NBSIR 77-1285

Report of Operating

Experiences in Coal

Conversion Plants

Material of Construction - Incoloy 800

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 77-1285

REPORT OF OPERATING

EXPERIENCES IN COAL

CONVERSION PLANTS

Material of Construction - Incoloy 800

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

I

This report was prepared as an account of work sponsored by Che 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 FoAsil Energy Applications (l) , which is publishedbimonthly. 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.

^

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

I. AUXILIARY PROCESS EQUIPMENT

Hygas 3

2. Synthane 4

3. Synthoil 5

4. Westinghouse _ 6

II. MATERIAL EVALUATION

1. Carbonate 9

2* Clean Coke 11

3. COED - 14

4. CO

2 Acceptor 15

5. Combustion Power Company 18

6. Hygas . 19

7. Solvent Refined Coal 20

III. PIPING

1. Hygas / 23

2. Synthane 29

3. CO^ Acceptor 30

4. Hygas 36

5. Lignite 37

6. Solvent Refined Coal 38

7. Synthane ' 39

8. Westinghouse 40

VI
Page

IV. PRESSURE VESSELS

1. Hygas 45

2* Synthane 46

V. THERMOCOUPLES

1. Synthane * 51

VI. VALVES

1. CO^ Acceptor 57

X

VII
INFORMATION NUMBER INDEX

[formation

Number

Page

Number

Information

Number

Page

Number

Information

Number

Page

Number

1 19 169 12 341 54

13 3, 23, 45 176 36 344 28

20 15 180 14 351 40

22 15 182 11 353 40

26 20 183 12 365 29

56 17 191 6 366 18

79 19 194 26 370 38

88 30 205 25 377 46

89 30 210 24 378 5 93 31 213 23 393 48

94 31 220 27 398 47

95 32 224 37 399 48

99 16 236 24 404 47

102 32 258 46 405 39

103 16 267 20 409 41

112 33 273 13 410 39

117 57 285 26, 28

128 10 286 25

130 33 300 51

138 10 303 51

148 34 308 52

149 34 311 4 158 7 .319 52

159 7 325 53

161 35 337 54

\

VIII
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 use of Incoloy 800 in coal conversion

processes. The Incoloy 800 summaries are categorized into subgroups of

specific components: auxiliary process equipment, piping, pressure vessels,

thermocouples, valves and material evaluation. Each component subgroup is sorted

by coal conversion process (such as CO2 , 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, ADP 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
.

'
AUXILIARY

PROCESS

EQUIPMENT

I.N PROCESS SEARCH CP ITER!

13 HYGAS AUXILIARY PROCESS EQUIPMENT

FAILURE ANALYSIS REPORT ,11/30/73, FROM M .HOWES , II TR I , TO F . SCHOR A , IGT

METALLOGRAPHIC EXAMINATION OF FIVE SAMPLES FROM THE HYGAS PLANT

SUMMARY

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

LIGNITE 8ED AT 600 F FLUIDIZED WITH A GASICONTAINS 1M H2S) AT 12C0 F AND 1000 PSI. FAILURE OCCURRED BY CORROSION AT SCREW THREADS .RECOMMEND

COATING AND REDESIGN TO ELIMINATE SCREW THREADS.

2. WELDED 4X3 IN REDUCE ' : 446 S.S. SERVICE LIFE OF 6 MONTHS . FMV I RONMFNT

1500 F AT 25 »S I , FLU I DT ZED LIGNITE-INTERNAL, NITROGEN-EXTERNAL .FA ILUR

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

PROPAGATED IN 8QTH D IRECTIONS. REASON BEING MATERIAL EMBRITTLEMENT AND

RESIDUAL STRESSES. RECOMMEND STRESS RELIEVING.

3. BELLOWS: INCOLOY 800(20 GAUGE ) .SER VI C5 LIFE OF 9 MONTHS. ENVIRONMENT,

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

SURFACE OXIDATION AND INTERGRANULAR ATT ACK . RECOMMEND REDESIGN.

4. REFORMER QUENCH °0T SHELL: INCOLOY 800. SERVICE LIFE OF 6 MONTHS. ENVIRONMENT

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

'TEMPERATURE CONDI T I ONS .RECOMMEND REDESIGN.

5. BUTTERFLY VALVE: 446 S.S. S ER VICE LIFE QR 2 YEARS. ENVIRONMENT , 1400 F.

FAILURE DUE TO INTERNAL CORROSION AND RESIDUAL STRESSES. RECOMMEND

STRESS RELIEVING.

« * * * *

3 -
r.N. PROCESS SEARCH CRITERIA

311 SYNTHANE AUXILIARY PROCESS EQUIPMENT

ERDA MAT. AND COM°. FAIL. REPORT T 3/12/76»F ROM J. JEWELL , LUMMUS

INTERMEDIATE HEAD 0C-202

SUMMARY

FAILURE: HEAD BUCKLED INTO REVERSE DISH.

SERVICE LIFE: UNKNOWN

ENVIRONMENT: AMBIENT, C02 GAS, OPEN TO A IP . MAX. PRESS • 80 PSIG.

MATERIALS: HEAD-321 S.S..CONE AND P I PES-I NCOLOY 800.

CAUSE: ALLOWABLE DIFFERENTIAL PRESSURE WAS EXCEEDED.

ACTION: FAILURE ANALYSIS TO BE PERFORMED BY LUMMUS CO.

4
I.N PROCESS SEARCH CRITERIA

378 SYNTHOIL AUXILIARY PROCESS EQUIPMENT

LETTER REPORT, A/27/77, FROM T..COX TO J. BATCHELOR, ERDA

REVIEW OF MATERIALS OF CONSTRUCT I ON FOR SYNTHOIL PDU

SUMMARY

EXPERTS FROM ORNL , ANL ,N8S , AND THE MATERIALS BRANCH OF MER HAVE EXAMINED

CERTAIN CRITICAL AREAS OF THE SYNTHOIL PDU. GENERAL CONSENSUS IS THAT THE

MATERIAL SELECTION IS QUITE GOOD. SOME TROUBLE SPOTS ARE PINPOINTED.

POTENTIAL PROBLEM AREAS

1. FROM THE EXPERIENCE AT THE SRC PILOT PLANT » CASINGS AND IMPELLERS IN THE

CENTRIFUGAL PUMPS WILL RAPIDLY DETER I ORATE. OES IGN OF THESE PUMPS SHOULD

8E REVIEWED.

2. HIGH PRESSURE HYDROGEN LINES: UNTIL THE SAFETY OF CARBON STEEL TUBING

CAN BE ESTABLISHED BY APPROPRIATE TESTS, THESE LINES SHOULD BE

CONSTRUCTED OF 304-L S.S.

3. "HAIRPIN" HEAT EXCHANGERS: POORLY DESIGNED FROM AN EROSION AND

FABRICATION VIEWPOINT.

4. REACTOR FEED HEATER PIPING: INLET PIPING DESIGN COULD LEAD TO EROSION

FROM TURBULENT FLOW INDUCED BY HYDROGEN.

5. MESH SCREENS: CONTAIN CATALYSTS IN REACTOR FEED SURGE VESSEL AND THE

REACTORS. THEY SEEM TO BE VULNERABLE TO EROSIVE WEAR. DESIGN SHOULD RE

CHANGED TO ALLOW EASY REPLACEMENT.

* # * *

5
UN- PROCESS SEARCH CRITERIA

19 L WESTINGHOUSE AUXILIARY PROCESS EOUIPMEMT

SCIENTIFIC PAPER, 11/25/75, BY L . ALBERT IN AND J- CUNNINGHAM, WESTING HO USE ANO

S.TENOULKAP, ANO P .CH£RI SH, 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 ANO NOZZLE EXPERIENCED A SEVERE FORM OF HIGH TEMP. CORROSION

BY CARBURIZATION AND OXIOATIGN DUE TO EXCESSIVE TEMP. AND ALTERNATING

RE DUC I MG—OX ID I Z I NG ENVIRONMENTS.

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

CRACKING OF THE NOZZLE PLATE-PILOT INLET HOUSING WELD, PR08ABL E MALFUNCTION

OF SEVERAL NOZZLES , AND ACCUMULATION OF HEAVY CARBON ' DEPOSI TS AHEAD OF

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 6CI WHICH HAS GOOD RESISTANCE TO CARBURIZATION AND OXIDATION.

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

COMPONENTS TO PREVENT FUTURE GAS GENERATOR FAILURES.

* * . * * *

6
MATERIAL EVALUATION
.
I.N. PROCESS SEARCH CR ITER I A 158 CARBONATE MATERIAL EVALUATION

LETTER REPORT FROM' E.HOXIE TO R.SARRAF, ATOMICS I NTERNAT I ONAL, 6/ l 1/75.

CORROSION TEST SPOOL-6376

SUMMARY

CORROSION TEST SPOOL-6376.

TWELVE ALLOYS WERE TESTEO FOR CORROSION RESISTANCE UNDER THE FOLLOWING

CONDITIONS:

PROCESS UNIT: 3 GALLON RETORT AT 120 PSIG

CORROSIVE MEGIA: COAL GASIFICATION PROCESS QUENCH TANK LIQUOR

AVERAGE TEMPERATURE: 350F

AERATION: NONE

AGITATION: NONE

LENGTH OF TEST: 9.5 DAYS

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

GENERAL CORROSION RESISTANCE AND RESISTANCE TO STRESS CORROSION CRACKING.

REMARKS: NO AGITATION IN TEST VES SEL .CONS IDERABLE AGITATION WILL BE

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

I .N. PROCESS SEARCH CRITERIA

159 CARBONATE MATERIAL EVALUATION

LETTFR REPORT FROM E.HOXIE T 0 R. SARR AF, ATOM IC S I NTERNAT I ONAL » 7/ 1 1 /75.

CORROSION TEST SPOOL-6375

SUMMARY

CORROSION TEST SPOOL-6375.

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

FOLLOWING CONDITIONS.

PROCESS UNIT: 3 GALLON RETORT AT 120 PSIG.

CORROSIVE MEDIA: COAL GASIFICATION PROCESS QUENCH TANK LIQUOR.

AVERAGE TEMPERATURE: 350F

AERATION: NONE

AGITATION: NONE

LENGTH OF TEST: 29.5 DAYS

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

INCONEL 600 RECOMMENDED FOR USE AS A CONSTRUCTION MATERIAL.

9
I.N.: PROCESS SEARCH CRITERIA

128 CARBONATE MATERIAL EVALUATION

TEST REPORT BY J . G. BRUC E , AT0MI C S I NTERNAT IONAL ,7/23/75.

CORROSION TESTS OF MATERIALS IN HIGH TEMPERATURE MOLTEN SALT

22 MATERIALS WERE CORROSION

(FROM THE OCR COAL

ZR02, MGO, AND 8EO

THE MOST CORROSION

SUMMARY

TESTED IN STATIC, 1900F MOLTEN SODIUM CARBONATE

GASIFICATION PROGRAM) FOR 100 HRS. THE CERAMICS AL2D3,

AMD THE METALS PLATINUM AND UNILOY 50491 WERE FOUND TO BE

RESISTANT MATERIALS.

I.N.

138

PROCESS

CARBONATE

SEARCH CRITERIA

MATERIAL EVALUATION

REPORT, 10/1/75 , BY P. SARRAF, ATOMICS INTERN AT IONAL .CORROS ION TESTING OF

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 AND 175 F IN STRESSED AMD UNSTRESSED CONDITION.

