Lochkorrosion durch Flußmittel an Kupferrohren in der Trinkwasserinstallation

Pitting Corrosion at Copper Tubes of Tap Water Systems released by Soldering Flux The pitting corrosion is the mostly observed reason for getting corrosion damage of copper tubes in tap water systems. In case of loss the reason for corrosion attack is ascribed to rests of cracked drawing compounds at the copper tube wall. The results from own examinations of copper tubes corroded in different tap waters show in case of loss the reason for corrosion damage as cracked soldering flux. This gets by the different described ways into the copper tube and becomes cracked by the soldering temperature. This way formed corrosion attacks often show breaches firstly far away from the soldered joint so that mostly other reasons of damage (cracked drawing compounds) are simulated.     

Metal dusting (catastrophic carburization) of a waste heat boiler tube

A waste-heat boiler at a chemical plant suffered an unusual tube failure. The boiler is part of the partial oxidation (POx) syngas production for a 2-ethyl hexanol unit. The syngas primarily consists of H₂, CO and CO₂ with trace amounts of CH₄. Steam is also reportedly injected into the process. The syngas enters the boiler at approximately 1800°F (980°C) on the internal side of the tube and is cooled, while generating approximately 640 psi (4.41 MPa) steam at 490°F (255°C) on the outside of the tube. The internal surface of the tube contained a region of metal loss that was approximately 1 inches long by inch wide (44.5 mm by 19 mm). The metal loss was very localized with little evidence of attack elsewhere on the tube's surface. Molten salt attack, sulfidation and metal dusting were considered as possible mechanisms for the metal loss. It was determined that metal dusting, also called catastrophic carburization, was the cause of the metal loss. The cause of the metal dusting was localized overheating of the tube, which developed because of water/steam flow disruption due to contact of the tube baffle with the tube. Approximately one year after this tube failure, the boiler suffered two more tube failures, which were also attributed to metal dusting.     

Feed Water Chemistry-Related Corrosion Failures in Subcritical 250 MW Coal-Fired Boiler

This paper emphasis on the study of typical premature failure of water wall tubes of two thermal power plant boiler of same capacity (250 MW) and same operational parameter but with different boiler water chemistry. The investigation concludes on the water-side corrosion in both of the cases. One boiler is running with coordinated phosphate treatment (CPT) and another with all volatile treatment (AVT). The causes of corrosion were discovered and proposed measures for their elimination were given. Visual examination, chemical analysis of deposits, oxide scale thickness measurement, and microstructural examination were carried to ascertain the probable cause/causes of failure. From the investigation, it was finally concluded that the combination of localized high tube metal temperature and wall thinning due to under deposit corrosion led to the premature tube failure in boiler running with CPT and localized pitting corrosion in boiler running with AVT. Based on the results and discussions, a possible way to combat the corrosion was proposed.     

超临界“W”火焰炉氢腐蚀爆管原因分析

针对超临界“W”火焰炉氢腐蚀爆管现象,采用宏观检查和金相检验的方法对水冷壁管爆口进行了检测分析,宏观检查表明爆口附近有多处鼓包、壁厚变薄,金相检验说明了爆口内壁金相组织出现严重的脱碳和沿晶腐蚀裂纹,即高温氢腐蚀。根据水冷壁的材质、超临界水汽特性和水质情况的分析,精处理混床出水氯离子超标是引起此次爆管的一个关键因素。     

Investigations on the Failure of Economizer Tubes in a High-Pressure Boiler

This article describes the results of an investigation concerning the failure of economizer tubes of a high-pressure boiler in a dual-purpose power/water cogeneration plant. The failure was observed in the form of rupturing of one tube and a macrohole or pinhole in another tube. The boiler had an operating period of 116,123 h since its inception. For approximately the first 100,000 h, the fuel for the boiler was crude oil, which was replaced by Bunker C oil. The boiler tube is fabricated from carbon steel SA 210A1. The location of the failure was determined by on-site visual inspection of the boiler. Detailed macro- and microexaminations of inner and outer scales on the tube were begun to determine the cause of the rupture. The composition of the fire- and waterside scale and ash deposited on the outer surface of the tubes was analyzed by energy-dispersive x-ray (EDX) technique. The reduction percentage of wall thickness of the tube facing inside and outside the furnace was calculated. The cause of the failure of the economizer tube appears to be H₂SO₄ dew-point corrosion. The relatively low temperature of feedwater lowered the tube metal temperature and promoted the condensation of H₂SO₄. The external deposits on the tubes, as a result of bunker oil firing, further helped to lower the tube metal temperature, thus promoting H₂SO₄ condensation over the deposit and subsequent corrosion of the tube wall. Recommendations are given to prevent/minimize such failures.     

