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Cassio Barbosa, Simone Kessler de Barros, Ibrahim de Cerqueira Abud, Joneo Lopes do Nascimento, Sheyla Santana de Carvalho
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.pulp.c9001564
EISBN: 978-1-62708-230-3
... Abstract An 8 in. diam stainless steel black liquor feed pipe to a carbon steel digester had failed within one year of service. The material was type 316 molybdenum-containing austenitic stainless steel. The service environment was alkaline black liquor at 175 deg C (350 deg F). The pipe had...
Abstract
An 8 in. diam stainless steel black liquor feed pipe to a carbon steel digester had failed within one year of service. The material was type 316 molybdenum-containing austenitic stainless steel. The service environment was alkaline black liquor at 175 deg C (350 deg F). The pipe had developed cracks on the inside surface coincident with an external support gusset. The cracks initiated at wide corrosion grooves. The early stages were corrosion-assisted fatigue cracks. The cracks initiated at the corrosion grooves and propagated as transgranular SCC with characteristic branching. Evaluation indicated the cracks were localized in an area of high cyclic stresses as a consequence of geometrical constraints on the piping and unsupported cantilever loads. No cracks were found elsewhere in the pipe. In the absence of highly localized service stresses (exceeding yield strength of the material), the corrosion grooving and subsequent SCC would not have occurred in this service environment. The pipe support system was modified with additional gussets to reduce the magnitude of cyclic stresses at the critical areas. The modification was apparently successful.
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in Multiple Cracking of 2 In. Thick Boiler Drum From Thermal Shock
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001065
EISBN: 978-1-62708-214-3
... Abstract A 460 mm (18 in.) diam suction line to the main feed water pump for a nuclear power plant failed in a violent, catastrophic manner. Samples of pipe, elbow, and weld materials (ASTM A106 grade B carbon steel, ASTM A234 grade WPB carbon steel, and E7018 carbon steel electrode...
Abstract
A 460 mm (18 in.) diam suction line to the main feed water pump for a nuclear power plant failed in a violent, catastrophic manner. Samples of pipe, elbow, and weld materials (ASTM A106 grade B carbon steel, ASTM A234 grade WPB carbon steel, and E7018 carbon steel electrode, respectively) from the suction line were analyzed. Evidence of overall thinning of the elbow and pipe material and ductile tearing of fractures indicated that the feed water pipe failed as a result of an erosion corrosion mechanism, which thinned the wall sufficiently to cause rapid, ductile tearing of the material after its design stress had been exceeded. It was recommended that steel with a higher chromium content be used to mitigate the erosion corrosion potential in the lines and that more rigorous nondestructive (ultrasonic) examinations be performed.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001327
EISBN: 978-1-62708-215-0
... Abstract Three ASME SA106 grade B carbon steel feed water piping reducers from a pressurized water reactor showed indications of flaws near welds during ultrasonic testing. Further examination and testing indicated that the cracks resulted from a low-cycle corrosion fatigue phenomenon...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001477
EISBN: 978-1-62708-229-7
... surface was considered. This aspect was further explored and it ultimately transpired that the shutdown prior to the decision to proceed with the repairs to water wall tubes was occasioned by the failure of a pipe supplying feed water to an injection type steam desuperheater situated above the drum...
Abstract
During the routine hydraulic pressure test of a boiler following modification, failure by leakage from the drum took place and was traced to a region where extensive multiple cracking had occurred. Catastrophic rupture or fragmentation of the vessel fortunately did not take place. Prior to the test, cracking was present already, extending up to 90% of the wall thickness. Analyses of brownish deposit material did not reveal the presence of any substances likely to cause stress-corrosion cracking of a Ni-Cu-Mo low-alloy steel.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0091528
EISBN: 978-1-62708-229-7
... of a steam line to feed concentrated caustic during chemical cleaning, the preventive measure may be no more complicated than exclusion of the corrodent from that region of the system. In many instances, however, reduction of the level of residual stress is the most effective means of minimizing...
