NBSIR 77-1284 {(C)

Report of Operating

Experiences in Coal

Conversion Plants

Failure Mode - Corrosion

William A. Willard

John H. Smith

Failure Prevention Information Center

Institute for Materials Research

National Bureau of Standards

Washington, D.C. 20234

Summary Report

December 1977

This work was sponsored by

Department of Energy

Washington, D.C. 20545

NBSIR 77-1284

REPORT OF OPERATING

EXPERIENCES IN COAL

CONVERSION PLANTS

Failure Mode - Corrosion

William A. Willard

John H. Smith

Failure Prevention Information Center

Institute for Materials Research

National Bureau of Standards

Washington, D.C. 20234

Summary Report

December 1977

This work was sponsored by

Department of Energy

Washington, D.C. 20545

U.S. DEPARTMENT OF COMMERCE, Juanita M. Kreps, Secretary

Dr. Sidney Harman, Under Secretary

Jordan J. Baruch, Assistant Secretary for Science and Technology

NATIONAL BUREAU OF STANDARDS, Ernest Ambler, Acting Director

This report was prepared as an account of work sponsored by the United

States Government. Neither the United States nor the Energy Research and

Development Administration, nor any of their employees, nor any of their

contractors, subcontractors, or their employees, makes any warranty, express

or implied, or assumes any legal liability or responsibility for the accuracy,

completeness or usefulness of any information, apparatus, product or process

disclosed, or represents that its use would not infringe privately owned

rights.

Certain trade names and company products are identified in order to adequately describe the effect of the coal conversion processes on materials

and components. In no case does such identification imply recommendation or endorsement by the National Bureau of Standards, nor does it imply that the

products are necessarily the best available for the purpose.

Foreword

The NBS Failure Prevention Information Center is a centralized computerbased system for gathering, critically evaluating, and disseminating information about operating experiences, material evaluation, and component failures

in coal conversion plants. Information sources include the coal conversion

process development units and pilot plants and ERDA sponsored laboratories

conducting diagnostic failure analyses. The objective of this program is to establish a reliable data base of component malfunctions and materials

performance which will be useful in extending the lifetimes and reliability

of plant components and which will help minimize the possibility of plant

shutdowns

.

An information gathering network has been developed for the reporting of

all significant operating incidents and component failures to the NBS Failure

Prevention Information Center. The reports are reviewed and evaluated for

completeness and accuracy. A detailed technical summary is prepared of each

incident and the information is indexed by process, date, material, failure

mode, component category, and information source. The technical summary and

indexed information are stored on a computer database management system

(Computer Corporation of America Model 204) for ease of retrieval and analysis.

This information is analyzed to identify significant problem areas, to determine

corrective actions for solving component problems, and to conduct failure mode

analyses for coal conversion plants.

It is especially intended that the information in the data base reach

plant designers and plant operators. However, access to the Information

Center is available to all interested parties. The information in the data

base is being disseminated in several ways. All direct inquiries to the

Information Center are answered. Reports of failures and summaries of

diagnostic failure analysis reports are published in the ERDA Newsletter,

Materials and Components in Fossil Energy Applications (1) , which is published

bimonthly . This report is an example of the type of summary reports of

operating experiences that will be prepared and issued by the Failure Prevention

Information Center with emphasis on failure mode, materials of construction and

plant components.

N \

(1 ) The Newsletter is published by Battelle, Columbus Labs, 505 King Avenue,

Columbus, Ohio 43201. Editor: R. Schorr.

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TABLE OF CONTENTS

Page

FOREWORD III

GLOSSERY OF COAL CONVERSION PLANTS IV

INFORMATION NUMBER INDEX VIII

1. AQUEOUS

1. Piping 3

2. CARBURIZATION

1. Auxiliary Process Equipment 9

2. Piping 10

3. Pressure Vessels 15

3. MATERIAL EVALUATION

1. Research Projects involving Corrosion in Metals 19

4. METAL DUSTING

1. Auxiliary Process Equipment 43

2. Piping 44

5. OXIDATION

1. Auxiliary Process Equipment 49

2. Piping 50

3. Thermocouples 53

6. PITTING

1. Bellows ' x 57

2. Piping 60

3. Pressure Vessels 68

4. Valves 73

VI
TABLE OF CONTENTS (continued)

Pa8 e

7. SULFIDATION

1. Piping 77

2. Pressure Vessels 89

3. Thermocouples 90

8. OTHER

1. Auxiliary Process Equipment 95

2. Piping 97

3. Pressure Vessels 107

4. Thermocouples 108

5. Valves 110

VII
INFORMATION

NUMBER

INDEX

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Abstract

This report consists of a group of summaries of operating experiences at

coal conversion pilot plants, materials evaluation reports, and diagnostic

failure analysis reports dealing with the problem of corrosion in the coal

conversion industry. Reports received up to June, 1977 are included. The

corrosion summaries are categorized into subgroups of specific types of

corrosion: aqueous, carburization, metal dusting, oxidation, pitting, sulfidation and material evaluation. Within each subgroup of corrosion the summaries are grouped by component type (piping, pumps, valves, etc.) in alphabetical

order. Each component category is sorted by coal conversion process (such as

C02» Hygas, Synthene, etc.) in alphabetical order and each process is sorted

by the date of the report from the earliest to the latest.

If further information is needed on any summary in this report, please

contact the Failure Prevention Information Center and refer to the Information

Number (I.N.) located at the top of each summary.

Acknowledgement

The authors wish to thank Mrs. Shirley Harrington, ADF Operations Division,

Department of Commerce and Mrs. Dianna Mills and Miss Judy Bolden, Metallurgy

Division, National Bureau of Standards for their help in preparing this report.

IX

AQUEOUS

I.N PROCESS SEARCH CRITERIA

10 HYGAS PIPING

FAILURE ANALYSIS REPORT , 10/31/74, BY A. MAC NAB, C. F. BRAUN AND CO.

FAILURE OF CARBON STEEL CONDENSER TUBING

SUMMARY

PITTING AND NONUNIFORM CORROSION OF CARBON STEEL PIPE IN HEAT EXCHANGER.

ATTACK IS FROM INSIDE OF TUBING INDICATING AN AGGRESSIVE ENVIRONMENT IN

PROCESS RAW GAS C0ND5NS ATE .P IP E IS 3/4"00 X 0.965" W.T. CARBON STEEL. IN

SERVICE FOR 6 MONTHS GASIFICATION OUT OF THR E E YEARS USE . ENVIRONMENT:

PROCESS CONDENSATE IS HIGHLY ACID. AMMONIA ADDED FOR PH CONTROL.

METAL LOSS: 53 MILS MAX, 33 MILS AVG.

I.N.

275

PROCESS

HYGAS

SEARCH CR ITER I

A

PIPING

FOSSIL ENERGY ADVISORY R=PORT NO. 12 , 3/26/75

.

HYGAS PILOT PLANT-CONDENSOR TUBING-RAW GAS QUENCH COOLER

SUMMARY

MATERIAL: CARBON STEEL

FLUID: CHI SANITARY DISTRICT CANAL WATER OUTSIDE. PROCESS CONDENSATE, NH

3

NEUTRALIZED INSIDE.

DISCUSSION: UNIT IN SERVICE 3-1/2 YPS., OPERATED 1-1/2 YPS UNDER GASIFICATIO

CONDITIONS. CORRODED. AVG. METAL LOSS 10-20 MILS. MOST CORROSION PROBABLY

OCCURREO DURING SHORT UNINHIBITED PERIODS OF OPERATION SIGNIFYING THAT THE

PROCESS FLUID IS HIGHLY "AGGRESSIVE" TO CARBON STEEL.

RECOMMENDATION: AVOID EVEN SHORT PERIODS OF ACIDIC CONDITION OR USF M OR.F RESISTANT MATERIAL.
I.N. PROCESS SEARCH CRITERIA

367 MERC PIPING

METALLOGRAPHIC <? "PORT, M . 0. , 8 Y R.3RAY,CRNL.

METALLOGRAPHIC EXAMINATION OF TWO SECTIONS OF TYPE 310 S.S. 1/4" 00 TUBING

SUMMARY

SAMPLE HISTORY: 2 SECTIONS OF 310 S.S. 1/4" 00 SCHEDULE 40 TUBING WERE

RECEIVED FOR A METALL GGRAPHT C EXAM INATION. ONE SAMPLE WASEXPOS^D TO

1400-1700 F TEMP. IN A FLUIDIZED BED COMBUSTOR t EXPOSURE TIME NOT STATED.

THE SECOND SAMPLE WAS REPRESENTATIVE OF PRIOR FLUID I ZED—BED TREATED

MATERIAL.

EXAMINATION: TUBES HAD BEEN FABRICATED WITH A SEAM WELD WHICH IS BAD F^OM A CORROSION AND CYCLIC STRESS VI SWPO INT .THE FLUIDIZED BED EXPOSURE ERASED

THE DENDRITIC MICROSTRUCTUPE IN THE WELD BY RECRYSTALL I ZAT I ON . A NEW PHASE

THAT APPEARS TO BE SIG^A HAS FORMED IN THE WELD AND 34SE MFT 4L . THE SEAM

WELD NOTCHES WERE SERIOUSLY AGGRAVATED BY THE FLUIDIZED BFD EXPOSURE.

COMMENTS: CONSIDERATION SHOULD BE GIVEN TO THE USE OF SEAMLESS TUBING TO

AVOID SEAM WELDS AND THE PROBABILITY OF SUBSEQUENT CORROSION FATIGUE

FAILURES. THE PRESENCE OF SIGMA PHASE HAS BEEN REPORTED TO RESULT IN A LOWER DUCTILITY AND SEVE°E LOSS OF NOTCH IMPACT STRENGTH IN 25CR-2CNI

STEELS.

SEE I.N. 371,372,373,374,375,376 FOR BACKGROUND INFORMATION.

* * * * *

r.N. PROCESS SEARCH CRITERIA

371 MERC PIPING

LETTER, 2/25/77, FROM S . DAPKUNAS , ERDA , TO R. COOPER. ORNL.

OPERATING CONDITIONS- FLUIDIZED BED EXCHANGER TUBES

SUMMARY

BACKGROUND INFORMATION PERTAINING TO PI°E SECTIONS METALLOGRA PH I CALLY

EXAMINED BY R . GR A Y , OR NL . S E F I.N. 367 FOR REPORT.

MATERIAL: 310 S.S. SCHEDULE 40

OPERATING CONDITIONS: COOLED WITH UNTREATED TAP WATER. EXIT WATER TFMP.

WAS' 200 F. EXPOSURE TIMF-160 HRS. 1C-100 CYCLES FROM AN UNFIRED TO A FIRED

CONDITION.

•^COMMENT: THE BED TEMPERATURE WAS RAISED TO 2000 F TO INITIATE COMBUSTION

OF THE C3AL BEFORE THE COOLING WATER WAS PASSED THROUGH THE TUBES. EACH

EXPOSURE TO 2000 F(10-100 CYCLES) LASTED ABOUT 10 MINS. IT IS NOT UNLIKELY

THAT THE CORROSION IN THE EXAMINED TUBES IS THE RESULT OF THIS 2000 F EXPOSURE.

4
I.N. PROCESS search cpiteria

80 MI SC. PIPING

PAPER BY R.OS M AN, EXXON, AT 1974 AICHE SYMPOSIUM ON AMMONIA PLANTS

HEAT EXCHANGER PROBLEMS IN A 1500 ST/SD AMMONIA PLANT

SUMMARY

1. C02 REMOVAL SYSTEM RE90ILER TUBES: AN APPARENT ATTEMPT TO STRESS RELIEVE

304 S.S. U-RENDS LEO TO CARBIDE PRECIPITATION AT THE GRAIN BOUNDARIES

AND HENCE TO TUBE FAILURES FROM INTERCRYSTALLINE CRACKING. THIS OCCURRED

IN ONLY ONE BUNDLE. OTHER BUNDLES INCLUDING REPLACEMENT O.K.

2 . WASTE HEAT BOILER TUBES: DEPOSITION OF BOILER FEED WATER IMPURITIES IN

THE U-BENDS OF THE VERTICAL WATER TUBE WASTE HEAT BOILER LED TO TIJ3E

FAILURES FROM OVERHEATING AND CORROSION. C-1/2M0 STEEL TUBES. 1500 PS IG

BOILER FEEDWATEo (600*) FLOWS TH POUGH TUBES. HOT ( 1655F) SECONDARY

REFORMER EFFLUENT FLOWS ON THE SHELLSIDE. CURE-CLEAN UP WATEP SUPPLY.

INSULATE OUTSIDE SURFACE OF EACH U-BENO.

3. SYNGAS COMPRESS n R INTERCOOLER BUNDLES: COOLING WATER FLOWING OM TH=

SHELLSIDE OF CARBON STEFL COOLER TUBES AND HAVING RELATIVELY POOR WATER

TREATMENT CAUSED RAPID TUBE C nRROSION FAILURES, FORCING FREQUENT BUNDLE

REPLACEMENT. CU°E-CLEAN UP WATER SUPPLY. REDESIGN BUNDLES. COAT

TUBES WITH PHENOLIC EPOXY.

4. A BIMETALLIC SHELL DESIGN IN A FIXED TUBESHEET EXCHANGER INTENDED TO

MINIMIZE "AXIAL" THERMAL EXPANSION DIFFERENCES LED TO CRACKING AT THE

SHELL TO TU8ESHELL JUNCTION DUS TO the "RADIAL" THERMAL EXPANSION

DIFFERENCE. TUBES ARE C-l/2 MO, THE SHELL IS PART CARBON STEFL AMO PART

304 S.S.. CRACKS WERE GROUND OUT AND WELDED WITH INCONEL 18? FILLER

WIRE. REPLACEMENT WILL BE REDESIGNED AND ALL PARTS MADE FROM C-l/2 MO

STEEL.

5 . LOW TEMPERATURE SHIFT FEED COOLER: AN INLET DISTRIBUTOR CHANGE IN A CROSSFLOW EXCHANGER LED TO RAPID TUBE FAILURES FROM FLOW INDUCED VIBRATION

CURE-REDESIGN USING 9 TUBE SUPPORT BAFFLES VS THE ORIGINAL 4.

* * * * *

5

CARBURIZATION

I.N PROCESS SEARCH CP ITER I A

191 WESTINGHOUSE AUXILIARY PROCESS EQUIPMENT

SCIENTIFIC PAPER, 11/25/75, 5Y L.ALBERTIN AND J . CUNN INGHAM, WE ST INGHOUSF AMO

S. TENDULKAR ANO P-CHERISH, ENERGY SYSTEMS.

MATERIAL PROBLEMS IN A SYNTHESIS GAS GENERATOR FOR A MULTI-STAGE COAL

GASIFICATION SYSTEM

* SUMMARY

GOOD PROCESS DESCRIPTION OF THE WESTINGHOUSE COAL GASIFICATION SYSTEM.

FAILURES:

1. NOZZLE PLATE AND NOZZLE EXPERIENCED A SEVERE FORM OF HIGH TEMP. CORROSION

BY CARBURIZATION AND OXIDATION DUE TO EXCESSIVE TEMP. ANO ALTERNATING

REDUCING-OXIDIZING ENVIRONMENTS.

2. MELTING OF SHROUD MATERIAL WAS RESULT OF LOCAL OVERHEATING CAUSED BY

CRACKING OF THE NOZZLE PLATE-PILOT INLET HOUSING WELD , PR03A8L E MALFUNCTION

OF SEVFRAL NOZZLES, AMD ACCUMULATION OF HEAVY CARBON DEPOSITS AHBAO OF

THE BURNERS.

3» CRACKING IN THE SYNTHESIS GAS GENERATOR WAS RESULT OF EMBRITTLEMENT DUE

TO EXCESSIVE CAR3IDE PRECIPITATION AND THERMAL STRESSES EXPERIENCED

DURING CYCLING.

RECOMMENDATIONS:

1. REDESIGN 8URNER SECTION OF THE GENERATOR SO THAT HIGH TEMP. OF OPERATION

CAN BE AVOIDED.

2. USE INCONEL 601 WHICH HAS GOOD RESISTANCE TO CARBURIZATION AND OXIDATION.

3. EXPLORE THE USE OF REFRACTORY MATERIALS AND WATER COOLING OF BURNER

COMPONENTS TO PREVENT FUTURE GAS GENERATOR FAILURES.

* * * * *

9
I

I.N. PROCESS SEARCH CRITERIA

17 C02 PIPING

LETTER REPORT, 2/16/70, FROM J.LETERLE .CONOCO.

HIGH TEMPERATURE CORROSION OF PARTS FROM C02 PILOT PLANT

SUMMARY

REACTOR VESSEL-310 S.S. THERMOWELL S- HA STFLLOY X AND INCONEL.

SEVERLY CORRODED. TEMP. RANGE 140C-2000F. ATMOSPHERE. N2,

S02 » ANO H2S.

ALL METALS

C02 » CO* H20,

CONCLUSIONS

1. IT APPEARS THAT SULFUR HAS REACTED WITH ALL THREE METALS TO FORM A LOW

MELTING POINT EUTECTIC OF SULFUR, CHROMIUM, NICKEL, AND IRON.

2. THE 310 S.S. HAS BEEN HIGHLY CARBURIZED.

3. IF THE ENVIRONMENT THAT CAUSED THIS CORROSION IS TYPICAL THEN CAREFUL

CONSIDERATION MUST BE GIVEN TO ALLOY SELECTIONS.

* * *

I.N. PROCESS SEARCH CRITERIA

124 CO 2 PIPING

INTEROFFICE REPORT FROM H. CROWDER TO F .J . R ADD , CONOCO , 8 /25 /70.

METALLURGICAL STUDY OF RF ACT OR AND GASIFIER VESSELS FROM THE LIGNITE

GASIFICATION PRE-PILOT PLANT, CONSOL

SUMMARY . THE BENCH SCALE LIGNITE GASIFICATION PLANT, OPERATED AT LIBRARY, PA HAS

EXPERIENCED HIGH TEMPERATURE CORROSION AMO EMBRITTLEMENT PROBLEMS.

THIS REPORT SUMMARIZES WORK ON THE FOLLOWING PARTS:

1. GASIFIER VESSEL

2. REGENFRATOR VESSEL

3. REGENERATOR PRE-HEAT COIL

4. REGENERATOR THERMOWELL

CONCLUSIONS: ALL FOUR OF THE PIECES HAVE EXPERIENCED ONE OR MORE OF THE

FOLLOWINGS PROBLEMS. HIGH TEMPERATURE SULFUR CORROSION, EMBR ITTLFMENT

FROM CARBURIZING, E M 8 0 ITTLEMENT FROM NITRIDING.

THESE PROBLEMS COVER THE TEMPERATURE RANGE OF 950-1900 F.

10
PROCESS SEARCH CRITERIA

I

r.N.

93 C02 PIPING

FAILURE REPORT, 2/7/74, BY R. PERKINS AMO W. COONS .LOCKHEED LAB TO CONSOL

MET. ANALYSIS OF CORRODED INCOLOY 800 TUBE FROM A RECYCLE GAS HEATER.

SUMMARY

MET ANALYSIS OF CORRODED INCOLOY BOO TUBE FROM A RECYCLE GAS HEATER.

THE TUBE HAD A VERY COMPLEX HISTORY. NOT REPRESENTATIVE OF NORMAL OPERATING

CONDITIONS.

CONCLUSIONS

1. THE PIPE HAS BEEN DEGRADED BY A COMBINATION OF CARBURIZATION,

SULFIDATION, AND OXIDATION.

2.. CARBURIZATION IN DEPTH PRECEDED THE OTHER REACTIONS AND ESTABLISHED A CR-RICH PHASE AT the GRAIN BOUNDARIES.

3. INCOLOY 800 OOES NOT APPEAR TO HAVE ADEQUATE RESIST ANCF TO OXIDATION

IN THE ENVIRONMENT EOR THIS APPLICATION. A HIGHER CR ALLOY WHICH CAN FOR M

A MORE PR n TECT IVE OXIDE FILM TO RETARD THE DIFFUSION OF CARBON AND SULFUR

TO THE UNDERLYING METAL may GIVE BETTER PERFORMANCE.

ADDITIONS OF AL, TI, ANO SI ALSO WOULD BE HELPFUL.

* * * * *

i.n. PROCESS SEARCH CRITERIA

112 • C02 PIPING

FINAL REPORT FROM D. QUALLS TO J .L STE RLE ,C ONOCO , 1 1/7/74.

EVALUATION OF HEATER TUBES FROM RAPID CITY CONSOL

SUMMARY

EVALUATION OF HEATER TUBES FROM RAPID CITY CONSOL

FIVE HEATER TU8E SAMPLES WERE SUBMITTED. THEY HAD BEEN INSPECTED RY MAGNETIC

INSPECTION WHICH INDICATED SOME DAMAGE.

A MICROSTPUCTUR AL EVALUATION WAS REQUESTED TO CORRELATE ACTUAL DAMAGE WITH

MAGNETIC INSPECTION RESULTS.

ALONIZED 304 S.S. TUBE WAS GOOD. THE FOUR SAMPLES OF INCOLOY 300 TUBING

CONTAINED VARYING DEGREES OF CORROSION AND STRUCTURAL DAMAGE. THE OARAGE WAS

< 12.2? OF THE MINIMUM MEASURED WALL THICKNESS.

11
1

'

K

I »N» PROCESS SEARCH CRITERIA

148 . CO 2 PIPING

ERDA MAT. AND COMP. FAIL. REPORT. C02.C. SC HUL 2. 10/3/75.

REBUILT 3-205 ALPHA FURNACE COIL

SUMMARY

FAILURE: A 9-FT 9-IN SECTION OF OLD MATERIAL IN THE "A" PASS WAS REPLACED

DUE TO THINNING AND A S M A L L PIN HOLE.

SERVICE LIFE: 581 HRS SINCE REBUILD.

PRIOR REPAIRS: COIL WAS REBUILT REPLACING ALL THIN SECTIONS IN DEC. 1974

WITH ALONIZED RA-330.

ENVIRONMENT: TEMP. 1000-1500F.. INERT GAS (33-87? N2, 6-12? C02, 0.2-9. 6? 02)

AND RECYCLE GAS (80? N2, 17? C02, 3? CO, CARBONYL SULFIDE 50 PPM).

MATERIALS OF CONSTRUCTION: INCOLOY BOO WITH SECTIONS OF ALONIZED RA-330.

CAUSE OF FAILURE: PROBABLY DUE TO CARBURIZATION AND SULFIDATION.

ACTION: DIAGNOSTIC ANALYSIS TO BE PERFORMED BY CONOCO.

* * * <r

t.N. PROCESS SEARCH CRITERIA

54 C02 PIPING

FINAL REPORT ,10/9/75, FROM L . WOLFE , °QNC A CITY, TO J . LETER LE , CONOCO

EXAMINATION OF TYPE 321 S.S. FURNACE TUBE FROM 8205 FURNACE

SUMMARY

FAILURE: FURNACE TUBES HAVE EXPE°IENCED FREQUENT TROUBLE FROM THINNING.

THINNING ORIGINATES FROM INSIDE OF TUBES.

SERVICE LIFE: UNKNOWN

ENVIRONMENT: 90QP. 3-4? CO, 26? C02, 70? M2, 20-75 »PM‘ COS.

MATERIAL: 321 S.S. 1-5/8" 00 X 0.109" W.T.

, RESULTS

1. INIT ALLY GET CARBURIZATION, NITRIDING, AND SOME SULFIDATIONTHEN GET OXIDATION.

2. SULFUR ATTACK OCCURS, BUT NOT ENOUGH TO BE SIGNIFICANT AT THESE

TEMPERATUC E

3. MAJOR METAL LOSS AND THINNING IS DUE TO OXIDATION OF CHROMIUM.

4. THINNING IS FROM INSIDE. OXIDATION ON OUTSIDE IS ALONG GRAIN BOUNDARIES.

12
r.N PROCESS . SEARCH CRITERIA

149 CO 2 PIPING

ERDA MAT.ANO COMP. FA IL. REPORT, 10/17/75, FROM C. SCHUL Z , C02.

REBUILT B— 20 5 ALPHA FURNACE COIL

SUMMARY

FAILURE: THE TUBE WALLS IN SEVERAL AREAS HAO GREATLY THINNED REQUIRING

REPLACEMENT OF THE COIL.

SERVICE LIFE: 919 HRS SINCE REBUILDING

ENVIRONMENT: SEE ATTACHMENT FOR HRS AND TYPES OF ATMOSPHERE

PRIOR REPAIRS: COIL WAS REBUILT REPLACING

ALONIZED RA 330 AND A 9*-Q " SECTION WAS

MATERIALS: INCOLOY 800 AND RA 330

• CONCLUSIONS: THINNING WAS PROBABLY DUE TO

AND SULFIDATION. NEW COIL FABRICATED OUT

ACTION: REPLACED PART .ANALYSIS BY COMPANY

* *

ALL THIN SECTI0NS»12/74* WITH

REPLACEQ 9/75.

A COMBINATION OF CARBURIZATION

OF INCONEL 702.

LABS.

* *

r.N* PROCESS SEARCH CRITERIA

151 C02 PIPING

ERDA MAT.ANO COMP. FAIL. REPORT , 1 1/24/75. C02.C .SCHULZ.

B—205 GAMMA FURNACE COIL.N

SUMMARY

FAILURE: THREE HOLES IN THREE DIFFERENT TUBE PASSES NEAR THE OUTLET END.

SERVICE LIFE: 61.5 HRS

ENVIRONMENT: SEE ATTACHMENT

MATERIAL: INCONEL 702

CONCLUSIONS: FAILURE PROBABLY OUE TO VERY SEVERE CORROSION FROM SULFUR

AND/OR CARBONIZATION.

ACTION: PART REPLACED. ANALYS I S BY CONOCO LABS.

13
i.n. PROCESS SEARCH CRITERIA

344 HYGAS PIPING

FINAL FAILURE ANALYSIS REPORT, 12/76 , BY S.DANYLUK £ S .GREENB ER G , A NL

.

HYGAS ASH AGGLOMERATING GASIFIER INTERNAL CYCLONE DIPLEG FAILURE

SUMMARY

FAILURE: THE WALL MATERIAL OF THE AAG CYCLONE OIPLEG WAS SEVERELY

CORROOEO, WHICH RESULTED IN THE DETACHMENT OF THE FLAPPER VALVE A T THE BOTTOM QF THE DIPLEG. CARBURIZATION AND SULFIDATION OF THE DIPLEG

HAD OCCURRED WITH THE CORROSION BEING MORE SEVERE NEAR THE BOTTOM.

IN SOME AREAS L/3 OF THE PIPE WALL WAS CONVERTED TO METAL SULFIDES.

MOLTEN SLAG WAS PRESENT NEAR THE TOP OF THE DI °LEG, CLOSE TO THE CYCLONE,

WHICH INDICATES THAT THE DIPLEG WAS EXPOSED TO QFF-OES I GN { H IGH ) TEMP.

ENVIRONMENT: GASIFIER WAS OPERATED WITH BOTH STEAM AND OXYGEN AND THE DIPLEG

WAS EXPOSED TO THIS FOR ABOUT 2CD0 HRS,3CO HRS OF WHICH WERE IN A LOW

STEAM ATMOSPHERE. BED TEMPERATURE IS 1850-I975F AND THE GAS COMPOSITION

30? CQ2 » 1 5? CO, 15? H2,5? N2 AND THE 8ALANCE WATER.

MATERIAL OF CONSTRUCTION: INCOLOY 8 CC

CAUSE: THE FAILURE OF THE DIPLEG IS BELIEVED TO BE ASSOCIATED WITH HIGH

TEMPERATURE (OFF-PROCESS ) OPERATION WHICH LED TO SULFIDATION AND

CARBURIZATION. . RECOMMENDATIONS

1. PROCESS TEM °ERATURES MUST BE KEPT WITHIN THE DESIGN LIMITS FOR INCOLOY BOO.

2. USE OF A HIGHER CHROMIUM CONTENT STAINLESS STEEL SHOULD ALLEVIATE THE

SULFIDATION PROBLEM.

3. WE CONCUR WITH THE SUGGESTION BY HYGAS PERSONNEL TO ALONIZE THE FLAPPER

VALVE, WHICH .MAY PROVIDE IMPROVED PERFORMANCE OF THIS COMPONENT.

* * * * *

14
i.n. PROCESS SEARCH CRITERIA

182 CLEAN COKE PRESSURE VESSEL

INTERIM REPORT, 3/72-4/74, FROM USS ENGINEERS AND CONSULTANTS, INC. TO OCR.

CLEAN COKE PROJECT

SUMMARY

3-IN CARBONIZER: SECTIONED FOR OBSERVATION AFTER 60 HRS SERVICE AT TEMP.

