Professional Documents
Culture Documents
Minutes of the August 31, 2005 TAPPI Digester Corrosion Task Group Meeting
4.1
Overview of Activities of the TAPPI Digester Cracking and Corrosion Task Groups Angela Wensley, Angela Wensley Engineering, White Rock, BC Angela Wensley has chaired the Task Group since 1986. During her tenure the focus of the Task Group shifted to include rapid corrosion thinning of digesters, corrosion problems with ancillary vessels, and batch digester corrosion. Meetings were held twice per year - the Spring meetings were expanded to 2 days in an educational format devoted to enhancing the understanding of digester corrosion problems and the available alternatives for protection.
4.2
The Continuous Digester Cracking Task Group 1980-1985 Dave Bennett, Corrosion Probe, West Nyack, NY Dave Bennett was the original chairman of the task group from 1980 until 1986. Under his leadership, the Task Group issued four reports that were invaluable for the industry in clarifying the mechanism of the cracking, the extent of the problem in the industry, the best methods of nondestructive testing to find the cracks, and recommendations on evaluation and repair of cracks. Dave also chaired the TAPPI/IPC Digester Cracking Research Committee that was formed to investigate the causes of caustic stress corrosion cracking and the methods to prevent it. The DCRC was funded both from digester owner/operators and by Kamyr Inc. Research contracts were awarded to The Institute of Paper Chemistry, Paprican, and Battelle Columbus
4.3
Digester Cracking at Procter and Gamble Charlie Guzi, Retired, Cincinnati, OH Charlie Guzi was the original secretary of the Task Group. During this time he was employed by Proctor & Gamble whose Grande Prairie AB and Flint River GA mills were used to test out many of the digester cracking preventive measures including sealed thermal spray coating, weld overlay, anodic protection, and stress relief heat treatment. Unfortunately, Charlie was unable to make it to the August 31, 2005 meeting of the task group. His presentation is included in Appendix C.
Minutes of the August 31, 2005 TAPPI Digester Corrosion Task Group Meeting
4.4
The Digester Cracking Research Committee Sandy Sharp, MeadWestvaco, Laurel, MD Sandy Sharp was the chairman of the Digester Cracking Research Steering Committee that consisted of: - Dave Bennett (Packer Engineering) - Dave Bowers (IPC) - Pete Donofrio (Champion Paper) - Carl Elmore (Kamyr Inc.) - Fred Ferrari (Scott Paper) - Charlie Guzi (Proctor & Gamble) - Roger Kilgore (Boise Cascade) - Larry Laliberte (International Paper Co.) - Angela Wensley (MacMillan Bloedel) Sandy's presentation is included in Appendix C.
4.5
Research into Caustic Stress Corrosion Cracking Doug Singbeil, Paprican, Vancouver BC Doug Singbeil had presented a paper on caustic stress corrosion cracking of carbon steel in white liquor at the 3rd International Symposium on Corrosion in the Pulp and Paper Industry held only months before the Pine Hill failure. As part of the DCRC research program, Doug and Andy Garner developed a ring-weld specimen to investigate various crack preventive measures. Doug's presentation is included in Appendix C.
4.6
Anodic Protection Anodic protection was one of the three crack preventive measures ultimately approved by the DCRC.
4.6.1 Ian Munro, P.Eng., Aurora, ON Ian Munro was employed by Corrosion Service Inc. at the time of the Pine Hill failure. He helped develop some of the first commercial anodic protection systems for digesters and was active in the Task Group from the early days. Ian's presentation is included in Appendix C.
Minutes of the August 31, 2005 TAPPI Digester Corrosion Task Group Meeting
4.6.2 Winston Shim, Corrosion Service Co, Downsview, ON Winston Shim was present during the installation of some of the earliest anodic protection systems in continuous digesters, including the system installed in the rebuilt Pine Hill digester in 1985. Winston's presentation is included in Appendix C. 4.6.3 Martti Huttunen, Savcor Consulting, Vancouver, BC Martti Huttunen has been involved with installations of anodic protection systems in continuous digesters since the late 1980's, and has been an active participant in the Task Group since the late 1980's. Martti's presentation is included in Appendix C. 4.7.1 Panama City Batch Digester Failure Overview Max Moskal, M&M Engineering, Indian Head Park, IL Max Moskal was with Stone Container Corporation and was active in the early days of the Task Group. He was still with Stone Container at the time of the catastrophic failure of a batch digester at their Panama City, FL, mill in 1994. Max's presentation is included in Appendix C. 4.7.2 Duplex Stainless Steels for Digesters Max Moskal, M&M Engineering, Indian Head Park, IL Stone Container Corporation was one of the first pulp and paper companies in North America to construct new batch digesters using duplex stainless steels. Max Moskal has given several reports on the status of duplex digesters in North America to the Task Group. Max's presentation is included in Appendix C. 4.8 Investigations into Corrosion of Weld Overlay in Batch Digesters Craig Reid, Bacon Donaldson, Richmond, BC Craig Reid reviewed the corrosion of batch digesters and in particular their protection using stainless steel weld overlay. Craig has previously given a number of comprehensive presentations to the Task Group on the corrosion of stainless steel weld overlay in batch digesters, first when he was with MacMillan Bloedel, and continuing after he moved to Bacon Donaldson (now Acuren). Craig's ultimate presentation is included in Appendix C.
