Case Study -2nd Regenerator Secondary Cyclones.

Prepared By
Mr. Tran Anh Vu
Deputy Technical Manager
1. Summary
2. Drawing
3. History
4. Observation/ Findings
5. Root Cause Analysis
6. Recommendation
7. Repair Method
8. Lesson Learnt
CONTENTS
The RFCC unit was shut down for 2
nd
TA in 2014. During
inspection secondary cyclone CY-1504 E~H in the 2
nd
regenerator D-1503 were found severe damaged. The carbon
steel portion in the cyclone barrel were replaced with SS-304H
material after detail analysis of root cause for damages by
performing NDT methods like UTM, Hardness test, replica etc.
Summary
Drawing
Drawing
refractorycrack
refractorycrack
History
In 1st TA, some crack were found in the refractory around the carbon steel
portion of cyclone barrel
BeforeHacking
AfterHacking
BracingBowing
Observation/ Findings (TA 2014)
Picture 2
refractorycrack
BeforeHacking
refractorycrack
Observation/ Findings
Licenser Design Detail design & Actual
LicensorDesign Detail design&Actual
Dis-similar weld joint is slanting and near
to 2nd regenerator shell
Dis-similar weld joint is horizontal and
far away from 2nd regenerator shell
Have extrenal refractory to cover
dis-similar weld
125mm thick refractory outside the
carbon steel material
In cyclone barrel less carbon steel and
more SS material inside re-regenerator
In cyclone more carbon steel and less
SS material inside re-generator
Di s-si mi l ar
wel d j oi nt
Observation/ Findings
Picture 4 shows degradation/metal flakes in cyclone barrel (Carbon
Steel portion). For all 4 cyclones same condition
Observation/ Findings
CycloneF
Dissimilar weld metal found crack in the heat affected zone of carbon steel
portion in two cyclones E &F.
CycloneE
Observation/ Findings
Picture 6b show horizontal Stiffener bracing found bend(Bowing) at
middle of bracing & Picture 6a show crack in one of the dipleg weld
metal
Picture 6a Picture 6b
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Philosophy
NDT inspection is carried out based on the API 579
Fitness for service philosophy.
For Assessment of fire damage chapter 11 fig: 11.7.
NDT inspection are carried out step by step process
First perform Hardness test to evaluate the hardness
limit. If hardness limit is lower 240HB that means
the metal is good
If the hardness value is higher than 240 HB check the
microstructure and follow subsequent test as per flow
chart.
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Philosophy
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Observation/ Findings
NDT- UTM Result
UTM result confirms there is no major thickness
reduction. From the dis-similar weld zone to about 0.6
meter in height towards Carbon Steel cannot measure the
thickness due to high flaking of material and above 0.6
meter For all four cyclones the similar condition.
Picture 1 shows the thickness near the dis-similar weld
seamis reduced about 3-4mm.
Picture 1
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Observation/ Findings
NDT- Hardness Result
Hardness test result confirms that from the dis-
similar weld zone to about 0.7-0.9 meter in height
towards Carbon Steel the hardness value is very high
around 600HB and many locations cannot measure
hardness due to flaking. Above 0.9 meter the
hardness value is with in the acceptable range. All
four cyclones has the similar condition.
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Observation/ Findings
NDT- Replica Result
Replica result says that Carbon steel material in the
cyclone has undergone many damage mechanism like
creep voids, degraded microstructure, no carbide have
only ferrite, high temperature sulfidation, graphitation
and microstructure degradation due to high temperature
corrosion etc
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Observation/ Findings
NDT- Replica Result
Cyclone H replica result says the Carbon steel material about 0.7 m above dis-similar
weld joint has creep voids and degraded microstructure
Report 3
CY 1504-E
Cyclone E replica result by PVI and Vietnam Material Institute says the Carbon steel
material near the dis-similar weld zone is no carbide have only ferrite
Report 4
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Observation/ Findings
NDT- Replica Result
Cyclone E replica result says the Carbon steel material about 0.5 m above
dis-similar weld joint was damaged due to high temperature sulfidation, graphitation and
microstructure degradation. Even after remove 5mm of degraded carbon steel material the
replica result shows that the material microstructure structure is decomposed
Report 5
Cyclone G replica result says the Carbon steel material about 0.6 m above
dis-similar weld joint was damaged due to high temperature sulfidation,
Report 6
CY 1504-F
Cyclone F replica result says the Carbon steel material about 0.3 m above
dis-similar weld joint was partially degraded microstructure due to high
temperature corrosion
Report 7
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Observation/ Findings
Metal Laboratory Analysis result
The flaking metal portion was detailed analyzed in the laboratory, the
results says that this is the corrosion product, which is iron oxide, a
product of metal oxidation at high temperature.
The laboratory report says the cause for corrosion at cyclone is due to the
damage refractory. Oxygen has contacted with metal surface through the
defect positions which led to chemical corrosion at high temperature.
The corrosion products are iron oxides under the form of magnetite
(Fe3O4) and hematite (-Fe2O3).
