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    Easwaran-IIT Madras CoSS 27 Feb 2015

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    Arunprasad Murugesan
    The document discusses failures of stainless steel components in steam generating power plants. It describes 22 mechanisms of boiler tube failures including stress rupture, fatigue, corrosion, erosion, and issues arising from lack of quality control. Specific examples of failures from stress corrosion cracking, overheating and creep, corrosion fatigue, erosion, dissimilar metal welds, weld and material defects are presented along with micrographs. Proper material selection, quality of manufacturing and operation are important to prevent premature failures in power plant equipment.

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    Easwaran-IIT Madras CoSS 27 Feb 2015

    Uploaded by

    Arunprasad Murugesan
    52 views27 pages
    The document discusses failures of stainless steel components in steam generating power plants. It describes 22 mechanisms of boiler tube failures including stress rupture, fatigue, corrosion, erosion, and issues arising from lack of quality control. Specific examples of failures from stress corrosion cracking, overheating and creep, corrosion fatigue, erosion, dissimilar metal welds, weld and material defects are presented along with micrographs. Proper material selection, quality of manufacturing and operation are important to prevent premature failures in power plant equipment.

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    The document discusses failures of stainless steel components in steam generating power plants. It describes 22 mechanisms of boiler tube failures including stress rupture, fatigue, corrosion, erosion, and issues arising from lack of quality control. Specific examples of failures from stress corrosion cracking, overheating and creep, corrosion fatigue, erosion, dissimilar metal welds, weld and material defects are presented along with micrographs. Proper material selection, quality of manufacturing and operation are important to prevent premature failures in power plant equipment.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    52 views27 pages

    Easwaran-IIT Madras CoSS 27 Feb 2015

    Uploaded by

    Arunprasad Murugesan
    The document discusses failures of stainless steel components in steam generating power plants. It describes 22 mechanisms of boiler tube failures including stress rupture, fatigue, corrosion, erosion, and issues arising from lack of quality control. Specific examples of failures from stress corrosion cracking, overheating and creep, corrosion fatigue, erosion, dissimilar metal welds, weld and material defects are presented along with micrographs. Proper material selection, quality of manufacturing and operation are important to prevent premature failures in power plant equipment.

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    of 27

    Failures of SS Components:

    Manufacturing and In-service experience with


    Stainless Steels for steam generating
    equipment of Power Plants

    R. Easwaran
    Welding Research Institute & Labs,
    Bharat Heavy Electricals Limited,
    Tiruchirappalli

    IIT, Madras Course of Stainless Steels CoSS-2015 27 February 2015

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    Power Stations are very complex

    Boiler Tubing
    for a 500 MW set

    PDMS Link

    • 443 km length of tubing


    • 27400 tube butt welds
    • 6 types of butt welding processes
    • Over 28000 Despatchable Units (DUs)
    • More than 1 Lakh components
    • Weighing about 20,000 tons

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    Walk through view of Boiler Island

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    Boiler Tube Failures in Power Plants
    Twenty Two Mechanisms of Boiler Tube Failures (Courtesy: EPRI)
    Stress Rupture Fatigue
    1. Short Term Overheating 12. Vibration Fatigue
    2. High Temperature Creep 13. Thermal Fatigue
    3. Dissimilar metal Welds 14. Corrosion Fatigue
    Waterside Corrosion Erosion
    4. Caustic Corrosion 15. Fly Ash Erosion
    5. Hydrogen Damage 16. Falling Slag Erosion
    6. Internal Pitting (localised corrosion) 17. Soot Blower Erosion
    7. Stress Corrosion Cracking 18. Coal Particle Erosion
    Fireside Corrosion Lack of Quality Control
    8. Dew Point Corrosion 19. Maintenance Cleaning Damage
    9. Water Wall Fireside Corrosion 20. Chemical Excursion Damage
    10. High Temperature Coal Ash Corrosion 21. Material Defects
    11. High Temperature Oil Ash Corrosion 22. Weld Defects
    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India
    Stress Corrosion Cracking

     Common Mechanism in austenitic stainless steels…. Stress


    and corrodents being ubiquitous, wet chloride being one of
    the most common corrodents

     Medium side contamination in many cases …..


