EBT 423 Materials Selection Design Mid Semester 1 Test Academic Session 2009/ 2010 Time : 60 minit This

s question paper has ONE question. Answer ALL questions. Question A schematic diagram of a tube illustrated in Fig. 1 is one of numerous tubes that failed in the boiler located at first stage superheater tubes. The tubes were found cracked after 3 months of service. It had been moderately cold-bent during installation, and was not stress-relief-annealed. The steam drum lacked adequate devices for separation of steam and water, and load swings were frequent, possibly causing carryover of boiler water. Microstructural analysis revealed plastically deformed grains from the cold bending. The cracks were highly branched and ran between the grains (intergranular) as they passed through the tube wall. The corrodent was sodium hydroxide from boiler-water carryover. The tube was then removed and sends to your consultancy firm for further failure investigation.

Figure 1: Schematic diagram shows the transverse crack in a bent carbon steel superheater tube. Note small "window" that has been blown out of the wall.

i)

To initiate the failure investigation, you have to make a site visit to the plant to get some background information. Identify the important information needed from plant engineers that could helps you getting some primary clues. [20 marks]

1. Location, 2. name, 3. Part No, 4. Description, 5. Manufacturer or fabricator 6. Function of item 7. Maintenance procedures 8. Maintenance history 9. Cleaning procedures 10. Cleaning history 11. Operational procedures (temp./ pressure etc) 12. Type of materials (Chemical composition) 13. Operational documentation
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 13.

(standard, temp./ pressure etc) 14. Service deviations 15. Normal stress orientations 16. Extent of incident 17. Precipitating events 18. Drawings
14. 15. 16. 17. 18.

19. Photographs 20. Previous inspections reports, 21. Opinions of related personnel
19. 20. 21.

## 1 POINT = 1 MARK

ii)

From the above statement, what your hypothesis regarding the root cause of the tube failure? [10 marks] Stress-corrosion cracking

Exactly Accurate 10

Acceptable 5

Less Acceptable 3

Confuse 1

Nonsense 0

iii)

Give four (4) reasons to justify your hypothesis. [20 marks]

1. Moderately cold-bent during installation results residual/ internal stress 2. Not stress-relief-annealed results residual/ internal stress still present in the tube 3. The steam drum lacked adequate devices for separation of steam and water, and load swings were frequent, possibly causing carryover of boiler water results hot water enter the tube & forces the acceleration of oxidation reaction 4. Micro structural analysis revealed plastically deformed grains from the cold bending shows an elongated grain proves the presents of residual/internal stress 5. The cracks were highly branched shows the presents of stress 6. ran between the grains (intergranular) shows the presents of corrosion 7. The corrodent was sodium hydroxide from boiler-water carryover shows hydroxide ion from NaOH acts as active corrosion agent Given statement Exactly Accurate 2 Exactly Accurate Acceptable 1 Reason Accurate Acceptable Less Acceptable Confuse Nonsense Confuse 0.5 Nonsense 0

iv)

Concisely, plan the procedures that should be carried out to implement failure analysis on the failed tube and briefly give reason for each of procedures [30 marks]

Procedures 1) Obtaining background data

Reason To investigate the basic information to be a primary clue of the root cause analysis. To record of the original & locations condition

2) Visual examination followed by closed-up photographs by digital camera. 3) Chemical composition analysis by using XRF or spark emission spectrometer

To make sure whether the material meets the specified composition limits.

5) Metallographic analysis by metallurgical microscope.

As-polished microstructure, to identify the presence of defects such as inclusions and voids or microstructural anomalies Etched microstructure, to determined and the relationship between the microstructure and the type of materials, manufacturing process and/ or the damage mechanism SEM analysis: to identify of the fine scale features fracture mode. EDS: to Identify of the chemical species present in the corrosion deposits Failure mechanism: to determine the root cause of the failure, Recommendations to determine whether the components should be replaced or not and to eliminate or reduce the frequency of future failures. For documentation To be send to customer Procedure

6) Fractographis analysis (SEM) & microanalysis (EDS) 7) Determination of failure mechanism & recommendations

7) Report writing

Procedure & equipment stated 3 Exactly Accurate 4

v)

Only Procedure stated 1

Only equipment stated 1

Nonsense 0

Reason Accurate 3 Acceptable 2 Less Acceptable 1 Confuse 0.5 Nonsense 0

Considering the root cause of failure, recommends a) two (2) types of tube materials that should be replacing carbon steel, and

1. 2. 3. 4.

Killed carbon steel (3 marks) Stainless steel (3 marks) High chromium steel (1 marks) Superalloys (0.5 marks) Max = 6 marks

b) three (3) corrective actions that should be taken in order to prevent the same future failure. [20 marks]

1. Reduce the concentration of chemical species that promotes corrosion. (2) 2. Avoid cold bending during installation process (3) 3. Avoid bending in the plants design. (3) 4. Proper stress-relief-annealing (4) 5. Intelligent corrosion monitoring and smart sensors (3) 6. Signal analysis and artificial intelligence (3) 7. First-class practice in inspection management (3) 8. Implement fitness for service test before operation (3) 9. Expert system on failure analysis (3) 10. Mind setting aim for zero failure (3) Max = 14 marks