Minutes of the August 31, 2005 TAPPI Digester Corrosion Task Group Meeting
4.9
Cracking of Duplex Stainless Steel Bottom Scrapers Margaret Gorog, Weyerhaeuser, Federal Way, WA Cracking of bottom scrapers is currently the major unresolved materials and corrosion problem in continuous digesters. Weyerhaeuser mills have several bottom scrapers constructed using duplex stainless steel. Some of these have experienced cracking. Margaret's report was an update of a comprehensive presentation that she gave to the Task Group in March 2005. Margaret's presentation is included in Appendix C.
4.10
Summary: What have We Learnt? Andy Garner, Andrew Garner and Associates, Vancouver, BC Andy Garner was at Paprican when the Pine Hill failure occurred. He directed much of the research into caustic stress corrosion cracking of digesters. He retired as director of the Vancouver laboratory of Paprican in 2004. Andy had given a presentation on the history of the DCRC at the February 2004 meeting of the Task Group. Andy's presentation is included in Appendix C.
5.
Other Business Angela Wensley stepped down after serving for 20 years as the Chairman of the Digester Corrosion Task Group.
6.
7.
Adjournment The meeting was adjourned at 10 a.m. on August 31, 2005. Angela Wensley was - and still is - grateful for the bouquet of flowers from Elisabeth Torsner.
Appendix A
A-1
Appendix B
ACTIVITIES OF THE TAPPI DIGESTER CORROSION/CRACKING TASK GROUP September 26, 1980 - Catastrophic failure of the Pine Hill continuous digester. October 29, 1980 - First meeting of the Continuous Digester Cracking Task Group in Montgomery, AL. - To develop industry guidelines for inspection, repair, and prevention of weld and/or metal failure in continuous digesters to ensure safe operation on an industry-wide basis. - A task group of the NDT subcommittee, chaired by John Ridgeway (INDT). - Dave Bennett (Hammermill Paper) appointed Task Group chairman - Larry Lalibert (IP) appointed Task Group vice-chairman - Charlie Guzi (Proctor & Gamble) appointed Task Group secretary. November 6, 1980 - Second meeting of the Task Group, in Atlanta GA. - Discussion of NDT techniques - Field reports of digester cracking December 2, 1980 First Report of the Task Group - Summary of inspections - Inspection procedures and recommendations - Request for information December 15, 1980 Second Report of the Task Group - Findings and recommendations concerning repair of cracks. December, 1980 Third meeting of the task group February 17, 1981 Fourth Meeting of the Task Group - No minutes extant for either meeting in the Task Group archives April 8, 1981 Fifth meeting of the Task Group, in Toronto ON. - Report on cracking and numerous through-wall leaks in an impregnation vessel at Zellstoff und Papierfabrik in Frantschach, Austria, between 1978 and 1980. April 8, 1981 Third Report of the Task Group - Weld repair of cracks considered a temporary repair. - Post weld heat treatment (PWHT) recommended for new digesters September 28, 1981 Sixth Meeting of the Task Group, in Atlanta GA. - Reviewed responses received on digester inspections. February 1, 1982 Seventh Meeting of the Task Group, in Chicago IL. - Report of re-cracking of welds in the new replacement top section of the Pine Hill continuous digester. - Report of cracking up to 0.6 inches deep in a fully stress-relieved vessel. - Results of acoustic emission (AE) inspections not good. B-2
Appendix B