     During Transportation .. VCI pellet
     Storage and erection … Rats
     Excessively machined locations
     Hydrostatic Testing …. Poor water quality
     Chemical Cleaning
     Intermediate Shut downs
     ……

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    Stress Corrosion Cracking … Bends … VCI Pellets

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    SS347H Insert
    Ø 51 x 6 mm
    SS 347H
    Bifurcate
    INV063/ 06 SS347H Insert Ø 51 x 7.5 mm
    Ø 63.5 x 12.5 mm
    (8mm near STBW)

    SS347H Tube
    Ø 63.5 x 8.0 mm

    Weld
    STBW joint
    joint

    Stress Corrosion Cracking at Machined Regions

    SH bifurcate assembly with weld


    joints, Ø 63.5X 8.0/ 12.5 + Ø 51x
    6.0 mm, SA213 TP347H,
    Less than one month service
    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India
    Stress Corrosion Cracking … Hydro-test water quality

    SH-2 outlet header stub to coil (SH 06) (Waste Heat Reheater Boiler),
    Ø 38.1 x 3.6 mm & SA 213 TP 316, Failure during commissioning
    Bore water used for hydro test at site which contains chlorides
    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India
    Stress Corrosion Cracking:
    Chemical Cleaning carry over

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    Corrosion and its Control: Stress Corrosion Cracking
    Typical Portable Root Verification Appearance N.D.E. Corrective
    Locations Cause Action
    SH, RH at -Corrosive -Internal Fine branched Flourescent *Replacement
    regions of: conc. from chlorides, cracks Multiple dye check *Surveillance for
    -Conc. of drum carry hydroxides cracks Hydro test UT carry over
    chlorides, over or -External Thick edges *Hear treatment
    sulphates or attemperator sulphates, of bends
    hydroxide spray poly thionic *Care during
    -Stressed in -SS tube acid chemical
    fabrication, material -Stress cleaning
    service etc. sensitized analysis *Use of 347H
    like bends, -Stress tube
    attachment
    welds

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    Stress Corrosion Cracking: Martensitic SS
    SA582 Gr. 416 Valve Stem

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    Hardness 330-350 against
    302 max

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India
    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India
    Platen Super heater Tube
     51 x 5.0 mm
    SA 213 TP 347H
    Service: 1,14,000 Hrs

    Overheating and Creep


    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India
    1,10,890 hrs Dia 51x 4.5
    SA213TP347H

    Overheating and Creep

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    Tube Ø38.1x7.1 mm SA213 T91 Sleeve:
    SS347H & Spacer Rod: Ø 20 mm SS310S

    Fatigue

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    Fatigue – Tie weld

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    SS 304 Ash cooler tube CCDP- Gasifier

    Inside medium: Cooling water, Outside


    Medium: Ash flow with Syngas (1000°C max)

    Corrosion Fatigue

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    External Erosion

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    Sea Water Corrosion
    ACW Piping to vacuum pump - SS Pipe Cut
    Piece …. used for sea water handling
    Ø273.1X9.27 mm & SA312 TP316L

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    Dissimilar Metal Weld Failure

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    Dissimilar Metal Weld Failure

    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India


    Lack of Fusion
    Weld Defects
    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India
    SA 213 TP 347H
    Ø 63.5 X 4 mm welded to Ø 63.5 X 12 mm

    Raw Material Defect


    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India
    Leaked RH Vertical spaced Reheater Tube
    Ø 63.5 x 5 mm SA 213 TP 347H

    Delta ferrite content in the weld metal (single


    bead) and tube material is found to be 0.0 to 0.25
    in the weld metal and 0.20 in the tube material.
    This indicates that no filler material is used for
    welding.

    Lack of Discipline: Stray Arcing


    Other issues could be ferritic contamination ….
    Shot blasted SS casting rusting; contamination
    from files, ferritic grindng dust ….
    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India
    Committed to be a World Class Institute Welding Research Institute, Tiruchirapalli, India

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