某超临界600 MW机组锅炉水冷壁管泄漏原因分析

某电厂超临界600MW机组锅炉水冷壁管在运行过程中发生泄漏。通过宏观检查、内壁垢量测定、化学成分分析、金相检验、扫描电镜及能谱分析、力学性能试验、硬度测试等方法对水冷壁管的泄漏原因进行了分析。结果表明:水冷壁管内壁垢层较厚且分布不均匀,锅炉燃烧不稳定,导致水冷壁管的外壁出现腐蚀性热疲劳裂纹,内壁出现热疲劳裂纹,最终导致其发生泄漏失效。     

火电厂水冷壁管腐蚀失效常见形式简介

在火电厂锅炉的4种受热管中以水冷壁管的腐蚀风险最高,水冷壁管的腐蚀失效严重威胁电厂锅炉的安全性与经济性。从水冷壁的水侧和烟气侧两方面介绍了火电厂水冷壁管常见的几种腐蚀形式,重点分析了引起这几种腐蚀的常见原因,并提出了相应的防护措施。电厂实际运行中应综合分析水冷壁的运行工况、腐蚀特征等来判定水冷壁的腐蚀失效形式。     

某高压锅炉水冷壁管开裂原因分析

某热电厂高压锅炉在水压试验过程中水冷壁管发生开裂,通过宏观分析、壁厚测量、化学成分分析、硬度测试、金相检验、扫描电镜分析和能谱分析等方法,对水冷壁管的开裂原因进行了分析。结果表明:该水冷壁管是垢下腐蚀氢损伤导致的脆性开裂。水冷壁管发生氢腐蚀,且在腐蚀过程中汽水反应生成的部分原子氢扩散渗入金属内部,与珠光体中的碳化物反应生成甲烷,较大的甲烷分子聚集于晶界而使晶界开裂,在内壁形成沿晶微裂纹,裂纹扩展最终导致水冷壁管发生脆性开裂。     

国产1000MW超超临界机组水冷壁管典型横向裂纹分析

对国产1000MW超超临界燃煤机组水冷壁管普遍存在的横向裂纹进行分析研究,通过割取典型管样进行磁粉检测、显微组织分析、硬度试验、扫描电镜能谱分析、拉伸性能试验和断口分析,结果表明该锅炉水冷壁管表面横向裂纹是轴向交变应力作用下产生的热疲劳裂纹,腐蚀介质的存在加速了热疲劳裂纹的扩展。为防止此类失效问题,建议相关电厂采取了有效的针对性防范措施,同时对其它超超临界机组水冷壁管的安全运行提供技术参考。     

锅炉水冷壁管横向裂纹形成原因分析

某锅炉在运行期间发生水冷壁管泄漏事故,检查发现数十根管材外壁存在横向裂纹。通过宏观检查、化学成分分析、力学性能测试、金相检验和扫描电镜分析,对锅炉水冷壁管横向裂纹的形成原因进行了分析。结果表明:在壁温波动导致的热疲劳应力和腐蚀气氛的共同作用下,锅炉水冷壁管向火侧管壁发生了腐蚀疲劳开裂,形成了密集的横向裂纹,最终导致水冷壁管泄漏。     

600MW烟气超低排放锅炉水冷壁的失效分析

为满足当前对大气环境质量越来越高的要求,现有燃煤锅炉必须实现超低排放改造才能达到大气排放标准,其中锅炉的低氮燃烧改造是必由之路。锅炉改造后燃烧工况发生了变化,易造成水冷壁的高温化学腐蚀产生裂纹失效。以某600 MW锅炉为例,通过金相和能谱等手段分析了化学腐蚀的特性,结果表明:水冷壁的高温腐蚀主要是由煤燃烧产生的硫化物对水冷壁高温硫化的作用,加之热交变应力形成腐蚀裂纹。提出了预防发生高温化学腐蚀的措施,即减小外二次风旋流强度,增强炉膛中心氧浓度,使主燃区中心燃尽率提高,减少腐蚀气体生成;在锅炉侧墙易腐蚀部位增加贴壁风,减小腐蚀气体浓度;在腐蚀区域喷涂防腐蚀层,使金属外壁与燃烧气氛隔离开;通过上述措施可阻止进而抑制腐蚀裂纹的产生。     

