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INTERNAL CORROSION OF BOILERS

DURING NORMAL OPERATION OF THE BOILER A STAIN IMPERVIOUS FILM OF PROTECTIVE OXIDE LAYER IS FORMED ON THE METAL SURFACE WHICH PROTECT THE BASE METAL FROM INTERNAL CORROSION.IF BY SOME MECHANISM,THIS PROTECTIVE LAYER IS DISTURBED GIVING RISE TO LESS ADHERENT POROUS LAMINATED OXIDE LAYER OR CRACKS IN THE PROTECTIVE LAYER ,TUBES WILL CORRODE AT FASTER RATE. IN RUNNING BOILER MAINLY TWO TYPES OF CORROSION TAKE PLACE MAINLY CAUSTIC CORROSION OR DUCTILE GAUGING CAUSTIC CAN GET INTO THE BOILER IN FOLLOWING WAYS IF CAUSTIC PHOSPHATE TREATMENT IS FOLLOWED. DUE TO CONDENSER TUBE LEKAGE WHEN COOLING WATER CONTAINS HIGH BICARBONATE WHICH BREAKS UP IN THE BOILER PRODUCING CAUSTIC. FAULTY MAKE UP WATER. NORMAL CAUSTIC CONCENTRATION ARE NOT CORROSIVE BUT UNDER DEPOSIT WHEN CONCENTRATED IT DISSOLVES MAGNETIC LAYER AND THEN STEEL.THE DAMAGE PROGRESS TO FAILURE WHEN THE TUBE WALL THINS TO A POINT WHERE STRESS RUPTURE OCCURS LOCALLY.THERE IS NO CHANGE IN METAL MICROSTRUCTURE,IT RETAINS DUCTILITY.THE FAILURE IS DUE TO THINING OF METALS. HYDROGEN DAMAGE IT OCCURS WHEN A LOW PH BOILER WATER ENVIRONMENT IS PRODUCED FROM CONDENSOR TUBE LEKAGE OR SOME OTHER TYPE OF CONTANIMATION.THIS TYPE OF CORROSION OCCURS BENEATH A RELATIVELY DENSE DEPOSIT.ALTHOUGH SOME WASTAGE OCCURS THE TUBE NORMALLY FAILS BY THICK EDGE FRACTURE BEFORE THE WALL THICKNESS IS REDUCED TO THE POINT WHERE STRESS RUPTURE WOULD OCCUR.HYDROGEN PRODUCED IN THE CORROSION REACTION DIFFUSES THROUGH THE METAL,CAUSING DECARBURIZATION AND INTER GRANULAR MICRO-FISCURING OF THE STRUCTURE.BRITTLE FRACTURE OCCURS ALONG THE PARTIALLY SEPARATED BOUNDRIES AND IN MANY CCASE AN ENTIRE SECTION IS BLOWN OUT OF AN EFFECTED TUBE. PITTING CORROSION IT IS MAINLY CAUSED BY DISSOLVED OXYGEN IN WATER.THIS TYPE OF CORROSION IS COMMON IN ECONOMISERS.THIS MAY ALSO OCCUR IN SUPERHEATERS AND OTHER TUBULAR SECTIONS OF BOILERS IF PROPE SHUT DOWN PRACTICE IS NOT OBSERVED.

