Tm RRAACE MECUANICNIC [ONT C VSS RO Teh SS) Palade craters CO en on enting Failures in Steam Generating Equipme! ce Outline DA Basics — Operation & Design ® Damage Mechanisms Bese unm cey esl Be te acu UrR ere « Remedies ® Case StudiesDeaerator (DA) Basics Cie ee RR oN Rosier a ean ReUC Ruma ees eas) Seco hum uet emcee htc To heat the incoming makeup water and Reale eee TR nT temperature for: Oi lubility of the undesirable Oi Wen aL etary Deaerator (DA) Basics Steam Cycle w Hosterserators: ee ecu up water, then scrubbed with baff euch ne Rn anol ma NOES SU accra ee cern siy} Typical operational pressure = 5 — 15 psig Ete SN aretha Code co Tita}Typical DA ConfigurationsConventional Utility DA Conventional Utility DAConventional Utility DA “Football-Shaped” Water Box Improved Water System with Pipe HeaderExample of DeaeratorMaterials of Construction read Sire eae oc ot perenens Cee Crea Peano enero) ee a if New Material Trends Type 304L for deaerator heater shell and heads Duplex stainless steels for deaerator heater shell, heads, and water CT eae Cu ae Type 2304 (lean duplex)Damage Mechanisms in Deaerators ® Corrosion Fatigue (CF) ® Flow Accelerated Corrosion (FAC) ® Corrosion Pitting ORM a iale ciel ORR Tero) ue Mu sear}Corrosion Fatigue (CF) - Mechanism CF is the most catastrophic damage mechanism in DAs Protective oxide film on metal can rupture resulting in pitting, cracks follow Requires alternating tensile stresses, eR ESCM CF more likely if vessel is not post-weld stress relieved. History of Cracking Failures Before 1980's — DAs not considered high risk components First catastrophic failure: Germany 1971; didn’t receive much attention 1983 - Three more catastrophic ruptures in Canada and the USPine Hill, Alabama (Paper Mill) Box Plant - 2010sie a (lam (ol ieee ma ey -4C=s-1 0] LN ay 4(e] een OlU(—-1t()) DAs have been used to deoxygenate boiler water since the 1920s Why did it take until the 1980s for the problem of CF to be recognized? CF - Remedies eee CNTR mea ICC PeeWee cua cece) Cee Nea PWHT of vessels to minimize residual welding stresses (possible to do in the field) erick accent ee eet) eer ee merece ea ee eek tue Ss eset eer seu hue eco Ro eee RU Ca rieren me ante Cac a eat eneks cuts) Requires periodic inspection and testingFAC Factors WEI * Absence of Chromium ey * FAC rate pe: PE Raga). ese) an) Puke aigFAC - Characteristics & Locations Almost entirely confined to the shell and nozzle areas of the deaerator heater Any place where there is a nozzle penetration into the deaerator is an area where FAC can be found Only affects carbon steel in DAs FAC - LocationsBigger shot of area of FAC. Note proximity of eee eee eae creer)oS ~ ys. Note the top-hat type of vortex breaker in the foreground, FAC - Remedies » Alloy steels are resistant: 0.1% Cr Matta Cet csc Ren ener e ue aceOuoR Wek cir problems with water distribution (e.g. broken feedwater inlet nozzles) can create Boned a (o eee uke young erent mei Mcgee ee Weld overlaying the deaerator shell with Plena mee Rela) PrrCrateamate ate]LOfe) acos- (ola nelarsd Can be a precursor to CF Oxygen is necessary for pitting to o1 Camel Tice) Pitting usually occurs when the Cree a acute: tk Caen} extended period, allowing oxygen to be. Eloliel oR eeCorrosion Pitting - Characteristics & Location: Pitting may be difficult to detect because it is usually covered with layers of oxide (corrosion product) — have to remove the oxide to find it Most often found in the storage tank ® Prevalent in low regions where water fue Naselae rake Chg Corrosion Pitting - Remedies (Veielanees Melee SUVA GIay Ferrous Pn eee ecu ee err eee cera No teeter ay TR UI e AALs El oa Coe Lp Se Bere SateSteam Impingement Re Rem noy Pras truct the target and supports from Typ Beas) Syren RC ea od Veld sacrificial plates over affecSteam Impingement Weld Re-crackingMechanical Damage eee gt ee meen ra Full load trips can cause flooding damage Neh NCU ENA neu Cae ecy eee soe Eero Remedies: ENR in essed aon UT deaerator — operational controls Other Damage Mechanisms Thermal Fatigue Cracking Stress Corrosion Cracking (SCC) Down-time Corrosion Level ices os Relcere) iiAle] Mechanical Fatigue — vibration Galling Numerous other mechanisms that have fT Merl oR aM CULO aa aol Lu Le! by laboratory examinationDYN lciTNe omelets} een aS Cae Ue ee ee aT See en mm eee are ale Par} aaa] eres ueet a Maren) NACE technical papers: (Kelly, Bennett, ee ME aaa eS eto ron a) PYM RCs1=) (TAMU CecLaCCI SY NACE Standard RP 0590-2007, aren eUN Pe cena Rolie oaks Deemer eh ADE coral In and Fabrication Oe ERI csInspection Visual Inspection Te nRea Cacia, eae UT thickness of shell where inspection indicates local thinning WFMT by far the most comprehensive and Pe Cle en Cuma neskemarteti) Hear OmiCrack in Center of Vessel Near a Circumferential Weld (Corrosion Fatigue) Longitudinal Weld Cracks SYA clea agli se a 1a° Re) 81-1Weld Crack Between the Tray Box and Shell (Likely Fatigue) Incomplete Weld Penetration Exposed by FACWeld Overlay on FAC AreaBroken Spring in DA Spray Nozzle Fatigue from VibrationCracked Steam Target (Steam Impingement Leading to Tensile Overload) MU atclanar-| Molt 40 molml [elm sley 4 Enclosure to Shell Weld() ext lon Paps 7