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Root Cause Analysis
Replica result for CY-1504H microstructure @400X shows the
isolated creep void.
API 571, clause 4.2.8.3 point a says the rate of creep deformation is
a function of the material, load, and temperature.
API 571, clause 4.2.8 Table 4-2 says Threshold Temperatures for
Creep for Carbon steel material is 370C
API 571, clause 4.2.8.3 point b says If the metal temperature exceeds
threshold temperature values, then creep damage and creep cracking
can occur
Creep Damage
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Root Cause Analysis
Replica result for CY-1504E by PVI microstructure @100X near the dis-similar
weld zone in carbon steel shows no carbide so it is suspected that decarburization
might have happen.
API 571 clause 4.4.4.1 says decarburization is a condition where steel loses
strength due the removal of carbon and carbides leaving only an iron matrix.
Decarburization occurs during exposure to high temperatures, during heat treatment,
from exposure to fires, or from high temperature service in a gas environment
API 571 clause 4.4.4.3 point a says Time, temperature and carbon activity of the
process stream are the critical factors.
API 571 clause 4.4.4.3 point d says decarburization can decrease the strength of
the material.
Decarburization
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Root Cause Analysis
Laboratory result by PVI, clause III conclusion says Oxygen has
contacted with metal surface through the defect positions of refractory which
led to chemical corrosion at high temperature. Refer Table 1-4 for oxygen
percentage in the flake material
API 571 clause 4.4.1.1 says Oxygen reacts with carbon steel and other
alloys at high temperature converting the metal to oxide scale.
API 571 clause 4.4.1.3 point a says The primary factors affecting high
temperature oxidation are metal temperature and alloy composition.
API 571 clause 4.4.1.3 point b says Oxidation of carbon steel begins to
become significant above about 1000F (538C). Rates of metal loss
increase with increasing temperature.
API 571 clause 4.4 table 4-2 says the estimated corrosion rate for oxidation
of CS will be severe above 48 mils/year or 1.21 mm/year
Oxidation
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Root Cause Analysis
API 579 chapter 11, table 11.6 says when metal exposed to extreme heat
temperature above 730C (1350F) heavy scaled steel may be distorted due to
thermal stresses.
API 579 chapter 11 table 11.6 note 13 says Oxidation of low carbon steel occurs
rapidly above 730C (1350F) resulting in heavy scale build-up. Damage may be
less than it appears initially, since the volume of scale is from seven to 20 times
greater than that of the metal from which it formed. Heavily scaled parts should be
cleaned of scale, checked for thickness, grain structure, and hardness to facilitate
decisions regarding reuse.
After exposure to temperatures in excess of 730C (1350F), hardenable steels
may exhibit a wide range of hardness, toughness and grain structure depending on
exposure temperature and cooling rate (API 579).
If at temperatures in excess of 730C (1350F) is followed by rapid cooling steels
may show extremely high hardness and low toughness. Such hardened material is
extremely prone to delayed brittle fracture or hydrogen-assisted cracking and
therefore must be identified and removed prior to returning the equipment to service
Oxidation
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Root Cause Analysis
Replica result for CY-1504E microstructure @400X shows the metal was degraded
due to graphitization.
API 571 clause 4.2.1.1 point a says Graphitization is a change in the microstructure
of certain carbon steels and 0.5Mo steels after long-term operation in the 800F to
1100F (427C to 593C) range that may cause a loss in strength, ductility,
and/or creep resistance.
API 571 clause 4.2.1.1 point b says At elevated temperatures, the carbide phases in
these steels are unstable and may decompose into graphite nodules. This
decomposition is known as graphitization.
API 571 clause 4.2.1.3 point d says below 800F (427C), the rate of
Graphitization is extremely slow. The rate increases with increasing temperature.
Graphitization
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Root Cause Analysis
Replica result for CY-1504G microstructure @100X shows the metal
was degraded due to sulfidation.
API 571 clause 4.4.2.1 point a says Corrosion of carbon steel and
other alloys resulting from their reaction with sulphur compounds in
high temperature environments
API 571 clause 4.4.2.3 point c says Sulfidation of iron-based alloys
usually begins at metal temperatures above 500F (260C).
API 571 clause 4.2.1.3 point d says below 800F (427C), the rate
of Graphitization is extremely slow. The rate increases with increasing
temperature.
Sulfidation
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Root Cause Analysis
API 571 clause 4.2.12.1 says Cracking of dissimilar metal welds occurs in the ferritic
(carbon steel or low alloy steel) side of a weld between an austenitic (300 Series SS)
and a ferritic material operating at high temperature.
API 571 clause 4.2.12.2 says ferritic materials such as carbon steel and low alloy
steels that are welded to the austenitic stainless steels as well as any material
combinations that have widely differing thermal expansion coefficients
API 571 clause 4.2.12.3 point b says Cracking occurs because the coefficients of
thermal expansion between ferritic steels and 300 Series SS differ by 30% or more.