February 18, 1982 Fourth Report of the Task Group - Of 85 vessels in North America that were properly inspected, 22 had cracks, some in excess of -inch depth March 24, 1982 Eighth Meeting of the Task Group, in Chicago IL. September 16, 1982 Ninth Meeting of the Task Group, in San Francisco CA. - Failure of unsealed thermal spray. - Cracks in area that was shot peened. - Cracks found in an anodically protected soda digester - Cracking reported adjacent to corrosion resistant weld overlay. - Digester Cracking Research Committee (DCRC) - Chairman: Dave Bennett - Vice-chairman: Sandy Sharp - Secretary: Dave Bowers January 1983 Final report by to the DCRC by Ron Yeske of IPC on "Stress Corrosion Cracking of Continuous Digesters for Kraft Pulping." March 4, 1983 Tenth Meeting of the Task Group, in Atlanta GA. - Guzi reported on testing in the Grande Prairie digester. Non-stress relieved Ubends cracked; stress relieved U-bends did not crack. Unsealed plasma spray blistered. Cracks occurred adjacent to corrosion resistant weld overlay. September 15, 1983 Eleventh Meeting of the Digester Cracking Subcommittee, in Dallas TX. - Status changed from Task Group to Subcommittee. - Report of cracking of stainless steel nozzles. - Kamyr reported using Alloy 82 to overlay the circumferential weld seams in 20 digesters. - Anodic protection (AP) system installations looking good but some hardware failures. August 1984 Final report to the DCRC by Sharad Pednekar of Battelle Columbus on "Evaluation of Repair Methods for SCC in Continuous Digesters." August 1984 Final report to the DCRC by Doug Singbeil and Andy Garner of Paprican on "Research Program to Investigate Cracking of Continuous Digesters." September 19, 1984 Twelfth Meeting of the Digester Cracking Subcommittee, in Boston MA. - Joint meeting with the DCRC. - More examples of cracking of stainless steel.
B-3
Appendix B
March 29, 1985 Meeting of the Digester Cracking Subcommittee in Boston MA. - Grinding preparation of surfaces for nondestructive examination. - Overlay edge cracking. - In-situ corrosion monitoring September 19, 1985 Meeting of the Digester Cracking Subcommittee in Atlanta GA. - Draft of 5th Report reviewed: - Crack preventive measures (anodic protection, overlay, thermal spray coating, shot peening) - DCRC summary: - Only correlation of SCC was with lack of stress relief - SCC occurs only when corrosion potential in a critical range. - Cracking less-severe in lower-hydroxide liquors. - No cracking in simulated acid cleaning for 10 years. - Inspection guidelines - Request for information (questionnaire). March 18, 1996 Meeting of the Digester Cracking Task Group in Houston TX. - First meeting with D. A. Wensley as chairman - Status reverted to a Task Group of the Pressure Vessel and Tank Subcommittee - Reports on: - Overlay edge cracking - Ultrasonic imaging September 8, 1986 Report to the DCRC by Doug Singbeil and Andy Garner of Paprican on "Stress Corrosion Cracking of Full-Thickness Digester Weldments." September 23, 1986 Meeting of the Task Group in Seattle, WA. - Report by Pat Morris of IP: - discontinued use of weld overlays due to edge cracking - using arc spray - first N.A. installation of an AP system with wall-mounted cathodes - ultrasonic imaging successful in locating cracks March 9, 1987 - Meeting of the Task Group in San Francisco - Cracking of carbon steel cooking nozzles (D.A. Wensley). - Disbonding of overlaid SS cladding in a batch digester (Ken Donaldson). - Serious preferential weld corrosion reported in a small continuous digester (Chakrapani). September 16, 1987 - Meeting of the Task Group in New Orleans, LA - David Crowe (IPC) secretary. - Forum on cracking of steaming vessels constructed using 304 stainless steel.
