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07451 Caustic Gouging in a Refinery Boiler - Root Cause and Remediation

Picture for 07451 Caustic Gouging in a Refinery Boiler - Root Cause and Remediation
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Product Number: 51300-07451-SG
ISBN: 07451 2007 CP
Author: Stephen P. Wood, William J. Algeo, Robert A. Call, and Thomas M. Laronge
Publication Date: 2007
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During the pre-turnaround hydrostatic test, multiple tube leaks were discovered in the original water wall tubes of a 680 psig industrial boiler installed in 1954. Inspection of the water wall tubes of the boiler revealed significant pitting corrosion on the high heat ff ux side warranting tube repair or replacement, while the cold-side of the tube maintained close to original wall thickness. Metallurgical analysis determined the mode of failure to be caustic corrosion. Further investigation concluded that the physical root cause was localized higher heat flux due to the operation of low NOx burners installed in 1996.
During the pre-turnaround hydrostatic test, multiple tube leaks were discovered in the original water wall tubes of a 680 psig industrial boiler installed in 1954. Inspection of the water wall tubes of the boiler revealed significant pitting corrosion on the high heat ff ux side warranting tube repair or replacement, while the cold-side of the tube maintained close to original wall thickness. Metallurgical analysis determined the mode of failure to be caustic corrosion. Further investigation concluded that the physical root cause was localized higher heat flux due to the operation of low NOx burners installed in 1996.
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Under-deposit corrosion is a common mode of failure in boiler tubes. Mechanisms include phosphate attack, caustic gouging, hydrogen damage, and wall thinning due to metal loss. Many aspects of these mechanisms and their mitigation are well-understood, while certain specific details remain uncertain or subject to controversy.

 
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