Failure analysis on a primary superheater tube of a power plant

In this paper failure analysis on the SA213-T12 superheater tube by visual inspection, in situ measurements of hardness and finite element analyses is presented. A primary superheater tube has failed with a wide open burst after running at around 28,194 h. Heavy clinkers were found to almost entirely cover the primary superheater region. In situ hardness measurements were carried out on the selected primary superheater first row tubes at the middle region between furnace rear screen tube and primary superheater blower flow path. Hardness measurements are also taken on the as-received failed tube. Finite element analyses on possible features prior to failure are also conducted in order to illustrate and deduce the failure mechanism and failure root cause. Localized short-term overheating of the tube due to localized and concentrated flue gas flow resulted in a failure of the primary superheater tube.     

Metallographic investigations of the failed superheater tubes used in liquid hydrogen plant

2.25Cr–1Mo low alloy steel tubes of diameter 42.5 mm ID and 46.5 mm OD were used in superheater of liquid hydrogen plant. This superheater had 10 rows of tubes for carrying naphtha and steam and is heated by flue gas. The flue gas directly impinges on the first three tubes of the tube bank. A failure occurred in the first tube leading to the removal of a portion of the material causing to shut down of the plant.Detailed metallurgical investigations were carried out to understand the cause of failure. This paper brings out the metallographic investigations on the failed tubes and the necessary remedial actions thereon.     

Failure analysis of heat exchanger tubes

Primary waste heat exchanger tubes of material ASTM A213 grade T11 failed after operation of only three and a half months. The heat exchanger was of the bayonet type with boiler water inside the tubes and secondary reformer outlet process gas at the shell side. The heat exchanger environment was rich in hydrogen, carbon monoxide and nitrogen. The temperature of the process gases was 960 °C and the heat exchanger was producing steam at a temperature of 306 °C and a pressure of 1500 psig. The failed, used and new heat exchanger tubes were subjected to stereo/optical microscopy, chemical analysis and hardness testing. The cause of the failure was thoroughly investigated using optical/scanning electron microscope equipped with energy dispersive spectrometer. The study revealed that the material was exposed to thermal cycling and excessive local heating. The same was also confirmed by simulated experimentation. These conditions lead to thermal fatigue of the material with consequent failure.     

Failure analysis of superheater tube

The failure analysis of a ruptured superheater tube after 20 years service in the oil-fueled boiler, as the typical problems in power plants, was investigated. A thin-lipped rupture at failed region was observed in superheater tube. By measuring the tube’s wall thicknesses far from failed region, non-uniformity was seen. The suggested main root cause of failure was fireside corrosion of the tube during the service. Because of low grade of used fuel, sodium, sulfur, and vanadium elements were observed at the outer surface, which caused continuously scale formation and reduction of wall thickness, by metal consumption. In addition, it seems that it has been worsened by occurrence of long-term overheating. Coagulation of carbides at both outer and inner regions of tube was observed that could prove the occurrence of overheating during the service. In addition, the formation of sigma-phase particles was revealed because of being in the susceptible temperature after 20 years in service. At the end, in order to prevent or decelerate such failure, some recommended remedies were suggested.     

The dynamic creep rupture of a secondary superheater tube in a 43 MW coal-fired boiler by the decarburization and multilayer oxide scale buildup on both sides

A dynamic creep mechanism has been proposed and verified through a case study. A secondary superheater tube burst occurred in a 43 MW coal-fired boiler. Microstructural examination indicates that the overheating temperatures reached 900 °C (above Ac3). The overheating duration was estimated to be 3 h by calculating with LMP formula. The 710 μm steam-side scale and 960 μm fireside scale built-up in the short time of overheating. The burst scenario was a short-term severe overheating on the basis of the long-term creep. The multilayer oxide scales on both sides have been studied with ESEM/EDS, indicating FeO. At 900 °C, full decarburization had gone throughout the tube. As the strength reduced due to the decarburization, the creep mechanism transformed from long-term intergranular creep to short-term transgranular rupture. The two types of dimples on the fractograph and two types of cracks in the microstructures confirmed the mechanism transformation. The overheating, the scale buildup and the decarburization constituted the full picture of the dynamic creep rupture.     