CORROSION IN TURBINE MAIN DAMAGES FOUND IN THE STEAM TURBINE IS DUE TO DOWN TIME AND WET END CORROSION- IN DOWN TIME AND WET END CORROSION ATTACK IS ON CARBON STEEL PORTION DUE TO PRESENCE OF WATER DROPLETS AND CARBONDIOXIDE.NEUTRALIZING AMMINE IS THE SOLUTION.OXYGEN INGRESS IS TO BE AVOIDED IF THE UNIT IS NOT DRY. EROSION- IT IS DUE TO WATER DROP LETS AND SOLID PARTICLES IMPINGING AT THE BLADES AT HIGH VELOCITY.WATER DROPLETS MAY BE PRESENT IN STEAM IF DESUPERHEATING CONTROL IS NOT WELL MAINTAINED.THIS DROPLETS MAY CAUSE EROSION IN HP END. STRESS CORROSION CRACKING- THE MAIN CONTAMINANTS THAT CONTRIBUTE TO THIS TYPE OF FAILURE ARE CAUSTIC CHLORIDE AND SULPHIDE,WHILE CAUSTIC AND CHLORIDE ARE USUALLY PRESENT IN DEPOSITS AS A RESULT OF MECHANICAL CARRYOVER FROM THE BOILER,SULPHUR CAN BE PRESENT IN THE MAKE UP WATER AS HYDROGEN SULPHIDE AND LEAVE WITH THE STEAM WITH THE GAS OR MAY BE FORMED DUE TO DECOMPOSITION OF SODIUM SULPHITE WHEN USED FOR OXYGEN SCAVENGING. IN THE PRESENCE OF HYDROGEN SULPHIDE STRESS CORROSION ,CRACKING CN OCCUR AS HYDROGEN EMBRITTLEMENT.CAUSTIC EMBRITTLEMENT OF TURBINE ALLOYS RESULTS FROM THE REACTION BETWEEN CAUSTIC AND GRAIN BOUNDRIES OF THE STEEL IN THE ENVIROMENT OF HIGH STRESS HIGH TEMP AND HIGH CAUSTIC CONCENTRATION LEADING TO AN INTERGRANNULAR TYPE OF FAILURE. CORROSION IN COOLING WATER SYSTEM VARIOUS METAL METAL ALLOYS IN CONSTRUCTION IN THE COOLING WATER SYSTEM.THE CONDENSOR TUBES ARE NORMALLY MADE UP OF COPPER ALLOYS.VALVE BODIES ARE OF CAST IRON OR MILD STEEL.VALVE AND PUMP INTER MAY BE STAINLESS STEEL OR PHOSPHUR BRONZE. IN NORMAL COOLING WATER THE ABOVE MATERIAL GIVE GOOD SERVICE BUT WITH SALINE OR HEAVILY POLLUTED COOLING WATER CORROSION BETWEEN METAL TAKES PLACE. CONDENSOR TUBE CORROSION WHEN COPPER ALLOY CONDENSORS ARE EXPOSED TO COOLING WATER A VERY THIN PROTECTIVE OXIDE FILM IS FORMED WHICH PROTECTS THE METAL FROM FURTHER CORROSION.IN VERY AGGRESSIVE WATER THE CONDENSOR TUBES ARE EXPOSED BEFORE FORMATION OF THE FILM.

IRON PRESENT IN COOLING WATER ASSISTS IN THE FORMATION OF VERY TOUGH AND ADHERENT PROTECTIVE FILMS.SOURCE OF IRON MAY BE FROM CORROSION OF CONDENSOR WATER BOX. CORROSION DUE TO CONCENTRATION CELL FORMATION IF THE CONDENSOR TUBES ARE NOT CLEAN IF IT HAS DEPOSITS WHICH UNDERGOES CORROSION DUE TO FORMATION OF DIFFERENTIAL AERATION CELL .THE AREAS UNDER DEPOSIT IS LESS OXYGEN AND HENCE ANODE ,IN COMPARISION TO THE SURROUNDING METAL EXPOSED TO COOLING WATER WHICH CONTAINS MORE OXYGEN HENCE CATHODE. OVERHEATING FAILURE INTERNAL DEPOSITS ACCELERATE THE CORROSION OF BOILER TUBES.DEPOSIT ALSO PROMOTE MAJORITY OF TUBE FAILURE DUE TO OVERHEATING. SHORT TERM OVERHEATING FAILURE OCCURS WHEN METAL TEMP EXCEEDS LOWER CRITICAL TEMP OF PLAIN CARBON STEEL 723 DEGREE CENTIGRATE.AT THIS TEMP THE YEILD STRENGTH IS LOW,METAL DEFORMS PLASTICALLY AND FAILS..THIS FAILURE IS CHARACTERISED BY MASSIVE SWELLING,BULGING AND WIDE THIN EDGE RUPTURE,COMMONLY KNOWN AS FISH MOUTH OPENING. LONG TERM OVERHEATING FAILURE ARE CAUSED BY LOSS OF CIRCULATION EITHER BECAUSE OF CHOCKING OR LOSS OF WATER LEVEL IN THE DRUM.

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