QUENCH TANK CONDITION'S 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 .

2 . 3.

PRESS.

INCONEI.

FOR HANOLING QUENCH TANK LIQUOR AT 350 F, TO 120 PST G. THE

FOLLOWING ALLOYS HAD LOW CORROSION RATES:

RA333.

FOR THE QUENCH/REGENERATOR TANK USE ABOVE MATERIALS.

PRELIMINARY R

C SULTS ON PLASTICS TESTED INDICATE SUITABILITY

MATERIALS AT GREEN LIQUOR TEMPERATURES TO 200-250 F.

600, 601, 617, RA330,

OF R E VE D AL

10
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182 CLEAN COKE MATERIAL EVALUATION

INTERIM REPORT, 3/72-4/74, FROM USS ENGINEERS AN 0 CONSULTANTS , I NC . TO OCR.

CLEAN COKE PROJECT

SUMMARY

3-IN CARBON I ZER : SECTIONED FOR OBSERVATION AFTER 60 HRS SERVICE AT TEMP.

OVER 1 000 F INCLUDING 24 HRS OVER L300F. EXAM. SHOWED SIGNIFICANT

CARBURIZATION { C ART DES OF CR £ IRON) AT THE SURFACE OF THE 316 S.S. SHELL,

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

FLU 10 1 ZING GAS. THOUGH IT APPEARED TO BE STRONG AT HIGH TEMP., THF

CARBURIZED STEEL WAS EXTREMELY BRITTLE WHEN COOL. DE D TH OF CAR 3UR I ZA T ION

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

OF THE FLUID BED SECTION. ABOVE THIS POINT CARBURIZATION DECREASED

RAPIOLY TO ZERO NEAR THE TOP OF THE DFFNTRA I NMENT SECTION. CARBURIZATION

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

A CONTROLLED CONCENTRATION OF H2S WTLL BE MAINTAINED IN THE RECYCLF

FLUIDIZING GAS T 0 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 WER- RUN

USING 304 S.S., 316 S.S., INCONEL 600, INCOLOY 800, 310 S.S., AND ALONIZEO

316 S.S.

SERIES 1. 137 0 F, PRESS. 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 GRAMS

WITH NO EVIDENCE OF CARBON DEPOSITION.

SERIES 4. L250F , 100 PSIA, NO ADDED H2S AND NO CHAR BED. TEST LENGTH, 95

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

6 GPAMS OF CARBON DEPOSITS RECOVERED.

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

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

SHOWED SOME EVIDENCE OF THIS. CAR 8UR I ZAT ION IS A FUNCTION OF BOTH H2

CONCENTRATION ANO TEM PER ATUR E. 5 0- 1 00 PPM OF H2S SHOULD BE ADEQUATE TO

PROTECT INCOLOY 800 FROM CARBURIZATION.

* * *

11
i'.n. PROCESS SEARCH CRITERIA

169 CLEAN COKE MATERIAL EVALUATION

LETTER, 6/28/72, FRO* E. PHELPS .CORROSION TECHNOLOGY , TO P.MASCIANTONIO.USS CORP

MATERIALS OF CONSTRUCTION FOR THE CLEAN COKE PROJFCT CARBONIZATION POU

SUMMARY

AFTER REVIEWING FLOW DIAGRAMS AND PROCESS CONDITIONS FOR THE SUBJECT EQUIPMENT

THE FOLLOWING MATERIALS OF CONSTRUCTION ARE RECOMMENDED.

304 S.S.,316 S.S., CARBON STEEL, INCOLOY 800.

SEE TABLES I-IV FOR SPECIFIC RECOMMENDATIONS.

* * * *

r.N. PROCESS SEARCH CR ITER I A

183 CLEAN COKE MATERIAL EVALUATION

QUARTERLY R E P^RT , I , 2 , 3/ 75 , FROM USS ENGINEERS AND CONSULTANTS, I NC

CLEAN COKE PROJECT

SUMMARY

CARBONIZATION PDU: MAIN RECYCLE-GAS HEATER. 7 OF 45 ELEMENTS HAD

MALFUNCTIONED (6 BURNED OUT-, L BROKEN TERMINAL). FORMATION OF EXTENSIVE

CARBON DEPOSITS ON THE HEATER ELEMENTS CAUSED BURNOUT BECAUSE OF EXCESSIVE

TEMPERATURE WITHIN T H E CARBON- INSULATED SHEATHS. 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 AMO THE WASH

OIL RECIRCULATING PUMP FAILED. CAUSES NOT OISCUSSED. PUMP REPLACED WITH A SEALED CRANE CENTRIFUGAL PUM&.

CORROSION STUDIES: COUPONS O p VA D IOUS ALLOYS WERE EXPOSED IN SEVERAL

LOCATIONS IN THE PDU UNDER ACTUAL OPERATING CONDITIONS (800F AND 1300F).

AT LOW TEMPERATURE ONLY CARBON STEEL SHOWED SIGNIFICANT CORROSION. AT

HIGH TEMPERATURE ALONIZED INCOLOY SOO HAD A RELATIVELY HIGH CORROSION RATE.

PLAIN INCOLOY 800 SHOWED NO SIGNIFICANT CHANGE AFTER 244 HRS HIGH

TEMPERATURE TESTING. TABLES GIVE DETAILS AMD RESULTS OF TFSTS

12
I.N. PROCESS SEARCH CRITERIA

273 CLEAN COKE MATERIAL EVALUATION

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

CLEAN COKE PROJECT

SUMMARY

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

AROUND THE SHAFT. BELIEVED TO BE CAUSED BY LIGHT FACE LOADING ON THE S

C ALS.

THE REDESIGN INVOLVED CHANGING THE SEAL BALANCE FROM 70% TO 1C8% AND REDUCING

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

INSURE A MORE POSITIVE SEAL. DESIGN HAS PERFORMED SATISFACTORILY SINCE

INSTALLATION! 3/75)

CORROSION TESTS IN CARBONIZATION POU: A COMPLETE SERIES OF TFST SPECIMFNS

WERE EXPOSED IN THE PDU DURING OPERATION AT FLUIO BED TEMP. OF BOTH 80PF

AND 130GF.IN LOW TEMP . EXPOSURE ONLY CARBON STEEL SHOWED SIGNIFICANT

CORROSION. IN HIGH TEMP . LOCAT IONS NONE OF THE COPROSION RATES WERE GREATER

THAN 3.0 KPY.INCCLOY SCO SPECIMENS FROM HIGH TEMP. LOCAT IONS WERE EXAMINED

METALLOGRAPHICALLY AND SHOWED NO SIGNIFICANT CHANGE IN MICROSTRUCTURE.

TABLES PRESENT PERTINENT DATA FOR THE TESTS.

HYDROGENATION PDU: HIGH PRESSURE FITTINGS DEVELOPED LEAKS WHEN OPERATING

TEMP. REACHED ABOUT 70 OF. POSSIBLY R.ESUL T OF DIFFERENTIAL EXPANSION OF

DISSIMILAR METALS ( 316 S. S.30DY , AID S.S. GLAND NUT, 416 S.S. COLLAR).

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

13
I.N. PROCESS SEARCH CP ITER I A

130 COED MATERIAL EVALUATION

REPORT, NO DATE, NO AUTHOR.

MATERIALS , TEST PROGRAM-COED MATERIALS PROGRAM.

SUMMARY

MATERIALS TEST PROGRAM

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

STAGE TWO PYROLYSIS VESSEL (300F) AND THE STAGE THREE PYROLYSIS VESSEL

{ IOOOF ) * TOTAL TEST TIME WAS 4000 HOURS. MATERIALS, COMPOS IT IONS, AND

HEAT TREATMENTS OF COUPONS GIVEN IN TABLE XLVII. STAGE TWO SPEC I M5NS-G00D

CONDITION VISUALLY. STAGE THREE SPEC I MENS—CARBON STEEL COUPONS HAO

EXPERIENCED SEVERE ATTACK. TEST SPECIMENS SENT TO LUKENS STEEL FOR

METALLOGRAPHY.

OIL ABSORBER TOWER: TEST CQU°0\'S WERE INSTALLED IN THE BOTTOM SECTION.

TEMPERATURE WAS 60Q-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 PLAT

TEMPERATURE OF 709-80GF AND PRESSURE OF 2000-2500 PSIG. HYDROGEN

CONCENTRATION OF 90-95S. H2S CONCENTRATION OF 2?. TOTAL TEST TIME OF 2254

HOURS. INCO ANALYSIS RESULTS GIVEN IN TABLE LII.

* * * * *

14

in

»
I.N. PROCESS SEARCH CRITERIA

20 C02 MATERIAL EVALUATION

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

HIGH TEMPERATURE ALLOYS FOR C02

SUMMARY

MATERIAL EVALUATION OF INCOLOY 800 AND 310 S.S. IN CALCINEP AT LIBRARY, *> A

ATMOSPHERE: SULFUR 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 300 CAN BOTH BE USED.

REGENERATOR INTERNALS: TEMd/presS PROBES, THERMOWELLS. TEMPERATURE RANGE

1900— 1950F. SULFUR A30UT 0.2? AS $02, H2S , S2, COS. NO ALLOY SU

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

TEMPERATURE RANGE 1500-1950F. SULFUR FROM 0-0.1? AS H2S . USE 310 S.S.

OR INCOLOY 800 EQUALLY.

* *

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 3ENCH SCALE UNIT.

REGENERATOR INTERNALS: NO SUITABLE MATERIAL AVAILABLE. USE EXPENDABLE mptal

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

EXPOSE COUPONS IN C02 PLANT AND IN LAB.

REGENERATOR: 19SQF, REDUCING ATMOSPHERE, CO, H2S , COS, CS2, CP2, S2, M2,

use refractory lineo, NO SUITABLE METAL AVAILABLE. must BE REDUCING

(HIGH CO), TO ELIMINATE SLAG FUSION. 310 S.S. BETTER THAN INCOLOY 300

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

DOLOMITE RETURN LINES: 190CF, " INE RT“ PURGE GAS. NORMALLY DO NOT SEE SULFUR

BUT SOME LEAKS IN. USE 310 S.S. INSTEAD OF INCOLOY 300 TO REDUCE

SULFIDATION. PURGE GAS CONTAINS 3-4? CO THAT WILL CARBURIZE ANO EMBRITTLE

310 S.S. MUST MODIFY GAS.

COOLING WATER SYSTEMS: USE INHIBITOR ( D ICHRQMA TE ) WITH CARBON STEEL.

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

WELOINGr AVOID HIGH NI WELD RODS.

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

TO 1500F. NO REASON.

15
I.N. PROCESS SEARCH CRITERIA

99 C02 MATERIAL EVALUATION

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

BENDING PFOPERTIES AND HIGH TEMPERATURE SULFUR CORROSION RESISTANCE OF

ALONIZED INCOLOY 300..

SUMMARY

8ENDING PROPERTIES AND HIGH TEMPERATURE SULFUR CORROSION RESISTANCE OF

ALONIZED INCOLOY 800.

CONCLUSIONS

1. 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 I330P 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 I650F, A RADIUS OF 6 IN AT 130CF, 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 UNANNEALED CONDITION. OPENS UP CRACKS

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

RESISTANCE OF THE SURFACE.