Failure analysis and assessment on the exemplary water supply network

The subject of this paper is a failure analysis of water supply failure frequency in one of the cities in Poland. Operating data on the failure rate of water supply pipelines in the city were used. The analysis of water pipes' failures, including pipes diameters, their age, the material they are made from and their function in the water supply subsystem in the city was made. There is a noticeable downward trend in both the number of failures as well as the failure rates of water pipes. The value of failure rate indexes corresponds to national and international trends. The average failure rate for the main pipelines is λ_Mavg = 0.98 km^− 1 a^− 1, the distribution pipelines λ_Ravg = 0.42 km^− 1 a^− 1 and the water connections — λ_Pavg = 0.35 km^− 1 a^− 1. The majority of failures (45.62%) happen in the distribution pipelines, representing about 53% of the total length of the pipelines. Detailed analysis of the water network failure should be a main element of the managing system of the urban water networks, particularly in strategic modernization plans.     

Analysis of a diesel generator cylinder failure

This paper analyses a catastrophic cylinder failure of a four stroke 14 V diesel engine of an electrical power plant when running to nominal speed of 600 rpm. The rated power of the engine was 7.5 MW and before failure had accumulated 80,000 h in service operating mainly at full load. As a result, the piston and liner of cylinder 4 were broken; the crankcase and main crankshaft bearings next to this cylinder were also damaged. The mechanical properties of the liner (grey cast iron) and piston body (aluminium alloy) including tensile properties and Brinell hardness were evaluated. No signs of fatigue failure were identified in liner and piston. A finite element model of the liner has shown that the most heavily loaded areas match the fractured zones.     

High-velocity oxygen-fuel spray parameter optimization of nanostructured WC–10Co–4Cr coatings and sliding wear behavior of the optimized coating

In this paper, the Taguchi method was employed to optimize the spray parameters (spray distance, oxygen flow and kerosene flow) to achieve the highest hardness and, in turn, the best wear resistance of the high-velocity oxygen-fuel (HVOF) sprayed nanostructured WC–10Co–4Cr coating by investigating the correlation between the spray parameters and the hardness. The important sequence of spray parameters on the hardness of the coatings is kerosene flow > oxygen flow > spray distance, and the kerosene flow is the only significant factor. The optimal spray parameter (OSP) for the coating is obtained by optimizing hardness (330 mm for the spray distance, 2000 scfh for the oxygen flow and 6.0 gph for the kerosene flow). The coating deposited under the OSP with low porosity and high microhardness consists predominately of WC and a certain amount of W₂C phases. The coating deposited under the OSP exhibits better wear resistance compared with the cold work die steel Cr12MoV. The material removal of the coating is the extrusion of the ductile Co–Cr matrix followed by the crack and the removal of the hard WC particles.     

Failure analysis of water supply system in the Polish city of Głogów

The aim of this work is to diagnose the operation (and faults) of the water supply system in Głogów, Poland. The failure analysis has been conducted basing on the operating data from 2007–2010.About 140 km of main and distribution conduits with diameters of 80–700 mm and 42 km of house connections with diameters of 25–200 mm have been investigated. The pipes are mainly made of grey cast iron, steel, and plastic. The analysis of the number of failures and failure rate λ in each year and on average in the whole inspected period involves a division into types of water-pipe networks as well as into the materials and diameters of particular conduits.On average, in 2007–2010, the values of indicator λ (fail./(km a)) were equal to 0.18 for mains, 0.31 for distribution pipes, and 0.49 for house connections. Failure rates of main and distribution conduits made of steel, grey cast iron and plastics were equal to 0.68, 0.25 and 0.08, respectively. The failure rate was almost two times higher for water mains and distribution conduits in winter (0.41) than in the rest of the year (0.23). As the literature and own investigations indicate, the technical condition of water network in Poland is improving, also in Głogów. Nevertheless, failure rate is higher than in other European countries. In Poland, the old grey cast iron and steel conduits are being modernized, which entails the increase of water-pipe reliability, the decrease of water losses, and the improvement of water quality.     

