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Boiler plate
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Published: 01 January 2002
Fig. 11 Creep-induced failure of a boiler plate. (a) A polished cross section of the plate that shows necking, a feature of short-term creep. 2×. (b) Intergranular voids (dark areas) in an area near the fracture surface. Courtesy of B. Gabriel, Packer Engineering Associates, Inc.
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Published: 15 January 2021
Fig. 6 Photographs of boiler plates exhibiting caustic stress-corrosion cracking (arrows). Source: Ref 5
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Image
Published: 01 January 2006
Fig. 30 Recovery boiler sealed air ports. (a) Crack running along the heat-affected zone of a weld between a composite tube and a crotch plate in a spout opening. (b) Subsequent failure analysis found the crack penetrating into the carbon steel layer of the composite tube.
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Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006785
EISBN: 978-1-62708-295-2
... rivet holes and other areas of high stress when boiler water contained caustic soda (NaOH) or the boiler water chemistry was conducive to the formation of caustic soda ( Ref 4 ). In their 1926 paper, “The Cause and Prevention of Embrittlement of Boiler Plate,” researchers at the University of Illinois...
Abstract
Stress-corrosion cracking (SCC) is a form of corrosion and produces wastage in that the stress-corrosion cracks penetrate the cross-sectional thickness of a component over time and deteriorate its mechanical strength. Although there are factors common among the different forms of environmentally induced cracking, this article deals only with SCC of metallic components. It begins by presenting terminology and background of SCC. Then, the general characteristics of SCC and the development of conditions for SCC as well as the stages of SCC are covered. The article provides a brief overview of proposed SCC propagation mechanisms. It discusses the processes involved in diagnosing SCC and the prevention and mitigation of SCC. Several engineering alloys are discussed with respect to their susceptibility to SCC. This includes a description of some of the environmental and metallurgical conditions commonly associated with the development of SCC, although not all, and numerous case studies.
Series: ASM Handbook
Volume: 13C
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v13c.a0004159
EISBN: 978-1-62708-184-9
... and the deposition of soot ash can moderate the corrosive effects of deposited acids. In conventional boiler plants, the risk areas normally include the posteconomizer flue gas handling sections such as air heaters, ducting and precipitators, induced-draft fans, and chimney stacks. Dew-point corrosion problems...
Abstract
Dew-point corrosion occurs when gas is cooled below the saturation temperature pertinent to the concentration of condensable species contained by a gas. This article discusses dew-point corrosion problems in the susceptible areas of dry flue gas handling systems. The corrosion problems associated with the nitrate stress-corrosion cracking in heat-recovery steam generators are also discussed. The article presents general comments on the materials selection; plant operation; use of neutralizing additives; and maintenance, good housekeeping, and lagging (insulation). It concludes with information on guidance for maintaining specific sections of the plant.
Series: ASM Handbook
Volume: 13C
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v13c.a0004190
EISBN: 978-1-62708-184-9
... examines the corrosion problems in high-yield mechanical pulping, sulfite process, neutral sulfite semichemical pulping, chemical recovery, tall oil plants, wastewater treatment, and recovery boilers. It explains the stages of chlorine-based and nonchlorine bleaching, process water reuse for elemental...
Abstract
This article discusses the methods of pulp production, pulp processing, pulp bleaching, and paper manufacturing. It describes various types of digesters, their construction materials, the corrosion problems encountered, and methods to protect these digesters from corrosion. The article examines the corrosion problems in high-yield mechanical pulping, sulfite process, neutral sulfite semichemical pulping, chemical recovery, tall oil plants, wastewater treatment, and recovery boilers. It explains the stages of chlorine-based and nonchlorine bleaching, process water reuse for elemental chlorine-free and nonchlorine bleaching stages, selection of material for bleaching equipment, developments in oxygen bleaching, and the use of highly corrosion-resistant materials for bleach plant equipment. The article reviews the materials used in the construction of paper machine components and specific corrosion problems that affect them. It discusses the composition and corrosive nature of white water. The article also addresses the corrosion and chemical recovery associated with kraft pulping liquors.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006756
EISBN: 978-1-62708-295-2
... as a component that is no longer able to perform its intended function. This could apply at any time during the product life cycle. Damage does not necessarily mean failure. For example, power boiler superheater tubes undergo damage in the form of high-temperature degradation as the microstructure decomposes...
Abstract
The principal task of a failure analyst during a physical-cause investigation is to identify the sequence of events involved in the failure. Technical skills and tools are required for such identification, but the analyst also needs a mental organizational framework that helps evaluate the significance of observations. This article discusses the processes involved in the characterization and identification of damage and damage mechanisms. It describes the relationships between damage causes, mechanisms, and modes with examples. In addition, some of the more prevalent and encompassing characterization approaches and categorization methods of damage mechanism are also covered.
Book Chapter
Book: Fractography
Series: ASM Handbook Archive
Volume: 12
Publisher: ASM International
Published: 01 January 1987
DOI: 10.31399/asm.hb.v12.a0000605
EISBN: 978-1-62708-181-8
... of the steel during boiler start-up. Underneath the scale was a layer of metallic copper, an element often present as a feedwater impurity and which can plate out on the inner-diameter surfaces of boiler tubes. Overheating of the tubes to above 815 °C (1500 °F) caused accelerated diffusion of the copper along...
