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Chlorides
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001559
EISBN: 978-1-62708-229-7
... lines in the system had thru-wall cracks. Shallow incipient cracks were detected at the lowest elevations of one other line. The balance of the system had no signs of SCC attack. Chlorides and corrosion deposits in varying amounts were found throughout the system. The failure mechanism was transgranular...
Abstract
One inch diam Type 304 stainless steel piping was designed to carry containment atmosphere samples to an analyzer to monitor hydrogen and oxygen levels during operational and the design basis accident conditions that are postulated to occur in a boiling water reactor. Only one of six lines in the system had thru-wall cracks. Shallow incipient cracks were detected at the lowest elevations of one other line. The balance of the system had no signs of SCC attack. Chlorides and corrosion deposits in varying amounts were found throughout the system. The failure mechanism was transgranular, chloride, stress-corrosion cracking. Replacement decisions were based on the presence of SCC attack or heavy corrosion deposits indicative of extended exposure time to chloride-contaminated water. The existing uncracked pipe, about 75 percent of the piping in the system, was retained despite the presence of low level surface chlorides. Controls were implemented to insure that temperatures are kept below 150 deg F, or, walls of the pipe are moisture-free or the cumulative wetted period will never exceed 30 h.
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in Stress-Corrosion Cracking of a Stainless Steel Integral-Finned Tube
> ASM Failure Analysis Case Histories: Oil and Gas Production Equipment
Published: 01 June 2019
Fig. 1 Type 304 stainless steel integral-finned tube that cracked from chlorides and high residual stresses. (a) Section of integral-finned tube showing major crack (circumferential crack between fins). Dimension given in inches. (b) Branched transgranular cracking propagating from major crack
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in Failure Analysis of Heat Exchangers
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Fig. 9 Type 304 stainless steel integral-finned tube that cracked from chlorides and high residual stresses. (a) Section of integral-finned tube showing major crack (circumferential crack between fins). Dimension given in inches. (b) Branched transgranular cracking propagating from major crack
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Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c0090439
EISBN: 978-1-62708-220-4
... Abstract A section of clear polymeric tubing failed while in service. The failed sample had been used in a chemical transport application. The tubing had also been exposed to periods of elevated temperature as part of the operation. The tubing was specified to be a polyvinyl chloride (PVC...
Abstract
A section of clear polymeric tubing failed while in service. The failed sample had been used in a chemical transport application. The tubing had also been exposed to periods of elevated temperature as part of the operation. The tubing was specified to be a polyvinyl chloride (PVC) resin plasticized with trioctyl trimellitate. Investigation included visual inspection, micro-FTIR in the ATR mode, and thermogravimetric analysis. The spectrum on the failed tubing exhibited absorption bands indicative of a PVC resin containing an adipate-based plasticizer. Thermograms of the failed pieces and a reference sample of tubing that performed well showed that the reference material contained a trimellitate-based plasticizer and that the failed material contained an adipate-based material. The conclusion was that the failed tubing had been produced from a formulation that did not comply with the specified material and, as a result, was not as thermally stable as the reference material.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001654
EISBN: 978-1-62708-220-4
... sets of tubes. Microscopic examination revealed that the pits had a small mouth with a large subsurface cavity which is typical of chloride pitting of austenitic stainless steel. However, no pitting was found in other areas of the system, where the chloride content of the process water was higher...
Abstract
AISI type 321 stainless steel heat exchanger tubes failed after only three months of service. Macroscopic examination revealed that the leaks were the result of localized pitting attack originating at the water side surfaces of the tubes. Metallographic sections were prepared from both sets of tubes. Microscopic examination revealed that the pits had a small mouth with a large subsurface cavity which is typical of chloride pitting of austenitic stainless steel. However, no pitting was found in other areas of the system, where the chloride content of the process water was higher. This was attributed to the fact that they were downstream from a deaeration unit. It was concluded that the pitting was caused by a synergistic effect of chlorine and oxygen in the make-up water. Because it was not possible to install a deaeration unit upstream of the heat exchangers, it was recommended that a molybdenum-bearing stainless steel such as 316L or 317L be used instead of 321.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001403
EISBN: 978-1-62708-220-4
... precipitation. The transgranular cracks indicated that failure was due partly to stress-corrosion. It was concluded that the chlorides provided the main corrodent for both the stress and intercrystalline-corrosion cracking. Chemical processing equipment Chlorides Corrosion environments Heat...
Abstract
A process vessel heating coil, consisting of several 3 ft diam turns, was supplied with steam at 400 psi and a temperature of 343 deg C (650 deg F). At bi-weekly intervals well water was introduced to effect rapid cooling of the contents. After about eight months, leakage developed from a circumferential crack on the underside of the uppermost turn. Shorter cracks were found at a similar location on the bottom turn, and further leakage occurred at pinhole perforations adjacent to the crack in the top turn and near to a butt-weld in the coil. Microscopic examination revealed that the cracks were predominantly of the intergranular variety. In addition, transgranular cracks were present. Material was an austenitic stainless steel of the type specified but the absence of columbium and titanium in significant amounts showed that it was not stabilized against intergranular carbide precipitation. The transgranular cracks indicated that failure was due partly to stress-corrosion. It was concluded that the chlorides provided the main corrodent for both the stress and intercrystalline-corrosion cracking.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001273
EISBN: 978-1-62708-215-0
... Abstract One-quarter inch diameter 304 stainless steel cooling tower hanger rods failed by chloride-induced stress-corrosion cracking (SCC). The rods were located in an area of the cooling tower where the air contains drop lets of water below the mist eliminators and above the flow of water...