OVER 1000F INCLUDING 24 HRS OVER 13C0F. EXAM. SHOWED SIGNIFICANT

CARBURIZATION (CA8I0ES QF CR £ IRON) AT THE SURFACE OF THE 316 S.S. SHELL

,

IN AREAS WHERE THE HOT SURFACE WAS IN CONTACT WITH H2S FREE

FLUIDIZING GAS. THOUGH IT APPEARED TO BE STRONG AT HIGH TEMP., THE

CARBURIZED STEEL WAS EXTREMELY BRITTLE WHEN COOL. OEPTH OF CARBURIZATION

(20-25 MILS) WAS GREATEST FROM THE BOTTOM GAS INLET PIPE TO ABOUT THE TOP

OF THE FLUID BED SECTION. A 30VE THIS POINT CARBURIZATION DECREASED

RAPIDLY TO ZERO NEAR THE TOP OF THE DEENTRAINMENT SECTION. CARBURIZATION

IS ATTRIBUTED TO THE ABSENCE OF H2S IN THOSE AREAS WHERE TT OCCURRED.

A CONTROLLED CONCENTRATION OF H2S WILL BE MAINTAINED IN THE RECYCLE

FLUIDIZING GAS TO MINIMIZE CARBURIZATION. SOME THIN WALL 316 S.S. PIPING

HAS BEEN REPLACED WITH HEAVIER WALL I.NCOLOY 800.

CORROSION TESTS UNDER CARBONIZATION CONDITIONS: 4 SERIES OF TESTS WERE RUN

USING 304 S.S., 316 S.S., INCONEL 600, INCOLGY 300, 310 S.S., AND ALONIZED

316 S.S.

SERIES 1. 1370 F, PRESS. 125 PSIA, H2S CONTENT 25-40PPM.

TEST LENGTH 13.5 HRS. 18 GRAMS OF BLACK OEPOSIT RECOVERED.

SERIES 2. 1250F , 100 PSIA, 50-100 PPM H2S. TEST LENGTH, 92 HRS. NO

CARBON.

SERIES 3- SAME AS 2 EXCEPT 575 GRAMS OF CHAR PUT INTO REACTOR AROUND

COUPONS. TEST LENGTH, 95 HRS. RECOVERED CHAR WEIGHED 512 GRAMS

WITH NO EVIDENCE OF CAR 80N DEPOSITION.

SERIES 4. 1253F, 100 PSIA, NO ADOED H2S AND NO CHAR 3ED. TEST LENGTH, 95

HRS. H2S CONCENTRATION WAS 10-20 PPM FROM REACTIONS IN VESSEL.

6 GRAMS OF CARBON DEPOSITS RECOVERED.

MOST OF CARBON IN DEPOSITS .IS IN ELEMENTAL FORM. WHEN THIS IS

DEPOSITED ON AN ALLOY SURFACE IT CAN LEAD TO "METAL DUSTING". 304 S.S.

SHOWED SOME EVIDENCE OF THIS. CARBURIZATION IS A FUNCTION OF BOTH H2S

CONCENTRATION AMD TEMPERATURE 50-100 PPM OF H2S SHOULD BE ADEQUATE TO

PROTECT INCOLOY 800 FROM CARBURIZATION.

15
I

I.N. PROCESS SEARCH CRITERIA

17 C02 PRESSURE VESSEL

LETTER REPORT, 2/16/70, FROM J.LETER LE , CONOCO - HIGH TEMPERATURE CORROSION OF PARTS FROM C02 PILOT PLANT

SUMMARY

REACTOR VESSEL-310 S.S. THERMOWELL S-HASTELLOY X ANO INCONEL. ALL METALS

SEVERLY CORRODED. TEMP. RANGE 140Q-2000F. ATMOSPHERE, N2 , CG2 , CO. H20,

S02, AND H2S.

CONCLUSIONS

1 - IT APPEARS THAT SULFUR HAS REACTED WITH ALL THREE METALS TO FORM A LOW

MELTING POINT EUTECTIC OF SULFUR, CHROMIUM, NICKEL, AND IRON.

2.

THE 3 1C S.S. HAS BEEN HIGHLY CARBURIZED.

- 3. IF THE ENVIRONMENT THAT CAUSED THIS CORROSION IS TYPICAL THEN CAREFUL

CONSIDERATION MUST BE GIVEN TO ALLOY SELECTIONS.

* * - * * *

I.N. PROCESS SEARCH CRITERIA

124 CO 2 PRESSURE VESSEL

INTEROFFICE REPORT FROM H. CROWDER TO F. J . R ADO , CONOCO , 3/25 /70.

METALLURGICAL STUDY OF REACTOR AND GASIFIER VESSELS FROM THE LIGNITE

GASIFICATION PRE-PILOT PLANT, CONSOL

SUMMARY •

THE BENCH SCALE LIGNITE GASIFICATION PLANT, OPERATED AT LIBRARY, »A HAS

EXPERIENCED HIGH TEMPERATURE CORROSION AND EMBRITTLEMENT PROBLEMS.

THIS REPORT SUMMARIZES WORK ON THE FOLLOWING PARTS:

1. GASIFIER VESSEL

2. REGENERATOR VESSEL

3. REGENEPATOR PRE-HEAT COIL

4. REGENERATOR THERMOWELL

CONCLUSIONS: ALL FOUR OF THE PIECES HAVE EXPERIENCED ONE OR MORE OF THE

FOLLOWINGS PROBLEMS. HIGH TEMPERATURE SULFUR CORROSION, EMBRITTLEMENT

FROM CARBURIZING, EMBRITTLEMENT FROM NITRIDING.

THESE PROBLEMS COVER THE TEMPERATURE RANGE OF 950-1900 F.

16
MATERIAL EVALUATION

r.N. PROCESS SEARCH CRITERIA

71 CARBONATE MATERIAL EVALUATION

TECHNICAL REPORT, 8/15/69* BY L. GR A NT HAM£P. SHAW, ATOMICS INTERNATIONAL*

CORROSION OF MATERIALS IN MOLTEN CARBONATE PROCESS MELTS. II.

SUMMARY

THE PURPOSE OF THIS PROGRAM WAS TO DETERMINE WHICH MATERIALS ARP COMPATIBLE

WITH MELTS TO BE FOUND IN THE MOLTEN CARBONATE PROCESS FOR REMOVAL OF

SULFUR OXIDES FROM FLUE GASES.

34-7 S.S. IS RECOMMENDED FOR THE SCRUBBER AND THE REGENERATG 0 STEPS OF THE

PROCESSG. GNG ALLOY HAS SEEN FOUND THAT IS SUITABLE FOR THE REDUCTION STE°.

SCC OF UNSTABLIZED S.S. has BEEN OBSERVED UNDER CONDITIONS MORE EXTREME

THAN WILL RE FOUND IN THE PLANT.THEREFORE, IT IS IMPERATIVE THAT THE SCC

• PROGRAM BE EXPANDED TO DETERMINE WHAT THE CRITICAL PARAMETERS ARE FOR THIS

MODE OF ATTACK.

* * * *

r.N. PROCESS SEARCH CRITERIA

70 CARBONATE MATERIAL EVALUATION

TECHNICAL REPORT, 12/1/63 , BY L. GRANTHAM AND P . SHAW, ATOM ICS INTERNATIONAL.

CORROSION OF METALS IN THE MOLTEN CARBONATE PROCESS. I.

SUMMARY

THE PURPOSE OF THIS PROGRAM WAS TO DETERMINE WHICH MATERIALS ARE COMPATIBLE

WITH MELTS TO BE FOUMD IN THE MOLTEN CARBONATE PRGCESS FOR REMOVAL CF SULFUR

OXIDES FROM WASTE GASES.

THE MOLTEN ALKALI CARBONATE EUTECTIC CONSISTS OF ESSENTIALLY EQUAL PAOTS

BY WEIGHT OF L I TH IUM , SOD I'JM, AND POTASSIUM CARBONATE ANO MAY BE USED TO CONTROL

S02 AIR POLLUTION BY SCRUBBING STACK GASES WITH THE MOLTEN SALT. THE RESULTANT

FUSEO SALT CONTAINS SULFITE WHICH D I SPROPOR TI ONATES TO SULFATE AND SULFIDE.

SUITA8LE CONTAINMENT CF THESE MOLTEN SALTS IN H20,CQ2,AND H2S

GASEOUS ENVIRONMENTS IS REQUIRED FOR COMMERCIAL DEVELOPMENT OF THIS TECHNIQUE

TO CONTROL AIR POL LUT 1 0*’ . THE RESULTS OF SCREEN IMG, MEDIUM-TERM AND LONG— T ER

M

STATIC, OYNAMIC AND THERMAL CYCLE TESTS ARE GIVEN. AT 500C 347 S.S. IS GOn U

.

AT 600C LOW I RON, NICK EL -OR COBALT-BASED ALLOYS WITH ABOUT 2D* CR PERFORM

SATISFACTORILY. AT HIGHER TEMP. HIGH CR ALLOYS, CE RAM ICS ,C ER MeTS DO A GOOD JOB.

MATERIALS FOR THE SMALL PILOT PLANT ARE RECOMMENDED AND THE FUTURE CORROSION

PROGRAM IS'GUTLINEO.SEE I.fl. 71 FOR ADDITIONAL DETAILS.

19
I.N. PROCESS SEARCH CRITERIA

73 CARBONATE MATERIAL EVALUATION

TEST REPORT BY L. GRANTHAM, ATOMICS I NTERNAT I DNAL, 5/ 29/ 74.

SUMMARY OF FIRST YEARS OPERATION OF CORROSION AND COMPONENT TEST LOOP

SUMMARY

GOOD DESCRIPTION OF COMPONENTS USED IN THE TEST LOOP AND THEIR REACTIONS

TO CORROSION, WEAR , ETC

GIVES NAMES AND EVALUATIONS.

DURING THE FIRST YEA° , THE MOLTEN CARBONATE PROCESS CORROSION AND COMPONENT

TEST LOOP OPERATED 6577 HRS OR APPROX. 73S OF THE TIME. LOOP OPERATION SHOWED

THAT THE CANTILEVERED CENTRIFUGAL PUMP,GRAEOIL PACKED VALVES, MOD I F I ED BELLOWS

SEALED VALVES, SPRAY NOZZLE, VIEWP°RT ROD HEATERS, RING GASKET J 0 IN TS » CO D P ER

GASKET JOINTS, MODIFIED RAMAPO FLOWMETER. S ATU9 ABLE CORE TEMPERATURE CONTROLLERS

AND VARIOUS INSULATIONS WERE COMPATIBLE WITH THE MCP APPLICATION.HCWEVE 0 THE PRESSURE SENSORS, BAND HEATERS, OR IF ICES , AND WAT-PAK TEMPERATURE CONTROLLERS

WERE NOT SATISFACTORY AND REQUIRE FURTHER DEVELOPMENT.

347 S.S. WAS MORE CORROSION RES I STSNT TO EUTECTIC ALKALI CARBONATE-SULFIDE

SULFATE MELTS AT APPROX. 500C(930F) THAN EITHER 304 S.S. OR 321 S.S. TH°EE

STRESS CRACKS AND SOME LOCALIZED PITTING WERE OBSERVED ON 347 S.S. COMPONENTS.

WITH CONTROL OF THIS CRACKING AND PITTING ,347 S.S. WOULD HAVE A CORROSION

RATE OF APPROX. 20 MILS/YEAR UNDER THESE CONDITIONS.

* * * * *

I.N. PROCESS SEARCH CP ITER I A

1.58 CARBONATE MATERIAL EVALUATION

LETTER REPORT FROM E.HOXIE TO R.SARRAF, ATOMICS INTERNATIONAL, 6/II/75.

CORROSION TEST SPOOL-6376

SUMMARY

• \

CORROSION TEST SPOOL-6376.

TWELVE ALLOYS WERE TESTED FOR CORROSION RESISTANCE UNDER THE FOLLOWING

CONDITIONS:

PROCESS UNIT: 3 GALLON RETORT AT 120 PSTG

CORROSIVE MEDIA: COAL GASIFICATION PROCESS QUENCH TANK LIQUOR

AVERAGE TEMPERATURE: 350F

AERAT ION:. NONE

AGITATION: NONE

LENGTH OF TEST: 9.5 DAYS

INCONEL ALLOY 600 WAS THE MOST RESISTANT ALLOY TESTED BOTH IN REGAROS TO

GENERAL CORROSION RESISTANCE AND RESISTANCE TO STRESS CORROSION CRACKING.

REMARKS: NO AGITATION IN TEST VESSEL .CONS IDERA8LE AGITATION WILL BE

EXPERIENCED IN SERVICE. SEE I.N. 159 FOR ADDITIONAL TESTS.

20
I.N PROCESS SEARCH CRITERIA

L59 CARBONATE MATERIAL EVALUATION

LETTER REPORT FROM F.HOXIE TO R . SARR AF, ATOMIC S I NT5RNATI ONAL , 7/ 1 l /75.

CORROSION TEST SPOOL-6375

SUMMARY

CORROSION TEST SPOOL-6375.

SECOND GROUP OF 12 ALLOYS WAS TESTEO FOR CORROSION RESISTANCE UNDER THE

FOLLOWING CONDITIONS.

PROCESS UNIT: 3 GALLON RETORT AT 123 PSIG.

CORROSIVE MEDIA: COAL GASIFICATION PROCESS QUENCH TANK LIQUOR.

AVERAGE TEMPERATURE: 350F

-AERATION: NONE

-AGITATION: NONE

LENGTH OF TEST: 29.5 DAYS

THE OATA CONFIRM RESULTS FROM PREVIOUS TEST. SEE I.N. 158 FOR DETAILS.

INCONEL 600 RECOMMENDEO pnR USE AS A CONSTRUCTION MATERIAL.

* * * * *

I.N. PROCESS SEARCH CRITERIA

128 CARBONATE MATERIAL EVALUATION

TEST REPORT BY J . G. BRUC E , ATOMI CS INTERNATIONAL »7/23/75.

CORROSION TESTS OF MATERIALS IN HIGH TEMPERATURE MGLTEN SALT

SUMMARY

22 MATERIALS WERE CORROSION TESTED IN STATIC* 1900F MOLTEN SODIUM CARBONATE

{FROM THE OCR COAL

ZR02 1 MGO , ANO BEO

THE MOST CORROSION

GASIFICATION PROGRAM) FOR 100 HRS.

AND THE METALS ^LATINUM AND UNILOY

RESISTANT MATERIALS.

THE CERAMICS A L 203

50491 WERE FOUND TO BE

21
r.N. PROCESS SEARCH CRITERIA

138 CARBONATE MATERIAL EVALUATION

REPORT, 10/1/75, BY R. SARRAF, ATOMICS INTER NATIONAL .CORROSION TESTING PF

CONSTRUCTION MATERIALS IN AI COAL GASIFICATION PROCESS QUENCH TANK LIQUOR.

SUMMARY

CORROSION TESTING OF CONSTRUCTION MATERIAL IN AI COAL GASIFICATION PROCESS

QUENCH TANK LIQUOR.

CORROSION TESTS OF UP TO 90 DAYS EXPOSURE^ MATERIALS TESTED INCLUDED METALS

AND PLASTICS AT 350 F AMD 175 F IN STRESSED AND UNSTRESSED CONDITION.

QUENCH TANK CONDITIONS ARE SHOWN TO PRODUCE SCC TO SUSCEPTIBLE MATERIALS,

AND A GROUP OF SUITABLE MATERIALS ARE INDICATED. FIBREGLASS REINFORCED

PLASTICS ARE ALSO SHOWN TO HAVE LIMITED USEFULNESS.

1. FOR HANDLING QUENCH TANK LIQUOR AT 350 Ft PRESS. TO 120 PSIG THE

FOLLOWING ALLOYS HAO LOW CORROSION RATES: INCONEL 600, 601, 617, RA330,

RA333.

2. FOR THE QUENCH/REGENFP.ATOR TANK USE ABOVE MATERIALS.

3. PRELIMINARY RESULTS ON PLASTICS TESTED INDICATE SUITABILITY OF SEVERAL

MATERIALS AT GREEN LIQUOR TEMPERATURES TO 200-250 F.

* * * * *

X

22
I.N. PROCESS SEARCH CRITERIA

182 CLEAN COKE MATERIAL EVALUATION

INTERIM REPORT, 3/72-4/74, FROM USS ENGINEERS AND CONSULT ANTS , I NC . TO OCR.

CLEAN COKE PROJECT

SUMMARY

3-IN CARBONIZER: SECTIONED FOR OBSERVATION AFTER 60 HRS SERVICE AT temp.

OVER 1 000 F INCLUDING 24 HRS OVFR I30CF. EXAM. SHOWED SIGNIFICANT

CARBURIZATION { CAB IDES OF CR £ IRON) AT THE SURFACE OF THE 316 S.S. SHELL,

IN AREAS WHERE THE HOT SURFACE WAS IN CONTACT WITH H2S FR C E FLUIDIZING GAS. THOUGH IT APPEARFO TO BE STRONG AT HIGH T EMP. t THE

CARBURIZED STEEL WAS EXTREMELY RRITTLE WHEN COOL. DEPTH OF CAP BUR I ZA T I ON

(20-25 MILS) WAS GREATEST FROM THE BOTTOM GAS INLET °IPE TO ABOUT THE TOP

OF THE FLUID BED SECTION. ABOVE THIS POINT CARBURIZATION OECREAS c D RAPIDLY TO ZERO NEAR THE TOP OF THE DEENTRAINMENT SECTION. CARBURIZATION

IS ATTRIBUTED TO THE ABSENCE OF H2S IN THOSE AREAS WHERE IT OCCURRED.

A CONTROLLED CONCENTRATION OF H2S WILL BE MAINTAINED IN THE RECYCLE

FLUIDIZING GAS TO MINIMIZE CARBURIZATION. SOME THIN WALL 316 S.S. PIPING

HAS BEEN REPLACED WITH HEAVIER WALL INCOLOY 800.

CORROSION TESTS UNDER CARBONIZATION CONDITIONS: 4 SERIES OF TESTS WE»

US.ING 3Q4

316 S.S.

SERIES 1.

E PUN

S.S., 316 S.S., INCONEL 600, INCOLOY 800, 310 S.S., AND ALONIZED

1370 F, DRESS. 125 PSIA, H2S CONTENT 25-40PPM.

TEST LENGTH 13.5 HRS. 18 GRAMS OF BLACK DEPOSIT RECOVERED

SERIES 2. 1250F , 100 PSIA, 50-100 PPM H2S. TEST LENGTH, 92 HRS. NO

CARBON.

SERIES 3. SAME AS 2 EXCEPT 575 GRAMS OF CHAR PUT INTO REACTOR AROUND

COUPONS. TEST LENGTH, 95 HRS. RECOVERED CHAR WEIGHED 512

WITH NO EVIDENCE OF CAPBON DEPOSITION.

SERIES 4. 1250F, 100 PSIA, NO ADDED H2S AND NO CHAR BED. TEST L FNGT

HRS- H2S CONCENTRATION WAS 10-20 PPM FROM REACTIONS IN VES

6 GRAMS OF CARBON DEPOSITS RECOVERED.

MOST OF CAR80N IN DEPOSITS IS IN ELEMENTAL form. WHEN THIS IS

DEPOSITED ON AN ALLOY SURFACE IT CAN LEAD TO "METAL DUSTING". 304 S.

SHOWED SOME EVIDENCE n F THIS. CARBURIZATION IS A FUNCTION OF BOTH H2

CONCENTRATION AND TEMPERATURE 50-100 PPM OF H2S SHOULD BE ADEQUATE tq

PROTECT INCOLOY 800 FROM CARBURIZATION.

GRAMS

H, 95

SEl.

S.

S

23
I.N. PROCESS SEARCH CR IT E° I A

183 CLEAN COKE MATERIAL EVALUATION

QUARTERLY R EPCRT , 1 , 2 , 3/ 75 , FROM USS ENGINEERS AND CONSULTANTS, I NC

.

CLEAN COKE PROJECT

SUMMARY «. CARBONIZATION POU: MAIN RECYCLE-GAS H

c AT ER . 7 OF 45 ELEMENTS HAD

MALFUNCTIONED (6 BURNED OUT, 1 BROKEN TERMINAL). FORMATION nc EXTENS I VE

CARBON DEPOSITS ON THE HEATER ELEMENTS CAUSED BURNOUT BECAUSF OF EXCESSIVE

TEMPERATURE WITHIN THE CARBON-INSULATED SHE4TH5. NEW HEATER SUBASSEMBLY

ORDERED WITH IMPROVED MGO INSULATION AND WIRE ARRANGEMENT TO REDUCE WATT

DENSITY AND SUSCEPTIBILITY TO HEAT DETERIORATION.

DURING A LATER RUN THE GAS DISTRIBUTION PLATE BECAME PLUGGED AND THE WASH

OIL RECIRCULATING PUMP FAILED. CAUSES NOT DISCUSSED. PUMP REPLACED WITH A SEALED CRANE CENTRIFUGAL RUMP.

CORROSION STUDIES: COUPONS OF VARIOUS ALLOYS WERE EXPOSFD IN SEVERAL

LOCATIONS IN THE POU UN-ER ACTUAL OPERATING CONDITIONS (800F AND 1300F).

AT LOW TEMPERATURE ONLY CARBON STEEL SHOWED SIGNIFICANT CORROSION. AT

HIGH TEMPERATUP C ALONIZSD INCOLOY 800 HAD A RELATIVELY HIGH CORROSION RATE.

PLAIN INCOLOY 800 SHOWED NO SIGNIFICANT CHANGE AFTER 244 H»S OF HIGH

TEMPERATURE TESTING. TABLES GIVE DETAILS AND RESULTS OF TESTS.

* *

I.N. PROCESS SEARCH CRITERIA

273 CLEAN COKE MATERIAL EVALUATION

MONTHLY PROGRESS REPORT , 10/75, BY USS ENGINEERS AND CONSULTANTS , I NC.

CLEAN CCKE PROJECT

SUMMARY

CARBONIZATION PDU: RECYCLE GAS COMPRESSOR. PERSISTENT PROBLEM WITH GAS LEAKS

AROUND THE SHA FT. BEL I EVED TO BE CAUSED BY LIGHT FACE LOADING ON THE SEALS.

THE REDESIGN INVOLVED CHANGING THE SEAL BALANCE FROM 70S TO IDS'? AND REOUCING

THE SPRING FORCE BY ABOUT 20'S. THIS WOULD PROVIDE GREATER FACE PRESSURE TO

INSURE A MORE POSITIVE SEAL.OESIGN HAS PERFOR M ED SATISFACTORILY SINCE

INSTALLATION! 8/75)

.

CORROSION TESTS IN CARBONIZATION POU: A COMPLETE SERIES OF TEST SPECIMENS

WERE EXPOSEO IN THE PDU DURING 0° E RAT ION AT FLUID BED TEMP. OF 8PTH 8 "OF

AND 1300F.IN LOW TEMP .EXPOSURE ONLY CARBON STEEL SHOWED SIGNIFICANT

CORROSION. IN HIGH T EMP . LOC

A

T IONS NONE OF THE CORROSION RATES WERE GREATER

THAN 3.0 MPY. INCOLOY 800 SPECIMENS FROM HIGH TE MP . LOCATIONS WERE EXAMINED

METALLOGRAPHICALLY AND SHOWED NO SIGNIFICANT CHANGE IN MICROSTRUCTUPE.

TABLES PRESENT PERTINENT DATA FOR THE TESTS.

HYOROGE NAT I CN POU: HIGH PRESSURE FITTINGS DEVELOPED LEAKS WHEN OPERATING

TEMP. REACHED ABOUT TOOF .PQSS T SLY R-ESULT OF DIFFERENTIAL EXPANSION OF

OISSIMILAR M=TALS(3L6 S . S . 30 DY , 410 S.S. GLAND MUT,416 S.S. COLLAR).

DESIGN CHANGED TO MAKE ALL PARTS FROM 316 S.S.

24
I.N. PROCESS SEARCH CRITERIA

362 CLEAN COKE MATERIAL EVALUATION

MONTHLY PROGRESS REPORT , 1 1 /76 r BY USS ENGINEERS AND CONSULTANTS* INC.

CLEAN COKE PROCESS

SUMMARY

CARBONIZATION PDU: ALL COPROSION T=ST COUPONS FROM THE LOW TEMPERATURE OR

HIGH TEMPERATURE EXPOSURE SITES WERE REMOVED AND EVA LU ATED . LOW TEMPERATURE

COUPONSIUP TO 500 F ) WERE EXPOSED FOP 1566 HRS. IN THE GAS-COOLER POT ONLY

CARBON STEEL SHOWED SIGNIFICANT CORROS ION { 3 .2-22. 9 MPYl.IN THE INTER

.CHANGER POT CARBON STEELI37.5 MPY),409 S.S. (3.9 MPY) * AND 430 S.S.II.2 MPY)

HAD THE HIGHEST CORROSION RATES. ALL COUPONS REMOVED FROM INTFRCHA NGER POT

BOTTOM LOCATION GENERALLY HAD HIGHER CORPOSION RATES THAN PREVIOUS TESTS.

HIGH TEMPERATURE COUPONS (500-1700 F) FROM CHAR RECEIVERS WERE EXPOSED FOR

850 HRS-THOSE IN CARBONIZER AND HEATER-OUTLET LOCATIONS WERE EX°OSED FOR

1305 HRS. COUPONS GENERALLY SHOWED SMALL WEIGHT GA INS .GREATEST WEIGHT

LOSSES WERE CARSON STEEL AND 410 S.S. IN THE CHAR RECEIVERS AND 304 S.S.

AND 314 S.S. IN THE HEATER-OUTLET LOCATION. ALL COUPONS FROM THE CARBONIZE0

AND HEATER-OUTLET LOCATIONS SHOWED SULFIDATION ATTACK. INCONEL 601 AND

INCOLOY 8C0 WERE WORST.

TABLES PRESENT WEIGHT LOSS PATES FOR 27 DIFFERENT ALLOYS.

NEW COUPONS HAVE BEEN INSTALLED IN THE CARBONIZER AND HE ATER-OUTLET

LOCATIONS. SUFFICIENT DATA ARE NOW AVAILABLE FOR THE LOW TEMPERATUPE

LOCATIONS ANO CHAR RECEIVERS.

* * * . * *

\

25
r.N PROCESS SEARCH CRITERIA

180 COED MATERIAL EVALUATION

REPORT, NO DATE, NO AUTHOR.

MATERIALS TEST PROGRAM-COED MATERIALS PROGRAM.

SUMMARY

MATERIALS T c ST PROGRAM

PYROLYSIS VESSELS: TEST COUPONS WERE WELDED TO THE INSIDE VESSEL WALLS OF TH

STAGE TWO PYROLYSIS VESSEL (SQOE) AND THE STAGE THREE PYROLYSIS VESSEL

( 1000 F) • TOTAL TEST TIME WAS 4000 HOURS. MATERIALS, COMPOSITIONS, AND

HEAT TREATMENTS OF COUPONS GIVEN IN TAB LF XLVII. STAG* TWO S P EC I ME NS -GOOD

CONDITION VISUALLY. STAGE THREE S PEC IMENS-C ARBON STEEL COUPONS HAD

EXPERIENCED SEVERE ATTACK. TEST SPECIMENS SENT TO LUKENS STEEL FOR

metallography.

OIL ABSORBER TOWER: TEST COUPONS WERE INSTALLED IN THE BOTTOM SECTION.

TEMPERATURE WAS G600-700F. TOTAL TEST TIME WAS 6 MONTHS. INCO ANALYSIS

RESULTS GIVEN IN TABLE. TYPES 300 AND 400 S.S. GAVE SATISFACTORY RESULTS.

HYDROTREATING PLANT: TEST COUPONS WERE INSTALLED ON OIL DISTRIBUTION PLATE.

TEMPERATURE OF 70Q-300F AND PRESSURE OF 2000-2500 PSIG. HYDROGEN

CONCENTRATION OF 90-95?. H2S C ONC ENTR AT I ON OF 2?. TOTAL TEST TIME 0* 2254

HOURS. INCO ANALYSIS RESULTS GIVEN IN TABLE LIT.

* # * * *

r.N. PROCESS SEARCH CRITERIA

20 C02 MATERIAL EVALUATION

LETTER REPORT, 2/17/70, FROM G.CURR AN, CONSOL , TO C. SCHULZ , CONSOL

.

HIGH TEMPERATURE ALLOYS FOR C02

SUMMARY

MATERIAL EVALUATION OF INCOLOY 300 AND 310 S.S. IN CALCINER AT LIBRARY, PA.

ATMOSPHERE: SUL*UR BEARING GAS AT HIGH TEMPERATURES.

APPLICATIONS

GASIFIER-DEVOLATILIZER INTERNALS: CYCLONES, DIPLEGS, THERMOWELLS, PRESSURE

TAP PROBES, HEATERS. TEMPERATURE RANGE 1500-1600F. SULFUR AS H2S, 0.1?.

310 S.S- AND INCOLOY 800 CAN BOTH BF USED.

REGENERATOR INTERNALS: TEMP/PRESS PROBES, THERMOWELLS. TEMPERATURE RANGE

1900-1950F. SULFUR ABOUT Q.z<? AS S02, H25 , S2, COS. NO ALLOY SUTTABL*.

EXTERNAL PROCESS PIPING: HIGH TEMPERATURE HEATERS, SOLIDS TRANSFER LINES.