Abstract
This article is an atlas of fractographs that helps in understanding the causes and mechanisms of fracture of low-carbon steels and in identifying and interpreting the morphology of fracture surfaces. The fractographs illustrate the following: the intergranular fracture, bending impact fracture, brittle fracture, tensile-test fracture, transgranular fracture, cleavage fracture, delayed fracture, corrosion fatigue, inclusion morphology, fatigue crack propagation, and in-service fatigue fracture of various automotive components. These components include tie rod adjusting sleeves, automotive bolts, hydraulic jack shafts, crank handle collars, boiler tubes, drive shafts, bicycle pedal axles, lift-truck hydraulic-piston rods, and steel springs.
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006825
EISBN: 978-1-62708-329-4
... Abstract Failures in boilers and other equipment taking place in power plants that use steam as the working fluid are discussed in this article. The discussion is mainly concerned with failures in Rankine cycle systems that use fossil fuels as the primary heat source. The general procedure...
Abstract
Failures in boilers and other equipment taking place in power plants that use steam as the working fluid are discussed in this article. The discussion is mainly concerned with failures in Rankine cycle systems that use fossil fuels as the primary heat source. The general procedure and techniques followed in failure investigation of boilers and related equipment are discussed. The article is framed with an objective to provide systematic information on various damage mechanisms leading to the failure of boiler tubes, headers, and drums, supplemented by representative case studies for a greater understanding of the respective damage mechanism.
Series: ASM Handbook
Volume: 13C
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v13c.a0004124
EISBN: 978-1-62708-184-9
... fuel cells, and missile components. This article discusses high-temperature corrosion in boilers, diesel engines, gas turbines, and waste incinerators. Boilers are affected by stress rupture failures, waterside corrosion failures, fireside corrosion failures, and environmental cracking failures...
Abstract
High-temperature exposure of materials occurs in many applications such as power plants (coal, oil, natural gas, and nuclear), land-based gas turbine and diesel engines, gas turbine engines for aircraft, marine gas turbine engines for shipboard use, waste incineration, high-temperature fuel cells, and missile components. This article discusses high-temperature corrosion in boilers, diesel engines, gas turbines, and waste incinerators. Boilers are affected by stress rupture failures, waterside corrosion failures, fireside corrosion failures, and environmental cracking failures. Contamination of combustion fuel in diesel engines can cause high-temperature corrosion. Gas turbine engines are affected by hot corrosion. Refractory-lined incinerators and alloy-lined incinerators are discussed. The article provides case studies for each component failure.
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
... 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...
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.
Book: Fatigue and Fracture
Series: ASM Handbook
Volume: 19
Publisher: ASM International
Published: 01 January 1996
DOI: 10.31399/asm.hb.v19.a0002402
EISBN: 978-1-62708-193-1
... 1200 Tube, pipe … The 1 2 Cr- 1 2 Mo steel is produced to three strength levels and is approved in the ASME Boiler and Pressure Vessel Code (BPVC) for service to 540 °C (1000 °F). The 1Cr- 1 2 Mo and 1 1 4 Cr- 1 2 Mo steels are produced in three...
Abstract
Cr-Mo steels are preferred in the construction of high-temperature components because they possess excellent strength, toughness, and corrosion resistance relative to carbon steels and most low-alloy steels. This article discusses the composition and metallurgy of the heat-resistant Cr-Mo steels. It details the Charpy V-notch (CVN) toughness properties of Cr-Mo steels relevant to fatigue and fracture resistance. The fracture mechanics of Cr-Mo steels are reviewed. The article analyzes the characterization of low-cycle fatigue based on fatigue damage calculations. It concludes with information on fatigue crack growth and fatigue behavior of weldments.
Series: ASM Handbook
Volume: 18
Publisher: ASM International
Published: 31 December 2017
DOI: 10.31399/asm.hb.v18.a0006428
EISBN: 978-1-62708-192-4
... rub related damage. (f) Wear of combustor wear parts by gross slip sliding and impact Overview of Wear and Friction Issues in Steam Turbines Figure 2 gives a schematic illustration of a typical impulse steam turbine ( Ref 8 , 9 , 10 ). Steam from the boiler section is regulated...
Abstract
This article illustrates typical wear and friction issues encountered in gas and steam turbines and their consequences as well as commonly adopted materials solutions. It contains tables that present the summary of wear and friction related issues encountered in steam turbines and gas turbines. The article outlines the differences in the operating conditions and the nature of the components involved in gas and steam turbines. It discusses the constraints and applicable coating solutions for wear and friction issues, and concludes with a broad set of challenges that need to be addressed to improve performance and operability of gas and steam turbines.
Book: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0007036
EISBN: 978-1-62708-387-4
... magnification: 2500×. (b) Ductile fracture of an ASTM A213 grade T11 alloy steel boiler tube near a welded joint to a header. Elongated dimples are characteristic of ductile fracture due to shear stress. Original magnification: 1000× Ductile fractures can also be characterized in a metallographic section...
