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Stress-Corrosion Cracking of a Pandia Digester Inlet Cone Pandia消化器进口锥的应力腐蚀开裂
ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.pulp.c9001562
D. G. Chakrapani
{"title":"Stress-Corrosion Cracking of a Pandia Digester Inlet Cone","authors":"D. G. Chakrapani","doi":"10.31399/asm.fach.pulp.c9001562","DOIUrl":"https://doi.org/10.31399/asm.fach.pulp.c9001562","url":null,"abstract":"\u0000 The Pandia digester is a long cylindrical vessel which uses alkaline sulfite liquor to cook sawdust for pulping. The inlet cone was fabricated from AISI 304L stainless steel with E308 welds. Typical liquor concentration was approximately 80% NaOH, 20% Na2SO3 with chloride concentrations at 2 grams per liter. The operating pressures in the inlet cone were up to 1.2 MN/sq m (170 psig). The inlet cone had developed leaks within a year of service. Liquid penetrant inspection showed significant through-wall cracking near the fillet welds joining the bottom flange and side wall and the butt welds. Metallographic specimens were prepared from the welds to examine the microstructure and nature of the cracks. The cooking liquor at the inlet cone contained over ppm chlorides and was aggressive to 304 stainless steel. The cracking was identified as chloride-induced SCC. The inlet cone was replaced with an Inconel clad carbon steel inlet cone to combat the SCC.","PeriodicalId":290906,"journal":{"name":"ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment","volume":"25 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115569725","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Gray-Iron Paper-Drier Head Removed from Service 灰铁干纸机头已从使用中拆卸
ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.pulp.c0089567
{"title":"Gray-Iron Paper-Drier Head Removed from Service","authors":"","doi":"10.31399/asm.fach.pulp.c0089567","DOIUrl":"https://doi.org/10.31399/asm.fach.pulp.c0089567","url":null,"abstract":"\u0000 A paper drier head manufactured from gray cast iron was removed from service as a result of NDE detection of crack-like surface discontinuities. This component was subjected to internal steam pressure to provide heat energy for drying. Investigation (visual inspection, chemical analysis, mechanical testing, as-polished 54x magnification, etched with nital 33x/54x/215x/230x magnification) supported the conclusions that the NDE indications were the consequence of a cold-shut condition in the casting. The cold shut served as a stress-concentration site and was therefore a potential source of crack initiation. The combination of low material strength and a casting defect was a potential source of unexpected fracture during service, because the component was under pressure from steam. Recommendations included removing other dryer heads exhibiting similar discontinuities and/or material quality from service.","PeriodicalId":290906,"journal":{"name":"ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment","volume":"161 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127405113","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Failure of a Stainless Steel Black Liquor Feed Pipe 不锈钢黑液进料管失效
ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.pulp.c9001564
D. G. Chakrapani
{"title":"Failure of a Stainless Steel Black Liquor Feed Pipe","authors":"D. G. Chakrapani","doi":"10.31399/asm.fach.pulp.c9001564","DOIUrl":"https://doi.org/10.31399/asm.fach.pulp.c9001564","url":null,"abstract":"\u0000 An 8 in. diam stainless steel black liquor feed pipe to a carbon steel digester had failed within one year of service. The material was type 316 molybdenum-containing austenitic stainless steel. The service environment was alkaline black liquor at 175 deg C (350 deg F). The pipe had developed cracks on the inside surface coincident with an external support gusset. The cracks initiated at wide corrosion grooves. The early stages were corrosion-assisted fatigue cracks. The cracks initiated at the corrosion grooves and propagated as transgranular SCC with characteristic branching. Evaluation indicated the cracks were localized in an area of high cyclic stresses as a consequence of geometrical constraints on the piping and unsupported cantilever loads. No cracks were found elsewhere in the pipe. In the absence of highly localized service stresses (exceeding yield strength of the material), the corrosion grooving and subsequent SCC would not have occurred in this service environment. The pipe support system was modified with additional gussets to reduce the magnitude of cyclic stresses at the critical areas. The modification was apparently successful.","PeriodicalId":290906,"journal":{"name":"ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment","volume":"28 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126108736","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Stress-Corrosion Cracking of AISI 316 Stainless Steel AISI 316不锈钢的应力腐蚀开裂
ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.pulp.c9001650
P. J. Kenny