TEMPERATURE RANGE 1500-I950F. SULFUR FROM 0-0. 1? AS H2 S . USE 310 S.S.

OR INCOLOY 800 EQUALLY.

26
I.N. PROCESS SEARCH CRITERIA

22 C02 MATERIAL EVALUATION

LETTER REPORT, 3/4/70, FROM J.LETERLE , CONOCO, TO M.SHARRAH.

MATERIALS REVIEW C02 PILOT PLANT

SUMMARY

REVIEW OF OPERATION AND MATERIALS EXPERIENCE IN BENCH SCALE UNIT.

REGENERATOR INTERNALS: NO SUITABLE MATERIAL AVAILABLE. USE EXPENDABLE MFTAL

T.C . PROBE OR PERMANENT CERAMIC. WILL EXAMINE BENCH SCALE COMPONENTS AND

EXPOSE COUPONS IN C02 PLANT AND IN LAB.

•REGENERATOR: 1950F, REDUCING ATMOSPHERE, CO, H2S , COS, CS2, C02, S2, N2.

USE REFRACTORY LINER, NO SUITABLE METAL AVAILABLE. MUST BE REDUCING

{HIGH CO), TO ELIMINATE SLAG FUSION. 310 S.S. BETTER THAN INCOLOY 800

BUT EMBRITTLES ON CARBURIZING. SUGGEST ALONIZING FOR T.C.

DOLOMITE RETURN LINOS: I90DF, "INERT PURGE GAS. NORMALLY DO NOT SEE SULFUR

BUT SOME LEAKS IN USE 310 S.S. INSTEAD OF INCOLOY 800 TO REDUCE

SULFIDATION. °URGE GAS CONTAINS 3-47 CO THAT WILL CARBURIZE AND EMBRITTLE

310 S.S. MUST MODIFY GAS.

• COOLING WATER SYSTEMS: USE INHIBITOR (DICHROMATE) WITH C A R30N STEEL.

TO PREVENT SCC-CL DO NOT ALLOW WATER TO STAND IN PIPES ON SHUTDOWN.

WELDING: AVOID HIGH NI WELD RODS.

MISC.: BENCH SCALE TESTS SHOW CORROSION OF 310 S.Si AND HASTELLOY X AT 1400

TO 1500F. NO REASON.

* * * * *

I.N. PROCESS SEARCH CRITERIA

43 C02 MATERIAL EVALUATION

INTEROFFICE REPORT , 4/ 10/70 , FROM J.LETERLE TO J .K IRK, CONOCO. . MATERIALS RESEARCH PROGRAM FOR C02 _ SUMMARY

MATERIALS RESEARCH PROGRAM FOR CD2

SET UP THREE PHASE EVALUATIONS:

DFAILURE ANALYSIS OF BENCH SCALE COMPONENTS.

2)

HIGH TEMP. CORROSION, SULFIDATION, CARBURIZATION STUDY nf= MATERIALS.

3)

EXPOSUR E OF COUPONS IN PILOT PLANT.

REPORT GIVES DETAILS OF PROGRAM.

27
i

I.N* PROCESS SEARCH CRITERIA

77 C02 MATERIAL EVALUATION

SUMMARY REPORT FROM F.RAOD TO J.KTRK, PONCA CITY, 9/4/70,

PRESENT STATUS SUMMARY OF CONSOLtRAPID CITY METALLURGY RESEARCH BACKUP STUDIES

SUMMARY

MAJOR METALLURGICAL PR03LEMS OF CQ2 PLANT

1.. HIGH TEMPERATURE SULFIDE ATTACKS

2. CARBURIZATION AND OR OXIDATION.

3. C02 CAN PRODUCE CARBURIZATION OF CR 3EARING STEELS.

4. INCOLOY 800 TUBES IN GAS HEATERS (B-207) SHOULD BE CLOSELY INSPECTED

AT SHUTDOWNS.

5. ONE OF THE MAJOR UNRESOLVED PROBLEMS IS THE ULTIMATE LONG-LIVED MAT C R I ALS

FOR THE THERMOWELLS AND THE SAMPLING TUBES.

6. A CONTINUOUS, ON-STREAM INSPECTION IS VITAL TO A SUCCESSFUL LINING CUT

AND SMOOTH NORMAL OPERATION OF THIS PLANT. * * * * *

I.N. PROCESS SEARCH CRITERIA

91 C02 MATERIAL EVALUATION

LAB DATA FROM L. R I CHMQMD , S TEAR NS-ROG C R , TO C. SCHULZ, CONOCO.

OPERATING CONDITIONS— RAW LA8 DATA

SUMMARY

OPERATING CONDITIONS ON CQOROS ION .RAW LAB DATA OF OPERATING CONDITIONS COVERING

RECENT RUNS. TO BE USED FOR DETERMINING THE EFFECT OF OPERATING CONDITIONS

ON CORROSION. ALL AVAILABLE LAB ANALYSES AND OPERATING TEMPERATURES ARE ATTACHEO.

28
I.N. PROCESS SEARCH CRITERIA

99 C02 MATERIAL EVALUATION

REPORT FROM H. CROWDER TO J . LETERLE, PONCA C I TY, 5/ 13/ 74.

BENDING PROPERTIES AND HIGH TEMPERATURE SULFUR CORROSION RESISTANCE OF

ALONIZED INCOLOY 800. . SUMMARY

BENDING PROPERTIES AMD HIGH TEMPERATURE SULFUR COPROSION RESISTANCE OF

ALONIZED INCOLOY 800.

CONCLUSIONS

l.. THE ALONIZED LAYER ON INCOLOY 300 IS MADE UP OF TWO PARTS, A HARD BRITTLE

OUTSIDE LAYER AND A MORE DUCTILE INNER LAYER. THE INNER LAYER PROVIDES

THE MOST RELIABLE PROTECTION AGAINST CORROSION.

2. AN ANNEALING TREATMENT OF 133QF FOR 24 HRS MAKES THE OUTER ALONIZED

COATING MORE DUCTILE.

3. IN THE ANNEALED CONDITION TUBING COULD BE BENT TO A RADIUS OF 3.75 IN AT 16 50 F, A RADIUS OF 6 IN AT 1300F, OR A RADIUS OF 26 IN AT 1000F.

4. A SOUND ALONIZED LAYER GIVES PROTECTION AGAINST HIGH TEMPERATURE H2S

CORROSION.

5. BENDING, IN EITHER THE ANNEALED OR UNANNEAI.ED CONDITION, OP c NS UP CRACKS

IN THE OUTER LAYER, THEREBY REDUCING TO SOME DEGREE THE CORROSION

RESISTANCE OF THE SURFACE*

6. 8 ENDING IN THE " AS-ALONI ZED” CONDITION OR BENDING IN THE ANNEALED

CONDITION AT TOO LOW A TEMPERATURE WILL ALSO CRACK THE INNER L A YFR AND

GREATLY REDUCE THE CORROSION RESISTANCE OF THE ALONIZED COATING.

* * * ' * *

29
I.N PROCESS SEARCH CRITERIA

135 C02 MATERIAL EVALUATION

REPORT, 6/30/75,T0 CONSOLIDATED COAL CO. FROM S. DAKOTA SCHOOL OF MINES £ TECH.

CORROSION OF MATERIALS IN CONTACT WITH CACQ3-C A{ OH ) 2 MELTS.

SUMMARY

A STUDY WAS INITIATED TO IDENTIFY THOSE MATERIALS WHICH WOULD FUNCTION WELL

AS MELT CONTAINERS. S D ECIFIC AREAS INVESTIGATED WERE: 1) GROWTH OF THE

OXIDE LAYER ON ALLOY STEELS. 2) WEIGHT LOSS OF METAL SAMPLES IN CONTACT WITH

MELTS. 3) MICROSTRUCTURE OF OXIDIZED ALLOYS AND OXIDATION PRODUCTS.

CONCLUSIONS

1. WEIGHT LOSS M£ASURE M ENTS INDICATE THAT THE S.S. CORRODE PRIMARILY THROUGH

SPALLING OF THE PROTECTIVE OXIDE LAYER.

2- BECAUSE CORROSION RATE CECREASES AS THE CR CONTENT OF THE S.S. INCREASES

HIGH CR ALLOYS, IE, TYPES 309, 310, ANO 446 ARE BEST SUITED AS MELT

CONTAINERS.

3. THE ALLOYS WHICH CONTAIN RELATIVELY LARGE AMOUNTS OF NICKEL, I*.

INCONEL 600 AMO 601 AND NICKEL 20C WOULD NOT FUNCTION KELL AS MFLT

CONTAINERS EITHER BECAUSE OF DEVELOPMENT OF SURFACE POROSITY OR BECAUSE

OF HIGH CORROSION RATES.

* * * * *

T.N. • PROCESS SEARCH CRITERIA

56 C02 MATERIAL EVALUATION

REPORT, 10/20/75, BY H. CR CWOER , CONOCO.

CORROSION COUPON EV ALU AT I ON . SER IE S III*

SUMMARY

EVALUATION OF CORROSION OF SEVERAL ALLOYS IN REGENERATOR GAS.

EXPOSURE: SERIES II - 550 HRS, OXIDIZING

650 HRS, REDUCING

SERIES III*- 500 HRS, OXIDIZING

620 HP S , OXIDIZING

VERY DETAILED MET'ALLOG R A PH I C ANALYSIS. CORROSION RATES LO-360 MP Y.

ALLOYS TESTED: S.S.- 309, 310, 329. HAYNES - 40, 150, 706, 718.

INCONEL - 706, 7L8, 793. INCOLOY - 800, 301.

30
I.N. PROCESS SEARCH CR ITEPIA

57 C02 MATERIAL EVALUATION

LETTER, 11/7/75, FROM J.LETERLE, CONOCO, TO C . SC HULZ , L I 3RAR Y

.

THIRD SERIES OF METAL COUPON EXPOSURE TESTS

SUMMARY

SERIES 11-1200 HRS FXPOSIJR E »RUN 19,20,21

SERIES II I-ADDITIONAL 1100 HRS, RUMS 22,23,24

SUMMARY : 1 JHAYNES 150 ALLOY EXCELLENT COMPARED WITH HAYNES 133 AND 25 DIFFERENT

COBALT BASED ALLOYS. 2 ) ADD I T IONAL ANALYTICAL WORK TO BE DONE. * * * *

I.N. PROCESS SEARCH CR ITER I 366 CPC MATERIAL EVALU

REPORT , N. D. , BY J .DEV AN, R .COOPER ,W . HARR IS,ORNL.

MATERIAL EVALUATION-HEAT EXCHANGER TUBES

SUMMARY

MATERIAL SELECTION FOR HEAT EXCHANGER TUBES IN A MODULAR INTSGRATPQ

UTILITY SYSTEM

TEST PROGRAM: SURVEILLANCE COUPONS OP 310 AND 316 S.S.»INCOLOY 800 AND 325

WERE EXPOSED IN COMBUSTION POWER- COMPANY'S MODEL FLUIDIZED 8

C D REACTOR.

TEST CONDITIONS: TEMP. 16CC-1700 F , SEVERAL • HUNOR ED PERCENT EXCESS AIR. MO

COOLING TUBES IN BED. DOLOMITE ADDED TO TIE UP S02 AND A GEORGIA CLAY

ADDED AS A CORROSION INHIBITOR. SPECIMENS LOCATED IN THE FREE BOARD POSITION

JUST ABOVE THE FLUID BED . I NCOLQY 325 WAS EXPOSED FOR 1000 HRS. 310 AMO

316 S.S. AND INCOLOY 300 WE® E EXPOSED FOR 500 HP.S AND 1000 HRS.

RESULTS: SIGNIFICANT INTERGRANULAR OXIDATION OCCURRED ON ALL FOUR MATERIALS.

SCALE WAS THICKEST ON 316 S.S. NO INDICATION OF SULFIDATION OR CARBURIZATION

ANALYSIS OF DATA WILL CONTINUE.

FUTURE: CONTROLLED EXPERIMENTS DUPLICATING THE CONDITIONS EXPECTED IN THE

MIUS SYSTEM ARE NEEDED TO ASSESS COMPATIBILITY PROBLEMS.

31
I .N* PROCESS SEARCH CRITERIA

1 HYGAS MATERIAL EVALUATION

LETTER, 4/2/75, FROM A. MAC N A B, C . F . BRA UN , TO P.T4RMAN * IGTMATERIAL SELECTION FOR HYGAS STEAM/IRON GASIFICATION PILOT PLANT

SUMMARY

DISCUSSION OF MATERIALS TO RESIST SULFIDATION IN PIPING TO THE REACTOR

ANO SECOND STAGE REDUCER SPARGE RING-ATMOSPHERE WILL BE REDUCING GAS CONTA ININ

O.I MOLE PERCENT H2S AT 2COOF. I NCOLO Y 800 AND 310 S.S. WILL NOT HOLD UP.

RECOMMEND 50CR-50M I ( ASTM A560 OR UNILCY 50/50) OR ALONIZED 310 S.S. OR

ALONIZED INCOLOY 300.50CR-50NI HAS GOOD SULFIDATION RESISTANCE BUT POOR

HIGH TEMP. STRENGTH. RECOMMEND USE OF THIS MATERIAL AS CLADDING TO A SUBSTRATE

OF INCOLOY 800 OR 310 S.S.

* * * * *

I.N. PROCESS SEARCH CRITERIA

79 HYGAS MATERIAL EVALUATION

LETTER, 6/2/75, FROM P .T ARM AN , IGT, TO A. MAC N A8 , C -F .B R AUN

.

MEMO, 5/30/75, FROM R.BACHTA TO P.TARMAN, IGT.

FEASIBILITY AND AVAILABILITY OF INCOCLAD 671/800H PIPE

SUMMARY

TARMAN COMMENTS ON MAC NAB'S SUGGESTION OF USING 50CR-50NI AS CLADDING ON

INCOLOY 3C0 AND HIS RECOMMENDATION THAT IGT CONTACT HUNTINGTON ALLOYS FOR

INFORMATION.

NMEMO FROM BACHTA GIVES INFORMATION FROM HUNTINGTON ALL OY S . PR 03L EMS IN GETTING

THIS MATERIAL WOULD BE 1) SIZE- 31 GGR S T PRODUCED BY HUNTINGTON IS 2-l/2"00,

IGT NEEDS 4" 0D.2 ) CLADD IMG THE INTERIOR OF THE PIPE. MOST PRODUCTS CLAD

ON OUTSIDE ONLY.

NINCOCLAD 671/ BOOH PIPE HAS AN INCOLOY 300 SU8STRATE WHICH PROVIDES STRENGTH

AT HIGH TEMPERATURES AND INCONEL 67 1 ( APPROX. 50CR-50N I) CLADDING WHICH

PROVIDES RESISTANCE TO SULFIDATION.
I.N. PROCESS search criteria

250 HYGAS MATERIAL EVALUATION

LETTER* 7/30/75 , FROM A. MAC NAB* C.F. BRAUN, TO H. FRANKEL , ERO

A

INSPECTION OF HYGAS PILOT PLANT 3EF0RE USING EASTERN BITUMINOUS COAL

SUMMARY

HYGAS IS PREPARING TO CHANGE ITS FEEDSTOCK TO PASTERN BITUMINIUS COAL. IT'S

EXPECTED THAT THESE HIGHER SULFUR COALS WILL 8F MORE CORROSIVF THAN LIGNITE

AND THE CHANCES FOR COMPONENT FAILURE WILL BE INCREASED.THEREFno F TT IS

IMPERATIVE TO HAVE AS THOROUGH AM UNDERSTANDING OF THE PRESENT STATE rf THE

EQUIPMENT AS PQS S IBL E.TH I S SHOULD INCLUDE SECTIONING OF CRITICAL COMPONENTS

TO ESTABLISH DEPTH OF PENETRATION BY CORROSION.

ACTION IS BEING TAKEN TO IMPLEMENT THIS PROGRAM.

* * * * *

I.N. PROCESS SEARCH CRITERIA

255 HYGAS MATERIAL EVALUATION

TELECON, 12/22/76, FROM S -D AN YLUK , A NL , TO 8 . ORCHA RD , I GT

.

STATUS OF FAILURE ANALYSES OF FAILED COMPONENTS FROM HYGAS PILOT PLANT

SUMMARY

1. PROTECTION TUBE FROM AAG.

ANALYSIS HAS SHOWN THAT THE 310 S.S. THERMOWELL WAS mc LT ED AT THE ENO

OF THE TUBE WHICH WAS INSIDE THE GAS I F I ER . CAUS E OF FAILURE WAS EXCESSIVE

DEVIATION FROM SPECIFIED TEMPERATURES.

2. 1/4'* NITROGEN PURGE LINE.'

EMBRITTLEMENT OF THE GRAIN BOUNDARIES IS VERY SEVERE AND THE TUBE

FAILED BY BRITTLE FR ACTUR E. SULFUR CONTENT ON INNER PHASE OF TUBE IS

1-2?. ORIGIN OF SULFUR UNKNOWN.

3. ALON I ZED 316 S.S. AND 446 S.S. COUPONS.

EVALUATION OF GASLFIER COUPONS IS UNDERWAY.

33
r.N. PROCESS SEARCH CRITERIA

245 HYGAS MATERIAL EVALUATION

LETTER W/PHOTOS, 1/25/77, FROM S.DANYLUK , ANL , TO S- DA PKUNAS , ERDA

.

ELECTRON MICRQPR03E DATA-316 S.S. "A LON I ZED" COUPONS FROM GASIFIER

SUMMARY

TWO COUPONS HAVE 8EEN ANALYSED. ONE FROM PUN 61 AND A LONGER EXPOSURE COUPON

FROM RUN 67 . THE DATA SHOW THE NICKEL IS DEPLETED ANO SULFUR AND ALUMINUM

ARE ENRICHED IN THE SURFACE AREA FOR RUN 61. THESE EFFECTS ARE EXAGGERATED

AND GRAIN BOUNDARY PENETRATION OF SULFUR IS MORE EVIDENT AFTER RUN 67.

ANALYSES OF THESE SURFACE TREATED SPECIMENS IS BEING CONTINUED AND PROGRESS

WILL BE REPORTED.

* & * * *

34
I.N PROCESS SEARCH CRITERIA

372 MERC MATERIAL EVALUATION

QUARTERLY R EPORT , LC/ I- 12/3 1/71 , 3 Y MORGANTOWN ENERGY RESEARCH CENTER.

FLUIDIZED BED COMBUSTION-MATERIAL EVALUATION

SUMMARY

INVESTIGATION OF PERFORMANCE OF BOILER TUBES IN A FLUID BED COMBUSTTON

SYSTEM. SPEC IMENS WE^E TESTED IN THREE LOCATIONS: IDENTIFIED AS VERTICAL

WATER-COOLED BUNDLE (VWCB ) ,LOWFR TUBE BUNDLE (LTB) , UPPER TUBE BUNDLE ( UTB )

.

TUBE TEMPERATURES WERE BETWEEN 1100-1500 F.

OPERATING CONDITIONS: BITUMINOUS COAL WAS BURNED IN A BED OF LIMESGTONE

AT A FLUIDIZING VELOCITY OF 5.7 FT/SEC. AVG. HPERATING CONDITIONS WERF:

COAL RATE, 61. 3 LB/ H° -LIMESTONE RATE, 20 LBS/HR-FXCESS A I R , 1 3 . 6^-3 ED TEMP.,

1545 F-AVERAGE S ^ 2 EMISSION WAS 230 PPM. AVERAGE CARBON UTILIZATION WAS 86%.

TEST WAS TERMINATED AFTER 482 HRS WHEN THE CAR 3QN STEEL TUBE IN LOWEP

BUNDLE FAILED.

t CARBON STEEL: UT3-SEVE°LY CORRODED. LTB MIDDLE P OW-COMPLETELY REACTED.

VWCB- DESTROY ED COMPLETELY.

410 S.S.: UTB-TH IN LAYER OF CORROSION WITH COARSER CARBIDES IN STRUCTURE

THAN ORIGINAL. LTB-HFAVY CORROSION WITH COARSE CARBIDES IN GRAIN BOUNDARIES

VWCB-TUBE DESTROYED.

446 S.S.: UTB-NO CORROS ICN.LTB-SOME SIGMA PHASE IN MTC ROSTRUCTUR E WITH GRAIN

GROWTH ON OUTER SURFACE. VWCB-TUBE FAILED VIA A CORROSION CRACK.

304 S.S.: UTB-NO CORROSION, NO PREC I P ITA TES . LTB-SOM E GRAIN GROWTH GWITH

PRECIPITATION AT GRAIN 30UNDAR I ES . VWCB- INTER GR ANULAR CORP.OSr n N WAS PRESENT

316 S.S.: UTB-NO CORROSION, NO PREC IP ITATES . LTB-MOR E CORROSION THAN THE

G304 S.S. TUBES IN THIS POSI T ION WITH PPECIPITATES AT THE GRAIN BOUNDARIES

VWCB— LEAST CORROSION n F ANY TUBES TESTED.

CARBON STEEL, 410 S.S., AND 446 S.S. FROM VWCB HAD INTERNAL DEPOSITS WHICH

PROBABLY ALLOWED THE TUBES TO OVERHE AT .THESE TESTS ARE PROBABLY NOT VALID.

REPORT CONTAINS PHOTOM I C ROGRA t>HS OF SAMPLES. * * * * *

I.N. PROCESS SEARCH CRITERIA

373 MERC MATERIAL EVALUATION

MONTHLY REPORT, 1/72, FROM MORGANTOWN ENERGY RESEARCH CENTER.

FLUI OIZEO-BED COMBUSTION

* SUMMARY

THE THIRD AND FINAL 500 HR TEST WITH THE CORROSION. EROSION COMBUSTOR WAS

STARTED 1/25. COMPLETION DATE 2/17.

35
r.N. PROCESS SEARCH CRITERIA

374 MERC MATERIAL EVALUATION

MONTHLY REPORT, 2/72, FROM MORGANTOWN ENERGY RESEARCH CENTER.

FLUIDIZED BED COM8USTI ON-CORROS ION STUDIES

SUMMARY . THE THIRD AND LAST 500 HR TEST WITH THE COP ROS ION/ EROS ION COMBUSTOR WAS

WAS COMPLETED. TEST LENGTH, 505 HRS.

THE TUBES IN LOWER HORIZONTAL BUNDLE APPEARED TO BE IN GOOD CONDIT ICN.THF

TEMP. SHOULD NOT HAVE EXCEEDED HC1 F(NOT MEA SUREO ) .TUBES IN UPPER HORIZONTAL

BUNDLE HAO NO INDICATION OF EXTERNAL CORRQS ION .W AT ER COOLED VERTICAL TUBES

WERE COATED WITH A BL^CK DEPOSIT THAT PR0BA8LY WAS LARGELY CARBON.

PHOTOMICROGRAPHS INCLUDED OF TUBES FROM 1ST SERIES OF TESTS. THESE ARE IN ADDITION TO THE ONES PRESENTED IN QUARTERLY REPORT ( 1C-12/71 )

.

SEE I.N. 372 FOR FURTHER INFORMATION.

4c 4c 4c * 4c

I.N. PROCESS SEARCH CRITERIA

375 MERC MATERIAL EVALUATION

QUARTERLY REPORT , 1 / 1-3/ 31 / 72 , FROM MORGANTOWN ENERGY RESEARCH CENTER.

FLUIDIZED BED COMBUSTION-CORROSION STUDIES

SUMMARY

THE THIRD ANO LAST OF THE LONG DURATION TESTS WITH THE C OR R°S I ON /EPOS ION

COMBUSTOR WAS COMPLETED WITH A TOTAL TEST TIME OF 505 HRS. THE TUBES WERE

PHOTOGRAPHED AND ARE eEING PREPARED FOR SHIPMENT TO ALBANY, OR EGON FOR EXA^.

SEE I.N. 37 A FOR ADDITIONAL DETAILS.

36
I.N. PROCESS SEARCH CRITERIA

376 MERC material evaluation

MONTHLY REPORT, 4/72, FROM MORGANTOWN ENERGY RESEARCH CENTERFLUID-BED COMBUSTION-CORROSION STUDIES

SUMMARY

RESULTS FROM SECOND LONG-DURATION CORROSI 0/ EROS ION TESTS APE PR E S c NTEO.

LTB-LOWER TUBE BUNDLE . UTB— UPPER TUBE BUNDLE . VWC8-V ERT ICAL WATER-COOLED BUNDLE,

SEE I-N. 372 FOR OPERATING CONDITIONS.

CARBON STEELt SEAMLESS) : VWC3-N0 CHANGE FROM ORIGINAL. UTB-SL IGHT INTER

GRANULAR CORROSION ON EXTERNAL SURFACE.

410 S.S.: VWCB-MINOP EXTERNAL SURFACE CORROS I ON. LTR-M I DOLE TUBE HAS SIGNS

OF SURFACE DEC ARBUR I ZATION, COARSENING OF GRAIN STRUCTURE, PITTING AND

SCALING OF SURFACE.

V46 S.S.* VWCB-UNCHANGED.LT3— ALL TUBES HAD SOME GRAIN GROWTH AT SURFACE WITH

SLIGHT AMOUNT OF SURFACE CORROS ION .UT9-VERY SLIGHT SURFACE CORROSION.

.304 S.S.( WELDED) : LT9— SURFACE CORROSION, SOME PRECIPITATED CARBIDES.

UTB—MODERATE INCREASE IN GRAIN SIZE.

304 S.S. (SEAMLESS) : VWC5-INCREASE IN GRA I N SI ZE. LT B- I NCRE ASE IN GRAIN SIZE

WITH SURFACE CORROSION AND PRECIPITATED CARBIDES AT GRAIN BOUNDARIES.

UTB-INCREASE IN GRAIN SIZE WITH SLIGHT INTERGRANULAR

CORROSION AT SURFACE.

316 S.S. (WELDED) : VWCB-NO CHA NGE .UT B- INCREAS E IN GRAIN SIZE AND SLIGHT

CORROSION AT THE SURFACE.

316 S-S. (SEAMLESS) : VWC3-N0 CHANGE . LTB-SL I GHT CORROSION AT SURFACE WITH

CARBIDE PRECIPITATES AT GRAIN ROUN CAR I ES . UT B-SL I GHT INCREASE IN GRAIN SIZE

ANO SOME SURFACE CORROSION.

PHOTOMICROGRAPHS OF CORRODED SAMPLES INCLUDED IN REPORT.

CALCULATIONS ARE CONTINUING TO DETERMINE TU8E METAL TEMPERATURES AT the

INLET AND OUTLET OF EACH TUBE.

SEE I.N. 372 AND 374 FOR ADDITIONAL TESTS.

37
I.N. PROCESS SEARCH CRITERIA

L 54 M I SC . MATERIAL EVALUATION

PAPER, 12/1/71, BY R. 30RI0 £ R. HENS EL , COMBUST ION ENGINEERING.

COAL-ASH COMPOSITION AS PELATFD TO HIGH TEMPERATURE FIRESIDE CORP.OSION

AND SULFUR OXIDES EMISSION CONTROL

SUMMARY

COAL-ASH COMPOSITION AS PELATED TO HIGH TEMPERATURE FIRESIDE CORROSION A ND

SULFUR OXIOES EMISSION CONTROL.

THIS PAPER EVALUATES VARIOUS COALS IN TEPMS OF CORROSION POTENTIAL AND

SHOWS HOW HIGH TEMPERATURE CORROSION CAN 8F. REDUCED BY INTRODUCING PROPER

AMOUNTS OF ADD I T I V ES . TH<= EFFECTS Or ADDITIVES ON AIR POLLUTION AND ASH

DEPOSITION. ARE DISCUSSED.

* * * * *

I.N. PROCESS SEARCH CR ITER IA

142 MISC. MATERIAL EVALUATION

LETTER, 8/20/75»FR0M J. KELLY, ROLLED ALLOYS, TO H.FRANK EL, ERDA.

HOT CORROSION IN INCOLOY 900 COMPONENTS

SUMMARY

QUESTIONS CONCLUSIONS IN CONOCO TECHNICAL SERVICE REPORT 79-74-130L

DESCRIBING A HOT CORROS ION ' PROBLEM IN ALLOY 300 ( I NCOLOY )

.

L. DOES NOT BELIEVE THAT THERE IS A GAMMA-TO- AL PHA PHASE CHANGE IN AREAS

DEPLETED OF CHROMIUM BY INTERNAL OXIDATION. HE 8ELIEVES THAT THE

RESULTING NI RICH MATRIX WILL BE EVEN MORE STABLE THAN THE ORIGINAL

ALLOY WITH R6SPFCT TO TRANSFORMATION.

2. ONE OF THE REMEDIAL MEASURES WAS TO INCREASE THE GRAIN SIZE TO MINIMIZE

CARBURIZATION ATTACK. HIS EXPERIENCE INDICATES THAT FINER GRAINED

MATERIALS ARE MORE RESISTANT TO CARBURIZATION THAN ARE COARSE GRAINED

MATERIALS.