Failure analysis of cupronickel evaporator tubes of a chilling plant

Pin-hole leakage was observed in a number of 90/10 cupronickel evaporator tubes of a chilling plant which was in service for about 6 years. Chilled water is cooled from 12 °C to 7 °C which flows inside the evaporator tubes, while the OD side has LiBr environment. The failure investigation of the failed tubes revealed greenish/blackish uniform deposits together with some spots where localized thick deposits on the ID surfaces were present. Underdeposit corrosion beneath these thick deposits was the primary reason for failure of the tubes. Intergranular corrosion was also observed underneath the thick deposits. The ID surface of the failed tubes confirmed the presence of wide variety of deposits, e.g. carbonates, silicates, phosphates, and sulphur-bearing compounds. The stagnant conditions under the thick deposits alter the chemistry inside the crevices thus formed. The altered chemistry conditions caused rapid corrosion (and intergranular attack) on the cupronickel tubes. Remedial measures that may be undertaken to prevent future occurrence of the problem are addressed.     

Preparation,characterization and dissolution behavior of artemisinin microparticles

In the present study, a modified 4-fluid nozzle spray drier was used to prepare microparticles of a poorly water soluble drug, artemisinin with the aim of improving its solubility. We also investigated the effect of process variables on the physical properties and dissolution rate of spray dried artemisinin. A full factorial experimentally designed study was performed to investigate the following spray drying variables: inlet temperature and feed concentration. The artemisinin powder and spray dried artemisinin microparticles were characterized by scanning electron microscopy (SEM), differential scanning calorimetric (DSC), X-ray diffraction (XRD) and dissolution. SEM study suggested that the inlet temperature and feed concentration impacted on the particle size of the spray dried particles. The crystallinity of spray dried particles was slightly decreased with increasing inlet temperature and concentration. The dissolution of spray dried particles was markedly improved as compared to commercial artemisinin. A dissolution surface-response model was used to elucidate the significant and direct relationships between drug feed concentration and inlet temperature on one hand and dissolution on the other hand. The best dissolution was found to be 117.00 ± 5.15 μg/mL at the drug feed concentration of 10 g/L and inlet temperature of 140 °C.     

Failure assessment of crude oil preheating tubes in mono ethylene glycol–water mixture solution

Aqueous solutions of glycol are commonly used in many applications as heat transfer media. In this study, failure analysis and the leakage of oil tubes in a crude oil pre-heater of a desalting plant were assessed. Crude oil pre-heater (furnace) is a type of heat exchanger in which heat is transferred to oil tubes via ethylene glycol solution in order to increase its temperature for further processing. With the increase of temperature, the viscosity of the oil plus water mixture inside the tubes is reduced and desalting is facilitated. Reports show that, these tubes facing external corrosion in the form of smooth cavities finally lead to leakage. These tubes are made from ASTM A106 Gr B steel. The failure assessment of tubes was carried out by performing various chemical and metallurgical tests. Corrosion coupons were also immersed in ethylene glycol fluid at different places inside the furnace. The investigation revealed that degradation of ethylene glycol forming organic acids (acetic acid, carbonic acid, and formic acid), as the consequent reduction of the pH, take place progressively, being responsible for carbon steel acidic corrosion and eventually to the failure of pre-heating tubes. An action was taken to examine different pH stabilizers for mono ethylene glycol solution. The results obtained by polarization curves showed that, by using stabilizer EN231 at pH = 10.5, corrosion rate reduces to a minimum.     

