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Failure Analysis of Carbon Steel Tubes in a Reformed Gas Boiler Feed Water Preheater

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Abstract

This study involves the failure analysis of carbon steel tubes in a reformed gas boiler feed water preheater unit operating at an ammonia plant. It was determined that the incipient failure mechanism in the carbon steel tubes was pitting corrosion at the inner surface of the failed tube transporting boiler feed water. The spectroscopic and microscopic analysis revealed the presence of iron oxides, including magnetite (Fe3O4), on the surface of a hole inside a pit formed in the inner surface. A significant thickness reduction in the internal wall due to subsequent erosion–corrosion led to the formation of the hole. No voids/cracks were present in the grain boundaries in the (ferritic and pearlitic) microstructure of the carbon steel tube (A214). Due to the recurrent nature of the failure of the carbon steel tubes in the preheater unit, SS304L tubes are recommended to be used throughout the waterside of the preheater.

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Acknowledgments

The authors would like to acknowledge the support of Industrial Plant Services Limited in performing this study.

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Authors and Affiliations

  1. National University of the Altiplano, Puno, Peru

    A. Marquez

  2. Industrial Plant Services Limited, Pt. Lisas, Couva, Trinidad and Tobago

    Amrit Ramnanan

  3. Department of Mechanical and Manufacturing Engineering, University of the West Indies, St. Augustine, Trinidad and Tobago

    C. Maharaj

Authors
  1. A. Marquez
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  2. Amrit Ramnanan
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  3. C. Maharaj
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Correspondence to C. Maharaj.

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Marquez, A., Ramnanan, A. & Maharaj, C. Failure Analysis of Carbon Steel Tubes in a Reformed Gas Boiler Feed Water Preheater. J Fail. Anal. and Preven. 19, 592–597 (2019). https://doi.org/10.1007/s11668-019-00643-9

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  • DOI: https://doi.org/10.1007/s11668-019-00643-9

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