Erosion Corrosion on Oil Coolers for Navy Ships

Incorrect material selection does not always lead to corrosion. In addition to an inferior selection of materials, unsuitable operating conditions and poor design also contributed to the presented failure. A combination of erosion and corrosion caused a leak in an oil cooler of a Navy ship. Because there was no welding seam between the deflectors and tube plate on the carbon steel cooler, cooling water could stream between them, and the flow rate became excessive. This caused erosion on the tube plate. In addition, the repeated change of the cooling liquid after servicing caused a uniform corrosion attack.     

某自备电厂锅炉水冷壁管穿孔原因

某工业园区自备电厂锅炉水冷壁管在运行期间多次发生穿孔事故,通过内壁垢样分析和金相检验等方法,结合现场工况,对水冷壁管的穿孔原因进行了分析.结果表明:锅炉内水的电导率和SiO 2含量偏高,且现场缺少在线仪表监测,造成内壁结垢,继而引发了垢下局部碱腐蚀,造成管壁减薄至无法承受工作应力而穿孔爆裂.     

A novel coupled VM-PT cryocooler operating at liquid helium temperature

This paper presents experimental results on a novel two-stage gas-coupled VM-PT cryocooler, which is a one-stage VM cooler coupled a pulse tube cooler. In order to reach temperatures below the critical point of helium-4, a one-stage coaxial pulse tube cryocooler was gas-coupled on the cold end of the former VM cryocooler. The low temperature inertance tube and room temperature gas reservoir were used as phase shifters. The influence of room temperature double-inlet was first investigated, and the results showed that it added excessive heat loss. Then the inertance tube, regenerator and the length of the pulse tube were researched experimentally. Especially, the DC flow, whose function is similar to the double-orifice, was experimentally studied, and shown to contribute about 0.2 K for the no-load temperature. The minimum no-load temperature of 4.4 K was obtained with a pressure ratio near 1.5, working frequency of 2.2 Hz, and average pressure of 1.73 MPa.     

多孔陶瓷管式露点间接蒸发冷却器实验台设计研究

针对间接蒸发冷却器壁面亲水性的问题,提出采用多孔陶瓷材料,设计和搭建了多孔陶瓷管式露点间接蒸发冷却器实验台,并简述了实验台的运行过程。该实验台的搭建对多孔陶瓷管式露点间接蒸发冷却器的性能测试起着至关重要的作用。     

An Investigation on the Cracking of Air Tubes of Rotary Kilns in a Sponge Iron Plant

Cracking of an air tube used for supplying air in rotary kiln of a sponge iron plant is investigated in this paper. The material of the air tube is ASTM A297 HK 40, a member of the heat-resistant cast alloy family (H series) steels widely used for enhanced high-temperature properties. Microstructural degradation occurring at high temperature affects mechanical and corrosion-resistance properties of the component. The failure analysis consists of visual observation, chemical analysis, examination of microstructures using optical and scanning electron microscopes, and characterization with energy-dispersive spectroscopy (EDS). Microstructural characterization reveals (i) intergranular corrosion at the cross section of tube wall, (ii) formation of severe chromium carbide network at the grain boundary, (iii) formation of sigma phases along the grain boundary as well as within the matrix, and (iv) generation of crack at the grain boundary filled with oxides. Analyses of these results suggest that formation of carbide network and sigma phases at the elevated service temperature depletes the alloying elements from the surrounding matrix, enhancing intergranular corrosion, which leads to cracking of the air tube.     