Abstract
A 150 mm (6 in.) schedule 80S type 304 stainless steel pipe (11 mm, or 0.432 in., wall thickness), which had served as an equalizer line in the primary loop of a pressurized-water reactor, was found to contain several circumferential cracks 50 to 100 mm (2 to 4 in.) long. Two of these cracks, which had penetrated the pipe wall, were responsible for leaks detected in a hydrostatic test performed during a general inspection after seven years of service. Investigation (visual inspection, visual and ultrasonic weld examination, water analysis, and chemical analysis) supported the conclusion that the failure was caused by SCC due to stress, sensitization, and environment. Recommendations included replacing all pipe sections and installing them using low-heat-input, multiple-pass welding procedures.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001699
EISBN: 978-1-62708-234-1
... in the water (residuals) and the installation/monitoring of corrosion coupons installed in the system, was recommended. The monitoring of residual levels of chemicals and automatic feeding of chemicals was recommended to control corrosion and organic growth. Conclusions Experience in the investigation...
Abstract
A shopping mall in South Carolina was originally constructed in 1988 and a second phase completed in 1989. The HVAC system inside the mall included an open, recirculating condenser water loop that served various fan coil units located within tenant spaces. The system had a recirculating capacity of about 44,000 gal (166,000 L) of water. It consisted primarily of steel pipes fitted with threaded connectors on the 2 in. (46 cm) pipes and bolted flanged couplings on the larger pipes. Seven years following the completion of the mall, corrosion problems were noted at the outer and inner surfaces of the pipe. Visual observations on the inner diametral surfaces revealed that the pipes were, in almost all cases, filled with corrosion products. A significant amount of base metal loss was documented in all of the samples. The cause of the observed corrosion was determined to be a lack of corrosion monitoring and poor water quality. Pipe replacement and a regular water testing program were recommended.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001398
EISBN: 978-1-62708-229-7
... was found to be free from cracking. The de-superheaters were fed with treated feed water which, after demineralisation, was treated with activated sodium sulphite as an oxygen scavenger and sodium hydroxide to adjust the alkalinity. From this stage, water was fed to the de-superheaters and the boiler water...
Abstract
Several articulated bellows of 10 in. ID developed leakage from the convolutions after a service life of some 18 months. One of the units received from examination showed cracking at the crown of a convolution and at the attachment weld to the pipe. Sectioning of the bellows revealed many others cracks on the internal surface which did not penetrate to the outside. Microscopical examination showed multiple intergranular, tree-like cracking typical of stress-corrosion cracking. Concentration of sodium hydroxide occurred in the bellows unit and the stress-corrosion cracking which developed was of the form known as caustic cracking. It was recommended that water for de-superheater use should be taken after the deaerator and prior to the addition of salts which may deposit or concentrate in the desuperheater.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.usage.c9001434
EISBN: 978-1-62708-236-5
... subsequently developed. The rod was made from a medium carbon or low-alloy steel in the hardened and fully tempered condition. Evidence indicated that, following modification to the oil feed system, the rod that broke was returned to service with fine cracks present immediately below the weld deposit, which...
Abstract
One of the connecting rods of a vertical, four-cylinder engine with a cylinder diameter of 5 in. failed by fatigue cracking just below the gudgeon-pin boss. Failure took place in line with the lower edge of a deposit of weld metal. The fracture surface was smooth, conchoidal, and characteristic of that resulting from fatigue. The origin of the major crack was associated with a crescent-shaped area immediately below the weld deposit. This showed brittle fracture characteristics and appeared to be an initial crack that occurred at the time of welding and from which the fatigue crack subsequently developed. The rod was made from a medium carbon or low-alloy steel in the hardened and fully tempered condition. Evidence indicated that, following modification to the oil feed system, the rod that broke was returned to service with fine cracks present immediately below the weld deposit, which served as the starting points of the fatigue cracks. Following this accident, the remaining three rods (which had been modified in a similar manner) were replaced as a precautionary measure.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001713
EISBN: 978-1-62708-220-4
... temperature rise of 486 °C. It was estimated that this is an eleven-fold increase in the amount of heat that would be released if Al were not included in the mixture. One early scenario for the accident was that the feed tube became plugged during the second shift and the workers tried to purge...
Abstract
On 21 April 1995, the contents of a large blender (6 cu m) reacted and caused an explosion that killed and injured a number of workers at a plant in Lodi, NJ. A mixture of sodium hydrosulfite and aluminum powder was being mixed at the time of the accident. This report focuses on evaluations of the blender to determine if material or mechanical failures were the cause of the accident. The results indicate that the mixing vessel was metallurgically sound and did not contribute to the initiation of the failure. However, the vessel was not designed for mixing chemicals that must be isolated from water and excessive heat. Water leaking into the vessel through a graphite seal may have initiated the reactions that caused the accident.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c0048772
EISBN: 978-1-62708-220-4
... from a triolefin-unit heater ruptured ( Fig. 1a ). The bend was made from 115-mm (4 1 2 -in.) schedule 40 (6.0 mm, or 0.237-in., wall thickness) pipe of ASTM A213, grade T11, ferritic steel. The unit operated at 2410 kPa (350 psi), with a hydrocarbon feed stream (85% propylene) entering at 260...
