Failure analysis of superheat tube 2.25Cr-1Mo in biomass power plant
DOI:
https://doi.org/10.55713/jmmm.v29i4.500Keywords:
Biomass power plant, Erosion, Failure, Superheat tubeAbstract
The understanding of microstructures, their influences, and failure mechanisms are of necessary for determining lifetime and failure behaviors of metal parts being used in some severe environments. This research aims to study the failure causes and mechanisms of superheat tube used in a power plant. The tube examined in this experiment was 2.25Cr-1Mo (SA213 Grade T22) with a diameter of 33.5 mm and 4.33-mm wall thickness. This tube had been in-service for 7.5 years in a 9.9-MW biomass power plant. Visual inspection, chemical analysis with an optical emission spectrometer, optical microstructure, scanning electron microscope (SEM), energy dispersive X-ray (EDS), hardness measurement and tensile were employed to investigate the causes of superheat tube failure. The results showed that the damaged tube was subjected to the non-uniform loss of outer wall thickness due to erosion and presence of ferrous oxide at the outer tube surface. The hardness of outer and inner tube surfaces was found to be less than that of the mid-wall section. In addition, carbide particles were observable and uniformly dispersed throughout the microstructures. Regarding the SEM result, the tube failure was relevant to the bursting with ductile fracture.Downloads
References
H. Abbasfard, M. Ghanbari, A. Ghasemi, S. Ghader, H. H. Rafsanjani, and A. Moradi, “Failure analysis and modeling of super heater tubes of a waste heat boiler thermally coupled in ammonia oxidation reactor,” Engineering Failure Analysis, vol. 26, pp. 285-292, 2012. DOI: https://doi.org/10.1016/j.engfailanal.2012.06.012
S. Xu, C. Wang, and W. Wang, “Failure analysis of stress corrosion cracking in heat exchanger tubes during start-up operation,” Engineering Failure Analysis, vol. 51, pp. 1-8, 2015. DOI: https://doi.org/10.1016/j.engfailanal.2015.02.005
Damage mechanisms affecting fixed equipment in the refining industry. API 571;2003: 4.35 and 4.95.
J. Salonen, P. Auerkari, O. Lehtinen, and M. Pihkakoski, “Experience on in-service damage in power plant components,” Engineering Failure Analysis, vol. 14, pp. 970-977, 2007. DOI: https://doi.org/10.1016/j.engfailanal.2006.12.007
D. R. H. Jones, “Creep failures of overheated boiler, superheater and reformer tubes,” Engineering Failure Analysis, vol.11, pp. 873- 893, 2004. DOI: https://doi.org/10.1016/j.engfailanal.2004.03.001
A. I. Almazroueea, K. J. Al-Fadhalah, S. N. Alhajeria, and S.Alfehaidc, “High temperature corrosion of martensitic steel of reheater pipes in a desalination power plant,” Engineering Failure Analysis, vol. 85, pp. 89-96, 2018. DOI: https://doi.org/10.1016/j.engfailanal.2017.12.003
K. K. Parthiban, “Chorline induced high temperature superheater corrosion in biomass power plants,” Venus Energy Audit System.
McGraw-Hill, Nalco Guide to Boiler Failure Analysis, second ed., Nalco company, 2011.
