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Failure analysis of primary waste heat boiler tube in ammonia plant

机译：氨植物中原发性废热锅炉管的故障分析

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摘要

The primary Waste Heat Boiler (WHB) in an ammonia plant experienced cap leaking and the outer tube rupture after ten months since the last repair and replacement (total retubing). The leaking cap and the outer tube materials are low carbon steel SA-204 Gr. B and SA-209 Gr. T1a. The inappropriate vertical part of the leaked cap, which is 2.4 mm shorter than the design, might trigger turbulence flow inside the cap and lead to flow-accelerated corrosion (FAC), as suggested by the appearance of wall thinning and horseshoe pattern in the inner surface. This condition is severed by improper cap material selection with low chromium content (0.01%), which is more susceptible to FAC. The local turbulence flow might erode the oxide layer at the cap bottom and accumulate the oxide deposit around the circumference weld joint and the nearest nail spacer in the tube, represented by a thick Fe3O4 deposit. The primary WHB outer tube failure might occur due to the lack of cooling from boiler water because of cap leakage combined with a thick Fe3O4 scale deposit on the nail spacer that causes significant local temperature increases on the failed tube, which resulted in yielding and thin-lip rupture.
机译：氨气厂的主要废热锅炉（WHB）经历了盖帽泄漏，自上次修复和更换以来十个月后的外管破裂（总加工）。泄漏盖和外管材料是低碳钢SA-204 GR。 B和SA-209 GR。 t1a。泄漏帽的不恰当的垂直部分比设计短2.4毫米，可能会触发盖子内的湍流流动，并导致流动加速的腐蚀（FAC），如内在的墙壁变薄和马蹄形图案所示表面。这种情况被用低铬含量（0.01％）的不正确的帽材料选择切断，这更容易受到FAC。局部湍流流动可能侵蚀帽底部的氧化物层，并在圆周焊接接头周围累积氧化物沉积物，并由管中的最近的指甲间隔物累积，由厚的Fe3O4沉积物表示。由于盖板泄漏的锅炉水缺乏冷却，初级WHB外管失效可能会导致在钉子间隔物上与厚厚的FE3O4刻度沉积物联合导致故障管的显着局部温度增加，导致屈服和薄 - 唇部破裂。

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