Failure Analysis of Bank-Wall Side Boiler Tube in a Petrochemical Plant
Abstract
:1. Introduction
2. Materials and Methods
3. Results
3.1. Site Inspection of Boiler Tube
3.2. Boiler Tube Materials Verification
3.3. Visual Examination
3.4. Fractography Analysis
3.5. Microstructure Analysis
3.5.1. Microstructure Analysis of Corroded Surface
3.5.2. Microstructure Analysis of Leak Interface
3.6. Analysis of Deposit
4. Discussion
4.1. Deposit Formation Mechanism
4.2. Crack Propagation Mechanism
5. Conclusions
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Parameters | Values | Unit | |
---|---|---|---|
Operating condition | Maximum allowable working temperature | 371 | °C |
Maximum allowable working pressure | 5.5 | MPa | |
Feedwater temperature at boiler inlet | 147 | °C | |
Water velocity | 1.0 | m/s | |
The tube specification | Water-tube material | ASTM A178 Gr. A | |
Outside diameter | 76.2 | mm | |
Thickness | 4.0 | mm |
Element | ||||||
---|---|---|---|---|---|---|
C | Si | S | P | Mn | Fe | |
Sample | 0.067 | 0.121 | 0.006 | 0.026 | 0.495 | Balance |
ASTM A178 Gr A [16] | 0.06–0.18 | ….. | ≤0.035 | ≤0.035 | 0.27–0.63 | Balance |
Sample | ASTM A178 Grade A [16] | |
---|---|---|
Tensile Strength, MPa | 380 | ≥325 |
Yield Strength, MPa | 273 | ≥180 |
Elongation, % | 42 | ≥35 |
Location | Elements | |||||||||
---|---|---|---|---|---|---|---|---|---|---|
C | O | Mg | Al | Si | P | Ca | Mn | Fe | Cu | |
Bottom | 31.45 | 23.52 | 0.25 | 0.16 | 0.1 | 0.14 | 0.27 | 0.69 | 41.26 | 2.16 |
Top | 5.06 | 24.97 | 68.41 | 1.56 | ||||||
Short Crack | 29.9 | 0.55 | 69.54 | |||||||
Long Crack | 33.44 | 1.09 | 65.47 | |||||||
Grain boundary | 72.76 | 3.54 | 23.70 |
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Ardy, H.; Nurimam, A.; Hamdani, M.; Firmansyah, D.; Aditya, D.M.; Setiawan, A.R.; Wibowo, A. Failure Analysis of Bank-Wall Side Boiler Tube in a Petrochemical Plant. Metals 2022, 12, 2064. https://doi.org/10.3390/met12122064
Ardy H, Nurimam A, Hamdani M, Firmansyah D, Aditya DM, Setiawan AR, Wibowo A. Failure Analysis of Bank-Wall Side Boiler Tube in a Petrochemical Plant. Metals. 2022; 12(12):2064. https://doi.org/10.3390/met12122064
Chicago/Turabian StyleArdy, Husaini, Asep Nurimam, Mohammad Hamdani, Deny Firmansyah, Dominico Michael Aditya, Asep Ridwan Setiawan, and Arie Wibowo. 2022. "Failure Analysis of Bank-Wall Side Boiler Tube in a Petrochemical Plant" Metals 12, no. 12: 2064. https://doi.org/10.3390/met12122064
APA StyleArdy, H., Nurimam, A., Hamdani, M., Firmansyah, D., Aditya, D. M., Setiawan, A. R., & Wibowo, A. (2022). Failure Analysis of Bank-Wall Side Boiler Tube in a Petrochemical Plant. Metals, 12(12), 2064. https://doi.org/10.3390/met12122064