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T.L. da Silveira, I. Le May
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Helmut Thielsch, Robert Smoske, Florence Cone, Jason Husband
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J. F. Henry, F. V. Ellis, J. Alice, J. K. LaFontaine, P. C. Orban
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Book Chapter
Fatigue Cracking of Headers for Superheated Water Because of Notches at Welds
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0089734
EISBN: 978-1-62708-235-8
... Abstract A system of carbon steel headers, handling superheated water of 188 deg C (370 deg F) at 2 MPa (300 psi) for automobile-tire curing presses, developed a number of leaks within about four months after two to three years of leak-free service. All the leaks were in shielded metal arc butt...
Abstract
A system of carbon steel headers, handling superheated water of 188 deg C (370 deg F) at 2 MPa (300 psi) for automobile-tire curing presses, developed a number of leaks within about four months after two to three years of leak-free service. All the leaks were in shielded metal arc butt welds joining 200 mm (8 in.) diam 90 deg elbows and pipe to 200 mm (8 in.) diam welding-neck flanges. A flange-elbow-flange assembly and a flange-pipe assembly that had leaked were removed for examination. Investigation (visual inspection, hardness testing, chemical analysis, magnetic-particle testing, radiographic inspection, and 2% nital etched 1.7x views) showed varying IDs on the assemblies and supported the conclusions that the failures of the butt welds were the result of fatigue cracks caused by cyclic thermal stresses that initiated at stress-concentrating notches at the toes of the interior fillet welds on the surfaces of the flanges. Recommendations included using ultrasonic testing to identify the appropriate joints and then replacing them. Special attention to accuracy of fit-up in the replacement joints was also recommended to achieve smooth, notch-free contours on the interior surfaces.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0060154
EISBN: 978-1-62708-234-1
... Abstract One of the coils in the radiant section of a primary reformer furnace used in an ammonia plant was found leaking. The bottom of one of seven outlet headers (made of ASME SA-452, grade TP316H, stainless steel) was revealed during examination to be ruptured. It was revealed...
Abstract
One of the coils in the radiant section of a primary reformer furnace used in an ammonia plant was found leaking. The bottom of one of seven outlet headers (made of ASME SA-452, grade TP316H, stainless steel) was revealed during examination to be ruptured. It was revealed by metallurgical examination that it had failed as a result of intergranular fissuring and oxidation (creep rupture). The ruptured area revealed that the header had failed by conventional long-time creep rupture as a result of exposure to operating temperatures probably between 900 and 955 deg C. Three samples from different sections (ruptured area, slightly bulged but nonruptured area and visually sound metal) were inspected. The presence of pinhead-size intergranular fissures throughout the cross sections of the latter two samples was observed. An ultrasonic attenuation method was employed to investigate the remaining headers. All headers were revealed by ultrasonic readings to be in an advanced stage of creep rupture and no areas were found to be fissured to a degree that they needed immediate replacement. As a conclusion, the furnace was deemed serviceable and it was established that in the absence of local hot spots, the headers would survive for a reasonable period of time.
Book Chapter
Cracking at a Superheater Header Connection
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001001
EISBN: 978-1-62708-229-7
... Abstract Examination of the header of the third superheater of a boiler producing 150 t/h of steam at 525 deg C and 118 kPa, disclosed extensive internal cracking at the connection to the tube joining this to a safety valve. Cracking was observed within the tube and in the thickness...
Abstract
Examination of the header of the third superheater of a boiler producing 150 t/h of steam at 525 deg C and 118 kPa, disclosed extensive internal cracking at the connection to the tube joining this to a safety valve. Cracking was observed within the tube and in the thickness of the shell wall itself. The boiler had been in operation for approximately 160,000 h and was shut down for inspection when the cracking was detected. The material involved was 2.25 Cr, 1 Mo steel, and the unit had been subjected to 115 shutdowns. Initiation of the cracks was attributed to thermal shock, caused by the periodic return of condensate along the long connecting line (some 9 m long). Propagation of the cracks was due to thermal cycling, together with periodic pressure cycles, producing growth by low cycle fatigue. This was aided by corrosion within the cracks and by the wedging action caused by corrosion deposits at their tips. The failure suggests control of dissolved solids in the boiler feedwater may have been inadequate.