6. BENDING IN THE "A S- ALON I ZED’* CONDITION OR BENDING IN THE ANNEALED

CONDITION AT TOO LOW A TEMPERATURE WILL ALSO CRACK THE INNER LAYF.R AND

GREATLY REDUCE THE CORROSION RESISTANCE OF THE ALONIZED COATING.

* * *

I.N. PROCESS SEARCH CRITERIA

103 C02 MATERIAL EVALUATION

REPORT FROM S. WORDEN, P^NCA CITY, TO C .SCHULZ .CONSOL , 6/13/74.

ALONIZED INCOLOY 300 PREHEATER COIL FABRICATION GUIDELINES

SUMMARY

ALONIZED INCOLOY 800 PREHEATER COIL FABRICATION GUIDELINES.

SUMMARY OF CONOCO RESEAPCH REPORT 72-74-1301 OF THE STUDY MADE TO YIELD

GUIDELINES FOR 3ENDING ALONI ZFQ TUBING FOR PREHEATER COILS.

16
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56 C02 MATERIAL EVALUATION .

REPORT, 10/20/75, 3Y H. CRCWQER , CONOCO.

CORROSION COUPON EV ALUAT ION. SER IES 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 HRS, OXIDIZING

VERY DETAILED MET ALLOGRA PH I C ANALYSIS. CORROSION RATES 10-360 mpy.

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

INCONEL - 706, 718, 793. INCOLOY - 80C, 801.

* * * * *

17
I.N PROCESS SEARCH CR ITER I A

; 366 CPC MATERIAL EVALUATION

' REPORT, N. D. , BY J . DE VAN , P .COOPER ,W . HARR I S, QRNL . MATERIAL EVALUATION-HEAT EXCHANGER TUBES

. 'Hf . J SUMMARY

. MATERIAL SELECTION FOR HEAT EXCHANGER TU3ES IN A MOOULAR INTEGRATED

UTILITY SYSTEM

TEST PROGRAM: SURVEILLANCE COUPONS OF 310 AND 316 S.S.,TNCOLOY 800 AND 325

MERE EXPOSED IN COMBUSTION POWER COMPANY’S MODEL FLUIDIZED BEO REACTOR.

TEST CONDITIONS: TEMP. 160C-1700 F, SEVERAL HUNDRED PERCENT EXCESS AIR. NO

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

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

JUST A80VE THE FLUID BED. INCOLOY 325 WAS EXPOSED FOR 1000 HRS. 310 AND

316 S.S. AND INCOLOY 800 WE°E EXPOSED FOR 500 HRS AND 1000 HRS.

RESULTS: SIGNIFICANT INTERGRANULAR OXIDATION OCCURRED ON ALL FOUR MATS 0 1 AL S

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 THF

MIUS SYSTEM ARE NEEDED TO ASSESS COMPATIBILITY PROBLEMS.

* * * * *

18
PROCESS SEARCH CP ITERI

I .N.

1 HYGAS MATERIAL EVALUATION

LETTER, 4/2/75, FROM A. MAC N AB, C *F . BRAUN , TO P .TARMAN , 1 GT.

MATERIAL SELECTION FOR HYGAS STEAM/IRON GASIFICATION PILOT PLANT

SUMMARY

DISCUSSION OF MATERIALS TO RESIST SULFIDATION IN PIPING TO THE R E AC TCP

AND SECOND STAGE REDUCER SPARGE P IMG. ATMOSPHERE WILL BE REDUCING GAS CONTAINING

0.1 MOLE PERCENT H2S AT 2000F. I NCOLO Y 800 AND 310 S.S. WILL NOT HOLD UP.

RECOMMEND 50CR-5QN I ( A STM 4560 OR UNILOY 50/50) OR ALON I ZED 310 S.S. OR

ALONIZED INCQLOY 3C0. 50CR-50N I HAS GOOD SULFIDATION RESISTANCE BUT POOR

HIGH TEMP. STRENGTH. RECOMMEND USE ~*F THIS MATERIAL AS CLADDING TO A SUBSTRATE

OF INCOLOY 800 OR 310 S.S.

* * s * *

r.N. PROCESS SEARCH CR ITERI

79 HYGAS MATERIAL EVALUATION

LETTER, 6/2/75, FROM P. TARMAN, IGT, TO A. MAC NAB , C .F . BRAUN.

MEMO, 5/30/75, FROM R. . 3 ACHT A TO P. TARMAN, IGT . FEASIBILITY AND AVAILABILITY OF INCOCLAD 671/900H PIPE

SUMMARY

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

INCOLOY 800 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 l ) S I ZE, BI GGEST PRODUCED BY HUNTINGTON IS 2-l/2"00,

IGT MEEDS 4" 00.2) CLADDING THE INTERIOR OF THE PIPE. MOST PRODUCTS CLAD

ON OUTSIDE ONLY.

INCOCLAD 671/800H PIPE HAS AN INCOLOY 800 SUBSTRATE WHICH PROVIDES STRENGTH

AT HIGH TEMPERATURES AND INCONEL 671 (APPROX. 50CR-50NI ) CLADDING WHICH

PROVIDES RESISTANCE TQ * SUL F I DAT I ON.

19
I.N. PROCESS SEARCH CRITERIA

26 SRC MATERIAL EVALUATION

LETTER, 3/18/74, FROM A . HENKE , GULF R£D,TO 8 . SCHM TO , SRC

MATERIALS M C N I TOR I NG PROGRAM FOR SRC PROCESS

LETTER REPORT, 1/30/74, FROM J. MCCOY, GULF R£D,TO 8. SCHM ID, SRC.

CORROSION/EROSION MONITORING PROGRAM AT SRC

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 EOUIPM c NT.

2. VISUAL INSPECTION.

3. EVALUATION OF TFST COUPONS OF*.' 310 S.S., 321 S.S., 304 S.S., MONF L

INCOLOY 300, CARBON STEEL, STELL ITES » COLMONOY , TUNGSTEN CARBIDE,

321 S.S. I ALUMINIZEO)

* * $ * A

I.N.- PROCESS SEARCH CRITERIA

267 SRC MATERIAL EVAHmiCN

REPORT, 5/28/76, FROM D. CANFIELD TO L . SAMUELS , FT.L EH I S

FAILURE AND REPAIR CF THE WASH SOLVENT COLUMN

SUMMARY

FAILURE REPORT: THE SHELL OF TH C 3/3" CARBON STEEL (SA-515 GR. 55) COLUMN

STARTED TO LEAK BETWEEN THE 13TH 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 0<= LIQUID PHASE CONTACT WERE CORRODED MORE THAN THOSE IN CONTACT WITH VAPOR

PHASE, 3) 14 GAUGE 304 S.S. TRAYS HAD LOST ABOUT 7 MILS, 4) THE 16 AND 20

GAUGE 3.04 S.S. VALVES WERE THINNING AT CLIP ENDS, 5) THERE APPEARED TO BE

NO CORROSION PRODUCTS PRESENT.

FAILURE ANALYSTS: THE CORROSION APPEARS TO 8E SIMILAR TO NAPTHEWIC AC TO

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

CONCLUSIONS ARE MADE.

REPAIRS: THE TOP 13-FT SECTION CF THE 32-IN OD COLUMN WAS REPLACED USING

1/4-IN 316L S.S. THE TRAYS AND DOWNCOMER SUPPORTS WER p REPLACED WITH

316L S.S. NEW 316 S.S. TRAY VALVES WERE INSTALLED.

CORROSION TEST RESULTS: CORROSION RACKS W

C RE INSTALLED IN WASH SOLVENT

COLUMN TO EVALUATE MATERIALS. TY° = 321 S.S. AND INCOLOY 300 SHOWFD VERY

GOOD RESISTANCE TO THE CORROSIVE ENVIRONMENT. MOLY 8EARTNG ALLOYS (2-3?)

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

SEE I.N. -302 FOR FURTHER INFORMATION.

20
PIPING
*

.

.
I.N. PROCESS SEARCH CRITERIA

13 HYGAS BELLOWS

FAILURE ANALYSIS REPORT, 11/30/73, FROM M. HOWES, TITRI ,T0 F . SC HOR A . IGT

METALLOGRAPHIC EXAMINATION OF FIVE SAMPLES FROM THE HYGAS PLANT

SUMMARY

1. SLURRY ORYER GRID: INCOLOY 300. SERVICE LIFE OF 6 MONTHS. ENVIRON M EN'r

, LIGNITE BED AT 600 F FLUIDIZED WITH A GASICONTAINS 1? H2S1 AT 1200 F AND 1000 PSI. FAILURE OCCURS C D BY CORROSION AT SCREW THRE AOS .RECOMMEND

COATING AND REDESIGN TO ELIMINATE SCREW THREADS.

2. WELDED A X 3 IN REDUCER: 446 S.S. SERVICE LTFE OF 6 MONTHS . ENV I RON.MFNT

I5C0 F AT 25 PS I , FLU I D I ZED L IGNIT5-INTERNAL , NITROGEN-EXTERNAL .FA. ILUS

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

PRGPAGATED IN BOTH DIRECTIONS .REASON BEING MATERIAL EMBRITTLEMENT AND

RESICUAL STRESSES. RECOMMEND STRESS RELIEVING.

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

1650 F IN A CORROSIVE ATMOS p HER E . FA I LURE OCCURRED BY COMBINATION OF

SURFACE OXIDATION AND INTERGRANULAR ATTACK .RECOMMEND REDESIGN.

4. REFORMER QUENCH POT SHELL: INCOLOY 800. SERVICE LIFE OF 6 MONTHS .ENVIRONMENT,

1650 F AT ICO PSI. FAILURE DUE TO THERMAL FATIGUE CAUSED BY FLUCTUATING

TEM PEP.ATURE CONDI T I QNS . R ECO MM END REDESIGN.

5. BUTTERFLY VALVE: 446 S.S. SERVICE LIFE OF 2 YEARS . ENV IROMMENT , 1400 F.

FAILURE DUE TO INTERNAL CORROSION AND RESIDUAL STRESSES. RECOMMEND

STRESS RELIEVING.

* $ * * &

I.N- PROCESS . SEARCH CRITERIA

213 HYGAS BELLOWS

TEL EC ON, 4/ 13/76, FROM S . GR EFNBERG, ANL ,TQ 3 .ORCHAR D, I GT

THERMOCOUPLE PROTECTION TUBES , PRESS. TAP TUBES , GA SI F I £R TRANSFER LINE BELLOWS.

SUMMARY

THERM. PROTECTION TU8ES:TUBES TC-23 AND TC-5 IDENTIFIED AS INCOLOY 800.

PRESSURE TAP TUBES : SCALE REMOVED FROM OUTER SUPFACE CONTAINED 14. 4M S.

EXPANSION JOINT B E LLOWS : C OAL PRODUCT REMOVED FROM BELLOWS HAS A SULFUR CONTENT

OF APPROX. 3 'S * V E R Y CLOSE TO THAT OF FFED MATERIAL.

THESE RESULTS TEND TO CONFIRM VIEW THAT TUBES FAILED AS A RESULT OF SULFUR

ATTACK. META LL9GR A PHI C EXAM. IS IN PROGRESS.

23
I.N. PROCESS SEARCH CRITERIA

236 HYGAS BELLOWS

TELECON, 4/27/76, FROM S. GREENBERG, ANL, TO B .ORCHARD, I GT.

EXPANSION JOINT-GASIFIER TRANSFER LINE.