At high operating temperatures, the differences in expansion lead to high stress at the
heat affected zone on the ferritic side
API 571 clause 4.2.12.3 point c says As the temperature increases, differential
thermal expansion between the metals results in increasing stress at the weldment,
particularly if a 300 Series SS weld metal is used.
API 571 clause 4.2.12.3 point e says At elevated temperatures, the problem is
aggravated by the diffusion of carbon out of the heat affected zone of the ferritic
material and into the weld metal. The loss of carbon reduces the creep strength of the
ferritic material heat affected zone, thereby increasing the cracking probability
Dis-similar weld metal cracking
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Root Cause Analysis
API 571 clause 4.2.12.3 point f says The temperature at which carbon diffusion
becomes a concern is above 800F to 950F (427C to 510C) for carbon
steels and low alloy steels.
API 571 clause 4.2.12.3 point g says Ferritic/austenitic joints can generate
significant thermal expansion/thermal fatigue stresses at temperatures greater than
510F (260C). Refer ASME B 31.3 Table C-1 Total thermal expansion
Dis-similar weld metal cracking
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Root Cause Analysis
API 571 clause 4.2.12.1 point h says Dissimilar metal welds with a 300 Series
SS weld metal on a ferritic steel may also result in a narrow region of high
hardness at the toe of the weld, near the fusion line on the ferritic steel side. High
hardness zones render the material susceptible to various forms of environmental
cracking such as sulfide stress cracking or hydrogen stress cracking.
API 571 clause 4.2.12.1 point j says The ferritic heat affected zone will
preferentially corrode due to the large thermal strain. The results are long, narrow,
oxide wedges that parallel the fusion line of the weld
Dis-similar weld metal cracking
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Root Cause Analysis
JGC Heat Transfer Analysis
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Root Cause Analysis
JGC Heat Transfer Analysis
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Root Cause Analysis
JGC Heat Transfer Analysis
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Root Cause Analysis
JGC Heat Transfer Analysis
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Root Cause Analysis
JGC Heat Transfer Analysis
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Root Cause Analysis
JGC Heat Transfer Analysis
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Root Cause Analysis
JGC Heat Transfer Analysis
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Root Cause Analysis
JGC Heat Transfer Analysis
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Recommendation
API 571 clause 4.2.8.6 point c says Creep damage is not reversible.
Once damage or cracking is detected much of the life of the
component has been used up and typically the options are to repair or
replace the damaged component.
ASM Volume 17 Table 2, creep classification table says for few
cavities of creep damage need to re-inspect after 20,000hrs (less than
3 years estimated next Turn around)
API 579 chapter 11 figure:11.7 says if hardness value high,
microstructure is unacceptable, decarburized the material need to be
replaced
The laboratory sample test reports shows the Carbon steel metal was degraded due to high
temperature oxidation. Referring to the above table (API-571) based on the current
operation temperature of D-1503 the corrosion rate will be severe above 48 mils/year or
1.21 mm/year. As per design the allowable corrosion allowance is 1.5 mm for CS and
0.75mm for SS. This corrosion allowance is calculated for 25mm thickness of cyclone
barrel CS material.
Root Cause Analysis
Key Factors Recommendation
6. Project specification 8474L-000-JSS-6300-001 Rev-2 Clause 7.4.1 mention
requirement for minimum weld distance is 100mm or 2T:
Recommendation for Repair method
Option 1: Replacement (Permanent repair) as licenser design
The SS304H material can withstand the high temperature corrosion like
sulfidation, graphitization, oxidation etc.
Key factors recommendation should be considered in this option 1.
Option 2: Patching
API 510 calls this option 2 method as temporary method:
Temporary repairs should be removed and replaced with suitable permanent repairs at
the next available maintenance opportunity.
Temporary repairs may remain in place for a longer period of time only if evaluated,
approved, and documented by the engineer and inspector.
Recommendation
Option 2: Patching
Limitation for fillet welding patch
Fillet-welded Patches
Fillet-welded patches may be used to make temporary repairs to damaged, corroded,
or eroded areas of pressure vessel components.
This type of patch cannot control crack during opportunity maintenance
As per ASME PCC-2 calls:
i. Differential thermal expansion between the cyclone shell and the reinforcing
lap band sleeve shall be considered in the design and application of sleeves.
ii. Fillet welded patch repair is allowed up to 345C only. So the refractory
work shall make sure the temperature of CS is not over 345 C
iii. ASME PCC2 clause 3.5 call The fillet weld patch thickness should be 1.4
times the carrier steel
7/31/2014
Repair
After Cyclone barrel cutting
New Cyclone barrel
7/31/2014
Repair
After new Cyclone barrel welding
After completion of welding
When Carbon steel material is operating under creep range
for long period it undergoes multiple damage mechanisms.
Replica shall be done to analysis the microstructure. Fitness
for service should be followed to assess the damage.
The dis-similar welding should be monitored closely at the
every possible opportunity . When operating temperature is
high Nickel chrome filler wire should be used rather than
E-309 filler wire
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Lesson Learnt