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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001741
EISBN: 978-1-62708-234-1
... Abstract Butterfly-shaped microstructural features in tempered martensite in an otherwise clean steel suggested that overloading led to premature spalling of a coal-crushing plant taper bearing. Extensive rolling contact fatigue occurred because of the overload condition. The crusher...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001681
EISBN: 978-1-62708-234-1
... Abstract A microstructural analysis has been made of a burner nozzle removed from service in a coal gasification plant. The nozzle was a casting of a Co-29wt%Cr-19wt%Fe alloy. Extensive hot corrosion had occurred on the surface. There was penetration along grain boundaries, and corrosion...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0048331
EISBN: 978-1-62708-229-7
... of the rupture. A red and white deposit was found on the sides and bottom of the tube in the rupture area. The deposit was produced by attack of the steel by the alkali acid sulfate and had thinned the tube wall. It was concluded that rupture of the tube had occurred due to thinning of the wall by coal-ash...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001620
EISBN: 978-1-62708-229-7
... Abstract Two vertical coal-pulverizer shafts at a coal-fired generation station failed after four to five years in service. One shaft was completely broken, and the other was unbroken but cracked at both ends. shaft material was AISI type 4340 Ni-Cr- Mo alloy steel, with a uniform hardness...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c0047813
EISBN: 978-1-62708-229-7
... Abstract After being in service for ten years the ball-and-race coal pulverizer was investigated after noises were noted in it. Its lower grinding ring was attached to the 6150 normalized steel outer main shaft while the upper grinding ring was suspended by springs from a spider attached...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001730
EISBN: 978-1-62708-229-7
... Abstract A shaft can crack twice before it fails. A Detroit electric plant had this experience with one in a coal pulverizer. Because the first crack rewelded partially (by friction) in service, the pulverizer remained serviceable until the second crack developed. Coal pulverizers Shafts...
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Published: 01 January 2002
Fig. 11 6150 steel coal pulverizer shaft that failed by fatigue. (Left) Section through pulverizer showing the inner main shaft that fractured, repaired itself by friction welding, and fractured a second time. (Right) Photograph of the friction welded surface More
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Published: 01 January 2002
Fig. 27 Schematic illustration of the three layers formed during coal-ash corrosion of a superheater tube. More
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Published: 01 January 2002
Fig. 28 2.25Cr-1Mo steel superheater tube that ruptured because of thinning by coal-ash corrosion. More
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Published: 01 June 2019
Fig. 1 2.25Cr-1Mo steel superheater tube that ruptured because of thinning by coal-ash corrosion. More
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Published: 01 June 2019
Fig. 1 This is a sectional view of the central shaft of a coal pulverizer which failed twice at the indicated area before the mill had to be shut down. The first crack went through the shaft, but it was rewelded by friction due to the spring pressure and the weight of grinding mechanism. More
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Published: 01 June 2019
Fig. 1 Two failed coal-pulverizer shafts. The broken shaft is on the right; the cracked shaft is on the left. The arrow indicates the position of the bowl end crack in the cracked shaft. More
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Published: 01 June 2019
Fig. 1 6150 steel coal pulverizer shaft that failed by fatigue. (Left) Section through pulverizer showing the inner main shaft that fractured, repaired itself by friction welding, and fractured a second time. (Right) Photograph of the friction welded surface More
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Published: 15 January 2021
Fig. 16 Schematic of three-layer deposit on a boiler tube experiencing coal-ash corrosion. The middle layer tends to be molten, which reacts and dissolves the protective tube oxides, leading to corrosion at the 10 and 2 o’clock positions relative to the crown of the tube (12 o’clock). Adapted More
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Published: 30 August 2021
Fig. 54 Schematic illustration of the three layers formed during coal-ash corrosion of a superheater tube More
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.usage.c0048303
EISBN: 978-1-62708-236-5
... Abstract A tube in a radiant superheater, the boiler of which is coal fired, failed by creep after 17 years of service. The failed tube was specified to be made of ASME SA-213, grade T-22. Measurable swelling of the tube diameter by about 2.4 mm and tube wastage caused by corrosion or erosion...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.bldgs.c0047335
EISBN: 978-1-62708-219-8
..., and phosphorus. The high sulfur content is attributed to ferrous sulfide from a sulfate reducing bacteria frequently associated with clay soils. Reinforced coal tar protective coating was recommended. Bacteria Clay (material) Porosity Residues Soils (types) Gray iron Dealloying/selective leaching...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.pulp.c0045911
EISBN: 978-1-62708-230-3
... Abstract Within the first few months of operation of an 8 km (5 mile) long 455 mm (18 in.) diam high-pressure steam line between a coal-fired electricity-generating plant and a paper mill, several of the Inconel 600 bellows failed. The steam line operated at 6030 kPa (875 psi) and 420 deg C...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.petrol.c9001166
EISBN: 978-1-62708-228-0
... product from each pipe section were analyzed for carbon, sulfur, and iron and were found to consist mainly of iron sulfide mixed with soot and rust. The damage resulted from a high content of hydrogen sulfide in the gas (6% CO2, 20% CO, 8 to 12% H2, 0.5 to 1.5% CH4, remainder N2). To process the coal...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.power.c9001700
EISBN: 978-1-62708-229-7
... Abstract A straight-tube cooler type heat exchanger had been in service for about ten years serving a coal pulverizer in Georgia. Non-potable cooling water from a local lake passed through the inner surfaces of the copper tubing and was cooling the hot oil that surrounded the outer diametral...