Abstract
One-quarter inch diameter 304 stainless steel cooling tower hanger rods failed by chloride-induced stress-corrosion cracking (SCC). The rods were located in an area of the cooling tower where the air contains drop lets of water below the mist eliminators and above the flow of water The most extensive cracking was observed in the rod nuts and in the portions of the rod which were covered by the nuts. Cracking was transgranular with extensive branching, and some corrosion occurred along the crack paths. The clamping force from the nuts used on both sides of the supported member and residual stresses from thread rolling likely contributed to the stresses for the cracking mechanism, along with the stresses induced by the supported load. The external surfaces of the hanger rods were reportedly exposed to a chloride-containing atmosphere, likely due to the biocide. Type 304 stainless steel is not a suitable material for this application, and materials that resist SCC, such as Inconel, should be considered.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0048814
EISBN: 978-1-62708-229-7
... of the fracture to the pits on the inner surface of the vessel were revealed. Copper deposits with zinc were revealed by EDS examination of discolorations. Pitting was revealed to have been caused by poor oxygen control in the steam generators and release of chloride into the steam generators. It was concluded...
Abstract
A nuclear steam-generator vessel constructed of 100-mm thick SA302, grade B, steel was found to have a small leak. The leak originated in the circumferential closure weld joining the transition cone to the upper shell. The welds had been fabricated from the outside by the submerged arc process with a backing strip. The backing was back gouged off, and the weld was completed from the inside with E8018-C3 electrodes by the shielded metal arc process. Striations of the type normally associated with progressive or fatigue-type failures including beach marks that allowed tracing the origin of the fracture to the pits on the inner surface of the vessel were revealed. Copper deposits with zinc were revealed by EDS examination of discolorations. Pitting was revealed to have been caused by poor oxygen control in the steam generators and release of chloride into the steam generators. It was concluded by series of controlled crack-propagation-rate stress-corrosion tests that A302, grade B, steel was susceptible to transgranular stress-corrosion attack in constant extension rate testing with as low as 1 ppm chloride present. It was recommended to maintain the coolant environment low in oxygen and chloride. Copper ions in solution should be eliminated or minimized.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c0048691
EISBN: 978-1-62708-220-4
... Abstract AISI type 410 stainless steel tube bundles in a heat exchanger experienced leakage during hydrostatic testing even before being in service. The inside surfaces of the tubes was observed to have been pitted. Chloride-ion pitting was revealed by the undercutting in the cross section...
Abstract
AISI type 410 stainless steel tube bundles in a heat exchanger experienced leakage during hydrostatic testing even before being in service. The inside surfaces of the tubes was observed to have been pitted. Chloride-ion pitting was revealed by the undercutting in the cross section of a pit and further confirmed by x-ray spectrometry. It was concluded that the failure was caused by pitting due to chlorides in the water used to flush the tubes before service. The use of brackish water to flush or test stainless steel equipment was recommended to avoid pitting.
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in Failure Analysis of Brass Tubes
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Fig. 3 SEM fractographs (a,b) showing chloride particles on a tube fracture face.
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in Fractured Post of a Loading Gear
> ASM Failure Analysis Case Histories: Offshore, Shipbuilding, and Marine Equipment
Published: 01 June 2019
Fig. 2 Longitudinal section across welding seam. Etch: Copper ammonium chloride solution according to Heyn. 1 ×
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in Pitting Corrosion of Steel Tubes in an Air Preheater
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Fig. 14 SEMs showing the pits and chloride particles underneath the surface after removing the scale. (a) Note the numerous Cl particles. (b) Corrosive attack of the Cl particles and resultant pit/pore
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in Stress Corrosion Cracking Failures in Components Made of Austenitic Chromium Nickel Steels
> ASM Failure Analysis Case Histories: Failure Modes and Mechanisms
Published: 01 June 2019
Fig. 5 Stress corrosion cracking initiated in a chloride containing medium by welding stresses in a welded support on a tube of X5 CrNiMo 18 10 1 2 ×
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in Ductile Fracture of a Forged Steel Shaft at a Change in Section and at a Stainless Steel Weld
> ASM Failure Analysis Case Histories: Failure Modes and Mechanisms
Published: 01 June 2019
Fig. 1 Stub-shaft assembly, for agitator in a polyvinyl chloride reactor, that failed by ductile fracture. Top left: Configuration and dimensions (given in inches). Detail A: Sections through failure area showing original design, first revised design, and final design Element Chemical
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Published: 01 June 2019
Fig. 6 Micrograph near fracture surface. Etching: copper-ammonium-chloride (after Heyn). 1 ×
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Published: 01 June 2019
Fig. 7 Longitudinal section L —— L in Fig. 5 . Etching: copper-ammonium-chloride (after Heyn). 1 ×
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Published: 01 June 2019
Fig. 14 Longitudinal section through fracture. Etching: copper-ammounium-chloride (after Heyn). 2 ×
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in Corrosion Failure of the Rocky Point Viaduct
> ASM Failure Analysis Case Histories: Buildings, Bridges, and Infrastructure
Published: 01 June 2019
Fig. 6 Chloride distribution profiles for patch and original concrete from the west (W) to east (E) face of beam A1.
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in Fatigue and Corrosion Fatigue Failure Surfaces of Concrete Reinforcement
> ASM Failure Analysis Case Histories: Buildings, Bridges, and Infrastructure
Published: 01 June 2019
Fig. 3 Secondary electron image of one of the points of high chloride concentration in Figure 2 . The oxidation “eruption” is clearly seen to be related to the presence of Cl ions (Approx. × 2000).
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in Examination of a Blistered and Cracked Natural Gas Line
> ASM Failure Analysis Case Histories: Oil and Gas Production Equipment
Published: 01 June 2019
Fig. 3 Cross section of section 1, etch: copper ammonium chloride (according to Heyn). approx. 0.7×
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