Top of the REAC tube corrosion induced by under deposit corrosion of ammonium chloride and erosion corrosion

The crystal and deposition behavior of ammonium chloride salt (NH₄Cl) and multiphase flow simulation were investigated by using Aspen software and CFD technology. And the corrosion failure causes of inlet tube explosion of a refinery hydrocracking reactor effluent air cooler (REAC) were studied. The top of 10# carbon steel base tube corrosion is severe, and reveals an inhomogeneous thinning. The field with localized corrosion is mainly distributed in a range of approximately 1.5 m away from the liner tube. The NH₄Cl crystal temperature increases with the increase of feedstock chloride content, and the decrease of injected water volume. The NH₄Cl salt granules mainly distribute in the forepart of an inlet tube of the REAC system. The liquid phase mainly exists in the bottom of an inlet tube, and the gas phase in the top of the tube. Without the enough liquid water, the NH₄Cl in the gas phase crystallizes and deposits on the top of a pipeline, resulting in under deposit corrosion, which interacts with the flow erosive action accelerates the localized corrosion thinning at the top of forepart of an inlet tube. Outside of the range of corrosion failure, the possibility of ammonium salt crystal decreases with decreasing temperature, and the condensed water increases gradually, then the deposited ammonium salts completely dissolve, and reduces the corrosion of downstream system.     

High-Temperature Stress Relaxation Cracking and Stress Rupture Observed in a Coke Gasifier Failure

This article discusses the high-temperature metal degradation mechanisms that occurred in the failure of a nine-story tall coke gasifier, located in a refinery power plant. Cracking of gasifier internals, bulging and stress rupture of the vessel shell, and escape of hot syngas resulted in an external fire. The failure mechanisms include stress relaxation cracking of a large diameter Incoloy Alloy 825 tube, stress rupture of the 4.65-in. thick, 1¼ chromium steel shell wall, and oxidation of 1¼ chromium steel exposed to hot syngas. The gasifier process and operating conditions that contributed to the high-temperature degradation will be discussed.     

分离型二级脉管制冷机的实验研究第一部分20～40 K温区单级大功率脉管制冷机

为了满足液氦温区分离型二级脉管制冷机第二级预冷的需要,设计制作了1台20～40K温区单级大功率脉管制冷机.采用额定功率为6 kW的压缩机驱动该制冷机,最低制冷温度达13.8K,刷新了单级脉管制冷机最低制冷温度纪录.该制冷机在40 K可获得高达55.9 W的制冷量,基本可以满足15～40 K温区超导磁体等冷却的需要.着重分析了频率、充气压力和不同压缩机对系统制冷性能的影响,测试了长时间运行中系统性能的变化情况.     

An innovative configuration for thermoacoustically-driven pulse tube coolers

Obtainable lowest temperature of a thermoacoustically-driven pulse tube cooler is generally limited by the pressure ratio provided by the thermoacoustic engine with helium as working gas. It is also known that a thermoacoustic engine filled with nitrogen can generally provide much larger pressure ratio and lower frequency than the same engine filled with helium. Here we introduce an innovative system configuration which uses an elastic membrane as the interface between the thermoacoustic engine subsystem and the pulse tube cooler subsystem. The membrane can transport acoustic work from the engine to the cooler, and meanwhile separate the working gases used in respective subsystems. Through this way, it is possible for the engine to operate with nitrogen to provide larger pressure ratio and more suitable frequency for the pulse tube cooler which can still use helium as the working gas. To test this idea, a thermoacoustically-driven pulse tube cooler was built. With the innovative configuration, the pulse tube cooler reached a lowest temperature of 139 K. On the other hand, without the membrane, the PTC only achieved a lowest temperature of 186 K when using nitrogen and 145 K with helium for both the PTC and the engine.     