SUMMARY

SEM AND OPTICAL EX AM . REVEALED PITS ON INTERIOR AND EXTERIOR SURFACES IN THE

VICINITY OF COMPLETE PERFORATIONS BUT MOT IN AREAS OF APPARENTLY SOUND METAL

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

IN CLOSE PROXIMITY TO THE FOGE OF A PER FORA T I ON. IT WILL 8E ESTABLISHED

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

BELLOWS FAILURE RESULTING FROM INITIAL DEFECTS { MANUFACTUP. INGJ MUST ALSO

BE CONSIDEREDSEE I.N. 136,194,210, 274,235,286 FOR FURTHER INFORMATION.

* * *

I.N. PROCESS SEARCH CRITERIA

210 HYGAS BELLOWS

TELECON, 5/5/76, FROM S. GRE5NBER G, ANL , TO 3. ORCHARD, I GT

EXPANSION JOINT-GASIFIER TRANSFER LINESUMMARY

COAL PRODUCT-METAL REACTION PRODUCTS ARE FOUND GENERALLY ON BOTH SIDES OF

THE BELLOWS AND IN ALL AR FAS. I T SEEMS UNLIKELY THAT CORROSION IS THE MAIN

CAUSE OF BELLOWS PERFORATIONS.

CURPENT VIEWS ARE THAT THE PITS ARE DUE TO EROSION, AT LEAST IN THE

CASE OF INTERNAL SUPFACE PITS. PITTING WAS PRECEDED BY LOCALIZED FAILURE OF

THE LINEP. TUBE ALLOWING PAPTICAL IMPINGEMENT ON THE INTERIOR BELLOWS SURFACE

AFTER PERFORATION OF THE BELLOWS THE STRUCTURE OF THE TRANSFER LINE ASS EM8LY

ALLOWED PARTICLE IMPINGEMENT ON THE EXTERIOR SURFACE OF THE BELLOWS.

IT IS IMPORTANT TO EXAMINE THE REMAINDER OF THE BELLOWS AND ESPECIALLY

THE LINER TUBE.

SEE I.N. 186,194,236,274,285,286 FOR FURTHER INFORMATION.

24
I.N. PROCESS search criteria

205 HYGAS BELLOWS

ERDA MAT. AND COMP . FA I L .R EPORT, 5/7/76

FROM W. ORCHARD, IGT

3"' EXPANSION JOINT FROM LINE 322

SUMMARY

FAILURE: TWO LEAKS IN BELLOWS-LARGE LONGITUDINAL ANO CIRCUMFERENTIAL CPACKS

IN SHORT NIPPLE.

SERVICE LIFE: APPROX. 2 YR S INTERMITTENT SERVICE.

MATERIAL: INCOLOY 800

PRIOR REPAIRS: END NIPPLES CHANGED FROM TP446 TO INCOLOY 800 PRIOR TO

INSTALLATION.

ENVIRONMENT: EXTERNAL-N2 AT I20F. INTERNAL-SYNTHESIS GAS AT 1200F (72?

H20, 9? HZ, 93 CH4, A3 CO, 33 NZ, < 17 HZS.

COMMENTS: CRACKS IN END NIPPLE APPEAR TO BE LOCATED AT THE SAME POINT WHERF

THE LINER WAS ATTACHED TO THE END NIPPLE WITH A FILLET WELD.

ACTION: ANALYSIS TO BE PERFORMED BY ANL

* * * * *

I.N. PROCESS SEARCH CRITERIA

286 HYGAS BELLOWS

TELECOM, 5/1 2/76 ANO 5/13/76, FROM S . GR EEN8ER G, ANL , TO 3. ORCHARD, IGT

EXPANSION JOINT-GASIFIER TRANSFER LINE.

SUMMARY

MANY HOLES AND PITS DISCOVERED IN INCOLOY 800 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. METAL LOGRAPH I C 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 1000F.

MATERIAL RECOMMENDATIONS

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

(USE INVOLVES RISK OF SCO.

2. IF HIGH TEMP. GASEOUS CORROSION IS ALSO IMPORTANT THEM 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.

25
I.N. PROCESS SEARCH CRITERIA

194 HYGAS BELLOWS

TELECQN, 6/2/76, FROM S . GR EENBER G, ANL , TO 8. BAIR, IGT.

EXPANSION JOINT-GASIFIER TRANSFER LINE.

SUMMARY

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

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

FUTURE 6ELL0WS MIGHT BE FABRICATED FROM ALLOYS RES I

T ANT TO PITTING CORROSION

316 OR 317 S.S., INCONEL 625 ,HASTELLOY C.HOWEVER,NO EXISTING MATERIAL MIGHT

BE SATISFACTORY FOR BOTH AQUEOUS PITTING CORROSION AS WELL AS HIGH TEMP.

SULFIDATION IN TERMS OF A LONG SERVICE LIFE.

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

* * * * *

I.N. PROCESS SEARCH CRITERIA

285 HYGAS BELLOWS

TELECON, 6/15/76, FROM S. GREEN BERG, A NL, TO 8. ORCHARD, IG T . EXPANSION JOINT-GASIFIER TRANSFER LINE AND AAG DIPLEG.

SUMMARY

MATERIAL I DENT IF I CAT I ON : P I PES 1 S 2 -330 S.S. BELLOWS £ AAG DI PLEG-I NCOL OY 800.

THE HIGHER SI CONTENT OF 331 S.S. MAKES THIS ALLOY MORE SUSCEPTIBI 5

TO CRACKING OF WELD JOINTS .RECOMMEND INCOLOY 300 RATHER THAN 330 S.S. OR

18-8 S.S. WELDING RODS BE USED WHEN JOINING 330 S.S. OR 18-3.

STRESSES IMPORTANCE OF MAKING SURE THEY GET MATERIALS THF Y SPECIFY AND

ALSO THE IMPORTANCE OF CONTROLLING IN-PLANT WELDING PROCEDURES INCLUDING

SPECIFYING OF TYPE OF WELD ROD.

26
I.N.

220

PROCESS

HYGAS

SEARCH CRITERIA

BELLOWS

ERDA MAT »AND COMP . FA I L. R EPORT, 1/20/ 77, FROM W. ORCHARD , IGT.

BELLOWS FAILURE-321 LIME

SUMMARY

FAILURE: DURING START—

D PRESSURE TESTING, LEAKING GAS WAS OBSERVED NEAR

THE BOTTOM OF THE BELLOWS. EXACT LOCATION COULD MOT BE INDENT I F I FD.

SERVICE LIFE: 8 MONTHS INTERMITTENT SERVICE.

ENVIRONMENT: EXTERNAL-N2 (ALSO INTERMITTENTLY HYDRAULIC OIL, WATER, C^AL

DUST) INTERNAL-650 F (723 H20, 93 CH4 , 43 CO, 33 C02, 33 M2, < 13 H2S )

.MATERIAL: IMCOLOY 300 20 GAUGE.

CAUSE: EITHER PINHOLE LEAKS IN BELLOWS OR BELLOW SEPARATION FROM END PLATE

IS THE EXPECTED CAUSE OF FAILURE.

ACTION: RETURNED TO MANUFACTURER.

27
I «N » PROCESS SEARCH CR ITER I A 285 HYGAS OIPLEG

TELECON, 6/15/76, FROM S. GREENBERG, A,NL, TO 3.0RCHAR0, IGT*

EXPANSION JOINT-GASIFIER TRANSFER LINE ANO AAG DIPLEG*

SUMMARY

MATERIAL IDENT IF IC AT I ON : P I PES 1 £ 2 -330 S.S. BELLOWS £ AAG DI PLEG-I NCOL OY 800.

THE HIGHER SI CONTENT OF 330 S.S. MAKES THIS ALLOY MORE SUSCEPTIBLE

TO CRACKING OF WELD JO INTS .RECOMMEND INCOLOY 800 RATHER THAN 330 S.S. OR

18-8 S.S. WELDING RODS BE USED WHEN JOINING 330 S.S. OR 18-8.

STRESSES IMPORTANCE OF MAKING SURE THFY GET MATERIALS THEY SPECIFY ANO

ALSO THE IMPORTANCE OF CONTROLLING IN-PLANT WELDING PROCEDURES INCLUDING

SPECIFYING OF TYPE OF WELD ROD.

* *•

\I .N.- PROCESS .SEARCH CRITERIA

344 HYGAS DIPLEG

FINAL FAILURE ANALYSIS PFPOR T, 12/76 , BY S.DANYLUK £ S .GREENBERG , ANL.

HYGAS ASH AGGLOMERATING GASIFIER INTERNAL CYCLONE DIPLEG FAILURE

SUMMARY

FAILURE: THE WALL MATERIAL OF THE AAG CYCLONE DIPLEG WAS SEVERFLY

CORRODED, WHICH RESULTED IN THE DETACHMENT OF THE FLAPPER VALVE AT

THE BOTTOM OF THE DI PL EG. CAR BUR IZATION AND SULFIDATION OF THE DIPLEG

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

•IN SOME AREAS 1/3 OF THE °IPE WALL WAS CONVERTED TO M C T AL SULFIDES.

MOLTEN SLAG WAS PRESENT NEAR THE TOP OF THE DIPLEG, CLOSE TO THE CYCLONE,

WHICH INDICATES THAT THE DIPLEG WAS EXPOSED TO OFF-DES IGM ( HIGH I TEMP.

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

WAS EXPOSED TO THIS FOR ABOUT 2000 HRS, 300 HRS OF WHICH WERE IN A LOW

STEAM ATMOSPHERE. BED t E

m PER ATUR E IS 1350-1975F AND THE GAS COMPOSITION

30? C02 , 15? CC , 15? H2,5? M2 AND THE BALANCE WATER.

MATERIAL OF CONSTRUCTION: INCOLOY 300.

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

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

CARBURIZATION.

RECOMMENDATIONS

1- PROCESS TEMPERATURES MUST RE KEPT WITHIN THE DESIGN LIMITS FOR INCOLOY 300.

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

SULFIDATION PROBLEM.

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

VALVE, WHICH MAY PROVIDE IMPROVED PERFORMANCE OF THIS COMPONENT.

28
I.N. PROCESS search criteria

365 SYNTHANE DIPLEG

TELECOM, 3/31/77, FROM S.OANYLUK,ANL, TO D. DUB IS , SYNTHANE

BALLOONING OF C-MO STEEL D IPE ANO 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 ,CHEM ICAL ANALYSIS AND METALLOG D A°HIC

ANALYSIS WILL BE PERFORMED.

4. AT PRESENT CAUSE OF BALLOONING IS UNKNOWN.

B. CYCLONE DIPLEG-INCOLOY SOO

1. CORROSION PITS HAVE DEVELOPED.

2. SECTIONS OF PIPE ARE TO 8E SHIPPED TO A ML

3. SYNTHANE REQUESTS M ATERIAL IDENTIFICATION ANO REASON FOR PITTING.

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

* * * *

29
I . N. PROCESS SEARCH CRITERIA

89 C02 PIPING

INTEROFFICE REPORT , 8/7/72 , FROM H. CROWDER TO J . LETERLE* CONOCO.

METALLQGRAPHIC STUDY OF 4-INCH DIAMETER INCOLOY 803 PIPE • SUMMARY

TWO SAMPLES OF REMAINING DIPEISEE I.N.88) WERE EXAMINED TO DETERMINE

SUITABILITY FOR FURTHER USE.

