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Research Papers: Materials and Fabrication

Failure Investigation on Reheater Pendent Tubes Due to External Scale Exfoliation and Internal Scale Formation

[+] Author and Article Information
J. Ahmad

 Kapar Energy Ventures Sdn Bhd, Jalan Tok Muda, Kapar 42200, Malaysia

J. Purbolaksono1

Department of Engineering Design and Manufacture, Faculty of Engineering,  University of Malaya, Kuala Lumpur 50603, Malaysia; Centre of Advanced Manufacturing and Materials Processing,  University of Malaya, Kuala Lumpur 50603, Malaysiajudha@um.edu.my

A. K. Kadir, M. M. Rahman

Department of Mechanical Engineering,  Universiti Tenaga Nasional, Km 7 Jalan Kajang-Puchong, Kajang 43009, Selangor, Malaysia

1

Corresponding author.

J. Pressure Vessel Technol 133(6), 061402 (Oct 31, 2011) (5 pages) doi:10.1115/1.4004561 History: Received November 23, 2009; Accepted April 21, 2011; Published October 31, 2011; Online October 31, 2011

This paper presents failure investigation on reheater pendent SA213-T22 tubes through visual inspections, steam-side scale and tube wall thickness measurements, metallurgical examinations, and creep analysis. The investigations were carried out following subsequent tube failures of the reheater pendent region of a boiler unit. Interaction event of significant internal scale formation causing the higher metal temperature and external scale exfoliation as a result of high-temperature corrosion is identified to cause the failure of the reheater pendent tube. Prevention actions are recommended to avoid similar failures in the future.

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Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

Layout of the reheater pendent tubes and locations of the as-received tube for examinations

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Figure 2

Failed reheater pendent tube showing wall thinning and scattered fire-side scales

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Figure 3

Thick steam-side oxide scale inside the failed tube (left) and magnification of the scale by microscope (right)

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Figure 4

Locations of the samples for microscopic examination (top left) and the corresponding microstructures showing complete stages of spheroidizations

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Figure 5

Microstructures of the newly neighbor tubes (tubes 10 and 11) showing complete stages of spheroidizations

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Figure 6

Diagram of Larsen–Miller parameter with stress variation to rupture of annealed material 2.25 Cr-1Mo steel [8] (1 ksi = 6.895 MPa)

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