Book Chapter
Failure Analysis of Superheater Outlet Header
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001526
EISBN: 978-1-62708-229-7
... Abstract In Nov. 1998, the west superheater outlet header at an electricity generating plant began to leak steam. Subsequent investigation revealed the presence of a crack that extended for 360 deg around the full circumference of the header and through the full cross-sectional thickness...
Abstract
In Nov. 1998, the west superheater outlet header at an electricity generating plant began to leak steam. Subsequent investigation revealed the presence of a crack that extended for 360 deg around the full circumference of the header and through the full cross-sectional thickness. The subsequent inspection of this header and the east superheater header revealed the presence of extremely severe ligament cracking. They operated at 2400 psi (16.5 MPa) and a temperature of 540deg C (1005 deg F). Both were fabricated from seamless pipe produced in accordance with ASME Specification SA-335, and the steel was Grade P22, a 2.25Cr-1Mo alloy steel. Visual and metallurgical evaluations showed the cracking in the west superheater outlet header was caused by thermal fatigue. Tube holes had served as a preferential site for thermal fatigue cracking.
Book Chapter
Failure Investigation of Longitudinal Seam Welded Elevated Temperature Header
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001669
EISBN: 978-1-62708-229-7
... Abstract As the result of a leak detected in a plate-formed header at PENELEC'S Shawville Unit No. 3, an extensive failure investigation was initiated to determine the origin of cracking visible along the longitudinal weld seam. Fabricated from SA387-D material and designed for a superheater...
Abstract
As the result of a leak detected in a plate-formed header at PENELEC'S Shawville Unit No. 3, an extensive failure investigation was initiated to determine the origin of cracking visible along the longitudinal weld seam. Fabricated from SA387-D material and designed for a superheater outlet temperature of 566 deg C, the 11.4 cm thick header had operated for approximately 187,000 h at the time of the failure. Discussion focuses on the results of a metallographic examination of boat samples removed from the longitudinal seam weldment in the vicinity of the failure and at other areas of the header where peak temperatures were believed to have been reached. The long-term mechanical properties of the service-exposed base metal and creep-damaged weld metal were determined by creep testing. Based on the utility's decision to replace the header within one to three years, an isostress overtemperature lead specimen approach was taken, whereby failure of a test specimen in the laboratory would precede failures in the plant. These tests revealed approximately a 2:1 difference in life for the base metal as compared to weld metal.
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in Alloy 430 Ferritic Stainless Steel Welds Fail due to Stress-Corrosion Cracking in Heat-Recovery Steam Generator
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Fig. 7 Tube-to-header weld, axial section, Vilella's etch, 12.8× 12 : (a) header-weld HAZ; (b) tube-weld HAZ; (c) etched 100×; (d) as-polished 100×
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Image
Flange-to-pipe assembly of a carbon steel header, used for handling superhe...
Available to PurchasePublished: 01 January 2002
Fig. 17 Flange-to-pipe assembly of a carbon steel header, used for handling superheated water, that cracked by fatigue because of notches at welds. (a) Section through butt-welded joint showing crack (arrow A) that originated at toe of weld on inner surface, incomplete weld penetration (arrow
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Image
Type 347 stainless steel inlet header for fuel-to-air heat exchanger that c...
Available to PurchasePublished: 01 January 2002
Fig. 18 Type 347 stainless steel inlet header for fuel-to-air heat exchanger that cracked due to poor welding technique and unfavorable joint design. Dimensions given in inches
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Image
Header die made from AISI W1 tool steel that failed prematurely in service....