38
I.N. PROCESS SEARCH CRITERIA

26 SRC MATERIAL EVALUATION

LETTER, 3/ 18/74, FROM A. HENKE, GULF PSD, TO 8. SCHMID

MATERIALS MONITORING PROGRAM FGR SRC PROCESS

jLETT ER REPORT, 1/30/74, FROM J. MCCOY, GULF RED, TO

CORROSION/EROSION MONITORING PROGRAM AT SRC

, SRC .

B. SCHMID, SPC.

summary

ESTABLISHMENT OF A CORROSION/EROSION MATERIALS MONITORING PROGRAM AT SRC

PLANT. PROGRAM CONSISTS OF:

1. ULTRASONIC TESTING TO DETERMINE THICKNESS AT KEY POINTS IN THE EQUIPMENT.

2. VISUAL INSPECTION.

3. EVALUATION OF TEST COUPONS OF: 310 S.S., 321 S.S., 304 S.S., MONEL,

INCOLOY 800, CAPRCN STEEL, STELLITES, C OLMONQY » TUNGSTEN CARBIDE,

321 S.S. (ALUMINIZED).

* * * * *

I.N. PROCESS SEARCH CRITERIA

267 SRC MATERIAL EVALUATION

REPORT, 5/28/76, FROM D. CANFIELD TO L. SAMUELS , FT .LEWIS.

FAILURE AND REPAIR OF THE WASH SOLVENT COLUMN

SUMMARY

FAILURE REPORT: THF SHELL OF THE 3/8” CARBON STEEL (SA-515 GR . 55) COLUMN

STARTED TO LEAK BETWEEN THE L3TH AND 19TH TRAYS. ATTEMPTS TO PATCH THE

HOLE FAILED. THE TRAYS WERE REMOVED AND THE COLUMN WAS INSPECTED WITH

THE FOLLOWING RESULTS. I) NEARLY ALL THE TRAY SUPPORT RINGS AND DOWNCOMER

SUPPORTS FROM TRAYS 12-21 WERE ALMOST COMPLETELY CORROOED, 2 ) AREAS OF

LIQUID PHASE CONTACT WE°E CORRODED MORE THAN THOSE IN CONTACT WITH VA^CP

PHASE, 3) 14 GAUGE 304 S.S. TRAYS HAD LOST A80UT 7 MILS, 4) t H E 16 AND 20

GAUGE 304 S.S. VALVES WERE THINNING AT CLIP ENDS, 5) THEPE APPEARED TO BE

NO CORROSION PRODUCTS PRESENT.

FAILURE ANALYSIS: THE CORROSION APPEARS TO BE SIMILAR TO NAPTHENIC ACID

CORROSION AS DESCRIBED IN METALS HANDBOOK, VOL. 1. HOWEVER, NO OEFINITP

CONCLUSIONS ARE MADE.

REPAIRS: THE TOP 18-FT SECTION OF THE 32-IN OD COLUMN WAS REPLACED USING

1/4-IN 3I6L S.S. THE TRAYS AND DOWNCOMER SlJP°ORTS WERE REPLACED WITH

316L S.S. NEW 316 S.S. TRAY VALVES WE»E INSTALLED.

CORROSION TEST RESULTS: CORROSION RACKS WERE INSTALLED IN WASH SOLVENT

COLUMN TO EVALUATE MATERIALS. TYPE 321 S.S. AND rNCOLOY 800 SHOWED V

C RY

GOOD RESISTANCE TO THE CORROSIVE ENVIRONMENT . MOLY BEARING ALLOYS (2-3?)

ARE THOUGHT TO HAVE GOOD CORROSION RESISTANCE TO NAPTHENIC ACID CORROSION.

SEE I.N. 302 FOR FURTHER INFORMATION.

39
I.N* PROCESS SEARCH CRITERIA

341 SYNTHANE MATERIAL EVALUATION

TELECON, 11/29/76, FROM S.DANYLUK,ANL » TO B. MASSA ,LUMMUS.

SUBSTITUTE MATERIALS FOR 310 S.S. TO BE USEO IN GASIFIER

SUMMARY

310 S.S. WAS RECOMMENDED AS A SUBSTITUTE FOR INCOLOY 300 THERMOCOUPLE

SHEATHS WHICH WERE FAILING IN SERVICE. HOWEVER , 310 S.S. SHEATHS WILL NOT

BE AVA I LA8LG6 FOR SEVERAL MONTHS. 446 S.S. WAS RECOMMENDED BUT EMBRITTLEMENT

MAY BE A PROBLEM.

* * * * *

40

1
6

t.N PROCESS SEARCH CRITERIA

160 CLEAN COKE AUXILIARY PROCESS EQUIPMENT

MONTHLY PROGRESS REPORT ,12/75, 8Y USS ENGR. AND CONSULT ANTS , I NC . TO ERDA

CLEAN COKE PROCESS

SUMMARY

CARBONIZATION PDU: LEAKS IN THE LARGE FLANGES OF THE REACTOR. BELIEVED

TO BE A LOSS OF COMPRESSION ON THE RING SEALS BECAUSE OF VERY SLIGHT

ELONGATION OF THE STUD BOLTS AFTER MORE THAN 850 HR. EXPOSURE TO TEM°. IN

THE RANGE 1300-1400F. POSSIBLY DUE TO STRESS RELAXATION. BOTH THE

CAR80NIZER £ CYCLONE WERE IN EXCELLENT CONDITION AFTER 1724 HRS. OF POU

OPERATION (863 HRS. AT 1330F AND HIGHER).

THREE INCH CONTINUOUS CARBONIZER: PERSISTENT BURNOUT OF THE HEATING ELEMENTS

OF THE RECYCLE GAS HEATER. THESE HEATERS WERE REPLACED WITH HIGHER

CAPACITY HEATERS. CAUSE OF HEATER FAILURE WAS METAL OUSTING. H2S LEVELS

OF 50-100 PPM HAVE BEEN INTRODUCED INTO THE FLUIDIZING GAS TO INHIBIT THE

METAL OUSTING. ALSO 6-3% WATER IS INJECTED INTO THE GAS TO INHIBIT CARBON

DEPOSITION AND TO GASIFY A PORTION OF THE OEPOSITS THAT FORM.

BtNOER PREPARATION PDU: GEAR PUMP (POP-401) WAS REPLACED BECAUSE OF EROSION

BY CHAR PARTICLES IN THE WASH OIL. THIS PUMP WAS USED FOP TRANSFER 0^

FEED TO THE FEED TANK. REPLACED BY A DRUM TRANSFER PUMP WHICH IS BETTER

SUITED FOR THE ABRASIVE SERVICE. TOPPED TAR PUMP (PDP-4C3). LOSING

PRESSURE. LOOSE IMPELLOR DAMAGED PUMP SHAFT. CHAR FINES £ PROCESS

FLUID HAO ERODED THE BEARINGS. REPLACED ALL DAMAGED COMPONENTS £

MODIFIED PUMP WITH A LIP SEAL TO KEEP PARTICULATES AWAY FROM THE BEARINGS.

* * * * *

43
i.n. PROCESS SEARCH CRITERIA

95 CQ2 PIPING

FAILURE REPORT, 4/16/74, FROM L. WOLFE, CONOCO, TO J. LET ERLE, CONOCO.

MICROPROBE AND METALLOGRAPHIC STUDIES OF PITTED FURNACE TUBES.

SUMMARY ;

MICROPROBE AND MFTAL lOGRAPHIC STUDIES OF PITTED FURNACE TUBES. THE LIGNITE

GAS. PLANT HAS HAD SEVERE CORROSION PROBLEMS FROM HIGH TE^o. SULFUR. A ZINC OXIDE SYSTEM HAS INSTALLED FOR REMOVING SULFUR. TWO RUNS TOTALING

150 HRS WERE MADE WITH VERY LOW SULFUR GAS. DURING THFSE RUNS THE INSIDE

OF THE FURNACE TUBES WERE SEVERLY FITTED AND ONE BURST.

CONCLUSIONS

1. THE PITS ARE IN CARBURIZED METAL.

2. ORIGINAL SURFACE HAS SOME SULFUR CORROSION WHICH SEEMS TO RETARD THE

CARBURIZATION ANO PILING.

3. MOST PIT SURFACES ARE COVERED WITH BLACK, MAGNETIC SCALE WHICH IS OFTFN

IN TWO DISTINCT LAYERS.

4. THE OUTER, THICKER SCALE IS PARTICLES OF METAL AND METAL OXIDES.

5. THE INNER SCALE IS A THIN LAYER OF CR-RICH OXIDE WHICH CONTAINS SOMF IRON.

6. TUBES OF INCOLOY 800 AND 321 S.S. PITTED SIMILARY.

7. THIS ATTACK LOOKS SIMILAR TO "METAL DUSTING" WHICH OESCIBES THE SCALE

AS GRAPHITE WITH METAL PARTICLES. THE RAPID CITY SCALE IS CR-OEPLETED

METAL PARTICLES WHICH ARE PARTIALLY OXIDIZED.

* * 4 * *

I.N. PROCESS SEARCH CRITERIA

101 C02 PIPING

OFFICIAL MINUTES OF CONSOL PILOT PLANT COIL CORROSION MEET ING ,5/ 1/74.

PREPARED BY S. Vi. WORDEN.

SUMMARY

OFFICIAL MINUTES OF CONSOL PILOT PLANT COIL CORROSION MEE TING, 5/ 1 /74.

PRIMARY SU8JECT WAS CORROSION OF THE GASIFIED PREHEATER COILS AND HOW TO

REDUCE THE RATES OF ATTACK. .THE SULFIDATION PROBLEM WAS CURED BYINSTALL ING

A 06SULFURIZER IN THE SYSTEM. THI S .HOWEVER , INTRODUCED A NEW TYPE OF CORROSION

CALLED "METAL DUSTING" WHICH IS NORMALLY CONTROLLED BY A LOW LEVEL SULFUR

CONTENT IN THE GAS. RESEARCH INTO THE PROBLEM WAS RECOMMENDED 1)FP.0M THE

MATERIALS EVALUATION VIEWPOINT AND 2 JCHANGI NG PILOT PLANT PROCEDURE.

APPENDICES-SUMMARY OF SHUTDOWN CAUSES WITH DETAILS.

-OPERATING CONDITIONS FOR 6 COILS

44
I.N. PROCESS SEARCH CRITERIA

96 . C02 PIPING

INFORMAL NOTES, 5/1/74 BY H.CEIR, OCR . CONOCO CORROSION CONFERENCE.

SUMMARY

PROBLEM AREA t HESTER TUBES IN GASIFIER RECYCLE GAS SERVICE.

CONSENSUS WAS THAT THE KEY TO SATISFACTORY INTERIM PERFORMANCE OF THE HEATER

TUBES WAS THE FORMATION AND MAINTENANCE OF AN IMPERVIOUS FILM ON THE TUBE

SURFACE. SUGGESTED WAYS,. I) SULFIDING, 2) OXIDIZING, 3) ALONIZING, 4) COATING

OTHER THAN ALONIZING. ALL OF CONOCO'S METALLURGICAL STAFF £ A. MAC NA8

FAVORED SULFIDATION. R. PERKINS, C. FINK, H. CEIR FAVORED OXIDATION.

PROS AND CONS OF EACH DISCUSSED. (OFFICIAL MINUTES TO BE PREPARED BY S.

WORDEN, CONOCO).

SEE I.N. 101 FOR OFFICIAL MINUTES. * * * * *

I.N. PROCESS SEARCH CRITERIA

102 C02 PIPING

FAILURE REPORT FROM F. R ADD TO C. FINK, CONOCO ,5/30/74.

INCOLOY 300 HEATER COILS

SUMMARY

HIGH TEMPERATURE CORROSION CAUSATIVE AND CONTROL ANALYSIS FOR INCOLOY 900

ALLOY HEATER COILS. MANY ALLOYS ARE SUBJECT TO AN EXTREMELY VIRULENT

FORM OF HIGH TEMPERATURE PITTING ATTACK { "METAL DUSTING"). AN INCOLOY 300

HEATER COIL SUFFERED A HIGH TEMO. CORROSION FAILURE WITH DEEP SPHERICAL

PITS WHICH COVERED 30-405? OF THE SURFACE. THIS COIL WAS SUBJECTED TO AM

ASSESSMENT OF THE MAJOR CONTROLLING VARIABLES AND THE PRINCIPAL CAUSATIVE

MECHANISMS INVOLVED THAT COULD LEAD TO SUCH AN ATTACK. METALLOGRAPHIC.

X-RAY DIFFRACTION, AND X-RAY MICROPROBE ANALYSES WERE USED IN THE EXAMINATION

OF THE COIL. EXPLANATIONS ARE GIVEN TO EXPLAIN THE CAUSE OF THE "METAL

DUSTING" PHENOMENON.

45
' " V

III
OXIDATIO

r.N. PROCESS SEARCH CRITERIA

191 WESTINGHQUSE AUXILIARY PROCESS EQUIPMENT

SCIENTIFIC PAPER, 11/25/75, RY L . AL8ERTIN AND J. CUNN INGHAM, WE ST I NG HOUSE ANO

S .TENDULK AR ANO P. CHER I SH, ENERGY SYSTEMS.

MATERIAL PR08LEMS IN A SYNTHESIS GAS GENERATOR FOR A MULTI-STAGE COAL

GASIFICATION SYSTEM

SUMMARY

GOOD PROCESS DESCRIPTION OF THE WESTINGHQUSE COAL GASIFICATION SYSTEM.

FAILURES:

1* NOZZLE PLATE AND NOZZLE EXPERIENCED A SEVERE FORM OF HIGH TEMP. CORROSION

BY CARBURIZATION AND OXIDATION DUE TO EXCESSIVE TEMP. AND ALTERNATING

REDUCING—OX ID I Z ING ENVIRONMENTS.

2- MELTING OF SHROUD MATERIAL WAS RESULT OF LOCAL OVERHEATING CAUSED BY

CRACKING OF THE NOZZLE PLATE-PILOT INLET HOUSING WELD , PRORA 8L E MALFUNCTION

OF SEVERAL NOZZLES, AND ACCUMULATION OF HEAVY CARBON DEPOSITS AHEAD O c THE BURNERS.

3. CRACKING IN THE SYNTHESIS GAS GENERATOR WAS RESULT OF EMBRITTLEMENT DUE

TO EXCESSIVE CARBIDE PRECIPITATION AND THERMAL STRESSES EXPERIENCED

DURING CYCLING.’

.RECOMMENDATIONS:

1. REDESIGN BURNER SECTION OF THE GENERATOR SO THAT HIGH TEMP. OF OPERATION

CAN BE AVOIDED.

2. USE INCONEL 601 WHICH HAS GOOO RESISTANCE TO CARBURIZATION AND OXIDATION.

3. EXPLORE THE USE OF REFRACTORY MATERIALS AND WATFR COOLING OF BtJRNEP

COMPONENTS TO PREVENT FUTURE GAS GENERATOR FAILURES.

* *

* * * *

N

49
I.N. PROCESS SEARCH CRITERIA

93 C02 PIPING

FAILURE REPORT, 2/7/74, 3Y R. PERKINS AMO W.COONS.LOCKHEED LAB TO CONSOL.

MET. ANALYSIS OF CORRODED IMCOLOY 800 TUBE FROM A RECYCLE GAS HEATER.

SUMMARY

MET ANALYSIS OF CORRODED INCOLOY 800 TUBE FROM A RECYCLE GAS HEATER.

THE TUBE HAD A VERY COMPLEX HISTORY. NOT REPRESENTATIVE OF NORMAL OPERATING

CONDITIONS.

CONCLUSIONS

1. THE PIPE HAS BEEN DEGRADED BY A COMBINATION OF CARBURIZATION,

SULFIDATION, AND OXIDATION.

2. CARBURIZATION IN DEPTH PRECEDED THE OTHER REACTIONS ANO ESTABLISHED A CR-RICH PHASE AT THF GRAIN BOUNDARIES.

3. INCOLOY 300 DOES NOT APPEAR TO HAVE ADEQUATE RESISTANCE TO OXIDATION

IN THE ENVIRONMENT FOR THIS APPLICATION. A HIGHER CR ALLOY WHICH CAN FORM

A MORE PROTECTIVE OXIDE PILM TO PETARD THE DIFFUSION OF CARBON ANO SULF'JR

TO THE UNDERLYING METAL MAY GIVE BETTER PERFORMANCE

.

ADDITIONS OF AL, TI , AND SI ALSO WOULD BE HELPFUL.

* * * * *

I.N. PROCESS SEARCH CR ITERIA

54 C02 PIPING

FINAL REPORT, 10/9/75, FROM L .WOLFE , PONCA CITY, TO J. LETERLE .CONOCO

.

EXAMINATION OF TYPE 321 S.S. FURNACE TUBE FROM B205 FURNACE

summary

FAILURE: FURNACE TUBES HAVE EXPERIENCED FREQUENT TROUBLE FROM THINNING.

THINNING ORIGINATES FROM INSIDE OF TUBES.

SERVICE LIFE: UNKNOWN

••ENVIRONMENT : 900F. 3-4? CO, 26? C02, 70? N2, 20-75 PPM COS.

MATERIAL: 32L S.S. 1-5/8” OD X 0.109” W.T.

RESULTS

1. INITALLY GET CARBURIZATION, NITRIOING, AND SOME SULFIDATION

THEN GET OXIDATION.

2. SULFUR ATTACK OCCURS, BUT NOT ENOUGH TO BE SIGNIFICANT AT THESE

TEMPERATURE.

3. MAJOR METAL LOSS AND THINNING IS DUE TO OXIDATION OF CHROMIUM.

4. THINNING IS FROM INSIDE. OXIDATION ON OUTSIDE IS ALONG GRAIN BOUNDARIES.

50
I.N PROCESS search criteria

55 C02 PIPING

L ETT ER»II/I7/75fFRC>M J * LET ERIE » CONOCO, TO 0. GLASER STEARNS ANO ROGER.

HEATER B-205 EXAMINATION AFTER RUN 26A

SUMMARY

0 ISCUSS ION OF EXCESSIVE THINNING OF FURNACE HEATER TUBE OUE TO OXIOATION

ANO SULFIDATION. EXPECTED SULFUR LEVEL IS 10-100 PPM AT 9C2F AS COS. THIS IS

TOO LOW FOR AMOUNT OF DAMAGE SEEN IN TIME EXPOSED. MUST BE UNEXPECTED

SULFUR PRESENT.

RECOMMEND: INSTALL FILTER TRAP TO ANALYSIS SOLID PARTICLES IN FEED STREAM TO

FIND SOURCE OF EXCESS SULFUR.

* * * * *

r.N» PROCESS SEARCH CRITERIA

392 EXXON PIPING

1NTRALAB REPORT, 6/30/75 , FROM J.SLUSSER TO D.KINZLER , EXXON RESEARCH £ ENGR.

ANALYSIS CF COOLING COIL SAMPLES

SUMMARY

FAILURE: HEAVY CORROSION ANO METAL LOSS IS OCCURRING ON EXTFRIOR SURFACES

OF TUBE ELBOWS. STRAIGHT SECTIONS HAVE MINOR PITTING CORROSION.

SERVICE LIFE: 60 HRS.

ENVIRONMENT: C02,S02,02 AT TEMPERATURES OF 15C0-1850 F .TUB ES I DE , COOL T NG WATER.

MATERIAL: TUBES ARE 3/4" 00,0.048" W.T. 316 S.S. ELBOWS ARE 316L S.S..

CAUSE: HIGH TEMPERATURE GAS A TTACK ( OXI DAT ION , SULF ID AT ION ) HAS CAUSED MOST

OF THE CORROSION. PITTING CORROSION POSSIBLY CAUSED BY HIGH TEMPERATURE

SLAG ATTACK. WORST CORROSION ANO mcjal LOSS OCCURRED ON TUBE ELBOWS DUE TO

CONTINUOUS EROSION OF THE CORROSION PROOUCT RESULTING IN THE CONSTANT

EXPOSURE OF FRESH SURFACES TO THE CORRISIVE MEDIUM.

.'RECOMMENDATIONS: COOLING WATER SH^ULO BE TURNED ON AT STARTUP CF THE REACTION

TO KEEP TUBING TEMPERATURES < 1600 F.IF THIS IS IMPRACTICAL THEN USE

310 S.S. WHICH HAS BETTER HIGH TEMPERATURE CORROSION RESISTANCE.

51
I.N PROCESS SEARCH CRITERIA

13 HYGAS PIPING

FAILURE ANALYSIS R EPORT t l 1/30/ 73* FROM M. HOWES I I TR I .TO F.SCHORA, IGT.

METALLOGRAPHIC EXAMINATION OF FIVE SAMPLES FROM THE HYGAS PLANT

SUMMARY

1* SLURRY ORYER GRID: INCOLOY 800. SERVICE LIFE OF 6 MONTHS. ENVIRONMENT.

LIGNITE 3ED AT 6C0 F FLUIDIZED WITH A GAS (CONTAINS 15 H2S) AT 1200 F AND 1000 PSI. FAILURE OCCURRED BY CORROSION AT SCREW THREADS.RECOMMEND

COATING ANO REDESIGN TO ELIMINATE SCREW THREADS.

2. WELDED 4 X 3 IN REDUCER: 446 S.S. SERVICE LIFE OF 6 MONTHS. ENVIRONMENT.

1500 F AT 25 PSI .FLUIDI ZED LIGNITE-INTERNAL. NIT POGEN-EXTE0!N AL . FA ILUR

E

CAUSED BY CRACK THAT STARTED IN THE WELD BETWEEN THE PIPE AND FLANGE AMO

PROPAGATED IN BO^H D I R ECT I GNS . RE A SON BEING MATERIAL EMBRITTLEMENT AND

RESIDUAL STRESSES. RECOMMEND STRESS RELIEVING.

3. BELLOWS: INCOLOY 800(20 GAUGE ). SERVICE LIFE OF 9 MONTHS. ENVIRONMENT.

1650 F IN A CORROSIVE ATMOS PHERE . FA I LURE OCCURRED BY COMBINATION OF

SURFACE OXIDATION AND INTERGRANULAR ATTACK . RECOMMEND REDESIGN.

4. REFORMER QUENCH POT SHELL: INCOLOY 900. SERVICE LIFE OF 6 MONTHS. ENVI R0NM6NT

1650 F AT 100 PS I. FAILURE DUE TO THERMAL FATIGUE CAUSED BY FLUCTUATING

TEMPERATURE CONDITIONS. RECOMMEND REDESIGN.

5. BUTTS'? FLY VALVE: 446 S.S. SERVICE L I EE OF 2 YEARS. ENVIRONMENT. 1400 F.

FAILURE DUE TO INTERNAL CORROSION ANO RESIDUAL STRESSES. RECOMMENO

STRESS RELIEVING.

* * * * *

I.N. PROCESS

65 M I SC.

REPORT, 6/27/74, FROM W. SALOT, ALL I ED CHEMICAL CORP.

TROUBLE WITH HK-40 HIGH-PR ESS. REFORMER TUBE OPERATION IN AMMONIA PLANTS

\

SUMMARY

SUMMARY OF DATA FROM REFORMER INFORMATION NETWORK. NETWORK CONSISTS OF 16

MEMBERS COVERING 21 REFORMERS.

1. TUBE LIFE IMPROVEMENTS HAVE BEEN ACCOMPLISHED WITHOUT COMPLETE TUBE

REPLACEMENT.

2. PROJECTED AVERAGE TUBE LIFE HAS INCREASED SUBSTANTIALLY SINCF 1972.

3. SLIGHT* INCREASES IN TUBE W.T. OVFR 1ST GENERATION REFORMERS NO LONGER

APPEARS DETRIMENTAL. AN OPTIMUM THICKNESS MAY EXIST.

4. REPLACEMENT TUBE S°ECS COVER A VARIETY OF CHANGES IN THICKNESS, MATER IALS

AND OTHER REQUIREMENTS.

5. THESE REFORMERS ARE BEING COMPLETELY RETUBED WHEN MOST OF THEIR TUBES

STILL HAVE MANY YEARS REMAINING LIFE.

SEARCH CRITERIA

PIPING

52
I . N •- PROCESS SEARCH CRITERIA

8 HYGAS THERMOCOUPLES

FAILURE ANALYSIS REPORT, 7/25/75, BY A. MAC NAB,C .F.8RAUN CO.

THERMOCOUPLE SHEATHS-HYGAS

SUMMARY

FAILURE: THERMOCOUPLE TUBES USED IN THE STEAM-OXYGEN GASIFIER WERE 3EC0MING

EMBRITTLED AND CORRODEO AFTER SHORT EXPOSURES.

SERVICE LIFE: UNKNOWN

ENVIRONMENT: 200CF. 0 .4* H2S.

r MATERIAL: INCONEL 600 AND INCONEL 70*.

iCAUSE: "GREEN ROT" CORROSION WAS THE PRIMARY MECHANISM. OCCURS IN WFAKLY

OXIDIZING ENVIRONMENT. SULFIOATION ALSO OCCURRED AND THIS WAS O'JE TO

EXPOSURE TO REDUCING SULFIDE CONDITIONS.

RECOMMENDATIONS

L. USE AIR/NITROGEN PURGE.

2- CHANGE MATERIAL TO 310 S.S. OR INCOLOY 300.

3. LOWER N I CONTENT, INCREASF AMOUNT OF FE AND CR IN ALLOYS USED.

* * * *

I.N. PROCESS SEARCH CRITERIA

14 HYGAS- THERMOCOUPLES

FAILURE ANALYSIS REPORT , 10/ 14/75 , BY K. NATES AN, ANL.

ANALYSIS OF THERMOCOUPLE FROM HYGAS

summary

FAILURE ANALYSIS OF THERMOCOUPLE IN STEAM-OXYGEN GASIFIER

ENVIRONMENT: 1200 F,500 PSI STEAM

FAILURE CAUSE: INTERNAL OXIDATION OF CR AND AL CAUSES CRACKING

OXIDATION DEPENDS STRONGLY ON CR CONTENT AND TEMPERATURE

RECOMMEND: INCREASE CR TO CREATE PROTECTIVE LAYER OF OXIDE USE

310 S.S.

53



r.N PROCESS SEARCH CR ITER I A 363 CLEAN COKE BELLOWS

QUARTERLY REPORT, 2/77, BY USS ENGINEERS AND CONSULTANTS, INC.

CLEAN COKE PROCESS-REPORT FOR FOURTH QUARTER 1976

SUMMARY

BINDER PREPARATION PQU: A LEAK OCCURRED IN THE 321 S.S. EXPANSION BELLOWS

LOCATED BETWEEN THE MAIN FEED HE AT EP AND THE CONTINUOUS COLUMN. EXAM.

REVEALED PITTING ON THE INTERIOR SURFACE OF THE LEAK AREA. THE OIL THAT

FLOWED THROUGH THE BELLOWS CONTAINED 247 PPM OF CHLORIDE ION AND 0.8% WATER

NORMAL OPERATING TEMPERATURE IS 450 F .THE DESIGN WAS SUCH THAT THE OIL

COULD NOT BE COMPLETELY OR A I NED FROM THE SYSTEM DURING DOWNTIME.

THE CORROSION COULD HAVE OCCURRED DURING THIS PERIOD OR CO'.JLO 8E DUE T 0

THE CHLORINE IN THE OIL.

k A NEW COIL HAS 8EEN FABRICATED OF 316 S.S. ANO THE DESIGN MODIFIED TO

ALLOW COMPLETE DRAINAGE OF OIL FROM THE SYSTEM OURING DOWNTIME. * * * * *

I.N. PROCESS SEARCH CRITEPIA

110 C02 BELLOWS

FAILURE REPORT FROM H. CROWDER TO J . L ETERL 6 , CONOCO, 1 1 / 1 9/74.

FAILURE OF S.S. BELLOWS FROM LINE CD-206

SUMMARY

FAILURE OF S.S. BELLOWS FROM LINE CD-206

FAILURE: PITTING CORROSION OF BELLOWS FROM ACCEPTOR TRANSFER LINE BETWEEN

THE REGENERATOR AND THE GASIFIER.

CAUSE: MOIST DEPOSITS ON TNNER SURFACE OF BELLOWS. PRESENCE OF CHLORIDES.

RECOMMENDATIONS: NONE MAOE.
I.N. PROCESS SEARCH CRITERIA

113 C 02 BELLOWS

FAILURE ANALYSIS REPORT SUMMARY FROM S.T.MCLAURY TO 0. GLA SE R, CONOC 0 , l 2/9/ 74.

BELLOWS FROM EJ-4 AND EJ-5.

SUMMARY

BELLOWS FROM EJ-4 AND EJ-5.

EJ-4 9ELL0WS-F AILED BY SCC-CL.

EJ-5 BELLOWS-FAILEC BY PITTING CORROSION ALSn DUE TO CHLORIDES.

SINCE OPERATING

CRACKING OCCURRED

OTHER BELLOWS.

CONDITIONS ARE

IN ONE BELLOWS

PRESUMED TO

AND PITTING

BE THE SAMF IT IS UNKNOWN WHY

CORROSION OCCURRED IN THE

4e 4= < * * 4e

I .N. PROCESS SEARCH CRITERIA

236 , HYGAS BELLOWS

TELECOM, 4/27/76, FROM S. GREEN BFRG»ANL»TO B .ORCHARD, I GT

.