Cryogenic design and test results of 30-m flexible hybrid energy transfer line with liquid hydrogen and superconducting MgB2 cable

In this paper we present the development of a new hybrid energy transfer line with 30 m length. The line is essentially a flexible 30 m hydrogen cryostat that has three sections with different types of thermal insulation in each section: simple vacuum superinsulation, vacuum superinsulation with liquid nitrogen precooling and active evaporating cryostatting (AEC) system. We performed thermo-hydraulic tests of the cryostat to compare three thermo-insulating methods. The tests were made at temperatures from 20 to 26 K, hydrogen flow from 70 to 450 g/s and pressure from 0.25 to 0.5 MPa. It was found that AEC thermal insulation was the most effective in reducing heat transfer from room temperature to liquid hydrogen in ∼10 m section of the cryostat, indicating that it can be used for long superconducting power cables. High voltage current leads were developed as well. The current leads and superconducting MgB₂ cable passed high voltage DC test up to 50 kV DC. Critical current of the cable at ∼21 K was 3500 A. It means that the 30 m hybrid energy system developed is able to deliver ∼50–60 MW of chemical power and ∼50–75 MW of electrical power, i.e. up to ∼135 MW in total.     

Microstructural and mechanical property changes in HK40 reformer tubes after long term use

The microstructural change in the steam reformer tubes which had been used for approximately 60,000–90,000 h in a hydrogen manufacturing plant was investigated and their effect on the remaining creep-rupture life was studied by performing lifetime prediction using Larson–Miller Curves. In addition solutionization treatment at 1100–1200 °C was attempted on the used tubes in order to study the possibilities of extending the remaining lifetime and of improving the mechanical properties of the used tubes. The results showed that the remaining lifetime of the HK40 reformer tubes was largely dependent upon the precipitation of σ phase under the current operating conditions of 32–34 kgf/cm² pressure at 800–1000 °C, showing extensive degradation of the mechanical properties. Observed was no major improvement in the creep-rupture properties of the used tubes treated by solutionizing treatment at 1100–1200 °C, but the tensile properties, especially elongation and impact resistance at room temperature, however were enhanced extensively. Also the σ phase was decomposed by the treatment, indicating that the materials reliability against the embrittlement at room temperature could be improved in a great deal.     

Assessment on the use of common correlations to predict the mass-flow rate of carbon dioxide through capillary tubes in transcritical cycles

Capillary tubes are extensively used in small refrigeration and air-conditioning systems with synthetic refrigerants and hydrocarbons. For CO₂ transcritical applications, it has been shown that the capillary tube demonstrates an intrinsic capability of adjusting the upper pressure close to the optimal value in response to changes of gas-cooler heat sink temperature. The CO₂ flow rate through four capillary tubes of various lengths, diameters and materials was measured in a test rig. Each capillary tube was tested with inlet pressure varying from 7.5 MPa to 11 MPa and inlet temperature from 20 °C to 40 °C. Outlet pressure varied from 1.5 MPa to 3 MPa. The experimental results were validated against different numerical and approximate analytical solutions of the capillary tube equations. These models give good predictions only if the friction factor of the capillary tube is calculated accounting for its dependence on the tube roughness.     

Effect of geometry on crashworthiness parameters of natural kenaf fibre reinforced composite hexagonal tubes

The effect of geometry on energy absorption capability and load-carrying capacity of natural kenaf fibre reinforced composite hexagonal tubes had been investigated experimentally. A series of experiments were carried out for composite hexagonal tubes with different angles from a range of 40–60° in 5° steps. This range is suitable for obtaining a regular hexagonal shape. Kenaf fibre mat form was used in this work due to several advantages such as low cost, no health risk, light weight and availability. The kenaf density was usage 0.17 g/cm³ with thickness of 4 mm. Results demonstrated that structures failed in few distinct failure modes. Precisely in progressive failure mode and fragmentation failure associated with longitudinal cracks. The composite tube with β = 60° exhibited local buckling failure mode and displayed the highest specific energy absorption capability equal to 9.2 J/g. On the other hand, new crashworthiness parameter has been introduced as catastrophic failure mode indicator (CFMI). Furthermore, typical load–deformation histories were presented and discussed.     