CONCLUSIONS

1. THE INSIDE SURFACE HAS BEEN DAMAGED BY SULFUR CORROSION AND EY GRAIN

BOUNOARY 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 USED FOR FURTHER SERVICE.

* * * # *

I.N. PROCESS SEARCH CRITERIA

83 C02 PIPING

FAILURE REPORT BY L. WOL FE t CONOCO t 8 / 1 4/72

METALLURGICAL STUOIES OF A RUPTURED INCOLOY 800 TUBE.

SUMMARY

A 50— FT LENGTH OF A85-FT. VERTICAL SECTION OF A 4-IN ID X 3/16 IN WALL T HICK.

INCOLOY 800 TUBINGILINE C0-208-4”-S I C ) WH I CH CONNECTS THE ENGAGER °0T TO THE

REGEN c RAT0R RUPTUR EO ( EXPLOOEO ) . THE LINE WAS USED FOR TRANSPORTING POWDERED

DOLOMITE AND LIGNITE AT ABOUT 1350F AT A PRESSURE OF 150 PSI.THIS LINE WAS

INSULATED AND ENCLOSEO IN A CARBON STEEL PIPE. MOST OF THE FRACTURED SAMPLES

SHOWED SIGNS OF MELTING. THF UPPER PORTION OF THF TUBE BROKE 5RITTLELY AI.ONG

GRAIN BOUNDARIES. ALL SAMPLES HAD TITANIUM SULFIDE PRECIPITATES IN THE

GRAIN BOUNDARIES IN BOTH the HOT ZONES AND THE COOLER ZONES. THE ORIGINAL

ALLOY WAS NOT DEFECTIVE OR ABNORMAL.

30
I.N. PROCESS SEARCH

93 CO 2 PIPING

FAILURE REPORT ,2/7/74, BY

MET.4NALYSIS QF CORRODED

R.PERKIMS AND W. COONS , LOCKHEED LAB TO CONSOL

I NCOLOY 800 TU8E 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 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 OXIDE FILM TO RETARD THE DIFFUSION OF CARBON AND SULFUR * TO THE UNDERLYING METAL MAY GIVE BETTER PERFORMANCE.

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

4c 4c 4c 4< ~

I.N. PROCESS SEARCH

94 CO 2 PIPING

LETTER REPORT, 4/ P/74, FROM L . RI CE , C . F. BR AUN, TQ D. GLASER, STEARNS-RCGER.

RISER EXPANSION JOINT FAILURES.

SUMMARY

REMEDIAL RECOMMENDATIONS FOR PIPING EXPANSION JOINT SPECIALISTS.

1. WEAKNESSES OF PRESENT SLIP JOINT SET-UP.

A. PRESENT LOCATION WILL NOT PREVENT •' JACK-KNIFING11 . B. ANY BINDING, SEIZING PR FPICTIQN AT THE JOINT WILL CAUSE BUCKLING AND

DISTORTION OF THE TUBE DURING HEAT-UP AND SHUTDOWN.

2. CHANGES RECOMMENDED

A. THREE DESIGN SKETCHES ARE ATTACHED SHOWING PROPOSED MODIFICATIONS.

B. RECOMMEND THAT SLIP SLEEVES BE PURGED DOWNWARD RATHER THAN UPWAPQ

AS AT PRESENT. THIS WILL PREVENT SOLIDS FROM ENTEPING THE SLEEVE.

31
I .N. PROCESS SEARCH CRITERIA

95 C02 PIPING

FAILURE REPORT, 4/16/74, FROM L. WOLFE , CONOCO, TG J.LETERLE, CONOCO.

MICROPROBE AMO MET ALLOGRAPH I C STUDIES OF PITTED FURNACE TUBES.

SU MM ARY

MICROPROBE AMD MET ALLOGRAPHIC STUDIES OF PTTTED FURNACE TUBES. THE LIGNITE

GAS. PLANT HAS HAD SEVERE CORROSION PROBLEMS FRQ^ HIGH TEMP. SULFUR. A ZINC OXIDE SYSTEM WAS INSTALLED F0<? REMOVING SULFUR. TWO RUNS TOTALING

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

OF THE FURNACE TUBES WERE SEVERLY PITTED AND ONE 3URST

CONCLUSIONS

1. THE PITS APE IN CARBURIZED METAL.

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

CARBURIZATION AND PITTING.

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

IN TWO DISTINCT LAYERS.

A. THE OUTER, THICKER SCALE IS PAPTICLES OF METAL AND METAL OXIDES.

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

6. TU8ES OF INCOLOY 800 AND 321 S.S. PITTED SIMILARY.

7. THIS ATTACK LOOKS SIMILAR TO "METAL DUSTING" WHICH DFSCT8 C S THF SCALE

AS GRAPHITE WITH METAL PARTICLES. THE PAPID CITY SCALE IS CR-DEPLETED

METAL PARTICLES WHICH ARE PARTIALLY OXIOIZED.

$ * # * *

I.N. PROCESS SEARCH CRITERIA

102 C02 PIPING

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

INCOLOY 300 HEATER COILS

SUMMARY

HIGH TEMPER ATURF CORROSION CAUSATIVE AND CONTROL ANALYSIS FOR INCOLOY 800

ALLOY HEATER COILS. MANY ALLOYS AP C SU8.JECT TQ AN EXTREMELY VIPULENT

FORM OF HIGH TEMPERATURE PITTING ATTACK ("METAL OUSTING"). AN INCOLOY 300*

HEATER COIL SUFFERED A HIGH TEMP. CORROSION FAILURE WITH OEEP SPHERICA1

PITS WHICH COVERED 30-40? OF THE SURFACE. THIS COIL. WAS SUBJECTED TO AN

ASSESSMENT OF THF MAJOR CONTROLLING VARIABLES ANO THE PRINCIPAL CAUSATIVC MECHANISMS INVOLVED THAT COULD LEAD TO SUCH AN ATTACK. MET ALLOGR A PH I

. 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.

32
I.N. PROCESS SEARCH CRITERIA

L12 C02 PIPING

FINAL REPORT FROM D. QUALLS TO J . L ETS RLE ,C. ONOCO » 1 1 / 7/74 . EVALUATION OF HEATER. TU3ES FROM RAPIC CITY CONSOL

SUMMARY

EVALUATION OF HEATER TUBES FROM RAPID CITY CONSOL

F IVE HEATER TUBE SAMPLES WERE SUBMITTED. THEY HAD BEEN INSPECTED BY MAGNETIC

INSPECTION WHICH INDICATED SOME DAMAGE.

A MICRO STRUCTURAL EVALUATION WAS REQUESTED TO CORRELATE ACTUAL DAMAGE WITH

MAGNETIC INSPECTION RESULTS.

ALONIZED 304 S.S. TUBE WAS GOOD. THE FOUR SAMPLES OF INCOIOY 30Q TUBING

CONTAINED VARYING OEGREES OF CORROSION AMO STRUCTURAL DAMAGE. THF DAMAGE WAS < 12. 2% OF THE MINIMUM MEASURED WALL THICKNESS.

* *

I.N. PROCESS SEARCH CRITERIA

130 ' C02 PIPING

ERDA MAT. AND COMP .FA I L . REPORT, 3/25/ 75, FROM C. SCHULZ* C02.

3-205 ACCEPTOR LIFT HEATER

SUMMARY

FAILURE J THE FLOW IN THREE PASSES OF THE FURNACE WAS CONST® I C TPD 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: TEMP. 110C-1403F. GAS COMPQSITI ON—3-4? CO* 267 C^2» 70* N2.

CARBONYL SULFIDE 50 PPM NOMINAL (RANGES FROM TRACE TO 400 PPM).

MATERIAL CF CONSTRUCTION: INCOLOY 300.

CAUSE OF FAILURE: UNKNOWN.

ACTION: DIAGNOSTIC ANALYSIS TO BE PERFORMED BY CONOCO.

33
I . N . PROCESS SEARCH CRITERIA

148 C02 PIPING

ERDA HAT. AND COMP . F AIL . REPORT .C02 *C. SCHUL Z . 10 / 8/75

REBUILT 3-2C5 ALPHA FURNACE COIL

SUMMARY

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

DUE TO THINNING AMD A SMALL PIN HOLE.

SERVICE LIFE: 581 HRS SINCE REBUILD.

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

WITH ALONIZED R A—330

ENVIRONMENT: TEMP. 1000-I500F. INERT GAS

AND RECYCLE GAS (30% N2» 17% C02, 3% CO,

MATERIALS OF CONSTRUCTION: IMCOLOY 800 WITH SECTIONS OF ALONIZED

CAUSE OF FAILURE: PROBABLY DUE TO CARBURIZATION AND SULFIDATION.

ACTION: DIAGNOSTIC ANALYSIS TO BE PERFORMED BY CONOCO.

(83-87% N2, 6-12% C02, 0.2-9. 6%

CARBONYL SULFIOE 50 PPM).

RA-330.

02 )

I .N. PROCESS SEARCH CRITERIA

149 C02 PIPING

EROA MAT. AND COMP .F A I L . R EPOR J, 10 / 1 7/ 75 , FROM C . SCHULZ ,C02

REBUILT B-205' ALPHA FURNACE COIL.

SUMMARY

FAILURE: THE TUBE WALLS IN SEVERAL AREAS HAD GREATLY. THINNED

REPLACEMENT OF THE COIL.

SERVICE LIFE: 919 HRS SINCE REBUILDING

ENVIRONMENT: SEE ATTACHMENT FOR HRS AND TYPES OF ATMOSPHERE

REQUIRING

PRIOR REPAIRS: COIL WAS REBUILT REPLACING

ALONIZED RA 330 AND A 9'-0" SECTION WAS

MATERIALS: INCOLOY 800 AMD RA 330

CONCLUSIONS: THINNING WAS PROBABLY DUE TO

AND SULFIDATION. NEW COIL FABRICATED OUT

ACTION: REPLACED PART .ANAL YS I S BY COMPANY

ALL THIN

REPLACED

SECT IONS, 12/74,

9/75.

WITH

A COMBINATION OF

OF INCONEL 702.

LABS.

CAR BUR I Z AT ION

'l

34
I.N. PROCESS SEARCH CRITERIA

161 C02 PIPING

REPORT BY R. PERKINS AND W .COONS* 1 1/ L 9/75 .METAL LURG ICAL ANALYSIS OF INCOLOY 800

TUBE FROM 8-201 1A HE ATF-R COIL AFTER RUNS 20-22.

SUMMARY

METALLURGICAL ANALYSIS OF INCOLOY 800 TUBE FROM B-2QL-1A HEATER COIL AFTFR

RUNS 20-22. FOLLOW-UP TO PREVIOUS LOCKHEED REPORT (LMSC-0407190 ) . 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 SUE AND MEW PITS DID NOT FORM DURING

A 5 10—HR EXPOSURE OF INCOLOY 800 PIPE TO RECYCLE GAS WITH THE ADDITION

OF 30-50? STEAM..

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

AND SULFIDATION DURING THIS EXPOSURE.

3. THE ADOITION OF >80? STEAM TO THE RECYCLE GAS COUPLED WITH LITTLE, IF ANY

EXPOSURE TO ALTERNATE R EDUC I NG/OX I D I Z ING CONDITIONS APPEARS TO BE

RESPONSIBLE FOR THE GOOD RESISTANCE TO HIGH-TEMPERATURE PITTING.

