrosion Products ◽  
Background Information ◽  
Oil Well ◽  
Corrosion Failure Analysis ◽  
Corrosion Failure ◽  
Oil Pipeline ◽  
Oil Slick ◽  
Water Ratio

This paper presents corrosion failure analysis of an underground natural gas pipeline. The pipeline material grade is 20# steel. The pipeline transfers multiphase fluid (Crude oil and water) from an oil well to an oil gathering plant. A portion of the line failed due to pitting corrosion under unknown circumstances. Scanning electron microscopy (SEM) and X-ray diffraction (XRD) are employed to characterize the scales and/or corrosion products near the failed portion. Based on visual and microscopic analyses and reviewing the background information, the following pitting corrosion sequences were identified: When the water ratio was smaller than 50%, the oil slick could cover the surface of the 20# test samples. Some uncovered surface would be corroded. When the water ratio was more than 70%, the surface of 20# steel contacted with more water. The average corrosion rate increased, and the corrosion products also formed, which would behave as a good diffusion barrier to prevent the underlying steel from further dissolution. Meanwhile, because of the corrosion products, the penetration rate also increased, the trend of local corrosion became weak with the water ratio continued to increase. The pitting corrosion varied with the water ratio because of the protection conferred by the oil slick or the corrosion product layer. Under such conditions, pits emerged on the steel surface until one of them grew faster and failed the oil pipeline.

Influence and Mechanism of SO42−Ions on the Pitting Corrosion of Boiler Water-Wall Tubes

CORROSION ◽  
2012 ◽  
Vol 68 (1) ◽  
pp. 015001-1-015001-8
Author(s):  
S. Xiong ◽  
Z. Zhu ◽  
H. Zhang ◽  
L. Jing
Keyword(s):  
Pitting Corrosion ◽  
Boiler Water ◽  
Water Wall

Corrosion Failure Analysis of an SA210 Steel Used in High Pressure Evaporator Tube of the Gas Heat Recovery Boiler

2013 ◽  
Vol 791-793 ◽  
pp. 493-497
Author(s):  
Ling Shan Cen ◽  
Zhi Wu Wang ◽  
Liang Li ◽  
Yuan Mei Fei ◽  
Qian Qian Liu
Keyword(s):  
High Pressure ◽  
Failure Analysis ◽  
Heat Recovery ◽  
Steel Tube ◽  
Corrosion Products ◽  
Heat Recovery Boiler ◽  
Residual Water ◽  
Corrosion Failure Analysis ◽  
Corrosion Failure ◽  
Recovery Boiler

The corrosion failure analysis of an SA210 steel used in high pressure evaporator tube is conducted by XRD, SEM, OM. The result shows that the corrosion products in the inner wall of the steel tube is Fe3O4, mainly caused by the residual water in the evaporator tube corroding its inner wall with oxygen after the hydrostatic test of the boiler, finally leading to the corrosion leak of the tube.

scholarly journals Failure Analysis of 600 MW Supercritical Boiler Water Wall

2013 ◽  
Vol 6 (10) ◽  
pp. 1726-1731
Author(s):  
Fu Huilin ◽  
Cai Zhengchun ◽  
Yan Xiaozhong ◽  
He Jinqiao ◽  
Zhou Yucai
Keyword(s):  
Failure Analysis ◽  
Boiler Water ◽  
Water Wall

Internal Corrosion of High-Pressure Boilers

1967 ◽  
Vol 89 (3) ◽  
pp. 378-394
Author(s):  
P. Goldstein ◽  
I. B. Dick ◽  
J. K. Rice
Keyword(s):  
High Pressure ◽  
Research Study ◽  
Test Tube ◽  
Progress Report ◽  
Test Facility ◽  
Boiler Water ◽  
Internal Corrosion ◽  
Corrosion Failure ◽  
Internal Surfaces ◽  
Study Results