B-4
Appendix B
March 24, 1988 - Meeting of the Continuous Digester Cracking Task Group in St. Louis - MEI Charlton report (D. Chakrapani) - hot cracking of excessively-diluted nickel-base weld overlay - intergranular corrosion of stainless steel cladding adjacent to a circumferential weld. September 22, 1988 - Meeting of the Task Group in Chicago, IL. - Liquor heater tube corrosion and cracking forum. August 1989 Sixth report of the Continuous Digester Cracking Task Group, "Cracking of Continuous Digesters: an Updated Survey," published in TAPPI Journal, Volume 72 No. 8, pp. 211-215 (1989). - 73% of continuous digesters have experienced cracking. - SCC positively confirmed as the cracking mechanism in only 9 digesters. - Most cracking in digesters built between 1965 and 1971. - PWHT'd digesters are more resistant to cracking but severe cracking also reported in 56% of PWHT'd digesters September 14, 1989 - Meeting of the Task Group in Atlanta, GA - Overlay edge cracking - Anodic protection update September 27, 1990 - Meeting of the Task Group in Seattle, WA - Report by Max Moskal on through-wall cracking incident in Hodge, LA The cracks were adjacent to the central pipe support gussets. - Report by Chuck Gaines on through-wall cracking in Valliant. OK. The digester was condemned. October 3, 1991 Meeting of the Task Group in Nashville, TN. - High pressure feeder forum. - Report by Neil Risebrough on the rapid thinning of a continuous digester in Squamish, BC - Organizational meeting for the Continuous Digester Thinning Working Group was held immediately after the Task Group meeting. April 28, 1992 First meeting of the Continuous Digester Thinning Working Group, in Nashville, TN - Advisory bulletin and survey were sent out in November 1991. - Reports of rapid corrosion thinning of digester walls. September 17, 1992 Joint meeting of the Continuous Digester Cracking Tank Group and the Continuous Digester Thinning Working Group, in Boston, MA. - Report by Ian Munro on seminar on electrochemistry in kraft liquors. - Report by Pat Morris on applications of arc spray in batch and continuous digesters.
B-5
Appendix B
- Report by Max Moskal on local PWHT of two continuous digesters; SCC did not return in one digester but severe SCC recurred in the other. March 8, 1993 Meeting of the Digester Thinning Working Group, in New Orleans, LA. - Digester thinning survey update: - 31% of digesters reported rapid corrosion thinning September 1993 Digester Thinning Survey Report presented as a paper during the TAPPI Engineering Conference in Orlando, FL. Book 1, pp. 71-74. - Rapid corrosion thinning correlated with: - high-temperature acid cleaning - operational changes to extended delignification, increased production, higher temperatures. - pulping corrosive wood species September 22, 1993 Meeting of the Digester Corrosion Task Group in Orlando, FL - Presentation by Ian Munro on over-protection of stainless steel central pipes in digesters with AP. March 18, 1994 Meeting of the Digester Thinning Task Group in Vancouver BC. - A full-day meeting to discuss thinning of continuous digesters. - Results of a Kamyr AB survey of digesters outside North America were presented. - digesters with MCC, EMCC, or ITC more prone to rapid thinning. April 1994 Catastrophic failure of a weld overlaid batch digester in Panama City, FL. September 20, 1994 Joint meeting of the Continuous Digester Cracking Task Group and the Continuous Digester Corrosion Task Group, in San Francisco CA. - Digester Protection Forum: - Weld Overlay - Thermal spray coatings - Anodic protection March 13, 1995 Digester Corrosion Information Meeting, in Vancouver BC. - Name of task group changed to include corrosion and cracking problems in both batch and continuous digesters. - Reports of cracking in carbon steel seam welds in a stainless steel weld overlaid batch digester. - Report by Steve Clarke of Paprican on cracking of bottom scrapers. September 11, 1995 Digester Corrosion Information Meeting in Dallas, TX - Presentation by Craig Reid on the long-term performance of stainless steel weld overlays in batch digesters.
B-6
Appendix B
March 18, 1996 Digester Corrosion Information Meeting, in Vancouver BC. - Discussion on hydrogen cracking in continuous digesters. September 17, 1996 Digester Corrosion Information Meeting, in Chicago, IL. - Presentation by Bruce Lang on brittle cracking in batch digesters. March 3, 1997 Digester Corrosion Information Meeting, in Vancouver BC. - Presentation by Garry Rustan on severe erosion-corrosion of the digester wall inside screen headers. October 6, 1997 Digester Corrosion Information Meeting, in Nashville, TN. - Forum on the use of duplex stainless steels for digesters. March 19, 1998 Digester Corrosion Information Meeting, in Vancouver BC. - Forum on digester overlay using type 312 stainless steel. September 14, 1998 - Digester Corrosion Information Meeting, in Miami, FL. - Forum on anodic protection of digesters. May 3-4, 1999 - Digester Corrosion Information Meeting, in Austin, TX. - Forum on thermal spray