# * * #

35
</7

UJ

I.N. PROCESS SEARCH CRITERIA

176 HYGAS PIPING

ERDA MAT. ANO C QMP „F A I L . RE D ORT, 10/ 1 3/ 76 , FROM W . OR CHARD , IGT

P IPING FA ILURE—2ND STAGE GAS I F I E R REACTOR

SUMMARY

FAILURE: PIPE HAS ALMOST 360 DEGREE CIRCUMFERENTIAL BREAK IMMEDIATELY

ADJACENT TO O.D. WELD OF UPPER FLANGE, ALSO SOME LONGITUDINAL CRACKS ON

I.D. OF PIPE INSIDE SAME FLANGE.

ERVICE LIFE: 1-1/2 TO ? YEARS OF INTERMITTENT SERVICE.

NVIRONMENT: CHAR PLUS SYNTHESIS GAS AT ABOUT 1500 F(72H H20,9* CH4.4S CO,

3? C02,3S N2,< L® H2S ) . MATERIALS OF CONSTRUCTION: 53" LENGTH OF 3" SCH. 40 PIPEIRA 330 OR INCOLOY 30^)

EACH END HAVING A I5C L3 316 S.S. SLIP-ON FLANGE { WELDED WITH 312 OR 18? ROD).

CAUSE: BENDING FAT IGUE . LOWER END OF THIS VERTICAL PIPE HANGS FREE INSIDE

FLUIDIZED BED.

ACTION: REPLACED P ART . ANALYS IS BY ARGCNNE NATIONAL LA3.

* * * *

36
I

I . N.

224

PROCESS

L I GN I TE

SEARCH CRITERIA

PIPING

LETTER, 5/12/76, FROM D. SEVERSON, PROJECT LIGNITE, TO N . 8ERL I N, RA LPH PARSONS.

PERSONNEL PROTECTION-PROJECT LIGNITE

SUMMARY

EXAMPLES OF SAFETY MEASURES UNOERTAK c N AT PROJECT LIGNIT C FOR PFR SONNEL

PROTECTION. THE SINGLE MOST SERIOUS POTENTIAL HAZARD IS CO WHICH IS BOTH TOXIC

AND FLAMMABLE. METHODS OF DEALING WITH THIS PROBLEM APE OISCUSSED.

SECTIONS OF INCOLOY 300 TUBING FROM THE PDU HAVE BEEN EXAMINED PERIODICALLY

AND TO DAT5(5/12/76}TH5°E HAVE BEEN NO INDICATIONS OF THE SCC THAT PLAGUED

THE 316 S.S. TUBING.

SEE I.N.215 AND 225 FOR ADDITIONAL COMMENTS.

37
UN. PROCESS SEARCH CRITERIA

370 SRC PIPING

TRIP REPORT* 2/16/77, FROM R .KING C R. COOPER TO G. SLAUGHTERtORNL.

REPORT ON TRIP TO SRC PILOT PLANT AT TACOMA .WASHSUMMARY

SRC PILOT PLANT PROBLEM AREAS

A. SLURRY PREHEATER COIL

1. > 20 FT HIGH X 10 FT D IAM. , 1300-1700 FT LONG, 3" X SCHEDULE XX INCCLOY

800 HELICAL COIL, WITH BUTT WELDS.

2. PROBLEM IS AMOUNT OF COKING THAT OCCURS IN THIS COIL. IS IT SIGNIFICANT?

3. ORNL WILL TRY TO DEVELOP NOT METHODS FOR TESTING FOR COK ING, COR ROS ION

AND STRESS CORROSION IN THE COIL.

B. PARTIALLY COKED ELBOW

1. 5-0,4" SCHED. XX 347 S.S.tCOLD FORMED NOT STRESS RELIEVED) ELBOW.

2. OPERATING TEMP. 750-800 F.90^ PLUGGED BY A HARD RESIDUE.

3. IF ELBOW PLUGS THE PROCESS IS SHUTDOWN. ONE PIPE HAS RUPTURED DUE TO

AUTOMATIC HEATING OF A PLUGGEO PRESSURIZED LINE.

4. ORNL HAS A SECTION OF PLUGGED ELBOW FOR ANALYSIS.

C. DISSOLVER

1. A 347 S.S. LINER IN THE NOZZLE , WELDED TO A FLANGE THAT TS ATTACHED

TO THE OVERLAY.

2. THE LINER-FLANGE WELD HAS CR ACKED . POSS 1 8 IL ITY EXISTS OF CORROSIVE

ATTACK 3ENEATH THE SLEEVE.

3. ORNL WILL SUPPLY NOE GUIDANCE AMD POSSIBLY FIELD EXAMINATION.

D. PRESSURE LETDOWN VALVES

1. 1" FISCHER VALVES! 09 Q AND DROA) WITH FLOW FROM LARGE TO SMALL

DIAMETER.TR IM SETS APE TUNGSTEN CARRIDE.

2. VALVES ARE FAILING BY EROSION AND BREAKAGE FROM LODGED PARTICLES.

3. ORNL HAS RECOMMENOEO SOME DESIGN CHANGES.

4. FAILED TRIM SETS WILL BE ANALYZED BY ORNL.

E. CENTRIFUGAL PUMPS

1. DIERKO PUMPS WITH CD4MC0 HOUSINGS AND GOULD PUMPS WITH 12CP—HARDENED

STEEL CASES. REBUILT AND FLAME SPRAYED WITH TUNGSTEN CARBIDE.

2. EROSION/CCRROS ION FAILURES OCCUR IN APPROX. 33 DAYS.

3. ORNL STRONGLY RECOMMENDS A PROGRAM FOR EVALUATING WEAR RESISTANT

MATERIALS OIRECTLY IN THE SPC PROCESS STREAM. SRC MANAGEMENT WOULD

PR08ABLY SUPPORT THIS PROPOSAL.

F. PRESSURE VESSELS • 1. HIGH PRESSURE 0RUM( 1500 PS I

) -2-1/4CR-1M0 STEEL WITH A 2 FT 1.0.

X 5/6" THICK HEAD HAS A FORGE BONDED 304 S.S. CLAD.

2. STRESS CORROSION CRACKING OF HEAD IS PROBABLE.

3. INTERMEDIATE PRESSURE VESS6L(5O0 PSD-1/2M0 STEEL 2 FT I.D. X 5/6"W.T.

4. CRACKING OF HEAD CLACOING IS VISIBLE.

5. ORNL COULD USE NOE TO DETERMINE ATTACK OF BASE METAL. NEXT SHUTDOWN

THE HEAD COULD RE SECTIONED FOR COMPLETE ANALYSIS.

G. FRACTIONATION AREA

i. PROCESS STREAM IS HIGHLY ACIDIC WITH NAPTHALIC ACID ATTACK AT ALL

HOT AREAS BEING THE RULE. LOW ALLOY STEELS AND 304 S.S. ARE ATTACKED.

38
r.N. PROCESS SEARCH CRITERIA

405 SYNTHANE PIPING

QUALITY ASSURANCE REPORT, 5/31/77, FROM J .J EWELL , LUMMUS

CRACKING IN INCOLOY 8CG PIPE REDUCER

SUMMARY

FAILURE: NOZZLE NO. 50 DEVELOPED CRACKS IN THREE AREAS AROUND THE WELD. CRACKS

APPEAR TO BE IN HAZ WHERE MONEL LINER IS WELDED TO INSIDE OF REDUCER.

SERVICE LIFE: SINCE INITIAL START-UP.

ENVIRONMENT: 600 PSIGtSKIN TEMPER ATUPE, 300-400 F , DOAL PRODUCT GAS.

MATERIAL: NOZZLE IS 3" IN DIAM. AND REDUCES TO l-L/2" PIPE ANO FLANGE.

INCQLOY 800 LINED WITH MONEL OVERLAY.

CAUSE: UNKNOWN. REPORT DUE LATER.

ACTION: FAULTY WELD AREA HAS BEEN CUT nyr AND WILL BE REPLACED BY A 3" PIPE

SECTION WITHOUT THE REDUCER.

SEE I.N. 410 FOR FURTHER ANALYSIS OF FAILURE.

* * * *

I.N. PROCESS. SEARCH CRITERIA

410 SYNTHANE PIPING

MEMO, 7/1/77, FROM R .D0B3YN ,N3S, TO H. F RANKEL , 5RD A. CRACKING IN AN INCOLOY 300 REDUCEP-SYNTHANE PILOT PLANT

SUMMARY .

SEE I.N. 405 FOR INITIAL FAILURE R c PORT.

FAILURE MODE: METALLOGRAPHIC EXAMINATION BY C.E.LUMMUS INDICATED THAT

INTERGRANULAR STRESS CORROSION CRACKING WAS THE CAUSE OF FAILURE. IN ADDITION, THE AS-RECEIVED INCOLOY 300 BASE METAL WAS SENSITIZED.

RECOMMENDATIONS

1.

REMOVE NOZZLES 39 AND 41 INCLUDING FLANGES ANO RING JOINTS FOR

EXAMINATION BY LUMMUS.

2. INITIATE REPLACEMENT OF NOZZLES USING MONEL-LINED COMPONENTS IN

COMBINATION WITH ON -HAND INCOLOY COMPONENTS .ALL INCOLOY BOO USED WILL

BE SOLUTION ANNEALED ANO QUENCHED.

3. THIS WILL REQUIRE A SHUTDOWN OF APPROXIMATELY 5 WEEKS. DURING THIS TIME

VARIOUS OTHER MAINTENANCE AND REPAIR TASKS WILL 8E COMPLETED.

39
I.N. PROCESS SEARCH CRITERIA

351 WESTINGHOUSE PIPING

EROA MAT, AND COMP . FA I L . REPORT, 2/ 8 /77 , FROM E . V ANDERGR I FT , WEST INGHOUS E

PIPING FAILURE-CHAR/RECYCLE GAS LINE

SUMMARY

FAILURE: 1/32" OIAM. HOLE DEVELOPED IN »Y" BRANCH OF DOLOMITE DIVERSION

PIPE LINE.

SERVICE LIFE: 30 HRS.

ENVIRONMENT: 1200 F.OEAO BURNED DOLOMITE. 240 PSIG.

MATERIAL: Gl-INCH SCHEDULE AO INCOLOY 800 PIPE.

CAUSE: 45 DEGREE "Y" BRANCH INTERNALLY ERODED DUE TO ABRASION OF MATERIAL.

ACTION: REPLACED PART. ANGLE OF BRANCH CHANGED TO 90 DEGREES IN ORDER TO

REDUCE IMPACT VELOC IT I ES . ANALYS I S TO BE DONE BY COMPANY LABS. * * * * *

i.n. PROCESS SEARCH CRITERIA

3 53 WESTINGHOUSE PIPING

ERDA MAT. AND COMP . FAT L. REPGRT, 3/1 0/77, FROM E . VANOERGR I FT , WEST I NGHOUSE

PIPING FAILURE-RGS-25

SUMMARY

FAILURE: CRACK IN PIPE 1/32" WlDE,2/3 OF CIRCUMFERENCE .7/8" FROM FLANGE

TO F 1 1 4 HEATEP . SERVICE LIFE: 2 YEARS.

ENVIRONMENT: 525 F max. R6C IRCULAT ING GAS.

MATERIAL OF CONSTRUCTION: INCOLOY 300.1" DIAM. PIPE.