{"title":"Stress-Corrosion Cracking of AISI 316 Stainless Steel","authors":"P. J. Kenny","doi":"10.31399/asm.fach.pulp.c9001650","DOIUrl":"https://doi.org/10.31399/asm.fach.pulp.c9001650","url":null,"abstract":"\u0000 Several air heat exchangers failed in service in a pulp and paper operation. The tubes were made from AISI 316 stainless steel with an extruded aluminum fin mechanically bonded to the outside. Originally, the failures were blamed on poor tube to header welds. The units were sent back to the manufacturer for repair. Some of the units failed the hydrostatic test after they were repaired. Microscopic examination revealed the presence of branched transgranular cracks characteristic of stress-corrosion cracking. Only some of the tubes failed and these did so by stress-corrosion cracking. The most probable primary cause of the stress-corrosion cracking was local high residual stresses indicated by the areas of high hardness in the tubes. Low halogens in the water and airborne corrodents found normally in a pulp and paper mill were all that were required in the presence of high residual stresses in the tubes to initiate stress-corrosion cracking. Use of a low-carbon grade of stainless steel such as 316L was recommended to facilitate formation of the tube without producing excessive residual stresses. It was recommended also that failed units be segregated until it can be determined if the failure was related to operating pressure or some other unique cause.","PeriodicalId":290906,"journal":{"name":"ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment","volume":"164 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121030719","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Cracking in a Yankee Dryer Shell 洋基烘干机外壳开裂
ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.pulp.c0090276
{"title":"Cracking in a Yankee Dryer Shell","authors":"","doi":"10.31399/asm.fach.pulp.c0090276","DOIUrl":"https://doi.org/10.31399/asm.fach.pulp.c0090276","url":null,"abstract":"\u0000 Cracking was found in the heads on large Yankee dryers, large, cylindrical, rotating, pressurized, high-temperature, cast iron pressure vessels (ASME Boiler and Pressure Vessel Code Section VIII, Rules for Construction of Pressure Vessels), used to remove moisture from sheets of tissue paper during manufacturing. The typical components consist of a cast iron shell, two cast iron concave heads, and a large cast iron internal center stay attached to journals. The heads are attached to the shell and center stay with high-strength bolts. FEA and metallurgical investigation supported the conclusion that the cracking was caused by an unexpected type of load placed on the machine, namely corrosion product buildup at the head/shell interface causing the joint to displace open. It was also found that compressive bolting loads could slightly open the head/shell interface at the periphery. Recommendations included design changes in the head/shell joint, and detailed preventive maintenance inspection procedures were also suggested.","PeriodicalId":290906,"journal":{"name":"ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment","volume":"23 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115257364","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Combined EDX/AES Analysis of Failed Inconel 600 Steam Line Bellows 失效Inconel 600蒸汽管线波纹管的EDX/AES联合分析
ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.pulp.c0045911
{"title":"Combined EDX/AES Analysis of Failed Inconel 600 Steam Line Bellows","authors":"","doi":"10.31399/asm.fach.pulp.c0045911","DOIUrl":"https://doi.org/10.31399/asm.fach.pulp.c0045911","url":null,"abstract":"\u0000 Within the first few months of operation of an 8 km (5 mile) long 455 mm (18 in.) diam high-pressure steam line between a coal-fired electricity-generating plant and a paper mill, several of the Inconel 600 bellows failed. The steam line operated at 6030 kPa (875 psi) and 420 deg C (790 deg F). Metallographic sections, energy-dispersive x-ray spectra, chemical analyses, tensile tests, and Auger microscope analyses showed the failed bellows met the specifications for the material. However, investigation also showed entire oxide thickness was contaminated with relatively large amounts of sodium, calcium, potassium, aluminum, and sulfur, alkali, alkali earth, and other contaminants that completely permeated even the thin oxides on the fracture surfaces. Additional investigation of the purity of the steam itself as reported by the power plant showed that corrosion and cracks were ultimately caused by the steam. While under normal operation, the steam's purity posed no problem to the material, during boiler cleaning operations, the generating plant had allowed contamination to get into the steam line.","PeriodicalId":290906,"journal":{"name":"ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment","volume":"60 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133107714","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Corrosion of a Neck Fitting 颈套腐蚀
ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.pulp.c0089682
{"title":"Corrosion of a Neck Fitting","authors":"","doi":"10.31399/asm.fach.pulp.c0089682","DOIUrl":"https://doi.org/10.31399/asm.fach.pulp.c0089682","url":null,"abstract":"\u0000 A neck fitting (cast equivalent of AISI type 317) exhibited extreme corrosion with large, deeply pitted areas. It had been in service in a sulfite digester at 140 deg C (285 deg F) and 689 kPa (100 psi). The liquor was calcium bisulfite, and chloride content was reported to be low. Investigation (visual inspection, and micrographs of sections with electrolytic etching using 10 N KOH and then again after re-polishing and etching with Murakami's reagent) supported the conclusions that the casting never received a proper solution anneal. Recommendations included possible corrosion-screening tests in accordance with ASTM A 262 to ensure adequate corrosion resistance.","PeriodicalId":290906,"journal":{"name":"ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment","volume":"47 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124186328","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Cracking of a Weld That Joined the Head to the Shell of a Steam Preheater Because of Poor Root Penetration 由于根部渗透不良，蒸汽预热器头部与外壳的焊缝开裂
ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.pulp.c0047529
{"title":"Cracking of a Weld That Joined the Head to the Shell of a Steam Preheater Because of Poor Root Penetration","authors":"","doi":"10.31399/asm.fach.pulp.c0047529","DOIUrl":"https://doi.org/10.31399/asm.fach.pulp.c0047529","url":null,"abstract":"\u0000 A weld that attached the head to the shell of a preheater containing steam at 1.4 MPa (200 psi) and was used in the manufacture of paper cracked in service. The original joint contained a 6.4 by 50 mm backing ring that had been tack welded to the inside surface of the shell in a position to project beyond the fully beveled top edge of the shell. The projecting edge of the ring fitted against a deep undercut on the inner corner of the rim of the head. The internal 90-deg angle in this undercut was sharp, with almost no fillet. A bevel from the lower edge of the undercut to the outside of the head completed the groove for the circumferential attachment weld. Investigation (visual inspection and actual size views etched in hot 50% hydrochloric acid) supported the conclusion that cracking occurred in the HAZ in the head of the original design, originating in the sharp corner of the undercut, which was an inherent stress raiser. Recommendations included revised joint design to ensure full root penetration.","PeriodicalId":290906,"journal":{"name":"ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment","volume":"15 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126424592","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Stress-Corrosion Cracking in a Neck Liner 颈衬应力腐蚀开裂
ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.pulp.c0091622
{"title":"Stress-Corrosion Cracking in a Neck Liner","authors":"","doi":"10.31399/asm.fach.pulp.c0091622","DOIUrl":"https://doi.org/10.31399/asm.fach.pulp.c0091622","url":null,"abstract":"\u0000 A CF-8M (cast type 316) neck liner or manway was removed from the top of a digester vessel. Repeated attempts to repair the part in the field during its life cycle of many years had failed to keep the unit from leaking. The casting was a CF-8M modified with the molybdenum level at the top end of the range. The plate was standard 317L material. The filler metal was type 316, although marginal in molybdenum content. Investigation (visual inspection, chemical analysis, micrographs, and metallographic examination) supported the conclusion that the damage to the neck liner was due to Cl-SCC in an area of debris buildup. It appeared the original casting suffered SCC in a low-oxygen area high in chlorides from repeated wet/dry cycles where there was a buildup of debris. Recommendations included redesigning the neck liner to eliminate the abrupt change where there was debris buildup. If redesign was impossible, an alloy more resistant to Cl-SCC, such as a duplex stainless steel or a high-molybdenum (4 to 6%) austenitic stainless steel, should be used.","PeriodicalId":290906,"journal":{"name":"ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment","volume":"43 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123095706","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Corrosion-Fatigue Failure of Finned Stainless Steel Economizer Tubes Due to Differential Thermal Expansion 翅片不锈钢省煤器管因差热膨胀引起的腐蚀疲劳失效
ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.pulp.c0047615
{"title":"Corrosion-Fatigue Failure of Finned Stainless Steel Economizer Tubes Due to Differential Thermal Expansion","authors":"","doi":"10.31399/asm.fach.pulp.c0047615","DOIUrl":"https://doi.org/10.31399/asm.fach.pulp.c0047615","url":null,"abstract":"\u0000 After ten years of satisfactory operation, economizer-tube failures occurred in a large black liquor recovery boiler for a paper mill. The economizer contained 1320 finned tubes. Two fins ran longitudinally for most of the tube length and were attached by fillet welding on one side. The economizer tube leaks occurred at the end of the fin near the bottom of the economizer. A sample from a tube that had not failed showed heavy pitting attack on the inside of the tube, probably due to excess oxygen in the feedwater. Penetrant testing revealed numerous longitudinal cracks on the inside in the area of the fin tip. Cracking at the end of the fin-to-tube fillet weld was noted. The results indicate the failures were due to corrosion fatigue whose stresses were primarily thermally induced. A temporary solution included inspecting all tubes with shear-wave ultrasonics. Tubes with the most severe cracking were ground and repair welded. The square corners of the fins were trimmed back with a gradual taper so that expansion strains would be more gradually transferred to the tube surface. Water chemistry was closely evaluated and monitored, especially with regard to oxygen content.","PeriodicalId":290906,"journal":{"name":"ASM Failure Analysis Case Histories: Pulp and Paper Processing Equipment","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131022588","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
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