This report is the second in a series of three describing the progress of “A Research Study on Internal Corrosion of High Pressure Boilers.” The first progress report, presented by H. A. Klein and J. K. Rice at the 1965 Annual Meeting of the ASME, describes the background, scope, and organization of the program as well as the test facility. This second progress report describes the results of the first half of the study. Results of tests with volatile, coordinated phosphate, and caustic boiler water treatment under conditions simulating a boiler with clean internal surfaces and one whose surfaces have been fouled with typical preboiler corrosion products, are included. Data relating to deposition and corrosion in the aforementioned environments are presented. The corrosion failure of a test tube due to “caustic gouging” and the discovery of an unusual effect of deposits on boiling characteristics are described.

Rapid Pitting Corrosion Failure Analysis of 13Cr Stainless Steel as Thermocouple Protecting Material in Dry Gas Pipeline

2019 ◽  
Vol 394 ◽  
pp. 91-96
Author(s):  
Yun Ma ◽  
Yao Li ◽  
Yan Jun He ◽  
Xuan Wang ◽  
Hai Tao Bai
Keyword(s):  
Stainless Steel ◽  
Failure Analysis ◽  
Pitting Corrosion ◽  
Produced Water ◽  
Gas Pipeline ◽  
Background Information ◽  
Corrosion Failure Analysis ◽  
Corrosion Failure ◽  
Gas Leakage ◽  
Film Forming

This paper presents corrosion failure analysis of 13Cr stainless steel (SS) in gas pipeline ingas pipeline, which was used as thermocouple protecting material (TPM). A portion of TMP faileddue to pitting corrosion under unknown circumstances. Scanning electron microscopy (SEM) andX-ray diffraction (XRD) are employed to characterize the scales and/or corrosion products near thefailed portion. Based on visual and microscopic analyses, reviewing the background information andthe thermodynamic calculation, the following rapid pitting corrosion failure sequences wereidentified: Once the pitting appeared, in addition to the gas leakage and expansion, the temperaturedrop should lead a small amount of water in dry gas to condense on the surface of TPM. On one hand,the high salinity produced water will corrode the thermocouple. On the other hand, the high salinityproduced water will pass into the annular space of TPM through the pitting because of the pressuredrop, and the water will stay on inner surface for more time than that of external surface, whichaccelerated pitting of TPM. More and more pitting appeared, and the surface roughness increased.The film-forming property of condensation water will also increase. So, the TPM will be scrappedsoon.

The Effect of Materials and Design Geometry on Tube Plugs at High Pressure Steam Super Heater

2017 ◽  
Author(s):  
Mohammed S. AlSaud ◽  
Abdulrahman D. AlDakhil ◽  
Gys Van Zyl
Keyword(s):  
High Pressure ◽  
Failure Analysis ◽  
Good Condition ◽  
Metallographic Examination ◽  
Analysis And Design ◽  
Pressure Steam ◽  
Super Heater ◽  
Cause Of Failure ◽  
Ammonia Plant ◽  
Geometric Designs

A high-pressure (HP) steam super heater located in the primary reformer of Ammonia Plant of Saudi Arabian Fertilizer Company (SAFCO) has ruptured twice in two different tubes, in 2009 and again in 2014. On both occasions, the repair was performed by removing and plugging the failed tube. In January 2015, the new plug that was installed in 2014 failed and led to an emergency shutdown. The older plug was found to be in good condition. An investigation was initiated to determine the reason for failure of one plug within nine months of operation while another was still in good condition after 6 years of operation. The failed plug was subjected to a metallurgical failure analysis where visual and stereoscopic inspection, scanning electron microscopy, metallographic examination, and chemical analysis were performed. The two plugs had different geometric designs, and thermal and static structural finite element analyses were performed to compare the 2009 and 2014 designs. Based on the outcome of the investigation, the cause of failure and the reason for the discrepancy in lifetimes of the two plugs was determined. This paper will present the conclusions of the metallurgical failure analysis and design review which was performed, and the improved repair design that was developed as a result of the investigation.

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