CAUSE: FAILURF IN HAZ NEAP WELD. MATERIAL FLAW. FAILURE CAUSED 8Y VIBRATION

INDUCED CRACK PROPAGATION.

ACTION: REPLACED P ART . S AVED. NO ANALYSIS.

SEE I.N. 409 FOR ANALYSIS OF PIPING FAILURE.

40
I *N. PROCESS SEARCH CRITERIA

409 WESTINGHOUSE PIPING

PIPE IN THE

SCHFOULF

IN THE 2-INCH

MEMO, 6/21/77, FROM T. COX TO M. CARRINGTON, 5P.DA

CRACKING OF INCOLGY 300 PIPING IN WESTINGHOUSE PDU

SUMMARY

FAILURE: SIX FAILURES HAVE GCCUPREO IN THE 1-INCH, SCHEDULE 40

TRANSPORT LINES. FOUR FAILURES HAVE OCCURRED IN THE 4-TNCH,

40 PIPE IN THE TRANSPORT LINES. FOUR FAILURES HAVE OCCURRED

SCHEDULE 40 PIPE IN THE VENT PIPING. FAILURE CAUSE WAS CRACKING WHICH

OCCURRED CLOSE TO WELDS, BUT NOT NECESSARILY IN THE WELD METAL OR HAZ.

SERVICE LIFE: FAILURES OCCURRED OVER A PERIOD OF SEVERAL HUNDRED HOURS OF

OPERATION.

ENVIRONMENT: MAXIMUM TEMPERATURE IS 600F.

MATERIAL: INCOLOY 300

CAUSE: EVIDENCE INDICATES THAT THE FAILURES RESULTED FROM INTERGRANULAR

STRESS CORROSION CRACKING. EX AIM I NAT ION REVEALED THAT THE INCOLOY 300

WAS HIGHLY SENSITIZED. RESIDUAL STRESSES MAY BE DUE TO THE WELDING

OPERATION OR TO IMPOSED STRESSES DURING INSTALLATION.

THE CORRODING AGENT HAS NOT BEEN IDENTIFIED.

RECOMMENDATIONS

1. SENSITIZED PIPING MUST BE ELIMINATED.

H. REPLACE WITH SOLUTION ANNEALED AND QUENCHED MATERIAL WELDED USING A PROCEDURE TO AVOID SENSITIZATION IN THE HAZ.

3. EFFORTS SHOULD BE MADE TO IDENTIFY THE CORRODING AGENT.

4. COLLECTION POINTS SHOULD BE INSTALLED AT SUITABLE POSITIONS IN THE

PDU FOR OBTAINING SAMPLES OF THE CONDENSATES WHICH FORM IN THE LINES.

SEEI.N. 353 FOR INITIAL REPORT OF ONE OF THE PIPING FAILURES.

41
.
PRESSURE VESSELS

I.N PROCESS SEARCH CRITERIA

13 HYGAS PRESSURE VESSEL

FAILURE ANALYSIS REPORT, 1 1/30/73, FROM M. HOWES, IITRI ,T0 F. SCHOR A, IGT

METALLOGRAPHIC EXAMINATION OF FIVE SAMPLES FROM THE HYGAS PLANT

SUMMARY

1~ SLURRY DRYER GRIO: INCOLOY 800. SERVICE LIFE OF 6 MONTHS. ENVIRONMENT,

LIGNITE BED AT 600 F FLUIDIZED WITH A GAS ( CQNT A INS IT H2S) AT 1200 F AND 1000 PSI. FAILURE OCCURRED BY CORROSION AT SCREW THREADS. RECOMMEND

COATING AND REDESIGN TO ELIMINATE SCREW THREADS.

2 . WELDED 4 X 3 IN REDUCE^: 446 S.S. SERVICE LIFE OF 6 MONTHS . ENV I RONMFNT

1500 F AT 25 PS I , FL'J 1 0 1 ZED L I GN ITE- INTERNAL ,N ITROGEN-SXTERN AL .FA II.UR E CAUSED BY CRACK THAT STARTED IN THE WELD BETWEEN THE PIPE AND FLANGE AND

PROPAGATED IN BOTH D 1 ° ECTIONS .REASON BEING MATERIAL EMBRITTLEMENT AND

RESIDUAL STRESSES. RECOMMEND STRESS RELIEVING.

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

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

SURFACE OX I OAT I ON AND INTERGRANULAR ATTACK .RECOMMEND REDESIGN.

4. REFORMER QUENCH POT SHELL: INCOLOY 300. SERVICE LIFE OF 6 MONTHS. ENV I 9QNMEMT

1650 F AT 100 PSI. FAILURE DUE TO THERMAL FATIGUE CAUSED 3Y FLUCTUATING

TEMPERATURE CONDITIONS. RECOMMEND REDESIGN.

5. BUTTEPFLY VALVE: 446 S.S. SERVICE LIFE OF 2 YE4RS. ENVIRONMENT , 1400 F.

FAILURE DUE TO INTERNAL CORROSION AND RESIDUAL STRESSES. RECOMMEND

STRESS RELIEVING.

* * * * *

45
I.N. PROCESS SEARCH CRITERIA

258 SYNTHANE PRESSURE VESSEL

ERDA MAT. AND COMP . FA I L . R EPORT, 1 0/ 18 /76 , FROM J . JEWELL , BRUC ETON.

GASIFIER SHROUD

SUMMARY

FAILURE: GASIFIER SHROUD BUCKLED

SERVICE LIFE: 02 IN 9* HRS TO DATEtI8-l/2 HRS ON LAST RUN

ENVIRONMENT: HS STEAM, 02 .COAL AT I500F.RUN M.

MATERIAL: 1/3" THICK INCOt.OY ROOM ( S B-409-800 GR 2 ANNEALED)

CAUSE: EQUIPMENT MALFUNCT I ON. OVERHEAT IN G FAILURE.

ACTION: REPLACEO SHROUD . REPORT EXPECTED BY 1/2/77.

* * # #

I.N. PROCESS SEARCH CRITERIA

377 SYNTHANE PRESSURE VESSEL

QUALITY ASSURANCE REPORT , 4/23/77, BY J . J EWELL , LUMMUS

BUCKLED GASIFIER SHROUD

SUMMARY

FAILURE: CRACKS WERE FOUND IN THE WELD BETWEEN THE INTERFACE WITH THE COME.

SERVICE LIFE: 450 H^S OF OXYGEN.

ENVIRONMENT: COAL DUST , OXYGEN , STEAM , 600 PSIG,1500 F.

PRIOR REPAIR: SHROUD HAS BUCKLED PREVIOUSLY.

MATERIAL: INCOLOY 800

CAUSE: INTERNAL STRESS AND THERMAL STRESSES CAUSED BY 3UCKLE0 SHROUD LED

TO WELD FAILURE.

ACTION: PRESS SHROUD BACK INTO POSITION ANO REWELD.

COMMENT: THOUGHT SHOULD BE GIVEN TO A NEW DESIGN, ONE WITH LOOS^ PLATES, TO

ALLOW FOR EXPANSION ANO CONTRACT I ON. PRESENT DESIGN ALLOWS NO ROOM FOR

EXPANSION.

46
I.N. PROCESS search criteria

404 SYNTHANE PRESSURE VESSEL

INTEROFFICE MEMO , 5 /9/77 , FROM W.VAN SWER INGEN TO P.STRE3INGER,LUMM(JS.

CRACKING IN GASIFIER SHROUDS

SUMMARY

CRACKS HAVE AP°E A® ED IN THE CYLINDRICAL INCOLOY 800 MANWAY SHROUDS ON THE

7TH AND 10TH FLOORS. THESE CRACKS RUN CIRCUMFERENTIALLY FROM 8:00 TO 4:00

AND ARE APPROX. 3/4" AWAY FROM THE GASIFIER SHELL. THERE ARE SEVERAL SHOPr

AXIAL CRACKS BRANCHING FROM THE MAIN CRACK POSSIBLY CAUSED BY ATTEMPTED

WELD REPAIRS.

THE CRACKING WAS PROBABLY CAUSED BY THE SEVERE THERMAL GRADIENT THAT EXISTS

IN THE SHROUD (APPROX. 1400-200 F OVER 9") BETWEEN THE INSIDE OF THE CASTABLE

AND THE SHELL. ANOTHER HYPOTHESIS IS THAT CRACKING OCCURRED FROM A COMBINATION

OF EFFECTS-DIRECT THERMAL STRESSES, C YCL IC HEATING AND COOLING. AND VIBRATION

FATIGUE.

IT WAS CONCLUDED THAT THE CRACKS WILL DO LITTLE HARM. 3/3" HOLES WILL BE

DRILLED AT THE END OF EACH CRACK TO STOP ITS PROPAGATION..

SEE I.N. 377,393,399 FOR ADDITIONAL INFORMATION.

=* * * * #

I.N. PROCESS SEARCH CR IT5RI

398 SYNTHANE PRESSURE VESSEL

QUALITY ASSURANCE REPORT, 5/13/77, FROM J .JEWELL ,LUMMUS.

EROSION OF GASIFIER CYCLONE

SUMMARY

FAILURE: HOLE FOUND IN CONE SECTION OF CYCLONE. AFTER REMOVAL QF THE CYCLONE

A GENERAL EROSION PATTERN WAS FOUND.

SERVICE LIFE: APPROX. 1000 HRS.

ENVIRONMENT: 300 F, PRODUCT GAS, CHAR AND COAL DUST, 600 PSIG.

MATERIAL: INCOLOY 800'.

CAUSE: EROSION.

ACTION: REPAIRED BY ADDING TWO CONICAL COLLARS 1/8" THICK OVER ENTIRE CONE

AREA.

47
I.N. PROCESS SEARCH CRITERIA

399 SYNTHANE PRESSURE VESSEL

QUALITY ASSURANCE RE°OR T, 5 / l 3/ 77 , FROM R .LORO, LUMMUS

CRACK IN GASIFIER SHROUD

SUMMARY

FAILURE: CRACK IN SHROUDING IN 7TH FLOOR MANWAY FROM 8:00 TO 4:00 POSITION.

CRACK NEAR SHROUD TO SHELL WELD ABOUT 1/8" WIDE.

SERVICE L I c E : UNKNOWN.

ENVIRONMENT: UNKNOWN.

MATERIAL: INCOLOY 800.

CAUSE: APPARENT CAUSE OF FAILURE WAS THERMAL STRESSES.

ACTION: LEAVE AS IS FOR NEXT RUN, REPA IR , AND INSTALL NEW REFRACTORY OUR I NG

NEXT SHUTDOWN.

COMMENTS: 3/16" HOLES WERE DRILLED AT THE ENDS OF THE CRACKS THROUGH THE

SHROUD TO PREVENT FURTHER CRACKING.

SEE I.N. 377,393 FOR PREVIOUS REPORTS ON THIS PR08LEM.

* * *

I.N. PROCESS SEARCH CRITERIA

393 SYNTHANE PRESSURE VESSEL

QUALITY ASSURRAWCE R EPORT , 5/24/77 , FROM J . JEWEL L, LUMMUS

GASIFIER-BUCKLED SHROUD

SUMMAPY *

FAILURE: THE INNER SHROUD IN THE REACTION ZONE HAS BEEN BUCKLED FOR SOME

TIME. IT IS BELIEVED THAT THE BULGES INTERFERE WITH THE FLUIDIZED BED AND

POSSIBLY CAUSE THE FORMATION OF CLINKERS.

SERVICE LIFE: 400 HRS.