F. J. Chen, C. Yao, and Z. G. Yang, “Failure analysis on abnormal wall thinning of heattransfer titanium tubes of condensers in nuclear power plant part II: Erosion and cavitation corrosion,” Engineering Failure Analysis, vol. 37, pp. 42-52, 2014. DOI: https://doi.org/10.1016/j.engfailanal.2013.11.002
G. Das, S. G. Chowdhury, A. K. Ray, S. Das, and D. K. Bhattacharaya, “Failure of a super heater tube,” Engineering Failure Analysis, vol. 9, pp. 563-570, 2002. DOI: https://doi.org/10.1016/S1350-6307(01)00040-1
S. Srikantha, B. Ravikumarb, S. K. Dasb, K. Gopalakrishnaa, K. Nandakumarc, and P. Vijayanc, “Analysis of failures in boiler tubes due to fireside corrosion in a waste heat recovery boiler,” Engineering Failure Analysis, vol. 10, pp. 59-66, 2003. DOI: https://doi.org/10.1016/S1350-6307(02)00030-4
A. K. Pramanick, G. Das, S. K. Das, and M. Ghosh, “Failure investigation of super heater tubes of coal fired power plant,” Case studies in Engineering Failure Analysis, vol. 9, pp. 17- 26, 2017. DOI: https://doi.org/10.1016/j.csefa.2017.06.001
F. Daneshvar-Fatah, A. Mostafaei, R. Hosseinzadeh-Taghani, and F. Nasirpouri, “Caustic corrosion in a boiler waterside tube: Root cause and mechanism,” Engineering Failure Analysis, vol. 28, pp. 69-77, 2013. DOI: https://doi.org/10.1016/j.engfailanal.2012.09.010
J. Ahmad and J. Purbolaksono, “An incident investigation on stub tube at high temperature reheater outlet header region of a power plant,” Engineering Failure Analysis, vol. 17, pp. 1254-1259, 2010. DOI: https://doi.org/10.1016/j.engfailanal.2010.03.007
J. Purbolaksono, J. Ahmad, L. C. Beng, A. Z. Rashid, A. Khinani, and A. A. Ali, “Failure analysis on a primary superheater tube of a power plant,” Engineering Failure Analysis, vol. 17, pp. 158-167, 2010. DOI: https://doi.org/10.1016/j.engfailanal.2009.04.017
J. Ahmad, J. Purbolaksono, and L. C. Beng, “Thermal fatigue and corrosion fatigue in heat recovery area wall side tubes,” Engineering Failure Analysis, vol. 17, pp. 334-343, 2010. DOI: https://doi.org/10.1016/j.engfailanal.2009.06.014
J. Ahmad and J. Purbolaksono, “Analysis on a failed 2.25Cr–1Mo reheater bent tube at upper bank vertical tubes region,” Engineering Failure Analysis, vol. 18, pp. 523-529, 2011. DOI: https://doi.org/10.1016/j.engfailanal.2010.09.041
V. Meuronen, “Ash particle erosion on steam boiler convective section,” Lappeenranta University of Technology. Research Papers 64, Lappeenranta, 1997.
L. Zhang, V. Sazonov, J. Kent, T. Dixon, and V. Novozhilov, “Analysis of boiler-tube erosion by the technique of acoustic emission: Part I. Mechanical erosion,” Wear, vol. 250, Issues 1-12, pp. 762-769, 2001. DOI: https://doi.org/10.1016/S0043-1648(01)00714-1
G. I. Parslow, D. J. Stephenson, J. E. Strutt JE, and S. Tetlow, “Paint layer erosion resistance behavior for use in a multilayer paint erosion indication technique,” Wear, vol. 212, pp. 103- 9, 1997. DOI: https://doi.org/10.1016/S0043-1648(97)00118-X
G. Heiermann, H. Langner, C. Brinkmann, and H. Mondry, “Konstruktionskriterien zur erosionsminderung in wirbelschichtfeuerungen. wirbelschichtfeuerung und Dampferzeugung,” Essen, 1988.
M. Pronobis, “Modernisation of power boilers” (Modernizacja kotłów energetycznych) WNT Warsaw, 2002.
ASTM E92-2017, Standard Test Method for Vickers Hardness of Metallic Materials, 2017.
ASTM A213 T22 Alloy steel seamless tube.
G. E. Dieter, Mechanical metallurgy, SI metric edition. McGraw Hill Book Company, pp. 331, 1988.
ASTM A370 Standard Test Methods and Definitions for Mechanical Testing of Steel Products, 2017.
S. K. Das, K. M. Godiwalla, S. P. Mehrotra, K. K. M. Sastry, and P. K. Dey, “Analytical model for erosion behavior of impacted fly-ash particles on coal-fired boiler components,” Sadhana, vol. 31, pp. 583-595, 2006. DOI: https://doi.org/10.1007/BF02715915
M. Pronobis and W. Wojnar, “The impact of biomass co-combustion on the erosion of boiler,” Energy Conversion and Management, vol. 74, pp. 462-470, 2013. DOI: https://doi.org/10.1016/j.enconman.2013.06.059
W. D. Callister and Jr. D. G. Rethwisch, Callister, Material science and engineering an introduction. USA: John Wiley & Sons, Inc., 1940.
B. M. Jenkins, L. L. Baxter, T. R. Miles Jr., and T. R. Miles, “Combustion properties of biomass,” Fuel Processing Technology, vol. 54, pp. 17-46, 1998. DOI: https://doi.org/10.1016/S0378-3820(97)00059-3
ASME Section II, Part D, 2007.
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2019 Journal of Metals, Materials and Minerals
This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.
Authors who publish in this journal agree to the following terms:
- Authors retain copyright and grant the journal right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgment of the work's authorship and initial publication in this journal.
- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgment of its initial publication in this journal.