Abstract
In this article, a basic summary of fracture mechanisms in carbon and alloy steels is presented, along with numerous examples of these fractures. These examples include ductile fracture, brittle cleavage fracture, intergranular fracture, fatigue fracture, and environmentally assisted failure mechanisms.
Book Chapter
Book: Fractography
Series: ASM Handbook Archive
Volume: 12
Publisher: ASM International
Published: 01 January 1987
DOI: 10.31399/asm.hb.v12.a0000609
EISBN: 978-1-62708-181-8
... fracture, fracture by overpressurization, inclusion effect, fatigue crack propagation, ductile fatigue striation, secondary cracking, intergranular fracture, and elevated-temperature fracture of alloy steels used in pressure vessels, steam boiler superheater tubes, and box-girder bridges. alloy steel...
Abstract
This article is an atlas of fractographs that helps in understanding the causes and mechanisms of fracture of ASTM/ASME alloy steels and in identifying and interpreting the morphology of fracture surfaces. The fractographs illustrate the solidification cracking, creep failure, brittle fracture, fracture by overpressurization, inclusion effect, fatigue crack propagation, ductile fatigue striation, secondary cracking, intergranular fracture, and elevated-temperature fracture of alloy steels used in pressure vessels, steam boiler superheater tubes, and box-girder bridges.
Series: ASM Handbook
Volume: 13A
Publisher: ASM International
Published: 01 January 2003
DOI: 10.31399/asm.hb.v13a.a0003701
EISBN: 978-1-62708-182-5
... Abstract The corrosion process that occurs in industrial systems is often difficult to discern until extensive deterioration has occurred. For boilers to function properly, the incoming water must be processed to meet the water quality required for the boiler. This article discusses...
Abstract
The corrosion process that occurs in industrial systems is often difficult to discern until extensive deterioration has occurred. For boilers to function properly, the incoming water must be processed to meet the water quality required for the boiler. This article discusses pretreatment methods of the incoming water and preboiler corrosion protection methods. It analyzes internal treatment and condensate treatment of boilers. The article discusses three types of cooling systems: once-through systems, open recirculating systems, and closed recirculating systems. The corrosion processes which occur in water-recirculating systems and the effect of dissolved gases, temperature, pH, suspended solids, dissolved salts, and scale deposition on corrosivity of water, are also reviewed. The article also considers anodic and cathodic inhibitors and the control of corrosion in municipal water systems.
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
... of carbon steel for alloy or stainless steel, or vice versa ( Ref 1 ). Summary of statistics on pressure vessel failures compiled from 1981 through 1984 by the National Board of Boiler and Pressure Vessel Inspectors Table 1 Summary of statistics on pressure vessel failures compiled from 1981 through...
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.
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005557
EISBN: 978-1-62708-174-0
...: Section IX of the American Society of Mechanical Engineers (ASME) “Boiler and Pressure Vessel Code” AWS B2.1, “Standard for Welding Procedure and Performance Qualification” NAVSEA Technical Publication S9074-AQ-GIB-010/248, “Requirements for Welding and Brazing Procedure and Performance...
Abstract
Qualification of welding procedures and personnel is an important step to assure the quality and performance of any welded component or structure. This article summarizes common welding procedures, personnel qualification variables, and test methods. Welding procedure qualification tests can be categorized as either standard or special. The article discusses the purpose of qualifying a welding procedure to demonstrate that the resulting welds will meet prescribed quality standards and the qualification of the personnel.
Series: ASM Handbook
Volume: 13C
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v13c.a0004152
EISBN: 978-1-62708-184-9
...-to-tubesheet joint heater shell IN STEAM TURBINE ELECTRICAL POWER GENERATION PLANTS, turbine exhaust steam is condensed, and the condensate is reheated for return as feedwater to the boiler. Water from the condenser to the feedwater pump is called condensate, and from the pump to the boiler...
Abstract
This article addresses the major heat-transfer components of the water-steam loop of a power plant. It describes the various types of condensers, including water-cooled condensers and air-cooled condensers. The article explains the corrosion mechanisms encountered in the condensers, including erosion-corrosion, galvanic corrosion, and pitting corrosion. It discusses the types of deaerators and deals with their corrosion problems. The article provides a discussion on two types of feedwater heaters: channel feedwater heaters and header feedwater heaters. It summarizes the corrosion problems associated with common feedwater heater tube materials.
Series: ASM Handbook
Volume: 6
Publisher: ASM International
Published: 01 January 1993
DOI: 10.31399/asm.hb.v06.a0001474
EISBN: 978-1-62708-173-3
... of the most widely recognized codes, standards, and specifications that cover welding procedure qualification include: Section IX of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code American National Standards Institute/American Welding Society (ANSI/AWS) B2.1...
Abstract
Welding codes and standards usually require the qualification of welding procedures prior to being used in production. This is to ensure that welds will meet the minimum quality and mechanical property requirements for the application. This article provides an overview of the welding procedure qualification guidelines and test methods. It also reviews the codes, standards, and specifications that govern the design and fabrication of welded structures for the procedure qualification details that are appropriate for a given application.
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