EXPANSION JOINT-GASIFIER TRANSFER LINE.

SUMMARY

SEM AND OPTICAL EXAM. REVEALED PITS ON INTER

I

n R AND EXTERIOR SU^FACFS IN THE

VICINITY OF COMPLETE PERFORATIONS BUT NOT IN AREAS OF APPARENTLY SOUND METAL.

X-RAY ANALYSIS ESTABLISHED THE PRESENCE OF METAL-COAL REACTION PRODUCTS

IN CLOSE PROXIMITY TO THE EDGE OF A PERFORATION. IT WILL BE ESTABLISHED

WHETHER THIS IS UNIQUE TO PERFORATED AREAS OR HAS BROAD DISTRIBUTION.

BELLOWS FAILURE RESULTING FROM INITIAL DEFECTS! MANUFACTURING) MUST ALSO

BE CONS IOERED.

SEE I.N. 186,194, 210, 274,285, 286 FOR FURTHER INFORMATION.

58
I.N PROCESS SEARCH CRITERIA

286 HYGAS BELLOWS

TELECOM, 5/12/76 AND 5/13/76, FROM S. GREENBERG, ANL, TO B. ORCHARD, IGT.

EXPANSION JOINT-GASIFIER TRANSFER LINE.

SUMMARY

MANY HOLES AND PITS DISCOVERED IN INCCLOY 803 BELLOWS. DEPOSIT ON INNER

SURFACE IS MAINLY THE RESULT OF COUNTER-CURRENT CLEANING OPERATIONS.

CORROSION FILM ON EXTERIOR TS RESULT OF CONTAMINATION OF N2 ATMOSPHERE by

IN-LEAKAGE OF COAL, PRODUCT GAS, OIL AND WATER. METALLOGR A PH I C ANALYSIS

INDICATES PITTING INITIATED AT INSTOE SURFACE. WATER CONDENSATION DURING

SHUTDOWN MAY BE A CONTRIBUTING FACTOR. EVIDENCE FOUND OF SULFIDATION AND

OVER-TEMPERATURE 0PEPATICN_(1450F). NORMAL OPERATING TEMP. IS IOOOF. ~ MATERIAL RECOMMENDATIONS

1 ^ IF PITTING ATTACK IS CAUSE OF FAILURE, 316 OR 317 S.S. COULD BE USED

(USE INVOLVES RISK OF SCC).

2. IF HIGH TEMP. GASEOUS CORROSION IS ALSO IMPORTANT THEN INCONEL 625 OR

HASTELLOY C WOULD 35 PREFERABLE (ALSO REDUCE RISK OF SCO.

SEE I.N. 136, 194, 210, 236, 274, 235 FOR FURTHER INFORMATION.

*

I.N.

*

PROCESS

*

SEARCH CRITERIA

194 • HYGAS BELLOWS

TELECOM, 6/2/76, FROM S.GR EENBEP G, A NL , TO B. BAIR, IGT

•

EXPANSICN JOINT-GASIFIER TRANSFER LINE.

SUMMARY

ANALYSIS OF COAL PRODUCT FOUND IN BELLOWS SHOWED A SOLUBLE CHLORIDE CONC.

OF APPROX. 0.2 7. THUS PITTING CORROSION HYPOTHESIS IS POSSIBLE.

FUTURE BELLOWS MIGHT 3E FABRICATED FROM ALLOYS RESISTANT TO PITTING CORPOSION

316 OR 317 S.S. , INCONEL 625 ,H* STELLOY C. HOWEVER, NO EXISTING MATERIAL MIGHT

BE SATISFACTORY FOR 30TH AQUEOUS PITTING CORROSION AS WELL HIGH TEMP.

SULFIDATION IN TERMS OF A LONG SERVICE LIFE.

SEE I.N. 136,210,236,274,285,286 FOR FURTHER INFORMATION.

59
I.N. PROCESS SEARCH CRITERIA

161 C02 PIPING

REPORT BY R. PERKINS AND W . COON S , l 1 / 1 9/ 75 . METALLURG I C Al ANALYSIS OF INCOLOY 3C0

TUBE FROM B— 20 1 1A HEATER COIL AFTER RUNS 20-22.

SUMMARY

METALLURGICAL ANALYSIS OF INCOLOY 300 TUBE FROM B-201-1A HE AT rR COIL AFTER

RUNS 20-22. FOLLOW—

U

D TO PREVIOUS LOCKHEED REPORT t LMSC-D407190 ) . THAT

REPORT DESCRIBED PITTING IN THE COIL UP TO RUN NO. 19. THE ANALYSIS IN THIS

REPORT WAS FROM A SAMPLE TAKEN AFTER RUN NO. 22.

CONCLUSIONS

1. PREEXISTING PITS DID NOT GROW IN SIZE AND NEW PITS DIO NOT FORM DURING

A 5 1 0—HR EXPOSURE OF INCOLOY 800 PIPE TO RECYCLE GAS WITH THE ADDITION

OF 30—50'S STEAM.

2. THERE WAS NO SIGNIFICANT INCREASE IN THE AMOUNT OF INTERNAL CARBURIZATION

AND SULFIDATION DURING THIS EXPOSURE.

3. THE ADDITION OF >30^ STEAM TO the PECYCLE GAS COUPLED WITH LITTLE. IF ANY

EXPOSURE TO ALTERNATE REDUCING/OXIDIZING CONDITIONS APPEARS TO BE

RESPONSIBLE FOR THE GOOD RESISTANCE TO HIGH-TEMPERATURE PITTING.

* * # * *

I.N. PROCESS SEARCH CRITERIA

392 EXXON PIPING

INTRALAB REPORT , 6 /30/ 75 , FROM J.SLUSSFP TO D.KI NZLER, EXXON RESEARCH £ 6NGR.

ANALYSIS CF COOLING COIL SAMPLES

SUMMARY

FAILURE: HEAVY CORROSION AND METAL LOSS IS OCCURRING ON EXTFRIQR SURFACES

OF TUBE ELBOWS. STRAIGHT SECTIONS HAVE MINOR PITTING CORROSION.

SERVICE LIFE: 60 H»S.

ENVIRONMENT: CC2.S02.02 AT TEMPERATURES OF 1500-1850 F . TUBES I DE , COOL TNG WATER.

MATERIAL: TUBES APE 3/A” nr,, r. 043” W.T. 316 S.S. ELBOWS APE 316L S.S..

CAUSE: HIGH TEMPERATURE GAS A TT ACK ( OX I DAT ION . SULF I DAT I ON ) HAS CAUSFO MOST

OF THE CORROSION. PITTING CORROSION POSSIBLY CAUSED BY HIGH TEMPERATURE

SLAG ATTACK. WORST CORROSION ANO LOSS OCCURRED ON TUBE ELBOWS DUE TO

CONTINUOUS EROSION OP THE CORROSION PRODUCT RESULTING IN THE CONSTANT

EXPOSURE OF FRESH SURFACES TO THE CCRRISIVE MEDIUM.

RECOMMENDATIONS: COOLING WATER SHOULD BE TURNED ON AT STARTUP OF THE REACTION

TO KEEP TUBING TEMPERATURES < 1600 F.IF THIS IS IMPRACTICAL THEN USE

310 S.S. WHICH HAS BETTER HIGH TEMPERATURE CORROSION RESISTANCE.

60
T.N* . PROCESS SEARCH CRITERIA

10 HYGAS PIPING

FAILURE ANALYSTS RE°ORT , 10/31/74, BY A. MAC N AB, C. F. BR AUN AMD CO.

FAILURE OF CARBON STEEL CONDENSER TUBING

SUMMARY

PITTING AND NONUNIFORM CORROSION OF CARBON STEEL PIPE IN HEAT EXCHANGER.

ATTACK IS FROM INSIDE OF TUBING INDICATING AN AGGRESSIVE ENVIRONMENT IN

PROCESS RAW GAS COND6NS ATE. PIPE IS 3/4"0D X 0.965" W.T. CARBON STEEL. IN

SERVICE FOR 6 MONTHS GASIFICATION OUT OF THREE YEARS USE. ENVIRONMENT:

PROCESS CONDENSATE IS HIGHLY ACID. AMMONIA AOOEO FOR PH CONTROL.

METAL LOSS: 53 MILS MAX, 33 MILS AVG.

* * *

I.N. PROCESS SEARCH CRITERIA

233 LIGNITE PIPING

PARTIAL REPORT, NO AUTHOR , NO DATP.

CORROSION OF PDU COMPONENTS- PR OJ EC T LIGNITE

SUMMARY

SUMMARY OF 22 GENERAL SAMPLES SHOWING CORROSION AND/OR EROSION. 16 SAMPLES

SHOWED SCC, 3 SAMPLES SHOWED PITTING ATTACK AND 3 SUFFERED FROM EROSION.

REMEDIAL SOLUTIONS

1. REPLACED 316 S.S.. WITH INCOLOY 800 FOR NEW COILS, DISSOLVERS AND FLUID

LINES.

2. REPLACED CARBON STEEL SEPARATORS WITH CAST 316 S.S.

3. THERMOCOUPLE SHEATHS REPLACED WITH INCONEL 600.

4. EVALUATE NOT FOR CRACK DETEC T ION

•

5. CHECK FOR CAUSATIVE AGENTS OTHER THAN CHLORIDES.

61
I.N. PROCESS SEARCH CRITERIA

141 LIGNITE PIPING

FAILURE ANALYSIS REPORT » 3/ 14/75 , S Y L .OV c R STRE ET , RAL PH PARSONS CO.

METALLURGICAL ANALYSIS OF STAINLESS STEEL SAMPLES

SUMMARY

METALLURGICAL ANALYSIS OF STAINLESS STEEL SAMPLES

TYPE 316 S.S.HEAtc R COILS ARE CRACKING FROM CL-SCC .CRACKS HAVE BEEN MOST

SEVERE IN AREAS OF HIGH °ESIDUAL STRESS FROM COLD WORKING AMD AT POINTS

WHERE A CHLORIDE CONCENTRATING MECHANISM SUCH AS FLASHING WATER HAS SEEN

OPERATIVE.

HEATER OUTLET! ABOUT 800 F ) AND THE HIGH PRESSURE SEP ARATOR ( ABOUT 550F).

CHLORIDE SCC HAS OCCURRED WHEPEEVE 1? TENSILE STRESSES HAVE SEE'! PRESENT.

COLD WORK HAS PROVIDED THE CHIEF SOURCE OF TENSILE STRESS, BUT STRESSES FROM

WELDING AND, POSSIBLY, OPERATIONAL STRESSES ( INTERNAL HOOP STRESS AND BENDING OF

PIPING INSTALLATION OR FROM THERMAL EXPANSI ON ) AR E ALSO PRESENT.

CL STRESS CORROSION TN THE TYPE 316 S.S. HEATER TUBE HAS NOT BEEN ACCOMPANIED

BY PITTING. ON THE OTHER HAND CRACKS IN TY°E 304 S.S. HAVE ALWAYS STARTED AS

PITS. THE ONLY PITTING OCCURRING IN TYPE 316 S.S. WAS IN A SENSITIZFD REGION

WHlClB CONTAINED NO C°ACKS.

LOCALIZED CORROSION IN THE FORM OF PITTING AND WASHING AWAY OF A SMALL AREA

OF THERMOCOUPLE AND STRAIGHT PIPING to E-3 WAS THE RESULT OF ACID ATTACK.

LOWERING OF STP ESSES BY STRESS-RELIEF AND ALLOY CHANGES ARE THC PRIMARY

RECOMMENDATIONS FOR ELIMINATING THE CHLORIDE CRACKING PROBLEM.

APPENOIX B: SUMMARY OF METAL FAILURES 0UP TO CORROSION WHICH HAVE OCCURRED

IN PROJECT LIGNITE FROM INITIAL START-UP TO 7/24/75.

* * * * £

62
I.N. PROCESS SEARCH CRITERIA

280 LIGNITE PIPING

SUMMARY REPORT, 3/6/76 »FPOM D.C ANONI CO , OAK RIDGE NATIONAL LAB.

WORK DONE BY TOM SCOONOVER ON PROJECT LIGNITE

SUMMARY

PREHEATER COIL FAILURES: E-l COIL NO.l. COIL WAS CONSTRUCTED OF 95» OF

9/I6"0D X 5 / 1 6 " I D COLD DRAWN 316 S.S. TUBING WHICH HAD BEEN FABRICATED INTO

A HELICAL COIL APPROX. DIAM. OF 9-9/ 16” .COIL FRACTURED AT BOTTOM NEAR SLURRY

INLET AFTER A80UT 4CD HRSI125 HR.S WITH COAL ) .T EMP . 750-800F . PR ESS . 1250-1 500PS I

G

6—1 COIL NO. 2. FRACTURED IN SERVICE AFTER 250 HRSI20D HRS WITH COAL).

6-1 COIL NO. 3. FRACT URED IN SFRVICE AFTER ONLY 28 HRS(13 HRS WITH COAL).

COIL FRACTURED NEAR TOP ABOUT 60'* FROM SLURRY INLET. THIS COIL HAD BEEN

ANNEALED PRIOR TO FABRICATION.

ANALYSES BY PROJECT LIGNITE STAFF, GULF RSD CO., RALPH PARSONS CO. DETERMINED

THAT CAUSE OF FAILURE WAS SC C- CL. REPLACED 316 S.S. COILS WITH TNCOLOY BOO.

THERMOWELLS: PERFORATIONS OF SHEATHS WITH RESULTANT LEAKAGE-LOCATED AT EACH

END OF COOLER 6-2 IN THE LINE FROM DISSOLVER R-L TO THE SEPARATER S-l.

FABRICATED AT PLANT FROM 1/3" 00 304 S.S. PARSONS CO. ANALYSIS SHOWED 1)

DEEP PITTING, 2)T? ANSGR ANULAR SCC AT BOTTOM OF PITS .REPLACED WITH INCONEL 600

ONLY HIGH N I ALLOY READILY AVAILABLE IN REQUIRED FORM.

DISSOLVER VESSELS: SLOW LEAK DEVELOPED AT BOTTOM CLOSURE(OUTLET) OF ONE OF

THE TWO DISSOLVER VESSELS .CONSTRUCTED OF A 19*3" LENGTH OF 316 S.S. PIPE

WITH A 4— 1/2 "00 X 3-7/16" I D. ALL P I P I NG , CLOS UR E S, ETC. WERE OF 316 S.S.

CRACKING OCCURRED ON ALL CLOSURES BUT WAS SEVERS ON OUTLET CLOSUPES .ANALYS I

S

BY PROJECT LIGNITE STAFF REVEALED BRANCHED TRANSGR ANULAR SCC. REPLACED

MATERIAL WITH INCOLOY 3C0.

SEVERAL ADDITIONAL EXAMPLES A° E SHOWN OF CORR OSI ON , EROS ION, AND SCC

MOSTLY IN 316 S. S. COMPONENTS .ALL RE° LAC ED WITH INCOLOY 800. BANNED USE OF

TRICHLOROETHANE-HELP TO ELIMINATE CL. SINCE MAKING THE ALLOY CHANGES, MANY

HUNDREDS OF HOURS OF SERVICE INDICATES NO SCC OR SEVERE PITTING.

* * * * *

63
I.N. PROCESS SEARCH CRITERIA

401 MISC. PRESSURE VESSEL

REP0RT,2/76,8Y M. LAV IGNE, CANADA CENTRE FOR MINERAL AND ENERGY TECHNOLOGY.

SELECTION OF MATERIALS AND FABRICATION METHODS FOR A DEMONSTRATION

PLANT PRESSURE VESSEL

SUMMARY

METALLOGRAPHIC EXAMINATION OF 5 SAMPLES CUT FROM THE HOTTEST SECTIONS OF

THE ENERGY RESEARCH LABORATORIES 1 8BL/DAY PILOT PLANT.

l_ THIRO HEATER TUBE OF FEED LINE TO THE REACTOR VESSELS: 304 S.S.TUBE

(APPROX. 3 FT. LONG X 9/16" 00 X 5/32" ID) OPERATING TEMP. ,450 C.

REMOVED AFTER 6 MONTHS OPERATION DUE TO BEING PLUGGED. EXAM REVEALED NO

CORROSION. CHROMIUM CARBIDES WERE PRECIPITATED AT GRAIN BOUNDARIES AND

ON SLIP PLANES.

2. CENTRAL THERMOCOUPLE WELL OF THE VESSEL: 304 S.S. TU8E< APPROX. 12. 5 FT

LONG X L/2 "QD X 1/4" ID). END SEALED BY WELDING. THE WALL OF THE TUBE

HAD NO CORROSION. SOME CORROSION PRODUCTS WERE DEPOSITED ON A SECTION

OF THE WELD.

3. TOP PLUG OF PRESSURE VESSEL: 1-1/2" OD 316 S.S. SERVICE LIFE OF 2 YEARS.

INNER SURFACE OF PLUG WAS PITTED TO A DEPTH OF 0.002".

4.

TU8E FROM PRFSSURE VESSEL TO HOT RECEIVERS: 304 S.S. TUBE { 1/4" OD X 1/8" ID) CARRIED THE PRODUCTS FROM THE PRESSURE VESSEL TO THE HOT

RECEIVER AT TEMPERATURES OF 370-460 C . EX AM I NAT I ON REVEALED INTERGRANULAR

PITTING CORROSION WITH GENERAL CORROSION ALSO OCCURRING.

5.

HOT RECEIVE* DOWN TUBE: 304 S.S. SAMPLE TAKENG FROM FIRST SECTION OF THE

DOWN TUBE WHERE OPERATING TEMPERATURE IS 370 C. EX AM INAT ION

REVEALED PITTING CORROSION ON BOTH OD AND ID OF PIPE.

DESCRIPTION GIVEN OF VARIOUS FABRICATION METHODS FOR ASSEMBLY OF PRESSURE

VESSELS

.

THE RESULT OF THIS INVESTIGATION WAS THE SELECTION OF 316 S.S. FOR USE IN

THE PRESSURE VESSEL ANO RELATED COMPONENTS.

* * * . * . *

64
I.N. PROCESS SEARCH CRITERIA

350 PERC PIPING

REPORT, 1/26/77, BY R . COOPER ,ORNL

CORROSION ANALYSIS OF BOILER TUBES FROM A IOO HP BOILER

SUMMARY

ANALYSIS: CORROSION ANALYSIS WAS PERFORMED ON AI78 BOILER TUBE SEGMENTS

REMOVEO FROM A 100 HP BOILER OPERATED BY PERC.

SERVICE LIFE: 1000 HRS

ENVIRONMENT: 340F STEAM ANO FLUE GAS GENERATED FROM THE COMBUSTION OF NO 6

FUEL OIL-COAL SLURRY.

MATERIAL: CARBON STEEL. ASTM A178 SPEC.

DISCUSSION: STEAM SIOE CORROSION CAUSED LOCALIZED AREAS OF PITTING ANO

HEAVY SCALE ON PI°E EXT ER IORS .TH IS MAY RESULT FROM EITHER EXPOSURE TO

ATMOSPHERIC CONDITIONS DURING BOILER SHUTDOWN AND DI SASSE'*BLY OR AN

INCREASED DISSOLVED OXYGEN CONTENT OF THE BOILER WATER DUE TO IMPROPER

PROCESS CONTROL.

FLUE GAS CORROSION RESULTED IN A 3 MIL SCALE FORMING ON THE INTERIOR

WALLS OF THE PIPES. A LARGE PART OF THF SCALE OBSERVED ON THE TUBE WALLS

COULD BE THE RESULT OF EXPOSURE TO AN ACIDIC CONDENSATE FORMED DURING

THE MANY SHUTDOWN CYCLES. SOME OF THE SCALE MAY HAVE FORMED AS A RESULT

OF EXPOSURE OF THE TUBES TO ATMOSPHERIC CONDITIONS FOLLOWING REMOVAL

FROM THE FURNACE.

CONCLUSIONS

1. ANALYSIS REVEALED A MEASURA8LE CORROSION SCALE ON THESE TUBES.

2. WHAT FRACTION OF THIS CORROSION IS THF RESULT OF THE FLUE GAS ENVIRONMENT

IS UNKNOWN.

3. ADDITIONAL ANALYSIS CF THESE TUBE SEGMENTS WILL NOT PROVIDE USEFUL DATA.

4 • SINCE THERE IS NO PRACTICAL METHOD OF UTILIZING SURVEILLANCE COUPONS, T HE

DESTRUCTIVE ANALYSIS OF 30TLER TUBES IS THE ONLY AVAILABLE METHOD FOR

MEASURING CORROSION.

5. THESE MEASUREMENTS WILL ONLY PRODUCE MEASUREMENTS OF SCALE THICKNFSS

AND NOT PRECISE METAL LOSS DATA.

RECOMMENDATIONS

1. SURVEILLANCE TUBES SHOULD INITIALLY BE CORROSION FREE.

2. AS RECEIVED MATERIAL SHOULD BE SEALED IN AN INERT ATMOSPHERE AND HELD

FOR REFERENCE.

3. AN EFFORT SHOULD BE MADE TO MINIMIZE THE NUMBER OF SHUTDOWN AND

START-UP CYCLES. . 4. SAMPLE TUBES SHOULD BE EXPOSED FOR A MINIMUM OF 1000 HRS.

5. AT END OF RUN, TUBES SHOULD BE PROMPTLY REMOVED FROM THF BOIL ER, SECT IONED

INTO SAMPLES, SEALED IN AN INERT ATMOSPHERE , AND SENT TO THE TgSTING LAB.

* * * * *

65
r.N. PROCESS SEARCH CRITERIA

201 SYNTHAN 6 PIPING

FAIL. ANALYSIS RPT .*4/30/76* FROM L.ODEN , ALBANY MET. R ES . CTR . * TO F. GROM I CKO, PERC

.

EVALUATION OF CRACKED 316 S.S.PI°E SECTION FROM SYNTHANE PILOT PLANT

SUMMARY

THE FAILED PREHEATER PIPEIFROM THE GAS DISENGAGEMENT ZONE IN THE GAS

ENTRAINED FEED SYSTEM)SHCW$ GENERAL CORROSION AND PITTING OF THE INNER

SURFACE IN AOOIT ION TO SEVERE CRACKING WHICH IS PROBABLY SCO. THE CRACKING

rS BOTH INTER-AND TRANS-GR AMULAR

.

THE PIPE IS WELDED AND THE WELD METAL WAS ATTACKED LESS SEVERELY

THAN THE PARENT *ETAL.NO SENSITIZATION OF METAL ADJACENT TO WELD WAS OBSERVED

.OR CRACKING OF WELD METAL.

ELECTRON MICROPROBE ANALYSIS OF SCALE SHOWS SULFUR AND CHLORINE PRESENT

IN PROPORTIONS OF 5-10 S.

316 S.S.IS SUSCEPTIBLE TO CHLORIDE IONS. QUANTITY OF CHLORINE IN SCALE

INDICATES A CONTINUOUS SUPPLY FROM THE GAS STR EAM. SULFUR ACCENTUATES CORROSION

BY DECREASING THE PROTECTIVE NATURE OF THE OXIDE SCALE. RECOMMEND USING

CARBON DRUM TO REMOVE IMPURITIES FROM THE GAS.

* * & * *

I.N. PROCESS SEARCH CRITERIA

365 SYNTHANE PIPING

TELECON, 3/31/77, FROM S. OANYLUK , ANL , TO D.DURIS, SYNTHANE.

BALLOONING OF C-MO STEEL PIPE AND PITTING IN CYCLONE DIPLEG

SUMMARY

A. BALLOONING OF C-MO STEEL PIPE

1. DESIGN TEMP. AND PRESSURES COULD NOT PROVIDE SUFFICIENT STRESS TO

PLASTICALLY DEFORM THE PIPE.

2. WALL THICKNESS MEASUREMENTS SEEM REASONABLE.

3. TENSILE TESTS , HARDNESS TESTS, CHEMICAL ANALYSIS AND METALLOGRAPHIC

ANALYSIS WILL 8F- performed.

4. AT PRESENT CAUSE OF BALLOONING IS UNKNOWN.

B. CYCLONE DI PLEG-INCOLOY 800

1. CORROSION PITS HAVE DEVELOPED.

2. SECTIONS OF PIPE ARE TO BE SHIPPED TO ANL.

3. SYNTHANE REQUESTS MATERIAL IDENTIFICATION AND REASON FOR PITTING.

SEE I.N. 356,357 FOR FURTHER INFORMATION ON BALLOONING PROBLEM.

66
I.N. PROCESS SEARCH CRITERIA

407 SYNTHANE PIPING

TELECON, 5/31/77, FROM S . DANYLUK , ANL , TO D .DU8 IS , SYNTHANE

.

PITTING IN THERMOWELL TE-205G

SUMMARY I FAILURE: PITS, APPROX. 1/16" DEEP, HAVE BEEN SEEN IN GASIFIER THERMOWELLS.

SERVICE LIFE: APPROX. 500 HRS.

ENVIRONMENT: TEMP. 1500-1600 F.

MATERIAL: HASTELLOY C — 27 6

.

CAUSE: UNKNOWN. MATERIAL IS SUPPOSED TO HAVE GOOD PIT RESISTANCE.

ACTION: A SECTION OF THERMOWELL IS BEING SENT TO ARGONNE FOR ANALYSIS.

N

67
PROCESS SEARCH CRITERIA

*

I.N.

358 MERC PRESSURE VESSEL

FAILURE ANALYSIS REPORT , N_D. , BY J . F I SCHER , R .DE ANGEL I S » 0. HAHN , P. GI LL I S , U OF KY.

METALLOGRAPHIC ANALYSIS OF A COAL GASIFIER PLATE FAILURE

SUMMARY

FAILURE: CRACK PROPAGATION THROUGH THE WALL NEAR THE GRATE WHICH ALLOWED

COOLANT TO FLOW INTO THE REACTION CHAMBER

ENVIRONMENT: OPERATED AT A NOMINAL PRESSURE OF 120 PSI BUT WAS DESIGNED TO

BE CAPABLE OF OPERATING AT 350 PSI.

SPECULATIVE CAUSE: IT IS LIKELY THAT THE ASH EXERTED A STRESS WHICH WAS

CONCENTRATED AT THE NOTCH BETWEEN THE S.S. LUG ANO THE VESSEL* WHERE THE

CRACK INITIATED. THE POSSIBILITY EXISTED OF A DISSIMILAR METAL GALVANIC

CELL AT THE S.S. /WELD FILLER M = tal INTERF ACc .COR RO S I VE ATTACK IS PRFS C NT

AT THE NOTCH ON THE OTHER SIDE OF THE LUG. SINCE THE STRESS ALLIED TO THE

LUG BY THE PARTIALLY FUSEO ASH ALMOST CERTAINLY FLUCTUATED IN MAGNITUDE

IT IS SPECULATED THAT THE MECHANISM OF FAILURE WAS CORROSION FATIGUE.

CONCLUSIONS: IT IS TENTATIVELY CONCLUDED THAT THE CRACK WHICH LED TO

FAILURE DID SO ONLY BECAUSE TT WAS ABLE TO PROPAGATE THROUGH THE WALL

FOLLOWING A PATH ENTIRELY WITHIN THE WELD FILLER METAL. IF THIS IS TRUE

THEN THE S.S. LUGS SHOULD BE LOCATED AWAY FROM WELDS WHICH EX T END THROUGH

THE THICKNESS OF THE VESSEL.

* * * * *

68
r.N* PROCESS SEARCH CRITERIA

401 MISC. PRESSURE VESSEL

REPORT, 2/76, BY M.LAVIGNE, CANADA CENTRE FOR MINERAL AND ENERGY TECHNOLOGY.

SELECTION OF MATERIALS AND FABRICATION METHODS FOR A DEMONSTRATION

PLANT PRESSURE VESSEL

SUMMARY

' ;

METALLOGRAPHIC EXAMINATION OF 5 SAMPLES CUT FROM THE HOTTEST SECTIONS OF

THE ENERGY RESEARCH LABORATORIES I 8BL/DAY PILOT PLANT.

L. THIRD HEATER TUBE OF FEED LINE TO THE REACTOR VESSELS: 304 S.S.TU8E

{ APPROX. 3 FT. LONG X 9/16” 00 X 5/32” ID) OPERATING TEM°.,450 C.

REMOVED AFTER 6 MONTHS OPERATION DUE TO BEING PLUGGED . EX AH REVEALED NO

CORROSION. CHROMIUM CARBIDES WE«E PRECIPITATED AT GRAIN BOUNDARIES AND

ON SLIP PLANES.

2 . CENTRAL THERMOCOUPLE WELL OF THE VESSEL: 304 S.S. TUBE! APPROX. 12. 5 FT

LONG X 1/2 ”0D X 1/4” ID). END SEALED BY WELDING. THE WALL OF THE TUBE

HAD NO CORROSION. SOME CORROSION PRODUCTS WERE DEPOSITED ON A SECTION

OF THE WELD.

3* TOP PLUG OF PRESSURE VESSEL: 1-1/2" OD 316 S.S. SERVICE LIFE OF 2 YEARS.

