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08458 Thermal Fatigue in a De-Superheater Induced by Thermal Loads

Picture for 08458 Thermal Fatigue in a De-Superheater Induced by Thermal Loads
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Product Number: 51300-08458-SG
ISBN: 08458 2008 CP
Author: Bakheet Al-Yami
Publication Date: 2008
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A failure had occurred in a petrochemical plant in a weld joint of a de-superheater only six months after being in service. System was commissioned after making necessary repairs using same metallurgy since all the needed resources were long delivery-scheduled items. Leaking of steam through the weld joint revealed the failure location. Analysis of the failed samples by metallurgical techniques, none destructive testing (NDT), scanning electron microscopy (SEM), and Energy Dispersive X-ray (EDX) techniques indicated that the failure was caused by improper design of the injection of the BFW in the de-superheater that producing inner cyclic thermal differential loads leading to thermal fatigue. This paper will discuss the mechanism of the prevailing thermal fatigue failure was explored and explained.
A failure had occurred in a petrochemical plant in a weld joint of a de-superheater only six months after being in service. System was commissioned after making necessary repairs using same metallurgy since all the needed resources were long delivery-scheduled items. Leaking of steam through the weld joint revealed the failure location. Analysis of the failed samples by metallurgical techniques, none destructive testing (NDT), scanning electron microscopy (SEM), and Energy Dispersive X-ray (EDX) techniques indicated that the failure was caused by improper design of the injection of the BFW in the de-superheater that producing inner cyclic thermal differential loads leading to thermal fatigue. This paper will discuss the mechanism of the prevailing thermal fatigue failure was explored and explained.
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Thermal fatigue is a specific type of fatigue failure mechanism that is induced by cyclic stresses generated due to repetitive fluctuations in the temperature. These temperature change in the material induces thermal expansion (or contraction) and if surrounding material or external constraints hinder this expansion thermal stresses arise. The degree of damage is affected by the magnitude and frequency of the temperature swings and typically appears in the form of one or more surface cracks on the component.This paper presents two case histories of thermal fatigue failure along with detailed metallurgical analysis of stainless steel pressure components in a downstream Aromatics plant.The first case study is on failure of a UNS31803 duplex stainless steel heat exchanger tubing that occurred after four and half years in service. The damage was in the form of multiple parallel circumferential surface cracks with few cracks propagating through the wall thickness of tube. The equipment was subjected to a temperature differential of about 100 deg C every 4 hours of operation during alternate heating & cooling cycle.The second failure discussed is on 6” diameter UNS32100 process piping after around ten years of service. This is primarily a thermal mix point wherein demineralized water is injected in a hot gas stream resulting in a temperature gradient of more than 100 Deg C. The failure mode was also characterized by many circumferential cracks at location of injection as well as about 2-3 diameters downstream injection point.Keywords: Thermal Fatigue Stainless Steel Cyclic stresses Temperature differential
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