coatings in digesters. September 13, 1999 - Digester Corrosion Information Meeting, in Anaheim, CA. - Forum on cracking of solid stainless steel steaming vessels. February 24, 2000 - Digester Corrosion Information Meeting, in Providence RI. - Forum on corrosion of carbon steels and stainless steels in kraft digesters. September 18, 2000 - Digester Corrosion Information Meeting, in Atlanta, GA. - Forum on corrosion of flash tanks. February 26, 2001 - Digester Corrosion Information Meeting, in Portland OR. - Forum on rapid corrosion thinning of continuous digesters. June 13, 2002 - Digester Corrosion Information Meeting, in Toronto, ON. - Forum on bottom scraper corrosion and cracking. - Forum on the use of duplex stainless steels for digesters and ancillary equipment. September 11, 2002 - Digester Corrosion Information Meeting, in San Diego, CA. Presentations by: - Hakan Dedorsson of AvestaPolarit on the rupture of a type 317L stainless steel batch digester at a SAPPI mill in South Africa. - Brian Greenwood of Andritz on a corrosion accident in a continuous digester at the PT Tel Musi mill in Indonesia. B-7
Appendix B
- Steve Pawel of ORNL on using electrochemical noise probes for corrosion monitoring in digesters. - Angela Wensley of AWE Inc. on recent issues with digester corrosion and cracking. - Winston Shim of Corrosion Service on anodic protection of the Pine Hill digester. - Mike Place of Foster Wheeler on thermal spray coating of a circumferential band in a continuous digester. March 6, 2003 - Digester Corrosion Information Meeting, in Atlanta, GA. Presentations by: - Angela Wensley of AWE Inc. on external cracking of batch digester leg supports. - Mike Macke of GE Inspection Services on re-cracking experience with carbon steel weld restorations in continuous digesters. - Max Moskal of M&M Engineering on duplex stainless steel vs. carbon steel construction for digesters and on issues with stainless-clad digesters. - Preet Singh of IPST on corrosion testing of thermal spray coatings for digesters. - Martti Huttunen of Savcor on the anodic protection of two continuous digesters. - Bruce Newton of WSI on type 312 stainless steel weld overlay. - Angela Wensley of AWE Inc. on bottom scraper cracking and on duplex stainless steel head cracking during manufacture. - Preet Singh on IPST research projects on corrosion in pulping liquors. February 26, 2004 - Digester Corrosion Information Meeting, in Vancouver BC. - Mark Gilkey (FM Global) secretary. Presentations by: - Angela Wensley of AWE Inc. on digester inspection. - Martti Huttunen of Savcor on anodic protection. - Andy Garner of Paprican on the DCRC research project. - Mark Bosma of Bowater on cracking and repair of the top head weld seam in a continuous digester. - Dave Mauro of Canspec on surface preparation for inspection of continuous digesters. - Chris Dault of Canspec on creation and use of a roll-out drawing for continuous digester inspections. - Margaret Gorog of Weyerhaeuser on digester corrosion, protection, and inspection. - Pani Chakrapani of MEI Charlton on 17 years of experience with a stainlessclad digester in sulfite service. - Tim Charman of Celgar on weld overlay of a continuous digester. - Titak Linaksita of Conrex Steel on hot forming of duplex stainless steel heads for digesters. - Craig Reid of Bacon Donaldson on examination of boat samples of type 312 stainless steel weld overlay from a batch digester. B-8
Appendix B
- Carl Plate of AEC Engineering on quality assurance for new duplex stainless steel digesters. - Ralph Davison of Outokumpu on lean duplex stainless steel. March 21-22, 2005 - Digester Corrosion Information Meeting, in Glens Falls, NY. First day presentations by: - Martti Huttunen of Savcor on three case histories of anodic protection of continuous digesters. - Dave Bennett of Corrosion Probe on screen welding practice. - Gerry Ortner of Cariboo Pulp on weld overlay of a continuous digester. - Alex Nadezhdin of Nexfor on the effects of weld dilution on digester weld overlay. - Angela Wensley of AWE Inc. on the Uddcomb method of weld overlay. - Heikki Leinonen of VTT Industrial (Finland) on the SCC susceptibility of duplex stainless steel welds in kraft batch cooking. - Patrick Sullivan of Andritz on OEM experience with fabrication in type 2205 duplex stainless steel. - Ralph Davison of Technical Marketing Resources on duplex stainless steels for digesters and related equipment. - John Grocki of Advantage Resources Consulting on duplex stainless steels for kraft digesters. - Angela Wensley of AWE Inc. on experiences with fabrication and inspection of duplex digesters. - Margaret Gorog of Weyerhaeuser on scraper arm cracking. Second day presentations by: - Angela Wensley of AWE Inc. on the revised TIP 0402-03 on digester weld overlay. - Angela Wensley of AWE Inc. on the revised TIP 0402-27 on continuous digester inspection. August 31, 2005 - Digester Corrosion Information Meeting, in Philadelphia PA. - Final meeting of the Task Group, - Summary of Task Group activities over the past 25 years.