INNER SURFACE OF PLUG WAS PITTED TO A DEPTH OF 0.002”.

4 . TU8E FROM PRESSURE VESSEL TO HOT RECEIVERS: 304 S.S. TUBE! 1/4” OD X

1/8” ID) CARRIED THE PRODUCTS FROM THE PRESSURE -VESSEL TO THE HOT

RECEIVER AT TEMPERATURES OF 370-460 C. EXAMINATION REVEALED INTERGRANULAR

PITTING CORROSION WITH GENERAL CORROSION ALSO OCCURRING.

5. HOT RECEIVER DOWN TUBE: 304 S.S. SAMPLE TAKENG FROM FIRST SECTION OF THE

DOWN TUBE WHERE OPERATING TEMPERATURE IS 370 C. EXAMINATION

REVEALED PITTING CORROSION ON BOTH. OD AND ID OF PIPE.

DESCRIPTION GIVEN OF VARIOUS FABRICATION METHOOS FOR ASSEMBLY OF PRESSURE

VESSELS.

THE RESULT OF THIS INVESTIGATION WAS THE SELECTION OF 316 S.S. FOR USE IN

THE PRESSURE VESSEL AND RELATED COMPONENTS.

* * * * *

69
I.N. PROCESS SEARCH CRITERIA

30 SRC PRESSURE VESSEL

INTEROFFICE REPORT, 12/ l 3/74, FROM C. ACKERMAN £ L.FURLER TO G.CHENOWETH,SRC.

INSPECTION OF DISSOLVER A SUMMARY

TWO SEPARATE LEAKS DEVELOPED IN SLURRY DrSSOLVER A (02075001). ON NEXT

SCHEDULED SHUTDOWN THE VESSEL WAS CLEANED BY A COMBINATION OF STEAMING,

WATER, INERT GAS AND CARBONATE SOLUTION. HEAVY CARBCNACEHUS DEPOSITS W-RE

REMOVED FROM INSIDE THE VESSEL. CAREFUL VISUAL INSPECTION AND ULTRASONIC

TESTING TO DETECT CORROSION AND FLAWS WAS CONDUCTEQ-NO CORROSION OF FLAWS

WERE FOUND. OPERATION WAS RESUMED AS NORMAL AND SUBSEQUENT UT AND VISUAL

‘INSPECTION WAS TO RE DONE.

RECOMMEND: DETAILED DIAGNOSTIC FAILURE ANALYSIS

? EFFECT: OID NOT REQUIRE SHUTDOWN COULD WAIT TO END OF RUN AND THEN INSPECT.

* *- * * *

70
UN- PROCESS SEARCH CRITERIA

347 SRC PRESSURE VESSEL

INTERNAL REPORT , 9/9/76 * FP OM C. ACKERMAN £ 0. CANFIELD TO N .GR EENL EE , FT. LEW I S

INSPECTION AND CLEANING OF 5 02 PRESSURE VESSELS

SUMMARY

INSPECTION RESULTS

1. CRACKS IN THE CLADDING INSIDE THE COVER OF THE I.P. ANO RECYCLE

CONDENSATE SEPARATOR WILL REQUIRE MONITORING EVERY 3 OP 4 MONTHS BY

ULTRASONIC INSPECTION WHEN COLD. THE I.P. SEPARATOR COVER WILL NEED TO

BE REPLACED WITHIN THE NEXT YEAR.

2- A LARGE CRACK IN THE BREATHER RING ON THE MIDDLE OUTLET NOZZLE IN

DISSOLVER "A'» COVERS OVER 90 DEGREES OF THE INNER WELD. THE 3 a S E metal

UNDER THE CRACK HAS SUFFERED SOME PITTING CORROSION.

3* A SMALLER CRACK WAS FOUND IN THE BREATHER RING IN THE DISSOLVER "A"

INLET NOZZLE.

4- CHLORIDE INITIATED CRACKS WERE FOUND IN ONE BREATHER RING IN A SEPARATOR

BUT OTHER PLACES HAD NONE.

5. CORROSION RACK INSTALLED 12/10/74 IN RECYCLE CONDENSATE SEPARATOR

REMOVED 9>Y S. I BARRA , HARMARV ILLS, FOR EVALUATION.

RECOMMENDATIONS

L. THE I.P. SEPARATOR COVER BE REPLACED WITH A NEW COVER WITH STABILIZED

S.S. CLADDING OR WELD OVERLAY.

2. THE PRESENT I.°. SE ° AR A TOR COVER , RECYCLE CONDENSATE SEPARATOR COV^R,

ANO OISSOLVER "A" INLET AND SIDE NOZZLES BE MONITORED BY ULTRASONIC

INSPECTION ABOUT EVE° Y 3 MONTHS.

3* MORE CORROSION SAMPLES ( INCLUDING STRESSEO SAMPLES) 3E INSTALLED IN DISSOLVER "A" BELOW THE CENTER OUTLET, AND IN EACH OF THE SEPARAtqr$ in

THE GAS PHASE.

4- BETTER PROCEDURES AND EQUIPMENT FOR INSPECTION ARE NEEDED.

\

71
t.N. PROCESS SEARCH CRITERIA

348 SRC PRESSURE VESSEL

INTERNAL REPORT, 9/24/76 ,FRQM A .HENK E , HARM AR V IL LE ,TO J. WAR 0, DUPONT » WA^

INSPECTION OF SRC 02 PRESSURE VESSELS

SUMMARY

CONCLUSIONS AND RECOMMENDATIONS

, 1. THE CRACKING IN THE TOP HEAD CLADDING OF THE I.P. SEPARATOR WAS DUE

PRINCIPALLY tq POLYTHIONIC ACID SCC • SOME EVIDENCE OF SCC-CL WAS FOUND

IN THE CLADDING AS WELL AS THE 304 S.S. NOZZLE BREATHER RING.

2. CRACKING DUE TO POLYTHIONIC ACID SCC WAS SEEN IN THE PECYCLE CONDENSATE

SEPARATOR. CRACKING WAS NOTED IN THE CLADDED TCP HEAD. NO SCC-CL SEEN.

3. INSPECTION OF NOZZLES IN "A" DISSOLVER REVEALED THAT THE SIDE NOZZLE

SLEEVE HAD SEPARATED FROM THE WELO WHICH CONNECTED IT TO THE NOZZLE

BREATHER RING. THE BOTTOM NOZZLE ALSO HAD AN INDICATION OF A RUPTURE IN

THE LINING. EVIDENCE OF A SMALL CRACK BETWEEN THE NOZZLE SLFEVE AND THE

NOZZLE BREATHER RING.NO SIGNIFICANT CORROSION OF THE BASE METAL OF THE

NOZZLES OR THE SHELL.

4* RECOMMENDED THAT ALL COMPONENTS BE RETURNED TO SERV I CE . PER TOD IC

ULTRASONIC MONITORING ADVISED. A THOROUGH EXAMINATION SHOULD BE CONDUCTED

IN ABOUT ONE YEAR.
r.N. PROCESS SEARCH CRITERIA

59 SYNTHANE VALVES

ERDA MAT. AND COMP. FA IL. REPORT, 12/12/75* FROM R. JACK SON* SYNTHANE.

BALL UNIT OF XCV-27,EBV BALL VALVE

SUMMARY

FAILURE: EXCESSIVE SCALING AND PITTING OF BALL AND JOURNAL OF VALVE.

SERVICE LIFE: INSTALLED BUT HAD SEEN NO SERVICE

ENVIRONMENT: AMBIENT TEMP.

MATERIAL: 440C S.S.

ACTION: REPLACED PART. ANALYSIS BY COMPANY LA8.

*• * * * *

r.N. PROCESS SEARCH CRITERIA

60 SYNTHANE VALVES

ERDA MAT. AND COMP .FA I L.R EPORT, 1 2/18/75 , FROM R . JACK SON , SYNTHANE

.

BALL UNIT OF XCV-30»E3V BALL VALVE

SUMMARY

FAILURE: ONE SIDE OF BALL HAD PITS IN THE AREA OF THE SEAT.

SERVICE LIFE: INSTALLED BUT NOT PLACED IN SERVICE.

MATERIAL: 440C S.S. FORGED BAR WITH STELLITE SEAT.

ACTION: UNKNOWN.

73
'

'Jli


i.n. PROCESS SEARCH CRITERIA

17 C02 PIPING

LETTER REPORT, 2/16/70, FROM J. LETER L = , CONOCO.

HIGH TEMPERATURE CORROSION OF PARTS FROM C02 °IL0T PLANT

SUMMARY

REACTOR VESSEL-310 S.S. THERMOWELL S-HA STELLOY X AND INCONEL. ALL METALS

SEVERLY CORRODED. TEMP. RANGE 1400-2000F. ATMOSPHERE, N2, C02 . CO, H20,

S02, AND H2S.

CONCLUSIONS

1. IT APPEARS THAT SULFUR HAS REACTED WITH ALL THREE METALS TO FORM A LOW

MELTING POINT EUTECTIC OF SULFUR, CHROM IUM, NICKEL, AND IRON.

2. THE 310 S.S. HAS BEEN HIGHLY CARBURIZED.

3. IF THE ENVIRONMENT THAT CAUSED THIS CORROSION IS TYPICAL THEN CAREFUL

CONSIDERATION MUST 85 GIVEN TO ALLOY SELECTIONS.

*- * * * *

I.N. PROCESS SEARCH CRITERIA

124 CQ2 PIPING

INTEROFFICE REPORT FROM H. CROWDER to F.J^RADD, CONOCO, 3/25/70.

METALLURGICAL STUDY OF REACTOR AND GASIFIER VESSELS FROM THE LIGNITE

GASIFICATION PRE-PILOT PLANT, CONSOL

SUMMARY

THE BENCH SCALE LIGNITP GASIFICATION PLANT, OPERATED AT LIBRARY, PA HAS

EXPERIENCED HIGH TEMPFRATURE CORROSION AND EMBRITTLEMENT PROBLEMS.

THIS REPORT SUMMARIZES WORK ON THE FOLLOWING ° AR TS : 1. GASIFIER VESSEL

2. REGENERATOR VESSEL

3. REGENERATOR PRE-HEAT COIL

4. REGENERATOR THFdmowBLL

CONCLUSIONS: ALL FOUR OF THE PIECES HAVE EXPERIENCED ONE OR MOPE OF THE

FOLLOWINGS PROBLEMS. HIGH TEMPERATURE SULFUR CORROSION, EMBR I TT LEMFNT

FROM CARBURIZING, EMBRITTLEMENT FROM NITRIDING.

THESE PROBLEMS COVER THE TEMPERATURE RANGE OF 950-1900 F.

77
T.N. PROCESS SEARCH CRITERIA

89 CO 2 PIPING

INTEROFFICE REPORT, 8/7/72 , FROM H. CROWDER TO J . LETERLE , CONOCO.

METALLOGRAPHIC STUDY OF 4— INCH DIAMETER INCOLOY 300 PIPE

SUMMARY

TWO SAMPLES OF REMAINING PTPEISEE I.N.88) WERE EXAMINED TO DETERMINE

SUITABILITY FOR FURTHER USE.

CONCLUSIONS

1. THE INSIDE SURFACE HAS BEEN DAMAGED BY SULFUR CORROSION AND BY GRAIN

BOUNDARY PENETRATION BY SULFUR.

2. OVERHEATING CAUSED SOME INCREASE IN GRAIN SIZE.

3- MOST OF THE WALL THICKNESS IS STILL SOUND ENOUGH TO ALLOW THIS TOP SECTION

TO BE USEO FOR FURTHER SERVICE.

* * * *

I.N. PROCESS SEARCH CRITERIA

93 C02 PIPING

FAILURE REPORT, 2/7/74, BY R. PERKINS AND W. COON S , LOCKHEED LA8 TO CONSOL.

MET. ANALYSIS OF CORRODED INCOLOY 800 TUBE FROM A RECYCLE GAS HEATER..

SUMMARY

MET ANALYSIS OF CORRODED INCOLOY 300 TUBE FROM A RECYCLE GAS HEATER.

THE TUBE HAD A VERY COMPLEX HISTORY. NOT REPRESENTATIVE OF NORMAL OPERATING

CONDITIONS.

CONCLUSIONS

1. THE PIPE HAS BEEN OEGRAOED BY A COMBINATION OF CARBURIZATION,

SULFIDATION, AND OXIDATION.

2. CARBURIZATION IN DEPTH PRECEDED THE OTHER REACTIONS AND ESTABLISHED A CR-RICH PHASE AT THE GRAIN BOUNDARIES.

3. INCOLOY 800 DOES NOT APPEAR TO HAVE ADEQUATE RESISTANCE TO OXIDATION

IN THE ENVIRONMENT FOR THIS APPLICATION. A HIGHER CR ALLOY WHICH CAN FORM

A MORE PROTECTIVE ^XIOE FILM TO RETARO THE DIFFUSION OF CARBON AND SULFUR

TO THE UNDERLYING METAL MAY GIVE BETTER PERFORMANCE.

ADDITIONS OF AL, TI, AND SI ALSO WOULD BE HELPFUL.

78
I.N PROCESS SEARCH CRITERIA

98 C02 PIPING

INTEROFFICE REPORT , 5/ 13 /74, FROM D. QUALLS TO J . LETER LE* PONCA CITY.

FAILURE OF THE GASIFIER PROBE ANO SENSOR TUBES

SUMMARY

FAILURE OF THE GASIFIER PR08E AND SENSOR TUBES * BOTH THE PROBE AND SENSOR TUBES FAILED AS A RESULT QF STRESS ENHANCED

INTERGRANULAR SULFUR CORROSION. PROBE WAS 310 S.S. SENSOR TU8ES WE<?e 316 S.S.

OPERATING TEMP.-300-I600F. PURGE GAS CLAIMED TO BE INERT-SUSOECTE0, HOWEVER

OF CONTAINING A SULFUR CORRODENT. NO PROOF.

RECOMMENDATIONS: REMOVE STRESS CONCENTRATIONS PRODUCED BY DIFFERENCES IN

THERMAL EXPANSION AND CONTRACTION BETWEEN THE INSULATION BASKET ANO THP GAS

IFIER PR03E.REMCVE SULFUR from INCOMING PURGE GAS TO PREVENT PREMATURE FAILURE

DUE TO HIGH TEMPERATURE SULFUR CORROSION.

* * * * *

i.n. PROCESS .SEARCH CRITERIA

143 CO 2 PIPING

TEST REPORT »8/29/74»FRQM H.CROWOER TO J .LETEPLEt PONCA CITY.

DISBONDING OF HARD FACING MATERIAL FROM STAINLESS STEEL THERMOWELLS

SUMMARY

EXPERIMENTAL THERMOWELLS WERE MADE BY APPLYING HARD FACING MATERIALS TO

310 S.S. TUBES 3Y A PLASMA-ARC WELDING PROCESS. THE THERMOWELLS WERE INSTALLED

IN THE REGENERATOR, D-203, OF THE LIGNITE GASIFICATION PLANT.

THE THERMOWELLS FAILED AFTER A SEPVICE LIFE OF 24 HRS OR LESS.

NA CHRGOMIUM CARBIDE HARD SURFACING MATERIAL WAS AP°LI ED TO ONE THERMOWELL

BECAUSE IT HAO GIVEN GOOD SERVICE IN OTHER SEVERE ENVIRONMENTS. ALUMINUM

OXIDE AMD TITANIUM CARBIDE WERE AP°L I ED TO TWO OTHER THERMGWFLLS TO PROVIDE

ADDITIONAL MATERIALS FOR TESTING.

CONCLUSIONS

1. THE BOND BETWEEN THE COATING ANO THE BASE METAL APPEARS TO HAVE BEEN

SATISFACTORY.

2. SOME OF THE HARD SURFACING FAILED BECAUSE TT IS A BRITTLE MATERIAL WHICH

HAS BEEN DAMAGED BY MECHANICAL OR THERMAL SHOCK.

3. SOME €F THE MATERIAL FAILED BECAUSF OF HIGH TEMPERATURE SUL CUR CORROSION.

4.

UNLESS THERE IS A MATERIAL AVAILABLE THAT IS BETTER THAN 310 S.S. , WE

SUGGEST THAT AN ALONIZED 310 S.S. THERMOWELL 8E TRIED.

79
I

r.N. PROCESS SEARCH CRITERIA

L12 C02 PIPING

FINAL REPORT FROM 0. QUALLS TO J . LETE RLE , CONOCO , 1 1/ 7/ 74

.

EVALUATION OF HEATER TU3ES FROM RAPID CITY CONSOL

SUMMARY

EVALUATION OF HEATER TUBES FROM RAPID CITY CONSOL

FIVE HEATER TUBE SAMPLES WERE SUBMITTED. THEY HAD BEEN INSPECTED BY MAGNETIC

INSPECTION WHICH INDICATED SOME DAMAGE.

A MICROSTRUCTURAL EVALUATION WAS REQUESTED TO CORRELATE ACTUAL DAMAGE WITH

MAGNETIC INSPECTION RESULTS.

ALONIZED 304 S.S. TUBE WAS GOOD. THE FOUR SAMPLES OF INCOLOY 800 TUBING

• CONTAINED VARYING DEGREES OF CORROSION AND STRUCTURAL DAMAGE. THE DAMAGE WAS

< 12.2" OF THE MINIMUM MEASURED WALL THICKNESS.

* * *

r.N. PROCESS SEARCH CRITERIA

144 C02 PIPING

6RDA MAT. AND COMP

.

F A I L . R EPCRT, 8/ 8/ 75 , FROM C . SC HULZ » C02

.

I NLET OF LINE CD-206 IN THE REGENERATOR

SUMMARY

INLET OF LINE CD-206 IN THE REGENERATOR

.

FAILURE: THE INNER LINER OF CD-206 BROKE OFF AND FELL DOWN INTO VESSEL.

SERVICE LIFE: 850 HRS

ENVIRONMENT: 1830F FLUE GAS. THE TUBE IS IMMERSED IN A FLUIDIZING BED WITH A SUPERFICIAL VELOCITY OF ABOUT 3 FP S.PAR T I CL E S ARE 6X9 M

C SH DOLOMITE.

MATERIAL OF CONSTRUCTION: 6" X .25” W.T.310 S.S. WELDED TUBE.

CAUSE OF FAILURE: CORROSION DUE TO SULFUR. THE STRESS ANO STRAINS FROM THF

FLUIDIZED BED AND THERMAL CYCLING ACCENTUATED THE CORROSION AND WAS THE

IMMEDIATE CAUSE n F THE FAILURE.

NO RECOMMENDATIONS MADE.

80
r.N. PROCESS SEARCH CRITERIA

148 C02 PIPING

ERDA MAT. AND COMP. FAIL. REPORT. C02 .C* SCHULZ .10/8/75.

REBUILT B-205 ALPHA FURNACE COIL

SUMMARY

FAILURE: A 9-FT 9-IN SECTION OF OLD MATERIAL IN THE "A" PASS WAS REPLACED

DUE TO THINNING AND A SMALL PIN HOLE.

SERVICE LIFE: 581 H<?S SINCE REBUILD.

PRIOR REPAIRS: COIL WAS REBUILT REPLACING ALL THIN SECTIONS IN DEC. 1974

WITH ALONIZED RA-330.

ENVIRONMENT: TEMP. 1000-1500F. INERT GAS (83-37? N2, 6-12? C02. 0.2-9.62 02)

AND RECYCLE GAS (80? N2 , 17? C02, 3? CO, CARBONYL SULFIDE 50 °PM).

MATERIALS OF CONSTRUCTION: INC3L0Y 300 WITH SECTIONS OF ALONIZEO RA-330.

CAUSE OF FAILURE: PROBABLY DUE TO CARBURIZATION AND SULFIDATION.

ACTION: DIAGNOSTIC ANALYSIS TO BE PERFORMED BY CONOCO.

* * * * *

I.N. PROCESS SEARCH CRITERIA

54 CO 2 PIPING

FINAL REPORT, 10/9/75, FROM L .WOLFE .PONCA CITY, TO J.LETERLE, CONOCO.

EXAMINATION OF TYPE 321 S.S. FURNACE TUBE FROM 8205 FURNACE

SUMMARY

FAILURE: FURNACE TUBES HAVE EXPERIENCED FREQUENT TROUBLE FROM THINNING.

THINNING ORIGINATES FROM INSIDE OF TUBES.

SERVICE LIFE: UNKNOWN

ENVIRONMENT: 900F. 3-4? CO, 26? C02, 70? N2, 20-75 PPM COS.

MATERIAL: 321 S.S. 1-5/8" OD X 0.109" W.T.

RESULTS

1. INITALLY GET CARBURIZATION, NITRIDING, AND SOME SULFIDATION

THEN GET OXIDATION.

2. SULFUR ATTACK OCCURS, BUT NOT ENOUGH TO 8E SIGNIFICANT AT THFSE

TEMPERATURE.

5. MAJOR METAL LOSS AND THINNING IS DUE TO OXIDATION OF CHROMIUM.

4. THINNING IS FROM INSIDE. OXIDATION ON OUTSIDE IS ALONG GRAIN BOUNDARIES.

81
I .N.

149

PROCESS

C02

SEARCH CRITERIA

PIPING

EROA MAT.ANO COM° .FAI L . R EPPRT, 10/17/75 , FROM C . SCHUL Z ,C02

.

REBUILT B-205 ALPHA FURNACE COIL

SUMMARY

FAILURE: THE TUBE WALLS IN SEVERAL AREAS HAD GREATLY THINNED REQUIRING

REPLACEMENT OF the COIL.

SERVICE LIFE: 919 HR S SINCE REBUILDING

ENVIRONMENT: SEE ATTACHMENT FOR HRS AND TYPES OF ATMOSPHERE

PRIOR REPAIRS: COIL WAS REBUILT RE°LAC IMG ALL THIN S ECT IONS , 12 /74, WITH

ALONI ZED RA 330 AND A 9'-9'» SECTION WAS REPLACED 9/75.

MATERIALS: INCQLOY 300 AND RA 330

CONCLUSIONS: THINNING WAR PROBABLY DUE TO

AND SULFIDATION. NEW COIL FABRICATED OUT

A COMBINATION OF CARBURIZATION

OF INCONEL 702.

ACTION: REPLACED PART. ANALYSIS BY COMPANY LABS.

I.N.

55

PROCESS

C02

SEARCH CRITERIA

PIPING

LETTER, 11/17/75, FROM J . LETERLE , CONOCO , TO D. GLA SER, STEARNS AND ROGER.

HEATER B-205 EXAMINATION AFTER RUN 26A

SUMMARY

DISCUSSION OF EXCESSIVE THINNING OF FURNACE HEATER TUBE DUE TO OXIDATION

AND SULFIDATION. EXPECTED SULFUR LEVEL IS 10-100 PP* AT 900F AS Cn$. THIS IS

TOO LOW FOR AMOUNT OF DAMAGE SEEN IN TIME EXPOSED. MUST BE UNEXPECTED

SULFUR PRESENT.

RECOMMEND: INSTALL FILTER TRAP TO ANALYSIS SOLID PARTICLES IN FEED STREAM TQ

FIND SOURCE OF EXCESS SULFUR.

82
I.N. PROCESS SEARCH CRITERIA

151 C02 PIPING

ERDA MAT. AND COMP. FAIL.REPORT

B—205 GAMMA FURNACE COIL.N

, 11/24/75. C02. C. SCHULZ.

SUMMARY

FAILURE: THREE HOLES IN THREE

SERVICE LIFE: 61.5 HRS

ENVIRONMENT: SEE ATTACHMENT

MATERIAL: INCONEL 702

CONCLUSIONS: FAILURE PROBABLY

AND/OR CARBONIZATION.

ACTION: PART REPLACED. ANALYSIS

DIFFERENT TUBE PASSES NEAR THE OUTLET END.

DUE TO VERY SEVERE CORROSION FROM SULFUR

BY CONOCO LABS.

* * * * *

I.N. PROCESS SEARCH CRITERIA

392 EXXON PIPING

INTRALAB REPORT, 6/30/75 FROM J.SLUSSEP TO D .K I NZLER , EXXON RESEARCH S EN 3R

.

ANALYSIS OF COOLING COIL SAMPLES

SUMMARY

FAILURE: HEAVY CORROSION AND METAL LOSS IS OCCURRING ON EXTERIOR SURFACES

OF TUBE ELBOWS. STRAIGHT SECTIONS HAVE MINOR PITTING CORROSION.

SERVICE LIFE: 60 HRS.

* ENVIRONMENT : C02,S02,02 AT TEMPERATURES OF 15C0-I850 F .TUBES IOE , COOL ING WATER.

MATERIAL: TUBES ARE 3/4" 00,0.048'* W.T. 316 S.S. ELBOWS ARE 3I6L S.S..

CAUSE: HIGH TEMPERATURE GAS ATTACK ( OX I DATION , SULFI DAT I ON ) HAS CAUSED MOST

OF THE CORROSION. PITTING CORROSION POSSIBLY CAUSED BY HIGH TEMPERATURE

SLAG ATTACK. WORST CORROSION AND METAL LOSS OCCURRED ON TUBE ELBOWS OUE TO

CONTINUOUS EROSION OF THE CORROSION PRODUCT RESULTING IN THE CONSTANT

EXPOSURE OF FRESH SURFACES TO THE COPRISIVE MEDIUM.

RECOMMENDATIONS: COOLING WATER SHOULD BE TURNED ON AT STARTUP OF THE REACTION

TO KEEP TUBING TEMPERATURES < 1600 F.IF THIS IS IMPRACTICAL THEN USE

310 S.S. WHICH HASG BETTER HIGH TEMPERATURE CORROSION RESISTANCE.

83
I.N. PROCESS SEARCH CRITERIA

13 . HYGAS PIPING

FAILURE ANALYSIS REPORT , 1 1/30/73, FROM M. HOWES , II TR I ,T0 F.SCHOR A, IGT.

METALLQGRAPHIC EXAMINATION OF FIVE samples from THE HYGAS PLANT

SUMMARY

1. SLURRY ORYER GRID: INCOLOY 800. SERVICE LIFE OF 6 MONTHS. FNV

1

15 ONMFNT

,

LIGNITE BED AT 600 F FLUIDIZED WITH A GASCCONTAINS 1? H2 S ) AT 120C F AND 1000 PSI. FAILURE OCCURRED BY CORROSION AT SCREW THREADS. RECOMMEND

COATING AND REDESIGN TO ELIMINATE SCREW THREADS.

2. WELDED 4X3 IN REDUCE1?: 446 S.S. SERVICE LIFE OF 6 MONTHS. ENVIRONMENT*

1500 F AT 25 PS I * FLU I D I ZED LIGNITE— INTER NAL»N ITROGEN— EXTERN AL .F A ILUR E

CAUSED BY CRACK THAT STARTED IN THE WELD BETWEEN THE PIPE AND FLANGE AND

PROPAGATEO IN BOTH DIRECTIONS. REASON BEING MATERIAL EMBRITTLEMENT AND

RESIDUAL STRESSES. RECOMMEND STRESS RELIEVING.

3. BELLOWS: INCOLOY 800(20 GAUGE ) . SEP V I CE LIFE OF 9 MONTHS. ENVIRONMENT.

1650 F IN A CORROSIVE ATMOS PHERE . FA ILURS OCCURRED BY COMBINATION OF

SURFACE OXIDATION AMD INTERGRANULAR ATT ACK . RE COMMEND REDESIGN.

4. REFORMER QUENCH POT SHELL: INCOLOY 800. SERVICE LIFE OF 6 MONTHS. ENVIRONMENT

.

1650 F AT 100 PSI. FAILURE DUE TO THERMAL FATIGUE CAUSED BY FLUCTUATING

TEMPERATURE CONDITIONS . RECOMMEND REDESIGN.

5. BUTTERFLY VALVE: 446 S.S. SERVICE LIFE OF 2 YEARS. ENVIRONMENT, 1400 F.

FAILURE DUE TO INTERNAL CORROSION AND RESIDUAL STRESSES. RECOMMEND

STRESS RELIEVING.

* * * * *

I.N. PROCESS SEARCH CRITERIA

1 HYGAS PIPING

LETTER* 4/2/75, FROM A. MAC NAB, C .F. BRAUN, TO P .T ARM AN , I GT

.

MATERIAL SELECTION FOR HYGAS STEAM/IRON GASIFICATION PILOT PLANT

SUMMARY

DISCUSSION OF MATERIALS TO RESIST SULFIDATION IN PIPING TO THE PEACTOR

AND SECOND STAGE REDUCER SPARGE R ING .ATMQSPHER E WILL BE REDUCING GAS CONTAINING

0.1 MOLE PEPCENT H2S AT 2000F. INCOLOY 800 AND 310 S.S. WILL NOT HOLD UP.

RECOMMEND 50CR-50NI ( ASTM 4560 OR UNILOY 50/50) OR ALONIZEO 310 S.S. 0°

4L0NIZED INCOLOY BOO . 50CR-50N I HAS GOOD SULFIDATION RESISTANCE BUT POOR

HIGH TEMP*. STRENGTH. RECOMMEND USE OF THIS MATERIAL AS CLADDING TO A SUBSTRATE

OF INCOLOY 800 OR 310 S.S.