Estimation of useful life in turbines blades with cracks in corrosive environment

Geothermal turbines of 110 MW were installed in the Federal Electricity Commission in Cerro Prieto Mexico, which operating time exceeds 150,000 h. Therefore, the critical components which determine the useful life of the turbine should be evaluated to determine the rehabilitation or replacement of them. The critical components are the blades of the last stage in the steam turbine. It has been observed that different blades of the turbine of 110 MW with cracks presented corrosion products, which resulted in a failure for corrosion fatigue mechanisms. In this paper, it was studied the effect of crack propagation produced in a geothermal turbine blade of the last stage, L-0, which is made of stainless steel AISI 410 exposed to corrosion under a sea water solution. The corrosion phenomena including localized corrosion suffered by the cracking sample were studied through the electrochemical noise technique in current and potential and polarization curves. The tests were conducted on pieces of blades subjected to fatigue. The results indicated that the exposure to the corrosion solution modified the width and the length of the cracks. Using a scanning electron microscopy (SEM), the surface of the crack was observed, showing that the corrosion mechanism produced a significant increment of the velocity of crack propagation and therefore, a decrement of the useful life of the material. This research will allow us to understand the corrosion process in addition to estimate the useful life of the blades when they are subjected to load cycles.     

An detailed integrity assessment of a 25 MW hydro-electric power station penstock

The present paper describes a detailed integrity assessment of a riveted penstock in a hydro-electric station which supplies around 25 MW to the grid. It was found that the remnant life for (a) a collection of imposed severe operating conditions, (b) maximum corrosion damage conditions and (c) a stringent probability of failure value, P_f, of 10^?4 was estimated at 75 years. It was also shown that the possibility of a fast fracture event in this particular penstock was remote.Finally, a further future programme of NDT work, aimed at validating the present integrity assessment, was proposed to be carried out within the next 5–6 years. This NDT work aimed to inspect around 15% of all the rivets located in this penstock.     

Optimization of gas tungsten arc welding process by response surface methodology

Gas tungsten arc welding is widely used for connecting of boiler parts made of A516-Gr70 carbon steel. In this study important process parameters namely current, welding speed and shielding gas flow rate were optimized using response surface methodology (RSM). The simultaneous effects of these parameters on tensile strength and hardness were also evaluated. Applying RSM, simultaneous effects of welding parameters on tensile strength and hardness were obtained through two separate equations. Moreover, optimized values of welding process parameters to achieve desired mechanical properties were evaluated. Desired tensile strength and hardness were achieved at optimum current of 130 A, welding speed of 9.4 cm/min and gas flow rate of 15.1 l/min.     

Optimization and characterization of direct coating for ibuprofen particles using a composite fluidized bed

Ibuprofen particles (mean particle size, 27 μm and melting point, 76 °C) as core materials were directly coated with a water-soluble polymer. The primary particles were preserved using a composite fluidized bed with a dispersing mechanism at the bottom of the fluidized bed apparatus. Coated primary particles were obtained under the following 3 conditions: (1) Setting the spray air flow rate at 10 L/min from the initial to 2% coating, (2) adding the low-viscosity water-soluble polymer macrogol 6000 to the hypromellose coating solution, and (3) changing the spray air flow rate to 15 L/min from 2% coating. The particles obtained were confirmed to be coated primary particles by scanning electron microscopy of their cross sections prepared by the cryo-focused ion beam method. The dissolution test showed a marked improvement in the solubility of ibuprofen from the coated primary particles compared with that of a physical mixture. In conclusion, the optimization of the direct coating process made it possible to undertake primary particle coating of a raw material that has a low melting point and a particle size of not more than 50 μm. Primary particle coating contributes to improvements in the physicochemical properties of drugs.