Abstract
A return bend (made from ASTM A213, grade T11, ferritic steel) from a triolefin-unit heater ruptured after two years in service. The unit operated at 2410 kPa, with a hydrocarbon feed stream (85% propylene) entering at 260 to 290 deg C and leaving at 425 to 480 deg C. The fracture was found to terminate at the welds that joined the bend to the pipeline. A high concentration of both small and large inclusions was exhibited by the metallographic examination of the steel near the fracture. Branched cracks similar to those produced by stress corrosion of steel were observed in a section through the fireside edge of the fracture surface. Scale was observed over most of the crack path which acted as a stress raiser. The effect of the oxide was magnified during thermal cycles because of differential thermal expansion, with the steel having a greater expansion coefficient than the scale. It was recommended that material that is intended for critical applications where failure cannot be tolerated should be non-destructively examined.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c9001578
EISBN: 978-1-62708-233-4
... expansion joints. The purpose of the expansion joints was to isolate the boiler feed pump turbine from stresses induced by thermal growth of the horizontal condenser pipe. Thrust canceling rods were installed between the end cap and the main condenser. The thrust canceling struts transmitted the atmospheric...
Abstract
Vibration analysis can be used in solving both rotating and nonrotating equipment problems. This paper presents case histories that, over a span of approximately 25 years, used vibration analysis to troubleshoot a wide range of problems.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001826
EISBN: 978-1-62708-241-9
... (evaporating capability) 109.7 kg/s; 394,920 kg/h Steam temperature TSH outlet (from 50% MCR up to MCR) 525 °C Steam pressure TSH outlet (from minimum up to MCR) 84 (85) barg (A) Feed water temp. Eco. Inlet (from 50% MCR up to MCR) 235 °C Boiler water pH value 9.5–10.5 Firing system Crude...
Abstract
A back wall riser tube in a high pressure boiler failed, interrupting operations in a cogeneration plant. The failure occurred in a tube facing the furnace, causing eight ruptured openings over a 1.8 m section. The investigation consisted of an on-site visual inspection, nondestructive testing, energy dispersive x-ray analysis, and inductively coupled plasma mass spectrometry. The tube was made from SA 210A1 carbon steel that had been compromised by wall thinning and the accumulation of fire and water-side scale deposits. Investigators determined that the tube failed due to prolonged caustic attack that led to ruptures in areas of high stress. The escaping steam eroded the outer surface of the tube causing heavy loss of metal around the rupture points.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006812
EISBN: 978-1-62708-329-4
..., or 0.237 in., wall thickness) pipe of ASTM A213, grade T11 (1.25Cr-0.5Mo) ferritic steel. The unit operated at 2410 kPa (350 psi), with a hydrocarbon feed stream (85% propylene) entering at 260 to 290 °C (500 to 550 °F) and leaving at 425 to 480 °C (800 to 900 °F). The temperature of the combustion gas...
Abstract
This article discusses pressure vessels, piping, and associated pressure-boundary items of the types used in nuclear and conventional power plants, refineries, and chemical-processing plants. It begins by explaining the necessity of conducting a failure analysis, followed by the objectives of a failure analysis. Then, the article discusses the processes involved in failure analysis, including codes and standards. Next, fabrication flaws that can develop into failures of in-service pressure vessels and piping are covered. This is followed by sections discussing in-service mechanical and metallurgical failures, environment-assisted cracking failures, and other damage mechanisms that induce cracking failures. Finally, the article provides information on inspection practices.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001816
EISBN: 978-1-62708-180-1
..., or during periods of full-power operation, may be caused by sudden loss of circulation resulting either from general loss of circulation, for example, feed-pump failure, or from local loss of circulation affecting only a few tubes. Example 2: Rupture of Chromium-Molybdenum Steel Superheater Tubes Because...