84
r.N. PROCESS SEARCH CRITERIA

79 HYGAS PIPING

LETTER, 6/2/75, FROM P.TARMAN , IGT, TO A. MAC NA 8.C .F . BRAUN.

MEMO, 5/30/75, FROM R.BACHTA TO P.TARMAN, IGT.

FEASIBILITY ANO AVAILABILITY 0*= INCQCLAO 671/800H PIPE

SUMMARY

TARMAN COMMENTS ON MAC NAB'S SUGGESTION OF USING 50CR-50NI AS CLADOING ON

INCOLOY 300 AND HIS RECOMMENDATION THAT IGT CONTACT HUNTINGTON ALLOYS FOR

INFORMATION.

.MEMO FROM BACHTA GIVES INFORMATION FROM HUNTINGTON ALLOYS. PROBLEMS IN GETTING

THIS MATERIAL WOULD BE 1 ) S I ZE, 81 GGES T PRODUCED BY HUNTINGTON IS 2-l/2"00,

IGT NEEDS 4" 0D.2)CLADDING THE INTERIOR OF THE PIPE. MOST PRODUCTS CLAD

ON OUTSIDE ONLY.

- INCOCLAD 671/SOOH PIPE HAS AN INCOLOY 800 SUBSTRATE WHICH PROVIDES STRENGTH

AT HIGH TEMPERATURES AND INCONEL 671 (APPROX .50CR-50N I) CLADDING WHICH

PROVIDES RESISTANCE TO SULFIDATION.

* * * * *

I.N. PROCESS SEARCH CRITERIA

189 HYGAS PIPING

TELECOM, FROM S . GREEN8ER G, A NL , TO W. ORCHARD , I GT, 3/30/76.

HYGAS AAG THERMOCOUPLE PROTECTION TUBES AMD PRESURE TAPS

SUMMARY

1. THERMOCOUPLE PROTECTION TUBE TC-5 REMOVED AFTER RUN 59 IDENTIFIED AS

INCOLOY 800.

2. SCALE REMOVED FROM THE OUTSIDE SURFACE OF PRESSURE TAP FI983 AFTER PUN 60

HAD A SULFUR CONCENTRATION IN THE RANGE OF 5-10*?.

3. BAIR'S ASSUMPTION OF SULFUR ATTACK APPEARS TO BE JUSTIFIED £. RECOMMENOATIO

OF 310 OR 446 S.S..AS REPLACEMENT SHCULD WORK.

85
I.N- PROCESS SEARCH CRITERIA

213 HYGAS PIPING

TELECON, 4/13/76, FROM S. GREEN 8ERG, ANL , TO 8.0RCHAR0, IGT.

THERMOCOUPLE PROTECTION TUBES, PRESS* TAP TUBES , GAS I F I ER TRANSFER LINE BELLOWS.

SUMMARY

THERM. PROTECTION TUBES : TUBES TC-23 AND TC-5 IDENTIFIED AS INCOLOY 800.

PRESSURE TAP TUBES: SC ALE REMOVEO FROM OUTER SURFACE CONTAINED 14.4S S.

EXPANSION JOINT BELLOWS:COAL PRODUCT REMOVED FROM BELLOWS HAS A SULFUR CONTENT

OF APPROX. 3^, VERY CLOSE TO THAT OF FEED MATERIAL.

THESE RESULTS TEND TO CONFIRM VIEW THAT TUBES FAILED AS A RESULT OF SULFUR

ATTACK. METALLOGRAPHIC EXAM. IS IN PROGRESS.

* *- *

r.N* PROCESS SEARCH CRITERIA

286 HYGAS PIPING

TELECON, 5/12/76 AND 5/13/76, FROM S. GREENBERG, A NL, TO 8. ORCHARD, IGT.

EXPANSION JOINT-GASIFIER TRANSFER LINE.

SUMMARY

MANY HOLES AND PITS DISCOVERED IN INCOLOY 900 BELLOWS. DEPOSIT ON INNER

SURFACE IS MAINLY THE RESULT OF COUNTER-CURRENT CLEANING OPERATIONS.

CORROSION FILM ON EXTERIOR IS RESULT OF CONTAMINATION OF N2 ATMOSPHERE BY

IN-LEAKAGE OF COAL, PRODUCT GAS, OIL AND WATER. METALLOGRAPHIC ANALYSIS

INDICATES PITTING INITIATED AT INSIDE SURFACE. WATER CONDENSATION DURING

SHUTDOWN MAY BE A CONTRIBUTING FACTOR. EVIDENCE FOUND OF SULFIDATION AND

OVER-TEMPERATURE OPERATION (1450F). NORMAL OPERATING TEMP. IS 1 ODD F

.

MATERIAL RECOMMENDATIONS

1. IF PITTING ATTACK IS CAUSE OF FAILURE, 316 OR 317 S.S. COULD BE USED

(USE INVOLVES RISK OF SCC).

2. IF HIGH TEMO. GASEOUS CORROSION IS ALSO IMPORTANT THEN INCONEL 625 OR

HASTELLOY C WOULD BE PREFERABLE (ALSO REDUCE RISK OF SCC).

'SEE I.N. 186, 194, 210, 236, 274, 285 FOR. FURTHER INFORMATION.
r.N„ PROCESS SEARCH CRITERIA

282 HYGAS PIPING

TELEC0N,6/24/76,FR0 M S.GREENBERG^ANL ,TQ B .ORCHARD , IGT.

A AG INTERNAL CYCLONE DIPLEG

MAIN- GASIFIER TRANSFER LINE EXPANSION JOINT.

SUMMARY

1) DIPLEG: EXAM. INDICATES CARBURIZATION ANO SULFIDATION HAS OCCURRED.

2) GASIFIER TRANSFER PIPING: INTERGRANULAR CRACKING OF 330 S.S. PIPING IN

H.A.Z.OF WELDED JOINTS. SUSPECTED OF BEING CCRROSION FAILURES.

* * * *

i.n. PROCESS SEARCH CRITERIA

344 HYGAS PIPING

FINAL FAILURE ANALYSIS REPORT, 12/76 , BY S. DA NY L UK £ S .GREENBER G, ’ NL

.

HYGAS ASH AGGLOMERATING GASIFIER INTERNAL CYCLONE DIPLEG FAILURE

SUMMARY

FAILURE: THE WALL MATERIAL OF THE AAG CYCLONE DIPLEG WAS SEVERELY

CORRODED, WHICH RESULTED IN THE OET ACHMENT OF THE FLAPPER VALVE AT

THE BOTTOM OF THE DI PL EG. CAR BUR IZ ATION AND SULFIDATION OF THE DIPLEG

HAD OCCURRED WITH T-HE CORROSION BEING MORE SEVERE NEAR THE BOTTOM.

IN SOME AREAS 1/3 OF THE PIPE WALL WAS CONVERTED TO MET AL SULFIDES.

MOLTEN SLAG WAS PRESENT NEAR THE TOP OF THE DIPLEG, CLOSE TO THE CYCLONE,

WHICH INOICATES THAT THE OIPLEG WAS EXPOSED TO OFF-DSS IGN (HIGH) TFvp.

ENVIRONMENT: GASIFIER WAS OPERATED WITH BOTH STEAM AND OXYGEN ANO THE DIPLEG

WAS EXPOSED TO THIS FOR ABOUT 20DD HRS, 300 HRS OF WHICH WERF IN A LOW

STEAM ATMOSPHERE. BED TEMPERATURE IS 1850-1975F ANO THE GAS COMPOSITION

30'S C02 , 1 5? 00,15? H2,5? M2 AND THE BALANCE WATER.

MATERIAL OF CONSTRUCTION: INCOLOY 300

•CAUSE: THE FAILURE OF THE DIPLEG IS BELIEVED TO BE ASSOCIATED WITH HIGH

TEMPERATURE( OFF-PROCESS J OPERATION WHICH LED TO SULFIDATION AND

CARBURIZATION.

RECOMMENDATIONS

1. PROCESS TEMPERATURES MUST BE KE°T WITHIN THE DESIGN LIMITS FOR INCOLOY 800.

2. USE OF A HIGHER CHROMIUM CONTENT STAINLESS STEEL SHOULD ALLEVIATE THE

SULFIDATION PROBLEM.

3. WE CONCUR WITH THE SUGGESTION BY HYGAS PERSONNEL TO ALONIZE THE FLAPPER

VALVE, W^ICH MAY PROVIDE IMPROVED PERFORMANCE OF THIS COMPONENT.

87
r.N. PROCESS SEARCH CRITERIA

255 HYGAS PIPING

TELECOM, 12/22/76 , FROM S .DANYLUK.ANL , TO B. ORCHARD , l GT

.

STATUS OF FAILURE ANALYSES OF FAILED COMPONENTS FROM HYGAS PILOT PLANT

SUMMARY

1. PROTECTION TUBE FROM AAG.

ANALYSIS HAS SHOWN THAT THE 310 S.S. THERMOWELL WAS MELTED AT THE END

OF THE TUBE WHICH WAS INSIDE THE GAS I F I FR . CAUS E OF FAILURE WAS EXCESSIVE

DEVIATION FROM SPECIFIED TEMPERATURES.

2. 1/4” NITROGEN PURGE LINE.

EMBRITTLEMENT OF THE GRAIN BOUNDARIES IS VERY SEVERE AND THE TUBE

FAILED BY BRITTLE FRACTURE. SULFUR CONTENT ON INNER PHASE OF TUBE IS

1-2?. ORIGIN OF SULFUR UNKNOWN.

3. ALONIZED 316 S.S. AND 446 S.S- COUPONS.

EVALUATION OF GASIFIER COUPONS IS UNDERWAY

* * *r * *

I.N. PROCESS SEARCH CRITERIA

201 SYNTHANE PIPING

FAIL. ANALYS I S RPT. ,4/30/76, FROM L -ODEN , ALBANY MET -R ES. CTR . , TO F.GROMICKO, PERCEVALUATION OF CRACKED 316 S.S. PIPE SECTION FROM SYNTHANE PILOT PLANT

SUMMARY

THE FAILED PREHEATER PI PEI FROM THE GAS DISENGAGEMENT ZONE IN THE GAS

ENTRAINEO FEED SYSTEM ). SHOWS GENERAL CORROSION AND PITTING OF THF INNER

SURFACE IN ADDITION TO SEVERE CRACKING WHICH IS PROBABLY SCC.^HE CRACKING

IS BOTH INTER-AND TRANS-GR ANUL AR.

THE PIPE IS WELDED AND THE WELD METAL WAS ATTACKED LFSS SEVERELY

THAN THE PARENT METAL. NO SENSITIZATION OF METAL ADJACENT TC WELD WAS OBSERVED

NOR CRACKING OF W=LD METAL.

ELECTRON MICROPROS? ANALYSIS OF SCALE SHOWS SULFUR ANO CHLORINE PRESENT

IN PROPORTIONS OF 5-10

316 S.S. IS SUSCEPTIBLE TO CHLORIDE IONS .QUANTITY OF CHLORINE TN SCALE

INDICATES A CONTINUOUS SUPPLY FROM THF GAS STR EAM. SULFUR ACCENTUATES CORROSION

BY DECREASING THE PROTECTIVE MATURE OF THE OXIDE SCALE. RECOMMEND USING

CARBON DRUM TO REMOVE IMPURITIES FROM THE GAS.

88
I.N PROCESS SEARCH CRITERIA

17 C02 PRESSURE VESSEL

LETTER REPORT, 2/ 16/70, FROM J.LETERLE » CONOCO*

HIGH TEMPERATURE CORROSION OF PARTS FROM C02 PILOT PLANT

SUMMARY

REACTOR VESSEL-310 S.S. THERMOWELLS-HASTELLOY X AMO INCONEL. ALL METALS

SEVERLY CORRODED. TEMP . RANGE 1400-2000F. ATMOSPHERE, N2, C02, CO, H20,

S02 , AND H2S.

CONCLUSIONS

1* IT APPEARS THAT SULFUR HAS REACTED WITH ALL THREE METALS TO FORM A LOW

MELTING POINT EUTECTIC OF SULFUR, CHROMIUM, NICKEL, AMD IRON.

2. THE 310 S.S. HAS BEEN HIGHLY CAR8UR IZED

.

3. IF THE ENVIRONMENT THAT CAUSED THIS CORROSION IS TYPICAL THEM CAREFUL

CONSIDERATION MUST BE GIVEN TO ALLOY SELECTIONS.

* * * * *

i.n. PROCESS SEARCH CRITERIA

124 C02 PRESSURE VESSEL

INTEROFFICE REPORT FROM H. CROWDER TO F.J.RADO, CONOCO, 3/25/70.

METALLURGICAL STUDY op REACTOR AND GASIFIER VESSELS FROM THE LIGNITE

GASIFICATION PRE-PILOT PLANT, CONSOL

SUMMARY

THE BENCH SCALE LIGNITE GASIFICATION PLANT, OPERATED AT LIBRARY, PA HAS

EXPERIENCED HIGH TE M PER ATURE CORROSION AND EM BRI TTLEMENT PP03L C MS.

THIS REPORT SUMMARIZES WORK ON THE FOLLOWING PARTS:

1. GASIFIER V E S S

c L 2. REGENERATOR VESSEL

3. REGENERATOR PRE-HEAT COIL

4. REGENERATOR thermowell

CONCLUSIONS: ALL FOUR Q£ -THE PIECES HAVE EXPERIENCED ONE OR MORE OF THE

FOLLOWINGS PROBLEMS. HIGH TEMPERATURE SULFUR CORROSION, EMBRITTLEMENT

FROM CARBURIZING, EMBRITTLEMENT FROM NITRIDING.

THESE PROBLEMS COVER THE TEMPERATURE RANGE OF 950-1900 F.

89
I

r.N. PROCESS SEARCH CRITERIA

8 HYGAS THERMOCOUPLES

FAILURE ANALYSIS REPORT, 7/25/75, 8Y A.MAC NA8,C .F.3RAUN CO,

THERMOCOUPLE SHEATHS-HYGAS

SUMMARY

FAILURE: THERMOCOUPLE TU3ES USED IN THE STEAM-OXYGEN GASIFIER WERE BECOMING

EMBRITTLEO AND CORRODEO AFTER SHORT EXPOSURES.

SERVICE LIFE: UNKNOWN

ENVIRONMENT: 2000E. 0.4? H2S.

MATERIAL: INCONEL 600 AND INCONEL 702.

CAUSE: "GREEN POT" CORROSION WAS THE PRIMARY MECHANISM. OCCURS IN WEAKLY

OXIDIZING ENVIRONMENT. SULFIDATION ALSO OCCURRED AND THIS WAS DUE TO

EXPOSURE TO REDUCING SULFIDE CONDITIONS.

RECOMMENDATIONS

l- USE AIR/NITROGEN PURGE.

2. CHANGE MATERIAL TO 310 S.S. OR INC0LOY 800.

3. LOWER N I CONTENT, INCREASE AMOUNT OF FE AND CR IN ALLOYS USED.

* * * * *

r.N. PROCESS SEARCH CRITERIA

318 SYNTHANE THERMOCOUPLES

MEMO, 9/2/76, FROM D.DUBIS TO 8. LEW IS , SYNTHANE.

THERMOCOUPLE FA I LURE , GA S I F I ER DISTRIBUTOR CONE

SUMMARY

TELEPHONE REPORT FROM S. 0 ANYL-UK, ANL.

1. HARDNESS INDICATES COLD WORK IS PRESENT.

2. CHEMICAL ANALYSIS— I NCOLOY AND MGO MEET SPECS. CORROSION PRODUCT CONTAINS

L.4 WT /% SULFUR AND MO. 2 FUEL OIL CONTAINS 0.4 WT/? SULFUR.

3. OPTICAL, SEM, AND M TCRCPROBE EXAM, CORROSION ATTACKS OD OF TUBE AND WORKS

INWARD. SULFUR RICH ° ARTICLES FOUND IN MICROCRACKS AT FR ACTU° E SURFACE.

4. INTERNAL STEAM PRESSURE GENERATED FROM WATER IN MGO OR ELSEWHERE COULD

NOT CAUSE TU3E TO BURST.

RECOMMENDATIONS

1. ANNEAL TU8ES 3EF0RR INSTALLATION (1830F/1HR).

2. AVOID FLEXING TUBES.

3. INCREAS.E 3END RADII WHERE TUBES ENTER PLENUM.

4. INSTALL TUBING MADE OF 310 S.S.

VSEE I.N. 295, 298, 299, 300, 303, 307, 308, 312, 319 FOR ADDITIONAL DETAILS.

90
I.N PROCESS SEARCH CRITERIA

319 SYNTHANE THERMOCOUPLES

TELECON, 9/3/76, FROM S. 0 ANYLUK, AML , TO B. LEWIS AND D. BAILEY, SYNTHANE

FAILURE ANALYSIS OF DISTRIBUTOR CONE THERMOCOUPLE SHEATHS

SUMMARY

MICROHARDNESS MEASUREMENTS INDICATE COLD WORK AT FAILURE LOCATIONS.

CORROSION SCALE CONTAINS 1.4 WT * SULFUR. FABRICATOR DOES MOT UNDERSTAND

SULFIDATION AT THE LOW OPERATING TEMPERATURES. LEWIS STATED THAT NO. i

FUEL OIL CONTAINING 0.25% SULFUR WAS USED FOR START-UP AT A TEMPERATURE OF

1000 F. SINCE THIS COULD BE A PROBLEM , LEWIS SUGGESTED AND I AGREED, TO

USE PROPANE AS THE START-UP FUEL.

RECOMMENDATIONS: R E°L AC E INCOLOY 8C0 WITH 310 S.S.. BE CAREFUL NOT TO

INTRODUCE ADDITIONAL COLO WORK IN THE MATERIAL BY BENDING THE TUBES

OURING INSTALLATION.

SEE I.N. 295, 298, 299, 300, 303, 307, 308, 312, 318 FOR ADDITIONAL DETAILS.

* * * * *

T.N. PROCESS SEARCH CRITERIA

325 SYNTHANE THERMOCOUPLES

FINAL FAILURE ANALYSIS REPORT, 10/76 , FROM S.DANYLUKfL G. DR A GEL , ANL . SYNTHANE GASIFIER DISTRIBUTOR CONE THERMOCOUPLE SHEATH ( TE-268 ) FAILURES

SUMMARY

I FAILURE: CORROSION CRACKS INITIATED AT THE' 00 OF THE SHEATH MATERIAL AT

SURFACE CRACKS OR PITS. THE CRACKS PENETRATED TO THE ID AND THE MGD WAS

EXPOSED TO STEAM. THESE C°ACKS WIDENED BECAUSE OF FORMATION OF MG(0H)2

WHICH HAS DOUBLE THE MOLECULAR VOLUME OF MGO . AS THE PROCESS CONTINUED,

THE SHEATH PLASTICALLY DEFORMED AND RUPTURED ALONG THE TUBE AXIS.

ENVIRONMENT: THE THERMOCOUPLES ARE USED TO MONITOR PROCESS TEMPERATURE

AND THE SHEATHS ARE NORMALLY EXPOSED TO A STEAM AMD OXYGEN ENVIRONMENT.

600 PSIG AND 650F.

.MATERIALS OF CONSTRUCTION: CR-AL THERMOCOUPLES WITH A SHEATH OF INCOLOY 800

AND MGO AS AN INSULATING MATERIAL.

CAUSE: A COMBINATION OF CORROSIVE ENVIRONMENT, OFF-PROCESS TEMPERATURES,

SHEATH FABRICATION AND POSSIBLE COLD WORKING OF THE SHEATHS CONTRIBUTED

TO THE FAILURES.

RECOMMENDATIONS

1. BETTER •QUALITY CONTROL OF SHEATH FABRICATION. USE STANDARO (SPEC.

C7-6T i for metal sheath, ceramic insulated thermocouples.

2. A HIGHER CR S.S. (TYPE310) SHOULD SOLVE THE SULFIDATION PROBLEM.

3. SINCE THE FUEL OIL FOR START-UP CONTAINS SULFUR, SWITCH TO PROPANE.

4. CAREFUL HAN0LING OF TUBES AND ANNEALING PRIOR TO INSTALLATION WOULD

ELIMINATE THE COLD WORK.

SEE I.N. 295, 298, 299, 300, 303, 307, 308, 312, 318, 319, FOR PREVIOUS

REPORTS.
I.N. PROCESS SEARCH CRITERIA

337 SYNTHANE THERMOCOUPLES

LETTER W/COPY OF TC STANDARDS, 11/4/74, FROM S. DANYLUK , ANL t TO 8 .ROCH£ , LUMMUS

.

RDT STANDARD C7-6T W/SUPPLEMENTS

SUMMARY

THERMOCOUPLE MATERIAL AND THERMOCOUPLE ASSEMBLY

CHROMEL-P VERSUS ALUMEL

STAINLESS STEEL SHEATHED

MAGNESIUM OXIDE INSULATED

SEE SECTION ON SURFACE FINISH AND DEFECTS. IT DOES NOT APPEAR THAT THE

THERMOCOUPLE SHFATHS WS HAVE EXAMINED WOULD HAVE MET THESE SPEC I FI C AT IONS

.

IT MIGHT 3E A GOOD IDEA TO USE THESE SPECS AS A GUIDE WHEN ORDERING FUTURE

MATERIAL.

* * * *

I.N. PROCESS SEARCH CRITERIA

341 SYNTHANE THERMOCOUPLES

TELECON, 11/29/76, FROM S . D ANYLUK , ANL , TO 3. MASS A ,LUMMUS

.

SUBSTITUTE MATERIALS FOR 310 S.S. TO BE USED IN GASIFIER

SUMMARY

310 S.S. WAS RECOMMENOED AS A SUBSTITUTE FOR INCOLOY BOO THFRMOCOUPLE

SHEATHS WHICH WERE FAILING IN SER VI C F. HOWEVFR , 31 0 S.S. SHEATHS WILL NOT

BE AVAILABLGE FOR SEVERAL MONTHS. 44-6 S.S. WAS RECOMMENOED 8UT EMBRITTLEMENT

MAY BE A PROBLEM.

92

6
r.N. PROCESS SEARCH CRITERIA

263 C02 ''-AUXILIARY PROCESS EQUIPMENT

PROJECT ADVISORS MEETING, 5/21/74, NO AUTHOR.

DISCUSSION ON PR03LEMS AT C02 PILOT PLANT.

SUMMARY

BALL VALVES: RAPIO CITY USES CARBON SEATS WITH S.S. BALLS.

RAW COAL STORAGE SIN: FREEZE U» WILL OCCUR. RECOMMEND STEAM TRACING OR

ELECTRICAL TRACING.

INERT GAS COMPRESSOR AFTERCOOLER: CORROSION PROBLEMS DUE TO NITRIC nxiOSS

FORMING UNDER PRESSURE AND IN THE PRESENCE OF WATER. OR I GIMAL MATERIAL,

ADMIRALTY. NEW MATERIAL, 316 S.S. ELIMINATION OF MOISTURE APPEARS TO BE THE

SOLUTION.

GASIPIER OUTER SHELL: TEMP .SENSITIVE PA INT ( 400—500 F RANGE) SHOULD BE

APPLIED TO CUTER SHELL TO DETECT HCT SPOTS.

PRETREATER: POTENTIAL SCC COULD OCCUR IN PRETREATER DUE TO CHLORIDES FROM

THE FEED. 316 S.S. MIGHT CURE THE PR03LEM

.

RAYMOND CYCLONE SEPARATOR: ABRASION RESISTANT LINING SHOULD 3E APPLIED TO

THE INTERNAL SURFACE.

* * * * *

I.N. PROCESS SEARCH CRITERIA

193 HYGAS' AUXILIARY PROCESS EQUIPMENT

TELECON, 6/3/76, FROM S.GREENBEp G,ANL»TO B.BAIR, IGT.

ASH AGGLOMERATING GAS I F IER , INTERNAL CYCLONE DIP LEG

SUMMARY

CORROSION WAS MORE SEVERE AT BOTTOM. A SAMPLE WAS REMOVED FROM TOP SECTION

FOR MAT • L IOENT. AND MPT ALLOGRAPHIC EXAM. VISUAL EXAM. OF THIS SAM PL E REVEALED

AREAS OF DEEP PENETRATION CF THE INSIDE WALL BY CORROSION. ONE AREA HAO " 1/3

OF W.T. PENETRATED BY CORROS ION. EXAM . AT 30X MAG.CLEARLY SHOWED THAT MOLTEN

MATERIAL HAD BEEN IN CONTACT WITH WALL SUR FACS.PRESENCE MOLTEN SLAG IS

PROBABLY INDICATIVE OF CFF-DES I GN PERFORMANCE.

95
I.N PROCESS SEARCH CRITERIA

297 SYNTHANE AUXILIARY PROCESS EQUIPMENT

ENGINEERING INSPECTION PORT, 7/ 19/ 76, B Y J . JEW ELL , LUMMUS

.

RAW GAS SCRUBBER

.

SUMMARY

HOLD DOWN TRAY: CONSIDERABLE CORROSION, RESULTING IN MANY HOLES. HOLES

ARE LARGE ENOUGH FOR ° ALLS TO PASS THROUGH, THUS THE TRAY CANNOT PERFORM

ITS TASK.

.PACKING PALLS: POOR CONDITION AND CORRODED EXTENSIVELY. PARTS ARE MADE

FROM CARBON STEEL AND ARE NOT COMPATIBLE WITH GASSES AND LIQUIDS. THUS

SEVERE CORROSION OCCURS. ANS ARE TO REPACK THE VESSEL WITH 316 S.S.

PALLS AND INSTALL NEW RETAINING PLATES, IF NEEDED, ALSO OF 316 S.S.

‘SEE I.N. 309 FOR FURTHER INFORMATION.

* * * * *

I.N. PROCESS SEARCH CRITERIA

309 SYNTHANE AUXILIARY PROCESS EQUIPMENT

REPORT, 8/ 12/76, FROM J . J EWE LL .LUMMUS

.

OA— 201 RAW GAS SCRUB3ER VESSEL WALL CORROSION.

SUMMARY

INSPECTORS OBSERVED SEVERE CORROSION OF PALL RINGS AND HOLD DOWN PLATES

IN RAW GAS SCRUB3ER. THIS REPORT GIVES RESULTS GOF ULTRASONIC THICKNESS

MEASUREMENTS. THESE SHOW A LOSS OF THICKNESS UP TO 0.055-IN FROM AN

ORIGINAL 1-1/0 IN MINIMUM HALL THICKNESS (AS). DATA REAOTNGS ARE ATTACHED.

FUTURE READINGS WILL BE MADE TO PLOT PROGRESS OF CORROSION TO HEL° IN ASCERTAINING VESSEL LI^E.

SEE I.N. 297 FOR FURTHER INFORMATION.
I.N. PROCESS SEARCH CR ITER!

A

130 C02 PIPING

ERDA MAT. ANO COMP .FAIL. REPORT, 3/25/75* FROM C. SCHULZ, C02.

B-205 ACCEPTOR LIFT HEATER

SUMMARY

FAILURE: THE FLOW IM THREE PASSES OF THE FURNACE WAS CONSTRICTED DUE TO VERY

SEVERE SCALING. THE RUN TERMINATED DUE TO EXCESSIVE PRESSURE DROP ACROSS

THE COIL DUE TO ABOVE SCALING.

SERVICE LIFE: 1699 HRS

ENVIRONMENT: TEMO. U00-1400F. GAS COMPOSITION-3-4? CO * 26? C02, 70? N2

.

CARBONYL SULFIDE 50 PPM NOMINAL (RANGES FROM TRACE TO 400 PPM).

MATERIAL OF CONSTRUCTION: INCOLOY 800

CAUSE OF FAILURE: UNKNOWN

ACTION: DIAGNOSTIC ANALYSIS TO BE PERFORMED BY CONOCO. * * *

I.N. PROCESS SEARCH CRITERIA

42 HYGAS PIPING

PAPER,3/19/73»8Y K. YOUNG-SLUT , I GT .MAC E CONFERENCE , CORROS ION /73 . AN AHE IM , C A

.

EXPERIENCE WITH MATERIALS IN HYGAS PILOT PLANT

SUMMARY

DETAILED GENERAL REVIEW PAPER ON HYGAS MATERIAL PROBLEMS.

1. LOW PRESSURE OlL/COAt SLURRY PUMP: CENTRIFUGAL TY3 E .CAST STEEL WITH

PLASMA SPRAYED COATI NG. COATING ERODED AWAY THEN STEEL PARTS ERODED. PARTS

WERE THEN OVERLAID WITH STELLITE 12 AND THE PUMP SPEEO REDUCED BY 1/2.

PROBLEM HAS SEEN MINIMIZED.

2 . HIGH PRESSURE OIL/CIAL SLURRY PUMP: RECIPROCATING "MUD PIJMPS" WERF

SEL ECT ED. CHECK VALVE SEALS ARE A PROBLEM. US IMG VTTONIBEST MATERIAL

FOUNDIVALVE LIFE RANGES FROM A F?W HOURS TO A FEW DAYS. NOW USING VALVES

COATED WITH STELLITE AND SEAT RINGS OF STELLITE .VALVE DESIGN STILL NEEDS

TO 8E IMPROVED.