Root cause analysis for 316L stainless steel tube leakages

Perforation of ASTM A270 TP316L stainless steel tube, used for transportation of ozonated high purity water in a pharmaceutical plant, was discovered after 3 months in actual service. The current investigation was conducted in order to explore the root causes of failure. Various techniques including on-site investigation, emission spectroscopy, ion chromatography, radioscopy, optical microscopy, scanning electron microscopy, energy dispersive spectroscopy, and intergranular corrosion testing were implemented for failure analysis of the tube components. The results revealed that the perforation of tube was initiated from the outer wall and extended to the inner wall by pitting corrosion. The stagnant state of chloride-containing water was the main reason for inducing such corrosion attack. The weld metal was the most susceptible to corrosion attack leading to perforation of the wall thickness, although initiation sites of pitting corrosion were also observed in the base metal. The dimensions of each pit mouth are very small, but enlarged subsurface cavities were observed. The selective dissolution of material due to galvanic effects between delta-ferrite and the austenite matrix occurred in the weld zone. It is suggested that failure prevention could be achieved by controlling the quality of the insulation system. In addition, careful control of welding conditions must be implemented during fabrication.     

高频脉冲管制冷机特性分析

通过相位理论分析了提高频率可以减小制冷机体积的原理,通过脉冲管制冷机内部损失影响分析了实现微型高效脉冲管制冷机的方法.研究表明:在现有的50 Hz高频下,减小制冷机体积会导致效率降低,提高运行频率,提高充气压力并采用更小水力直径的回热器填料,可以在减小体积的同时获得高效的制冷机.     

Caustic Corrosion Failure of Back Wall Riser Tube in a High-Pressure Boiler

This article describes the results of an investigation concerning the failure of the back wall riser tube of a high pressure boiler in a SWCC dual purpose power/water cogeneration plant. The failure occurred in one tube (facing furnace) which contained eight ruptured openings covering a length of approximately 1.8 m. The tube material was carbon steel (SA 210A1). The cause of the failure was determined by on-site visual inspection of the boiler and detailed macro and micro examinations of inner and outer scales on the tube. The in situ non-destructive testing of selected boiler riser tubes was carried out using boroscope and ultrasonic test (UT). The composition of the tube material and fire and water-side scale deposits were analyzed by energy dispersive x-ray (EDX) and inductively coupled plasma (ICP) techniques. The cause of the failure of the riser boiler tube appears to be caustic attack. The inside brown scale that developed during service resulted in overheating, wall thinning due to caustic corrosion, and the associated ruptures of the tube in areas of high stress. The escaping steam eroded the outer surface of the tube resulting in heavy loss of metal around the rupture points (punch). Recommendations are given to prevent/minimize such failures.     

Enhancing the lifetime and corrosion resistance of gears made of carbon steel

Gears for structural machines require high fatigue strength for high performance. Generally, gears made of carbon steel easily corrode, thus, shortening their fatigue life. The aim of this paper is to improve the fatigue strength of carbon steel gears by means of heat treatment method which was nitriding composed of 95 % nitrogen gas as well as 5 % hydrogen gas, and to investigate its properties after nitriding. Therefore, in order to find the optimum nitriding temperature to increase the hardness and corrosion resistance of gears, the gas nitriding process was conducted at two different tube furnace temperatures: low (550 °C) and high (1150 °C), both for four hours. Microstructural and mechanical property evaluation of the low and high temperature nitrided low-carbon steel BS970-080A15 were studied and the results were compared to identify which gear had better performance in terms of hardness as well as corrosion resistance. The results from Vickers hardness test and weight loss analysis proved that high temperature nitrided carbon steel is harder and more corrosion resistant than the low temperature one.     

换热管与管板的连接工艺试验

在现代空分设备上,离心压缩机使用的二级冷却器采用贴胀+密封焊连接的不锈钢内翅片换热管与管板会经常出现窜漏。为了解决二级冷却器换热管与管板连接的泄漏问题,重新做换热管与管板的连接工艺试验。通过试验得出结论:换热管与管板的连接应采用强度胀连接。     

D210塔简体泄漏原因分析

采用化学成分分析、金相检验和断口分析等方法,对304L钢D210塔筒体泄漏原因进行了分析。结果表明：D210塔筒体泄漏原因是由于氯离子的存在而产生应力腐蚀开裂所致。由于敏感材料、应力腐蚀环境及应力三个条件共同存在,在一定温度下使其产生应力腐蚀裂纹,裂纹起始于筒体外壁角焊缝处,而后向内壁扩展,最终穿透筒壁,致使该塔筒体在角焊缝处产生破裂泄漏。