Abstract
This article explains the main types and characteristic causes of failures in boilers and other equipment in stationary and marine power plants that use steam as the working fluid with examples. It focuses on the distinctive features of each type that enable the failure analyst to determine the cause and suggest corrective action. The causes of failures include tube rupture, corrosion or scaling, fatigue, erosion, and stress-corrosion cracking. The article also describes the procedures for conducting a failure analysis.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001818
EISBN: 978-1-62708-180-1
..., ferritic steel. The unit operated at 2410 kPa (350 psi), with a hydrocarbon feed stream (85% propylene) entering at 260 to 290 °C (500 to 550 °F) and leaving at 425 to 480 °C (800 to 900 °F). The temperature of the combustion gas was 900 °C (1650 °F). Fig. 3 Return bend made of ASTM A213, grade T11...
Abstract
This article discusses the effect of using unsuitable alloys, metallurgical discontinuities, fabrication practices, and stress raisers on the failure of a pressure vessel. It provides information on pressure vessels made of composite materials and their welding practices. The article explains the failure of pressure vessels with emphasis on stress-corrosion cracking, hydrogen embrittlement, brittle and ductile fractures, creep and stress rupture, and fatigue with examples.
Book Chapter
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001791
EISBN: 978-1-62708-241-9
... during test on sea), as shown in Fig. 1 . When feeding of vapor generators is carried out with nontreated water, i.e., water which contains soluble salts, it can cause two main types of degradation: incrustation and corrosion. Degradation due to theses factors can be avoided by eliminating...
Abstract
A pipe in the lateral wall of a boiler powering an aircraft carrier flat-top boat failed during a test at sea. The pipe was made from ASTM 192 steel, an adequate material for the application. Microstructural analysis along with equipment operating records provided valuable insight into what caused the pipe to rupture. Although the pipe had been replaced just 50 h before the accident, the analysis revealed incrustations and corrosion pits on the inner walls and oxidation on the outer walls. Microstructural changes were also observed, indicating that the steel was exposed to high temperatures. The combined effect of pitting, incrustations, and phase transformations caused the pipe to rupture.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006835
EISBN: 978-1-62708-329-4
... solidification and contraction of the metal, when there may eventually be insufficient liquid metal to feed the last remaining portions as they contract. A concave cavity thus forms at the top of the ingot. The cavity usually forms in the shape of a cone, hence the term pipe . If the ingot is improperly...
Abstract
The primary purpose of this article is to describe general root causes of failure that are associated with wrought metals and metalworking. This includes a brief review of the discontinuities or imperfections that may be common sources of failure-inducing defects in the bulk working of wrought products. The article addresses the types of flaws or defects that can be introduced during the steel forging process itself, including defects originating in the ingot-casting process. Defects found in nonferrous forgings—titanium, aluminum, and copper and copper alloys—also are covered.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006808
EISBN: 978-1-62708-329-4
..., where stress concentration is greatest. Their occurrence may be minimized by pausing before breaking the arc, by breaking and restarting the arc several times to feed the shrinkage pipe, or by terminating welding on runoff tabs that are cut away later. If crater cracks are found, they should be ground...
Abstract
This article describes some of the welding discontinuities and flaws characterized by nondestructive examinations. It focuses on nondestructive inspection methods used in the welding industry. The sources of weld discontinuities and defects as they relate to service failures or rejection in new construction inspection are also discussed. The article discusses the types of base metal cracks and metallurgical weld cracking. The article discusses the processes involved in the analysis of in-service weld failures. It briefly reviews the general types of process-related discontinuities of arc welds. Mechanical and environmental failure origins related to other types of welding processes are also described. The article explains the cause and effects of process-related discontinuities including weld porosity, inclusions, incomplete fusion, and incomplete penetration. Different fitness-for-service assessment methodologies for calculating allowable or critical flaw sizes are also discussed.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006783
EISBN: 978-1-62708-295-2
... surfaces affects the resistance of the current path in the solution and the external circuit. Thus, if dissimilar pipes are butt welded with the electrolyte flowing through them, the most severe corrosion will occur immediately adjacent to the weld on the anodic member. Effect of Shape The geometry...
Abstract
Corrosion is the electrochemical reaction of a material and its environment. This article addresses those forms of corrosion that contribute directly to the failure of metal parts or that render them susceptible to failure by some other mechanism. Various forms of corrosion covered are galvanic corrosion, uniform corrosion, pitting, crevice corrosion, intergranular corrosion, selective leaching, and velocity-affected corrosion. In particular, mechanisms of corrosive attack for specific forms of corrosion, as well as evaluation and factors contributing to these forms, are described. These reviews of corrosion forms and mechanisms are intended to assist the reader in developing an understanding of the underlying principles of corrosion; acquiring such an understanding is the first step in recognizing and analyzing corrosion-related failures and in formulating preventive measures.