Submitted by: Angela Wensley Task Group Chairman 1986 2005 Note: minutes of the meetings since March 1994 are available in electronic form.
B-9
Appendix C
1. In the Beginning
September 26, 1980: Catastrophic failure of the continuous digester in Pine Hill AL.
Failure occurred at a weld seam at a circumferential-to-conical transition. Failure mechanism was caustic stress corrosion cracking (SCC). SCC found in all welds in the non-post weld heat treated top section of the digester. Top 6 rings and top head were replaced.
Failed Head
Appendix C
Grooves
Crack
Crack
2. Task Group
October 29, 1980: Continuous Digester Cracking Task Group formed; Dave Bennett chairman. Became the Continuous Digester Cracking Subcommittee (of C&ME) in 1983. Often met jointly with the Digester Cracking Research Committee (DCRC).
3. Reports
The T.G./Subcommittee produced 5 reports between 1980 and 1985:
Inspection findings Recommendations on proper inspection and repair of cracks. Crack preventive measures (anodic protection, thermal spray coating, weld overlay, shot peening). Questionnaire on digester cracking.
4. Aprs Bennett
First meeting of the task group with Wensley as chair was in March 1996. Sixth report on the results of the cracking survey was released in 1989.
Cracks reported in 73% of continuous digesters. PWHTd digesters most resistant.
5. Corrosion Thinning
1991: Report on rapid corrosion thinning of a digester in Squamish BC. 1991: Continuous Digester Thinning Working Group formed (Angela Wensley chair). Survey prepared by Dave Bennett. 1993: Report on results of thinning survey.
Thinning related to change in operation to extended delignification; higher temperatures; hot acid cleaning; corrosive wood species.
Appendix C
6. Back to Batch
1994: Catastrophic failure of a stainless steel weld overlaid batch digester in Panama City FL. 1995-6: reports on brittle cracking of carbon steel seam welds in batch digesters that had been overlaid.
9. Recent Issues
Erosion-corrosion behind headers. Effect of wood species on corrosion. Corrosion and cracking of bottom scrapers (duplex stainless steel cracks too). External cracking of leg supports for batch digesters. Quality assurance during construction of duplex stainless steel digesters.
Appendix C
Background
Joined TAPPI after attending the 3rd International Symposium on Corrosion in the Pulp and Paper Industry in 1980 Pine Hill digester exploded later in 1980 Invited to first meeting in Montgomery AL Volunteered to become secretary Traveled extensively with chairman Dave Bennett over the next 2 years
P&G Mills
Grande Prairie (GP) Alberta Flint River (FR) Georgia
Numerous U-bend specimens installed with various combinations of weld filler, overlays, plasma sprays, and stress relief
Appendix C
Appendix C
GP Top Replacement
The sealed plasma spray continued to protect the top of the digester until the top was replaced An anodic protection system was installed
Appendix C
Effect of [Si] in steel 1960s Mueller used pstat to show active-passive behavior basis for AP
Appendix C
Appendix C
How Does Liquor Chemistry Affect Cracking? Severity decreases with decreased NaOH Independent of Na2S203, Na2SO3, NaCl, Na2CO3 Some organics/species inhibitive Potential range for cracking mostly independent of NaOH level
Slow strain rate tensile tests showed how cracking depended on electrochemical potential
Fracture mechanics specimens were used to determine the rate of crack propagation
Appendix C
Under ideal conditions, cracks grow at ~ 10 mm/y, but not when anodically protected
10
Appendix C
Sorry I could not attend the meeting! See you next year!
