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Assignment # 01
Case Study of Failure of Stainless Steel Tubes in Transit/ Storage at
Power Plants

University Of Engineering and Technology, Lahore

Department: Metallurgical & Materials Engineering

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Contents
1.0 Introduction................................................................................................................................1
2.0 Materials Selection....................................................................................................................1
3.0 Case study..................................................................................................................................2
4.0 Ramedies....................................................................................................................................3
5.0 References..................................................................................................................................4
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1.0 Introduction:
Corrosion may be defined as a natural phenomenon which is marked by deterioration or
degradation of materials (generally metals) and its general properties resulting from their
reactions with the environment around them. Just like every other naturally occurring hazard,
e.g. tidal waves, severe snowfalls, flash floods, earthquakes etc., corrosion can result in hefty
damages, often causing death-blows to bridges, buildings, pipelines, vehicles. In the very same
manner, simple appliances used at homes are also subject to corrosion. However, unlike the
disasters caused by the weather, there are various ways of controlling and even preventing
corrosion. Though metals are more vulnerable to corrosion, all types of materials fall prey to
corrosion e.g. Aircraft wiring insulations (polymeric), especially in ageing aircrafts are prone to
corrosion, also, Corrosion has been noticed in ceramics.

Fig# 01: Corrosion of Metal

2.0 Materials Selection:

Metallic materials play a key role in the development of a country and its sustained growth in the
context of the global economy. During the course of the metal production it undergoes various
types of processes: mining of minerals, manufacturing and application and generation of gases,
liquids or solids that are released into the environment. Table 1 shows a classification and the
properties of different types of materials used in the industry.

Table1.
Materials in industry: Types, main properties and uses
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Material Main properties Uses

Metals and alloys
Mechanical resistance Cars, aircraft, tanks,
(carbon and stainless steels, non-
hardness infrastructure reinforcement.
ferrous alloys)
Ceramics High hardness, high Cutting tools, motor
(Metallic carbides, silica, glass, temperature and corrosion components, refractory
alumina) resistance bricks, ovens, etc.
Composites
Car bodies, aircraft
(glass and carbon fibers reinforced Light weight, high
components, vessels,
plastics, plastic matrixes reinforced strength and hardness.
construction.
with metallic particles)

3.0 Case Study

At a gas power station stainless steel condenser tubes were imported. After the installation
around 700 tubes failed during hydro testing. Failure investigations of tubes were carried which
indicated that the tubes had failed due to the chloride induced crevice corrosion and pitting
corrosion. It is suspected that the tubes were tied together by means of some rope and either
during transit or during storage seawater had ingressed the tubes bundles and remained stagnant
for some time resulting in the tubes being effected by crevice & pitting corrosion attack around
the portion where the tubes were tied with rope. That’s why more than 50% thickness was lost at
the places where crevice or pitting attack had taken placed and during hydro testing these tubes
were failed. Based on the studies the manufacturer replaced the failed tubes with the new tubes.

Fig# 02 Pitting and crevice corrosion of stainless steel tube

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Remedies:

 The selection of materials requires for tubes considering a large group of advantages and
disadvantages regarding the installation, operation, cost, and corrosion protection.
 Use AISI 316L or AISI 316T (based on the strength required) that are more pitting
corrosion-resistant stainless steels as compared to AISI 321.
 Do not paint stainless steel tubes as localized damages of painted surface can be sites
prone to pitting corrosion.
 In order to prevent condenser tubes leakages and consequent ingress of cooling water into
boiler water system, the first step is in proper design so that basics are not disturbed and
situations like crevice, stagnancy of water, galvanic action, impact damage are avoided.
 The condenser tube surfaces are kept free of scaling, fouling, corrosion & bio fouling by
application of site specific chemical treatment program.
 All condenser water tubes should be properly coated with high performance coating
system such as Vinyl Ester Glass Flake or 100% solids epoxy or polyuria system.
 In case of stainless steel based systems all tube to tube plate joints should be seal welded
so that seepages through tube holes are avoided.
 Also in case of stainless steel based system only impressed current Cathodic protection
system should be employed with potentials controlled little positive than -1.2 V.
 All contaminated water should be pre-treated to remove the contaminants. In case of
severe corrosive characteristics of the cooling water retrofitting the condensers with more
corrosion tube material may be considered.
 In case of already corroded tubes application of anticorrosive coatings on the internal
surfaces of the tubes to prolong the life of the condenser tubes.
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3.0 References:

https://www.intechopen.com/books/environmental-and-industrial-corrosion-practical-and-theoretical-aspects/
corrosion-control-in-industry

https://www.google.com/searchq=corrosion+of+metals

www.galvanizeit.org

https://www.researchgate.net/publication/
261133505_Corrosion_Of_Carbon_Steel_In_Waters_Of_Varying_Purity_And_Velocity

https://theconstructor.org/structural-engg/steel/different-types-corrosion/35536/