Available to PurchasePublished: 01 January 2002
Fig. 28 Header die made from AISI W1 tool steel that failed prematurely in service. (a) The striking face of the carbon tool steel die chipped. The die had been flush quenched through its center hole to harden the working surfaces. (b) Cold etching (10% aqueous nitric acid) of a longitudinal
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Interligament cracking in a failed secondary superheater outlet header from...
Available to PurchasePublished: 01 January 2002
Fig. 30 Interligament cracking in a failed secondary superheater outlet header from a boiler.
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Image
Flange-to-pipe assembly of a carbon steel header, used for handling superhe...
Available to Purchase
in Fatigue Cracking of Headers for Superheated Water Because of Notches at Welds
> ASM Failure Analysis Case Histories: Processing Errors and Defects
Published: 01 June 2019
Fig. 1 Flange-to-pipe assembly of a carbon steel header, used for handling superheated water, that cracked by fatigue because of notches at welds. (a) Section through butt-welded joint showing crack (arrow A) that originated at toe of weld on inner surface, incomplete weld penetration (arrow B
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Image
Type 347 stainless steel inlet header for fuel-to-air heat exchanger that c...
Available to Purchase
in Fatigue Failure of an Inlet Header Because of Poor Welding Technique and Unfavorable Weld-Joint Design
> ASM Failure Analysis Case Histories: Processing Errors and Defects
Published: 01 June 2019
Fig. 1 Type 347 stainless steel inlet header for fuel-to-air heat exchanger that cracked due to poor welding technique and unfavorable joint design. Dimensions given in inches
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Image
Photomacrograph showing the relative size of the detonator header assemblie...
Available to Purchase
in Corrosion of Gold Bridgewire in Electronic Components
> ASM Failure Analysis Case Histories: Failure Modes and Mechanisms
Published: 01 June 2019
Fig. 2 Photomacrograph showing the relative size of the detonator header assemblies involved.
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Image
Corrosion product build-up on a blue plastic header (a), degraded plastic a...
Available to Purchase
in Corrosion of Gold Bridgewire in Electronic Components
> ASM Failure Analysis Case Histories: Failure Modes and Mechanisms
Published: 01 June 2019
Fig. 6 Corrosion product build-up on a blue plastic header (a), degraded plastic and corroded Au bridgewire (b) after two years at 74 C. The corrosion produce on the solder is Au + In (OH) 2 Cl (c). The corroded bridgewire is shown in a stereo pair at the lower right (d).
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Image
in Selective Corrosion Attack at Brazed Joints
> ASM Failure Analysis Case Histories: Processing Errors and Defects
Published: 01 June 2019
Fig. 1 Section through brazed header assembly showing location of cracking.
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Image
in Alloy 430 Ferritic Stainless Steel Welds Fail due to Stress-Corrosion Cracking in Heat-Recovery Steam Generator
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Fig. 8 Tube-to-header weld, axial section (from Fig. 7 at arrow δ): (a) as-polished, 500×; (b) as-polished 1000×
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Image
Arrangement of nozzle connecting safety valve line to superheater header, s...
Available to Purchase
in Cracking at a Superheater Header Connection
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Fig. 1 Arrangement of nozzle connecting safety valve line to superheater header, showing cracking.
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Image
Cracking in the superheater outlet header associated with the longitudinal ...
Available to Purchase
in Failure Investigation of Longitudinal Seam Welded Elevated Temperature Header
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Fig. 1 Cracking in the superheater outlet header associated with the longitudinal weld seam.
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Image
Schematic diagram of Shawville 3 SH outlet header, with boat sample locatio...
Available to Purchase
in Failure Investigation of Longitudinal Seam Welded Elevated Temperature Header
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Fig. 2 Schematic diagram of Shawville 3 SH outlet header, with boat sample locations indicated.
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Image
Log creep strain-versus-Larson-Miller parameter comparison of header base m...
Available to Purchase
in Failure Investigation of Longitudinal Seam Welded Elevated Temperature Header
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Fig. 8 Log creep strain-versus-Larson-Miller parameter comparison of header base material and longitudinal seam-weld metal at 650 C and 31.7 MPa.
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