Risk Taker
Dave Bennett
Experience
Walter Mueller Tom Watson
Need
Pine Hill
Experience
Batch Digesters - Mueller, Watson and Webster
Late 1950s and 1960s Successfully Protected Several Kraft Batch Digesters Protected a Stainless Steel Overlaid Digester
11
Appendix C
Bennett Contacted Watson Due to His Previous Experience in Batch Digesters As I had Saved Tom Watsons Life from a Certain Sulphuric Acid Death, Anodic Protection became One of My Specialties
12
Appendix C
Summary
Anodic Protection of Continuous Digesters Only became a Viable Method to Prevent Cracking as a Result of the Coming Together of:
Prior Experience Research A Risk Taker A Need
13
Appendix C
AP of Continuous Digesters
First installation of continuous digesters was on a soda digester in 1979 Corrosion was successfully mitigated
AP of Continuous Digester
Catastrophic digester failure occurred in 1981due to stress corrosion cracking (SCC) Anodic Protection system was installed in 1985 to prevent SCC Original design was split pipe cathode longitudinally and install on center pipe at the impregnation zone
14
Appendix C
Design History
Pipe-on-pipe cathode at impregnation zone of conventional cooked digesters Top Separator and lower zone protection systems were added Linear Distributed Cathode (LDC) design for even current distribution (early 1990s) Newer cooking schemes (ie, Lo-Solids, EMCC, etc.) resulted in new challenges at the lower zones of digesters
15
Appendix C
16
Appendix C
TAPPI
Digester corrosion information meeting
Developments of AP System
Martti Huttunen
AP System Schematic
Feed back
1. CER 2. Results
Control unit
1. Analog control unit 1980s 2. Digital control unit 1985s 3. PC based control unit 1995s 4. Modular control unit 2006 AC / DC 380 V 0-15 V 250 Amps
Rectifiers
17
Appendix C
Cathodes
1. Crown cathode 2. Flat vertical or horizontal cathodes 3. Dummy plate cathodes 4. Rod cathodes 5. Taylor made cathodes for heaters etc.
References
Monitoring
350 330
Studies - CER
R e s is ta n c e & C u r r e n t v s T im e
Digester Anodic Protection
Resistance, kOhm
310
T e m p e ratu re in F ah re nh e it
290
0 1 0 -2 1 0 -4 1 0 -6 1 0 -8 1 0 -1 0 1 0 0
2 0 0 1 4 6
Current, mA
9 2 3 8 -1 6 1 2 2 4
T im e , m in
D133T
D167T
D299T
D308T
3 6
4 8
-7 0 6 0
18
Appendix C
AP Operation
04.03.2003 15:50:47 Anodic Protection System Continuous digester On On Liquor On On Impregnation Cook blank _---_ |___| / \ _____ _____ _____ _____ ----- ----- ----- |_____| Savcor Consulting Inc 230-1130 West Pender Street Vancouver, B.C. V6E 4A4 Canada Tel. +1-604-6627034 Ref 308-R1 299-R1 287-R1 251-R1 238-R1 217-R1 198-R1 179-R1 167-R1 155-R1 133-R1 115-R1 47 88 115 78 153 142 36 204 210 213 197 81 mV mV mV mV mV mV mV mV mV mV mV mV Temperatures 211 F 236 F 228 F
Inspection Report and Outage Support Summary May 2002 Continuous Digester Southern Mill Executive Summary
No new cracks were found in areas of the impregnation zone that were previously cleared of cracks. Additionally, no obvious propagation of existing cracks was noted. This is far more consistent with the expected effects of anodic protection.
On On On On On On
Corrosion rates in the lower zones of the digester continue to be essentially too low to measure.
Southern Mill
Kamyr Digester
Comparison of Previous and Present Thickness Readings taken in wash area to monitor Anodic Protection System Performance (Loss/Gain is in Inches) October 2000 GAIN / LOSS
V1 V2 V3 V4 Average
RING 1A H1 0.004 0.005 0.007 0.008 0.006 RING 1B H1 0.008 0.008 0.004 0 0.005
V1 V2 V3 V4 Average
RING 4 H1 0.006 0.011 0.004 -0.002 0.00475 RING 8 H1 0 0 0.002 0.002 0.001
Ring 14 7 5 3
V1 V2 V3 V4 Average
V1 V2 V3 V4 Average
19
Appendix C
20
Appendix C
Purpose of Survey:
Batch Digesters
Determine number of in-service digesters, both batch and continuous Assess experiences to date Estimate future DSS use for digesters 27 In-service completed 5 Re-build completed ? In planning stage
Continuous Digesters
1 Top replacement completed 1 Impregnation vessel completed 1 Single vessel digester completed
21
Appendix C
October 2002
February 2004
Summary
DSS adopted by 14 different paper companies for batch & continuous digesters since 1997 Both kraft & sulfite applications Most experience with 2205 DSS Some in-service corrosion reported 2403 has cost advantage over 2205
22
Appendix C
Conventional operation with external liquor heaters High NaCl liquor due to ocean transport of logs White liquor and chips added from the top