ENVIRONMENT: 1500 F,60B PSIG,COAL G AS , 02 , STE AM, CO AL CHAR.

MATERIAL: INCOLOY 900.

CAUSE: DREVinuS REPORT INDICATES THAT A POOR DESIGN WHICH FAILS TO ALLOW

FOR THERMAL EXPANSION IS THE CONTRIBUTING FACTOR. SEE I.N. 377.

ACTION: REMOVED 907 OF ALL SHROUD. WEL DED IN NEW SHROUD 360 DEGREES AS SHOWN

BY PHOTO.NO MENTION MADE OF DESIGN CHANGE.

48
THERMOCOUPLES
'

.
I.N PROCESS SEARCH CRITERIA

303 SYNTHANE THERMOCOUPLES

PRELIMINARY REPORT, 7/26/76, FROM O.DUBIS TO 3 . L EW I S , SYNTHANE

GASIFIER DISTRIBUTOR COME THERMOCOUPLE FAILURE.

SUMMARY

SUMMARY OF PRELIMINARY REPORT FROM S. DANYLUK , ANL

1. THE FAILURE APPEARS TO BE CAUSEO BY INTERGRANULAR CORROSION. THE C^ACK

STARTS AT OUTSIDE WALL AND PROGRESSES INWARD.

2. THIS FORM OF CRACKING IS AGGRAVATED BY A HIGH SULFUR ENVIRONMENT..

3. MGO IS HYOROSCOPIC AND THE EXPANDING MOISTURE WILL COMPLETE THE

TU8E SPLIT

4. USE 310 OR 330 S.S. FOR BETTER CORROSION RESISTANCE, DEFINITELY NOT INCCLOY

800.

5. CHECK ALL NEWLY INSTALLED THERMOCOUPLES WITH MAGNIFYING GLASS FOR CRACKS.

6. ANL PLANS TO DO CHEMICAL ANALYSIS OF SHEATH MATERIAL, MGO AND CORROSION

PRODUCT.

SEE I.N. 295, 293; 299, 300, 307, 308 FOR FURTHER INFORMATION.

* * * * *

I.N. PROCESS SEARCH CRITERIA

300 SYNTHANE THERMOCOUPLES

TELECON, 9/2/76, FROM R. IVINS, AML, TO B. ROCHE, LUMMUS.

FAILURE ANALYSIS OF DISTRIBUTION CONE THERMOCOUPLE SHEATHS.

\ SUMMARY

ANL HAS CONTACTED THERMOCOUPLE SUPPLIER AND HOPES TO OBTAIN SAMPLES FROM

SAME BATCH AS FAILED THERMOCOUPLES.

G. STANTON IS TO BRING BACK SAM°LES FROM A SECOND SATCH OF FAILED T/C SHEATHS.

•SEE I.N. 295,293,299,303,307,308 FOR FURTHER INFORMATION.

51
I.N. PROCESS SEARCH CR ITER I 4 308 SYNTHANE THERMOCOUPLES

6RDA MAT. AMO COM P . FA I L . RE PORT, 8/6/ 76 , FROM J . JE WELL , LUMMUS

GASIFIER THERMOCOUPLE TE 263

SUMMARY

FAILURE: SHEATH SSPARATEC, OPENED U° * EXTREME CORROSION.

SERVICE LIFE: 17 HRS

ENVIRONMENT: 600 PS 1 , 500F . STEA M AND OXYGEN-SOME ASH.

MATERIAL: INCOLOY 8C0

CAUSE: SHEATH MATERIAL VERY REACTIVE TO ENVIRONMENT.

ACTION: REPLACED. OIAGNOS IS TO BE PERFORMED BY ANL

SEE I.N. 295,298, 299 , 30G » 303 » 3 07 FOR FURTHER INFORMATION.

* * *-

I .N. PROCESS SEARCH CR ITE 3 I A 319 SYNTHANE THERMOCOUPLES

TELEC0N,9/3/76 t FR0M S. D AN YLUK , ANL , TO B. LEWIS AND 0. BAILEY, SYNTHANE.

FAILURE ANALYSIS OF DISTRIBUTOR CONE THERMOCOUPLE SHEATHS

SUMMARY

MICROHARDNESS MEASUREMENTS INDICATE COLD WORK AT FAILURE LOCATION*.

CORROSION SCALE CONTAINS 1.4 WT 7 SULFUR. FABRICATOR DOES NOT UNDERSTAND

SULFIDATION AT THE LOW OPERATING TEMPERATURES. LEWIS STATED THAT NO. 2

FUEL OIL CONTAINING 0 . 25 % SULFUR WAS USED FOP 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-iJP FUEL.

RECOMMENDATIONS: REPLACE INCOLOY 300 WITH 310 S.S.. 8E CARFRJL NOT TO

INTRODUCE ADDITIONAL COLO WORK IN THE MATERIAL BY BENDING TH= TUBES

DURING INSTALLATION.

' SEE I.N. 295, 293, 299, 3C0, 303, 307, 308, 312, 318 FOR ADDITIONAL DETAILS.

52
I.N. PROCESS SEARCH CRITERIA

325 SYNTHANE THERMOCOUPLES

FINAL FAILURE ANALYSIS REPORT, 10/76, FROM . S.DANYLUKG 6. DRAGEL , ANL

SYNTHANE GASIFIER DISTRIBUTOR CONE THERMOCOUPLE SHEA TH ( TE-268 ) FAILURFS

SUMMARY

FAILURE: CORROSION CRACKS INITIATED AT THE OD OF THE SHEATH MATERI AL AT

SURFACE CRACKS OR PITS. THE CRACKS PENETRATED TO THE 10 AND THE MGO WAS

EXPOSED TO STEAM. THESE CRACKS 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 AND OXYGEN ENVIRONMENT.

600 PSIG AND 650F.

MATERIALS OF CONSTRUCTION: CR-AL THERMOCOUPLES WITH A SHEATH OF INCOL^Y 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

X. BETTER QUALITY CONTROL OF SHEATH FABRICATION. USE STANDARD (SPFC.

’ C7-6T) FOR MFTAL SHEATH, CERAMIC INSULATEO THEP MOCOUP LE S.

2. A HIGHER CR S.S. (TY d E310) SHOULD SOLVE THE SULFIDATION PROBLEM.

3. SINCE THE FUEL OIL fqr START-UP CONTAINS SULFUR SWITCH TO PROPANE.

4. CAREFUL HANDLING OF TUBES ANO 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.

* * * * *

53
I .N- PROCESS SEARCH CRITERIA

337 SYNTHANE THERMOCOUPLES

LETTER W/CQPY OF TC STANDARDS, 11/4/74, FROM S. D ANYLUK , 4NL , TO 8 . ROCHE , l UM*«US • RDT STANDARD C7-6T W/SUPPIEMENTS

SUMMARY

THERMOCOUPLE MATERIAL AND THERMOCOUPLE ASSEMBLY

CHROMEL-P VERSUS ALUMEl

STAINLESS STEEL SHEATHED

MAGNESIUM OXIOE INSULATED

SEE SECTION ON SURFACE FINISH AND OEFECTS.IT DOES NOT APPEAR THAT THE

THERMOCOUPLE SHEATHS WE HAVE EXAMINED WOULD HAVE MET THESE SPECIFICATIONS.

IT MIGHT BE A GOOD IDEA TO USE THESE SPECS AS A GUIDE WHEN ORDERING FUTURE

MATER IAL.

* * * *

I .N. PROCESS SEARCH CRITERIA

341 SYNTHANE THERMOCOUPLES

TELECON, 11/29/76, FROM $ . D ANYLUK, AML , TO B. M ASS A , LUMMUS

SUBSTITUTE MATERIALS FOR 310 S.S. TO 86 USED IN GASIFIER

SUMMARY

310 S.S. WAS RECOMMENDED AS A SUBSTITUTE FOR INCOLOY 800 THERMOCOUPLE

SHEATHS WHICH WS°E FAILING IN S ER V I C E . HOWEV FR , 31 0 S.S. SHEATHS WILL NOT

BE AVAILABLE FOR SEVERAL MONTHS. 446 S.S. WAS RECOMMENDED BUT EMBRITTLEMENT

MAY BE A PROBLEM.

54
VALVES
I 

- • . - - ’
I.N. PROCESS SEARCH C R IT E° I A

117 CQ2 VALVES

ERDA MAT * AND COMP .F A I L . REPORT , l /3 1 /7 5, FROM C . SCHULZ , C02

XCV-201Q AUTOMATIC VALVE

SUMMARY

FAILURE: THE LINER OF THE VALVE WAS ERODED AWAY IN A SECTION 3” WIDE ON

THE BOTTOM TO L" WIDE ON THE TOP ON ONE SIDE OF THE VALVE.

.SERVICE LIFE: APPROX. 9 MONTHS.

ENVIRONMENT: TEMP. 1A-5CF. VELOCITY 55-iOO FT/SEC. ENTRAINED DOLOMTTE

8 X 20 MESH, RECYCLE GAS (CO, C02, N2 ) WITH SULFUR IN THE PPM RANGE.

MATERIAL OF CONSTRUCTION: INCOLOY 800

CAUSE OF FAILURE: THE INNER LINER WAS MISALIGNED DURING MANUFACTURE CAUSING

EROSION ON THE LINER.

ACTION: THE REPLACEMENT VALVE INNER LINER WAS PROPERLY ALIGNED.

* * * *

57
.
NBS-114A (SEV. 7-73) 1

' U.S. OEPT. OF COMM.

BIBLIOGRAPHIC DATA

SHEET

1. PUBLICATION OK REPORT NO. 2. Gov’t Accession

No.

4. TITLE AND SUBTITLE

Report of Coal Conversion Plants Operating Experiences

Materials of Construction - Incoloy 800

3. Recipient’s Accession No.

5. Publication Date

6. Performing Organization Code

7. AUTHOR(S)

William A. Willard and John H. Smith

8. Performing Organ. Report No.

9. PERFORMING ORGANIZATION NAME AND ADDRESS

NATIONAL BUREAU OF STANDARDS

DEPARTMENT OF COMMERCE

WASHINGTON, D.C. 20234

10. Projeet/Taslc/Worlc Unit No. 3120511

11. Contract/Grant No.

12. Sponsoring Organization Name and Complete Address (Street, City, State, ZIP)

Energy Research and Development Administration

20 Massachusetts Avenue, N.W.

Washington, D.C. 20545

13. Type of Report Sc Period

Covered

Summary Report to 6/77

14. Sponsoring Agency Code

15. SUPPLEMENTARY NOTES

16. ABSTRACT (A 200-word or less lactual summary oi most significant information. If document includes a significant

bibliography or literature survey, mention it here.)

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 use of Incoloy 800 in coal conversion

processes.

N

17. 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; failure analysis;

Incoloy 800; material evaluation

18. AVAILABILITY Unlimited

IS For Official Distribution. Do Not Release to NTIS

i

' Order From Sup. of Doc.t U.S. Government Printing Office Washington, D.C. 20402, SD Cat. No. ClI

|

I Order From National Technical Information Service (NTIS)

Springfield, Virginia 22151

19. SECURITY CLASS

(THIS REPORT)

UNCLASSIFIED

20. SECURITY CLASS

(THIS PAGE)

UNCLASSIFIED

21. NO. OF PAGES

22. Price

U SCOMU.OC Z9042-P74
. I 6 43 4

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