锅炉过热器管弯头开裂失效分析

某12Cr1MoVG钢锅炉在投入使用数月后发现过热器管弯头处发生开裂.采用光学显微镜、显微硬度计、扫描电子显微镜和能谱仪对锅炉过热器管弯头开裂进行了失效分析.结果 表明:过热器管弯头失效的主要原因为碱性环境下的应力腐蚀和氢脆,过热器管弯头在运行过程中局部存在浓缩碱溶液,浓缩碱溶液在高温和水的作用下腐蚀管道内壁并生成微量的氢,氢在残余应力的作用下侵入金属内部并在晶界处聚集引发氢脆,这是造成弯头内壁形成大量沿晶裂纹的根本原因.     

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.     

锅炉水冷壁管爆管原因分析

采用宏观检验、力学性能检测、金相检验、扫描电镜检查和X射线衍射分析等方法对某锅炉水冷壁管发生爆管的原因进行了分析。结果表明：水冷壁管爆裂是由于酸泄漏事故引起的,泄漏导致接触烟气侧的管内壁存在较多细小的微裂纹,使材料的拉伸强度和屈服强度大幅降低,加上锅炉水系统漏入酸溶液引起了氢腐蚀,最终导致水冷壁管在工作应力下发生氢脆断裂。     

Q345R高压空冷器焊接接头应力腐蚀开裂分析

某高压空冷器进气口换热管和管板胀管焊接处发生泄漏事故，通过宏观观察、机械拉断断口及裂纹面分析、金相组织分析、显微硬度测试、扫描电子显微镜(SEM)以及X射线能谱分析(EDS)等分析方法对泄漏失效处及关键位置材料进行检测和分析。研究发现高压空冷器进出口失效位置的裂纹均是由管箱内壁接头处向胀接间隙表面开裂，并且裂纹面能谱分析结果发现大量的S元素存在。结合管道受力情况、断口形貌、元素分析判定本次失效的模式为硫化氢应力腐蚀开裂(SSCC)。管内硫化氢为腐蚀源，在焊接残余应力集中和外载结构应力的协同作用下，焊趾发生SSCC开裂，裂纹沿着熔合线扩展至胀管外壁，发生泄漏失效。     

合成氨废热锅炉换热管开裂分析

对某石化厂合成氨废热锅炉换热管开裂进行失效分析,结果表明:换热管材料在该使用工况条件下产生高温氢腐蚀,进而引起沿晶开裂,此为锅炉换热管开裂的失效主要原因。并相应提出了防止产生类似失效情况的预防措施。     

Origins of tensile stress-induced circumferential cracking of waterwall tubes in boilers

Abstract

The leakage and rupture of boiler tubes in power plants is a serious problem that can lead to unscheduled and costly outages. The predominant failure location of current concern is circumferential cracking on the fireside of waterwall tubes in the furnace waterwall section of a boiler. Although there is basic agreement that cracking results from a combination of thermal fatigue and corrosion, a complete explanation of the basic phenomena needed to establish the root causes of this problem is lacking. The purpose of the present study was to analyse the sources of the tensile stress responsible for initiating circumferential cracking and to identify the key parameters controlling this tensile stress. The results of analytical modelling suggested that a combination of increasing tube wall temperature with increasing thickness of internal oxide layers, and temperature spiking due to deslagging events eventually may result in tensile stresses sufficient to crack the fireside oxide and initiate the development of circumferential cracks. This scenario also led to suggestions for reducing tensile stresses in waterwall tubes which, in turn, would be expected to delay/avoid circumferential cracking and improve the reliability of waterwall tubes.     