3 . HYDROGASIFIER INTERNALS: 1500 PSI, 600-1300 F,H2 TO 650 PSI. FAILURES IN 446 S.S. PIPING. REPLACED WITH INCOLOY 300. WHEN USING HIGH SULFUR COALS

THE INCOLOY 300 WILL BE REEVALUATED.

4 . PRODUCT GAS QUENCH SYSTEM: ALL WETTED PARTS OF CENTRIFUGAL PUMPS OVERLAID

WITH 304 S.S. ANHYDROUS AMMONIA ADDED FOR PH CONTROL . SUCC ES

S

CUL CHANGE.

5. HIGH PRESSURE WATER/CHAP, SLURRY PUMP: THE USE OF STELLIT* 12 OVERLAY AND

PUMP SPEED REDUCTION HAS BEEN SUCCESSFUL IN MINIMIZING PROBLEMS.

97
1

i

I.N. PROCESS SEARCH CRITERIA

238 HYGAS PIPING

MEMO, 4/29/76, FROM S.GREEN3ERG TO R. WEEKS, ARGONNE.

FAILED HYGAS COAL PRETREATMENT VESSEL COQLFR(N0.2)

SUMMARY

SECOND FAILED COOL ER .FA ILUR E IN 1ST COOLER WAS MECHANICAL WHILE THIS NEW

FAILURE IS SEVERELY CORRODED. FAILURE APPEARS TO BE THE RESULT OF RUPTURE

OF A CORROSION-THINNED PI D E WALL.

A DETAIL5C OPERATING HISTORY IS EXPECTED FROM HYGAS ALONG WITH A CLINKER

SAMPLE. A DETAILED METALLOGRAPHIC EXAM. OF FAILED COOLER WILL BE PERFORMED.

* * *

I.N. PROCESS SEARCH CRITERIA

206 HYGAS PIPING

ERDA MAT. AND COMP . FA I L . R EPORT , 5/ 7/ 76 , FROM W. ORCHARD ,IGT.

COOLING BUNDLE FROM PRETREATER REACTOR

SUMMARY

FAILURE: COOLING BUNDLE REMOVED AFTE 0 TEST NO. 50. TWO TUBES HAD SMALL

RUPTURES. SEVER AL TUBES WERE BENT. LARGE AREAS OF YELLOWISH-ORANGE DEPOSITS

ON OUTER SURFACE OF COOLING BUNDLE.

SERVICE LIFE: L3 50 HR S AT TEMP. 30 THERMAL CYCLES.

MATERIAL: SA-106-GR B CARBON STEEL

ENVIRONMENT: 300 F FLUIDIZED BEDtAIR AMD BITUMINOUS CO AL . STEAM ). SUPERFI C TAL

VELOCITY, 1/2 FT/SGEC.BEO DENSITY, 25 L B/ CU .FT .P AR T I CLE SIZE RANGE, -8 TO

>200 MESH.

CAUSE: ONE OF THE HOLES SEEMS TO HAVE BEEN CAUSED BY A STEAM JET FROM THE

OTHER HOLE. THE FIRST HOLE LOOKS TO HAVE RUPTURED DUE TO WALL THINNING.

ACTION: ANALYSIS 3Y ANL.

98
I.N PROCESS SEARCH CRITERIA

204 .HYGAS PIPING

EROA MAT. AND COMP .FAIL. REPORT, 5/7/76 , FROM W. ORCHARD, IGT.

THERMOWELLS AND PRESSURE TAPS

SUMMARY

FAILURE: THERMOWELLS AND PRESSURE TAPS WERE FOUND TO BREAK OFF IN SERVICE

AFTER EXPERIENCING SEVERE CORROSION AND EVIDENCE OF LOCAL MELTING.

MATERIAL: RA 330 PIPE. VARIOUS DIAMETERS.

SERVICE LIFE: SEE ATTACHMENTS.

•ENVIRONMENT: SEE ATTACHMENTS.

POSSIBLE CAUSE: PROBLEM COULD BE RELATED TO A NEW FEEDSTOCK MATERIAL

WHICH CONTAINS MORE SULFUR THAN THE PREVIOUS FEED.

‘ACTION: FAILURE ANALYSIS TO BE PERFORMED BY ANL. * * * * *

r.N. PROCESS SEARCH CRITERIA

209 HYGAS PIPING

TELECON, 5/18/76, FROM S . GR EENBERG, ANL ,T0 B. ORCHARD, IGT.

GASIFIER TRANSFER LINE 8ELLQWS AND A AG DIPLEG.

SUMMARY

ANOTHER EXPANSION JOINT FAILED AND WILL BE SENT FOR ANALYSIS WHEN RETURNED

FROM MANUFACTURER.

INITIAL EXAM. OF CRACKED PIPE THOUGHT TO BE INCOLOY 800( ACTUALLY 330 S-S.l

INDICATED THAT CRACKING WAS INTERGRANULAR AND THAT CORROSION WAS CONSIDERED

TO BE AT LEAST A CONTRIBUTING FACTOR.

AN INTERNAL CYCLONE DIPLEG FRO M THE ASH AGGLOMERATING GASIFIER FAILED

AND WILL BE SENT FOR FAILURE ANALYSIS.

99
I.N- PROCESS SEARCH CRITERIA

241 HYGAS PIPING

EROA MAT.ANO COMP. FA I L. REPORT, 1/20/77, FROM W. ORCHARD, IGT.

PIPING FA TLU p E— PUR GE LINE/PRESSURE TAP

SUMMARY

FAILURE: TUBING IS BRITTLE ANO WILL NOT BENDSERVICE LIFE: UNKNOWN

ENVIRONMENT: STEAM-OXYGEN ZONE OF HYGAS R E ACTOR. ABOUT 1600 F. INSIDE OF TUBE

USUALLY PURGED CONTINUOUSLY WITH NITROGEN.

MATERIAL: 316 S.S. 1/4” 0.0. X 0.04-9” WALL THICKNESS.

G

CAUSE: VISUAL INSPECTION SUGGESTS GRAIN GROWTH AND CORROSION OF THE INSIDE

SURFACE OF THE TUBE.

ACTION: REPLACED P ART .ANAL YS I S BY ARGONNE NATIONAL LAB.

* * * * *

I.N. PROCESS SEARCH CRITERIA

231 LIGNITE PIPING

MEMO, 7/24/75, FROM W. BARNEY TO STAFF

METAL FAILURES-PROJECT LIGNITE

SUMMARY

SUMMARY REPORT OF METAL FAILURES WHICH HAVE OCCURRED AT PROJECT LIGNITE

FROM START-UP TO PRESENT! 7/24/75 )

.

OPERATING CONDITIONS FOR THE THREE PREHEATER COIL FAILURES ARE GIVEN.

STATUS REPCPT OF FAILURE SAMPLE DEPOSITION AND STATUS OF FAILURE ANALYSES

BOTH FROM INPLANT AND OUTSIDE CONSULTANTS (RALPH PARSONS f. GULF RED).

RECOMMENDATIONS ARE MADE FOR IMPROVING FAILURE REPORTING ANO FAILURE

ANALYSIS.

%

100
I.N. PROCESS SEARCH CRITERIA

165 MI SC. PIPING

ABSTRACT :FIRESIDE CORROSION IN MUNICIPAL INCINERATORS VERSUS REFUSE COMPOSITION

SUMMARY

CORROSION OF HEAT RECOVERY TUBES EXPOSED TO COMBUSTION PRODUCTS FROM THE

BURNING OF MUNICIPAL AND INDUSTRIAL WASTES HAS BEEN A MAJOR PROBLEM. THE

THE RESEAPCH PROGRAM REPORTED HERE SOUGHT A BETTER UNDERSTANDING hf THE

FACTORS THAT CONTRIBUTE TO THE CORROSION OF STRUCTURAL AND ENERGY-RECOVERY

SYSTEMS ASSOCIATED WITH MUNICIPAL REFUSE INCINFR ATORS.THE RESULTS SHOW THAT

THE SULFUR AND CHLORINE CONTENTS OF REFUSE HAVE SIGNIFICANT EFFECTS ON THIS

TYPE OF CORROSION

ACCELERATING WHEN THE CHLORIOE CONTENT OF THE REFUSE

INCREASED ,8UT SLOWING DOWN WHEN THE SULFUR WAS INCREASED.

* Re- *

r.N. process SEARCH CRITERIA

324 PERC PIPING

LETTER REPORT, 10/27/76, FROM R. COOPER ,CRNL , TO D .8 I ENSTOCK , PERC

.

ANALYSIS OF NINE CORROSION SAMPLES

• SUMMARY

MATERIAL CHARACTERIZATION: CHEMICAL ANALYSIS OF THE BASE METAL AGREFO WITH

VENDORS CERTIFICATION.

STEAM SIDE CORROSION: CARBON STEELS IN STEAM ENVIRONMENTS AT MOOERATE TE“P.

USUALLY FORM A PROTECTIVE SCALE OF M AGNET ITE . THE LOCALIZED PITTING AND RAPID

SCALE GROWTH ON THESE SAMPLES IS BELIEVEO tq BE THE RESULT OF ATMOSPHERIC

EXPOSURE ASSOCIATED WITH BOILER SHUTDOWN AND SUBSEQUENT HANDLING OF THE TUBES

FOLLOWING DISASSEMBLY. THIS IS A SERIOUS PROBLEM IN COMMERCIAL BOILERS

ANO IS A COMMAN CAUSE OF PREMATURE FAILURE OF THE BOILER TUBES.

FLUE GAS CORROSION: BOILER COMBUSTION ZONE WAS OPERATED WITH EXCESS AIR

VARYING BETWEEN 20-3 5? . FLUE GAS ANALYSIS SHOWED SIGNIFICANT LEVELS OF

C02, H20 AND TRACES OF S02. SCALE FORMED IN THIS ENVIRONMENT IS NOT AS

TENACIOUS AND PROTECTIVE AS SCALE FORMED IN STEAM, THEREFORE THERE WILL RF

SIGNIFICANTLY HIGHER CORROSION RATES. RUST ON INSIOE SURFACES AVERAGED 3 MILS

IN THICKNESS (PROJECTED CORROSION RATE OF 12.5 MILS/YEAR).

FINAL REPORT WILL FOLLOW.

101
UN. PROCESS SEARCH CRITERIA

33 SRC PIPING

PAPER, 8/75, BY G. CHENOWETH ,S RC , PRESENTED AT U. OF PITTSBURGH.

PROGRESS REPORT—SRC PROCESS

SUMMARY . OPERATIONAL ANO MECHANICAL HISTORY SUMMARY

1. STUFFING BOX/CHECK VALVE FAILURES

2. INITIAL LOSS OF METAL DUE TO EROS I ON/CORROSI ON IN SLURRY PREHEATER COIL

THEN METAL LOSS ARRESTED

3. EROSION OF CONTROL VAI.VES

4. MECHANICAL PROBLEMS IN FILTRATION

5. SEVERE EROSION AND SEAL LEAKAGE IN ALL SCREW PUMPS HANDLING

DI ATOMAC I QUS EARTH. REPLACE WITH PISTON OR CENTRIFUGAL PU«PS

6. MANY SEAL FAILURES ON PUMPS

7. PLUGGING OF °IPI\'G SYSTEMS-HEAT TO 500F TO SOLVE

8. CORROSION OF SOLVENT RECOVERY SYSTEM-REPLACE CARBON STEFL WITH S.S.

* * * * *

UN. PROCESS SEARCH CRITERIA

267 SRC PIPING

REPORT, 5/28/76, FROM D. CANFIELD TO L. SAMUELS ,FT .LEW I S

.

FAILURE AND REPAIR OF THE WASH SOLVENT COLUMN

SUMMARY

FAILURE REPORT: THE SHELL OF THE 3/8" CARBON STEEL (SA-515 GR. 55) COLUMN

STARTED TO LEAK BETWEEN THE L3TH AND I9TH TRAYS. ATTEMPTS TO PATCH THE

HOLE FAILED. THE TRAYS WERE RE M 0 VED AND THE COLUMN WAS INSPECTED WITH

THE FOLLOWING RESULTS. 1) NEARLY ALL THE TRAY SUPPOR T RINGS AND DOWNCOMER

SUPPORTS FROM TRAYS 12-21 WERE ALMOST COMPLETELY CORROOFD, 2) AREAS OF

LIQUID PHASE CONTACT WE°E CORRODED «ORE THAN THOSE IN CONTACT WITH VAPOR

PHASE, 3) 14- GAUGE * 304 S.S. TRAYS HAD LOST ABOUT 7 MILS, 4) THE 16 AND 2D

GAUGE 3C4 S.S. VALVES WERE THINNING AT CLIP ENDS, 5) THERE APPEARED TO R

E

NO CORROSION PRODUCTS PRESENT.

FAILURE ANALYSIS: THE CORROSION APPEARS TO BE SIMILAR TO NAPTHENIC ACID

CORROSION AS DESCRIBED IN METALS HANDBOOK,. VOL. I. HOWEVER, NO DEFINITE

CONCLUSIONS ARE MADE.

REPAIRS:* THE TOP 13-FT SECTION OF THE 32-IN OD COLUMN WAS REPLACED USING

1/4-IN 316L S.S. THE TRAYS AND DOWNCOMER SUPPORTS WERE REPLACED WITH

316L S.S. NEW 316 S.S. TRAY VALVES WERE INSTALLED.

CORROSION TEST RESULTS: CORROSION RACKS WERE INSTALLED IN WASH SOLVENT

COLUMN TO EVALUATE MATERIALS. TYPE 321 S.S. AND INCOLOY BOO SHOWED VFRY

GOOD RESISTANCE TO THE CORROSIVE ENVIRONMENT. MQLY BEARING ALLOYS (2-3^)

ARE THOUGHT TO HAVE GOOD CORROSION PESISTANCE TO NAPTHENIC ACID CORROSION.

SEE UN. 302 FOR FURTHER INFORMATION.

102
I.N. PROCESS SEARCH CRITERIA

302 SRC PIPING

ERDA MAT. ANO COMP .FA IL . REPORT, 7/9/76 , FROM J. PIATT, SRC.

WASH SOLVENT COLUMN ,04075302.

SUMMARY

FAILURE: COLUMN SHELL DEVELOPED A LEAK DUE TO CORROSION.

^SERVICE LIFE: LB MONTHS.

-PRIOR REPAIRS: REBOILER PETUBED, 4/75 NEW TRAYS INSTALLED 12/75.

\ ENVIRONMENT : OVERHEAD, 450-525F, WASH SOLVENT. BOTTOMS, 600-670F, PROCESS

SOLVENT, 1QPSIG.

MATERIAL: SA-515 GR. 55 CARBON STEEL.

vCAUSE: CORRGSIVE ATTACK SIMILAR TO THAT OF NAPHTHENIC ACID CORROSION.

ACTION: REPLACED TOP 18-FT SECTION WITH 1/4-IN 316L S.S.

* * *

I.N. PROCESS SEARCH CR ITER I A 315 SRC PIPING

FAILURE REPORT, 7/28/76, FROM D.CANFIELD TO L .SAMUEL S , FT.L EW I S.

FAILURE OF THE WASH SOLVENT COLUMN

SUMMARY

THE WASH SOLVENT COLUMN DEVELOPED A LEAK BETWEEN THE L1TH AND 12TH T R AY S.

CAUSE AND DAMAGES THE SAMP AS PREVIOUS FA ILUR E ( SEE FA I LUR E

• °B p ORT IN I.N.267).

THE LEAK WAS FIXED WITH A TEMPORARY PATCH. A MAJOR SHUTDOWN IS SCHEDULED FOR

NOVEMBER ANO THE REST OF THE CARBON STEEL COLUMN WILL BE REPLACED AT

THAT TIME WITH 316L S.S.

AN INSPECTION QP T HE 316L S.S. SHELL AND TRAY SUPPORTS INSTALLS 3/76 REVEALED

NO NOTICEABLE CORROSION .THP 316 S.S. VALVES INSTALLED AT THE SAMP TIME ALSO

APPEARED TO BE IN EXC ELLENT SHAPE

.

SEE I.N. 267 AND 314 FOR ADDITIONAL OETAILS.

103
I.N. PROCESS SEARCH CRITERIA

314 SRC PIPING

ERDA MAT * AND COMP .F A I L . REPORT , 7/29/ 76 , FROM J. P IATT »FT. LEWIS.

WASH SOLVENT COLUMN 040753C2

SUMMARY

FAILURE: COLUMN SHELL DEVELOPED A LEAK.

SERVICE LIFE: 22 MONTHS

ENVIRONMENT: OVERHEAD, 450-525F, WASH SOLVENT. BOTTOMS, 600-670F, PRCCFSS

SOLVENT, 10 PSIG.

PRIOR REPAIRS: REBOILER RETUBED 4/75. NEW TRAYS INSTALLED 12/75.,

REPLACED TOP 13* WITH 316L S.S., 4/1/76

'.MATERIAL: SA-515 GR. B CARBON STEEL

CAUSE: CORROSIVE ATTACK SIMILAR TO NAPHTHENIC ACID CORROSION.

: ACTION : PATCHED HOLE. WILL REPLACE REMAINING CARBON STEEL COLUMN WITH 1/4"

316L S.S. DURING A MAJOR SHUTDOWN LATE THIS YEAR.

'.SEE I.N. 267, 315 FOR FURTHER INFORMATION.

I.N. PROCESS SEARCH CRITERIA

203 HYGAS PIPING

TELECON, 5/24/76, FROM S. GREEN BE RG»ANL»TO B.BAIR ,t GT

.

ASH AGGLOMERATING GASIFIER-INTERNAL CYCLONE DIPLEG

SUMMARY

INITIAL INSPECTION OF THE DIPLEG REVEALED VERY SEVERE COR R OS I ON, PARTICULARLY

AT THE BOTTOM. 310 S.S. IS RECOMMENDED FOR THE REPLACEMENT DIPLEG WITH

THE FLAPPER VALVE ALONIZEO.

THE PR08LEM WITH FAILURES LIKE THE DIPLEG AND EXPANSION RFLLOWS IS THAT

HYGAS IS OPERATING BEYOND THE EDGE OF EXISTING TECHNOLOGY AND THE NEED IS

FOR NEW MATERIALS DEVELOPMENT NOT MERELY TROUBLESHOOTING.

10A
I.N* PROCESS SEARCH CRITERIA

360 SYNTHANE PIPING

ENGINEERING INSPECTION REPORT, 3/21/77, BY J .JEWELL ,LUMMUS

.

PURGE PIPING CORROSION-GASIFIER

SUMMARY

FAILURE: CORROSION OBSERVED ON PURGE PIPING LOCATED IN GASIFIER BB-I OR B8.-3.

SERVICE LIFE: 114 HRS.

ACTION: ANALYSIS TO 8E PERFORMED BY ARGONNE.

* * * *

I.N. PROCESS SEARCH CRITERIA

317 WE ST INGHOUS E PIPING

ERDA MAT. AND COMP. FAIL. REPORT, 9/9/76, FROM E.VANDEP GRIFT » WESTINGHOUS c . WASTE WATER LINE-1" SCHEDULE 40

SUMMARY

FAILURE: PIPE FAILED AT ROOT OF THREAD OUE TO EROSION, CORROSION AND VIBRATION.

SERVICE LIFE: 18 MONTHS.

ENVIRONMENT: INTERNAL, COAL TAR LIQUOR AT 180 F.

MATERIAL: CARBON STEEL.

RECOMMENDATION: FUTURE CONNECTION TO BE SOCKET WELDED RATHER THAN THREADED.

316 S.S. SCHEDULE 90 PIPE WILL BE USED.

ACTION: PART REPLACED. NO ANALYSIS.

105
I.N. PROCESS SEARCH CRITERIA

316 WESTINGHOUSE PIPING

ERDA MAT. AND COMP .FAIL .REPORT, 9/9/76 , FROM E.VAMDERGRIFT, WESTI NGHOUSE.

WASTE WATER LINE-L/2" SCHEDULE 80

SUMMARY

FAILURE: PIPE FAILED AT ROOT OF THREAD DUE TO CORROSION AND VIBRATION.

SERVICE LIFE: 13 MONTHS

ENVIRONMENT: CHLORINATED COAL TAR LIQUOR

MATERIAL: CARSON STEEL

RECOMMENDATION: ELIMINATE THREADS, USE S.S.

ACTION: REPLACED PART .ANALYSIS TO 9E PERFORMED BY COMPANY LAB.

* * w *
I .N. PROCESS SEARCH CRITERIA

153 MI SC. PRESSURE VESSEL

PAPER BY A.L.PLUMLEY, J. JCNAKTN AND R . VU I A , 5 /20/66. A REVIEW STUDY OF

FIRESIDE CORROSION IN UTILITY ANO INDUSTRIAL BOILERS.

SUMMARY

A REVIEW STUDY OF FIRESIDE CORROSION IN UTILITY AND INDUSTRIAL BOILERS.

METHODS TESTED ANO RECOMMENDED FOR THE PRACTICAL PREVENTION OF CORROSION

INCLUDE FURNACE OPERATIONAL CHANGES * FUEL TREATMENT , ADDIT I VFS, PROTECTIVE

COATINGS, ALLOY SE LECT ION , AND DESIGN CHANGES.

# * * * *

r.N. PROCESS SEARCH CRITERIA

155 MISC. PRESSURE VESSEL

PAPER BY H. A. KLEIN, COMBUSTION ENGINE ER I NG .3 /17/72

.

CORROSION OF FOSSIL FUELED STEAM GENERATORS

SUMMARY

CORROSION OF FOSSIL FUELED STEAM GFN=RATORS.

PAPER DISCUSSES THE PROBLEM OF OPERATIONAL CORROSION IN HIGH P RES SURE

,

ORUM-TYPE STEAM G5NFR ATOR S . PAS T EXPERIENCE IS REVIEWED.

PRESENTED IS A THEORY OF BOILER CORROSION BASED ON THE ASSUMPTION THAT

SPECIFIC MECHANICAL AND CHEMICAL CONDITIONS MUST EXIST SIMULTANEOUSLY TO

INITIATE CORROSIVE ATT ACK . EMPHAS I S IS PLACED ON UNDERSTANDING THE PLUTO

DYNAMICS AND HEAT TRANSFER CONDITIONS WHICH MAY EXIST WITHIN A BOILER TUBE

IN DIFFERENT LOCATIONS IN THE BOILER .RECOMMENDATIONS FOR CHEMICAL CONTR°L

AND BOILER DESIGN TO MINIMIZE THE PROBLEM OF BOILER CORROSION ARE INCLUDED.

107

*
r.N. PROCESS SEARCH CRITERIA

308 SYNTHANE THERMOCOUPLES

ERDA MAT. ANO COMP .FAI L.P EPOPT, 8/6/76 , FROM J. JEWELL, LUMMUS.

GASIFIER THERMOCOUPLE TE 268

SUMMARY

FAILURE: SHEATH SEPARAT ED, OPENED UP, EXTREME CORROSION.

SERVICE LIFE: 17 HRS

ENVIRONMENT: 600 PS I , 50CF . STEA M AND OXYGEN-SOME ASH.

MATERIAL: INCCLOY 800

CAUSE: SHEATH MATERIAL VERY REACTIVE TO ENVIRONMENT.

ACTION: REPLACED. DIAGNOSIS TO BE PERFORMED BY ANL

.

* * * * *

i.n. PROCESS SEARCH CRITERIA

322 SYNTHANE THERMOCOUPLES

ERDA MAT. AND COMP .F A I L . P EPORT, L 0/ 1 B /76 , FROM J . JE WE LL , B RUC ETON

.

GASIFIER CONE THERMOCOUPLE TE-268

. SUMMARY

FAILURE: SHEATH COPRODED AWAY

PRIOR REPAIRS: THIRD THERMOCOUPLE ASSEMBLY. TO FAIL

MATERIAL: SHEATH MADE OF 304 S.S.

ACTION: REPLACED WITH 310 S-S. SHEATH. ANALYS I S BY COMPANY LABS.

108
I «N PROCESS SEARCH CRITERIA

305 WESTINGHOUSE THERMOCOUPLES

EROA MAT. AND COMP .FAIL. REPORT, 7/26/76, FROM 5. VANOER GR I FT , WE STINGHOUSE

.

THERMOCOUPLE TE 502-1

SUMMARY

FAILURE: SCRATCH IN SECONDARY COATING LED TO CORROSION OF SECONDARY SHEATH

AND BREAKDOWN OF INSULATION RESULTING IN ERRATIC OUTPUT.

SERVICE LIFE: 104 HP.S ENVIRONMENT: ZOQOF OXIDIZING AND REDUCING GASES

MATERIALS: SIC PRIMARY SHEATH, 0 1 S IL I Cl DE COATED MO SECONDARY SHEATH, MG02

INSULAT ION, W5RE/W26R E THERMOCOUPLE.

CAUSE: MANUFACTURING PROCESS CAUSED CRIMP IN SECONDARY SHEATH WHICH LED

TO ULTIMATE FAILURE BY PENETRATION OF TOXIC GASES.

ACTION: ANALYSIS 3Y COMPANY LABS
I *N PROCESS SEARCH CRITERIA

162 M I SC * VALVES

REPORT BY BATTELLE, COLUMBUS LABOR ATORY, 12/ 1 5/75.

A REVIEW OF LETOOWN VALVE EXPERIENCE IN COAL LIQUEFACTION SERVICE

SUMMARY

THIS SURVEY REPORT COVERS THE FOLLOWING ITEMS.

-.1. WEAR OF THE HIGH PRESSURE LETDOWN VALVE.

2. LITERATURE SURVEY COVERING LIQUEFACTION PROCESSING TECHNOLOGY. THIS

INCLUDES THE TECHNOLOGY OF THE CORROSIVE-EROSIVE WEAR PROCESS AND OF

PRESENT LETOOWN VALVE TRIM.

3. HISTORY OF EARLY EXPERIMENTAL COAL LIQUEFACTION PROCESSES FROM GERMANY

AND UNITED ST4TES.

4. LITERATURE REVIEW OF EROSIVE WEAR ON DUCTILE. BRITTLE AND COMPOSITE

CEMENTED CARBIDE MATERIALS AND the PROPOSED OPERATIVE MECHANISMS5- THE CEMENTED CARBIDES USED IN TRIM COMPONENTS SEEM TO HAVE A MARKED

DIFFERENCE IN QUALITY AND COMPOSITION FROM SUPPOSEDLY IDENTICAL GRADES

OF CARBIDE.

6. DISCUSSES THE VARIOUS DESIGNS OF TRIM IN USE, METHOD OF THROTTLING,

PROCEDURES USED TO MCDIFY VALVES, AMD OTHER WEAR PROBLEMS IN LIQUEFACTION

SYSTEMS.

* * * * *

110
:{|14A (REV. 7-73)

U.S. DEPT. OF COMM.

bliographic data

SHEET

1. PUBLICATION OR REPORT NO. 2. Gov’t Accession

No.

3. Recipient’s Accession No.

TLE AND SUBTITLE

l.eport of Coal Conversion Plants Operating Experiences

I'ailure Mode - Corrosion

5. Publication Date

6. Performing Organization Code

JTHOR(S)

ifilliam A. Willard and John H. Smith

8. Performing Organ. Reporc No.

ERFORMkNG ORGANIZATION NAME AND ADDRESS

NATIONAL BUREAU OF STANDARDS

DEPARTMENT OF COMMERCE

WASHINGTON. D.C. 20234

10. Project/Task/Work Unit No. 3120511

11. Contract/Grant No.

•ponsoring Organization Name and Complete Address (Street, City, State, ZIP)

Inergy Research and Development Administration

!0 Massachusetts Avenue, N.W.

7ashington, D.C. 20545

13. Type of Report Si Period

Covered

Summary Report to 6/77

14. Sponsoring Agency Code

SUPPLEMENTARY NOTES

ABSTRACT (A 200-word or less [actual summary o( most significant information. If document includes a significant

bibliography or literature survey, mention it here.)

rhis report consists of a group of summaries of operating experiences at coal

inversion pilot plants, materials evaluation reports, and diagnostic failure

analysis reports dealing with the problem of corrosion in the coal conversion

industry.

N

KEY WORDS (six to twelve entries; alphabetical order; capitalize only the first letter of the first key word unless a proper name; separated by semicolons

)

Coal gasification; coal liquefaction; component failures; corrosion; failure

analysis; material evaluation

AVAILABILITY gjg Unlimited

For Official Distribution. Do Not Release to NTIS

1 1 Order F rom Sup. of Doc., U.S. Government Printing Office Washington, D.C. 20402, SD Cat. No. Cl 5

1

1 ! Order From National Technical Information Service (NTIS)

:j| Springfield, Virginia 22151

19. SECURITY CLASS

(THIS REPORT)

UNCL ASSIFIED

20. SECURITY CLASS

(THIS PAGE)

UNCLASSIFIED

21. NO. OF PAGES

22. Price

USCOMM-DC 29041.P74

I