2.8 mm (0.11) spot welded 24 mm (15/16) thick shell 1953 2 Inconel 600 lined 2.8 mm (0.11) spot welded 30 mm (1 3/16) shell 6 bare A285C 51 mm (2) shell 1957 Hot plate boiling recognized as cause of corrosion Paper Published in Pulp and Paper Magazine of Canada, vol. 59, no.1 , 1958. Hans Wegerif 1962 2 additional bare batch digesters Kamyr digester
23
Appendix C
CORROSION RATES
unlined 316L lining 1957 Measurements 0.095/year 2.4 mm/year 0.009/year 0.23 mm/year
316L liners maintained by Inconel 600 strip lining and local weld overlay SAW overlay of barrels of bare and 316L lined digesters - 20 22% Cr deposits Manual overlay in domes and cones 310 filler hot cracked Re-overlay program in barrels due to thinning of SAW overlay - costly 2205 and Inconel 600 sheet and strip lining installed in barrels over old overlay and Inconel 600 lining, and in dome over bare carbon steel and hot cracked 310 overlay
but 316L linings had serious local thinning within 2 years of start up and required ongoing repair
1997 Measurements 0.009 /year 0.003 /year 0.24 mm/year 0.07 mm/year
2001
2002 to date
A dome leaked due to SCC under a leaking lining. Two domes replaced with thicker carbon steel 2002 Weld overlay program resumed: 312 filler applied over old overlay by SAW Up to 30% Cr obtained But cracking through full thickness of new overlay
2005
Re-overlay program continued using GMAW, FCAW, P-GMAW over old overlay 30% Cr obtained without cracking but minor subsurface fissuring with GMAW, P-GMAW Original Inconel 600 lining removed and replaced with P-GMAW 312 25 to 26% Cr over bare carbon steel - no cracking, fissuring or porosity
24
Appendix C
25
Appendix C
LINING
Starting in 1995 slot welded wallpaper sheet lining was installed over old overlay. 2205 and Inconel 600 liners were used. Aim was to protect overlay against hot plate boiling. The liner plates leaked but the overlay beneath was not attacked. Lining evolved to 6 wide strip lining seal welded to the shell instead of wallpapered. Lining was applied in several digesters until it became apparent that severe corrosion, including SCC, was occuring under leaking liners
26
Appendix C
27
Appendix C
in #12 Batch
cracking
32-15 #8 WSI 312 32-15 #3 28-10 #5 30-15 #4 32-15 #7
FCAW
In 2003 FCAW 312 overlay was performed in the #7 Batch digester 25 28% Cr was obtained over previous SAW overlay The FCAW overlay was sound
M ic ro h a rd n e s s (V H N )
28-11 #7
30-15 #2
28
29
30
31
32
33
Chromium (%)
28
Appendix C
P-GMAW #3 Batch 1965 Alloy Cladding 1991 Alloy Cladding 309 SAW Removed 1965 overlay by gouging 309 SAW applied
2004 West Coast 312 pulsed MIG over Industrial existing 1991 overlay in top 13 feet of the barrel Exocor 312 filler 1991 overlay was in good condition
29
Appendix C
340
M ic ro h a rd n e s s (V H N )
320 300
WSI 312
cracking
32-15 #3 28-10 #5 30-15 #4
Exocor 312 GMAW-P #14 2005 #3 2004 #9 2005
32-15 #7 32-15 #8
28-11 #7
30-15 #2
Exocor 312 #11 2005
28
29
30
31
32
33
Chromium (%)
30
Appendix C
E F
First inspection of 2205 duplex stainless steel arms after 16 months (B)
The same view after the arms were removed from the digester (B)
31
Appendix C
One, straight plate crack was cut out as a boat sample (C)
32
Appendix C
The crack is transgranular consisting of one primary branch and fine secondary branches. This was identified as environmentally assisted cracking. There were no deficiencies of the 2205 stainless steel.
Observations
More Observations 304L liners and 309L overlay have been the least successful in terms of maintenance. Carbon steel, 304L and 2205 have all cracked. Experience with 2205 suggests that cracking does not occur on a continuous basis. In the majority of cases 2205 is an improvement over other stainless steels. There is still the risk that it will crack. Recent material selection has focused on stress relieved, carbon steel with reinforcement or Inconel overlay on the leading edge. Wear is still an issue.
There is no correlation between cracking and the age of vessel, cooking process, arm style (solid or box). Corrosion has not been an issue on the adjacent shell and head. Typically the material is carbon steel. The cracks have the appearance of fatigue especially in carbon steel. Is mechanical loading understood? What role does it play in the cause of rake arm cracking?
33
Appendix C
Cracking Happens
34
Appendix C
35
Appendix C
flow-related corrosion
Batch digesters
splash zone corrosion ss weld overlay commonly applied
Batch digesters
ss weld overlay widely used, dilution control an issue,
All vessels
solid duplex sss now used, few problems to date
36