Corrosion of a copper U-shaped heating element: Some morphological and microstructural observations

In this work, observations of the corrosion on a failed copper U-shaped tube, of 1 mm nominal thickness, are presented. This tube was subjected to severe corrosion and subsequent cracking after a month of operation as the heating element of an electrical boiler. Morphological and microstructural observations of the failure area as well as cross sections of the corroded copper tube are presented. Moreover, the chemical composition of the material and the principal physicochemical characteristics of the tap water used for boiler operation were determined in the context of the failure investigation. The quality of the water used for boiler operation was a significant factor influencing the heating element efficiency and reliability. Hard water with high electrical conductivity accelerated salt precipitation and led to the corrosion and premature failure of the components.     

Prediction and real-time monitoring techniques for corrosion characterisation in furnaces

Abstract

Combustion modifications to minimise NO_x emissions have led to the existence of reducing conditions in furnaces. As regulations demand lower NO_x levels, it is possible (to a degree) to continue to address these requirements with increased levels of combustion air staging. However, in most practical situations, a number of adverse impacts prevent the application of deep combustion air staging. One of the more important limitations is the increased corrosion that can occur on wall tubes exposed to fuel rich combustion environments. Current boiler corrosion monitoring techniques rely on ultrasonic tube wall thickness measurements typically conducted over 12 to 24 month intervals during scheduled outages. Corrosion coupons are also sometimes used; typically require considerable exposure time to provide meaningful data. The major drawback of these methods is that corrosion information is obtained after the damage has been done. Management of boiler waterwall loss and system optimisation therefore requires a real-time indication of corrosion rate in susceptible regions of the furnace. This paper describes the results of a program of laboratory trials and field investigations and considers the use of an on-line technology in combination with innovative applications, also modelling and precision metrology to better manage waterwall loss in fossil fuelled boilers while minimising NO_x emissions.     

压力设备腐蚀失效案例统计分析

收集整理近年来有关压力容器管道的腐蚀失效案例,并对其进行了归纳与分析.从整体的腐蚀情况来看,应力腐蚀及其它应力作用下的腐蚀失效形式是压力容器管道比较突出的腐蚀失效问题,同时奥氏体不锈钢、碳钢及低合金钢三种材料的腐蚀失效较严重.     

燃煤锅炉水冷壁管爆管原因分析

某电厂3号锅炉水冷壁发生蠕变胀粗爆管。对爆破的锅炉水冷壁管进行了宏、微观检查,发现该管破口处严重胀粗,破口处显微组织为贝氏体 少量铁素体,是一种不完全的淬火组织。分析结果认为,由于螺桂堵塞节流孔使该管水循环不良,管子局部超温．最终导致撕裂爆管。     

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.     

柴油加氢装置高压换热器管束断裂原因与防护

对热高分气与混氢换热器断裂管束进行了失效原因分析。结果表明,氯化物应力腐蚀开裂是管束失效的主要原因,氢的存在及管板与管束在溶液环境组成的腐蚀电池加快了该腐蚀的速度。针对腐蚀原因采取了优化设计和制造、安装和操作等腐蚀防护措施,效果良好。     

二氯乙烷管线腐蚀失效分析

采用宏观分析,金相分析,硬度检测,扫描电子显微镜分析,能谱分析及X射线衍射分析等多种方法对某氯碱厂二氯乙烷输送管线爆裂泄露的原因进行综合分析。结果表明：管线三通处介质流向发生突变,使管壁受到严重的冲刷腐蚀作用,是管线失效的主要原因。物料中含有水分,与二氯乙烷反应得到氯化氢,加剧管线腐蚀。钢材本身存在一定的冶金缺陷易引发局部腐蚀。Cl^-在腐蚀坑处富集可加剧局部腐蚀。     

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。