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Investigation of Intergranular Stress Corrosion Cracking in the Fuel Pool at Three Mile Island Unit 1 三里岛1号机组燃料池晶间应力腐蚀开裂研究
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.power.c9001561
C. Czajkowski
An intergranular stress-corrosion cracking failure of 304 stainless steel pipe in 2000 ppm B as H3BO3 + H2O at 100 deg C was investigated. Constant extension rate testing produced an intergranular type failure in material in air. Chemical analysis was performed on both the base metal and weld material, in addition to fractography, EPR testing and optical microscopy in discerning the mode of failure. Various effects of Cl-, O2 and MnS are discussed. Results indicated that the cause of failure was the severe sensitization coupled with probable contamination by S and possibly by Cl ions.
研究了304不锈钢管在100℃、2000 ppm B的H3BO3 + H2O环境下的晶间应力腐蚀开裂失效。恒定拉伸速率试验在空气中产生了材料的晶间型破坏。除了对母材和焊缝材料进行化学分析外,还对断口学、EPR测试和光学显微镜进行了分析,以确定失效模式。讨论了Cl-、O2和MnS的各种效应。结果表明,失败的原因是严重的敏化加上可能的S和Cl离子的污染。
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引用次数: 0
Fatigue Failure of a Carbon Steel Water-Wall Tube Because of an Undercut at a Welded Joint 碳钢水壁管焊接接头下切引起的疲劳失效
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.power.c0048356
Welded to the top of a dust bin for rigid support, a furnace water-wall tube in a new stationary boiler broke at the welded joint shortly after start-up. The tubes measured 64 mm (2.5 in.) OD by 3.2 mm (0.125 in.) wall thickness and were made of carbon steel to ASME SA-226 specifications. Investigation supported the conclusion that a crevice-like undercut was likely the primary cause of the fracture and that the source of the necessary fluctuating stress was tube vibration inherent in boiler operation. Recommendations included magnetic-particle inspection of the remaining water-wall tubes in the row, replacing the broken tube, and repairing cracks in other tubes by welding.
某新型固定式锅炉的炉膛水壁管焊接在炉膛顶部作为刚性支撑,在启动后不久就在焊接处发生断裂。这些管子的长度为64毫米(2.5英寸)。外径为3.2 mm(0.125英寸)壁厚,由碳钢制成,符合ASME SA-226规范。调查结果表明,裂缝状的凹边可能是导致断裂的主要原因,而锅炉运行中固有的管振动是产生必要波动应力的来源。建议包括对排中剩余的水壁管进行磁粉检查,更换破损的管,并通过焊接修复其他管的裂缝。
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引用次数: 0
Fracture of a Carbon Steel Pipe in a Cooling Tower 冷却塔碳钢管断裂事故分析
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.power.c0048747
A 455 mm diam x 8 mm thick wall carbon steel (ASTM A 53) discharge line for a circulating-water system at a cooling tower fractured in service; a manifold section cracked where a Y-shaped connection had been welded. Investigation (visual inspection and photographs) supported the conclusion that the pipe failed by fatigue. Cracks originated at crevices and pits in the weld area that acted as stress raisers, producing high localized stresses because of the sharp-radius corner design. Abnormally high structural stresses and alternating stresses resulting from the pump vibrations contributed to the failure. Recommendations included changing the joint design to incorporate a large-radius corner and improving fitting of the components to permit full weld penetration. Backing strips were suggested to increase weld quality, and the pipe wall thickness was increased from 8 to 9.5 mm.
用于冷却塔循环水系统的455毫米直径x 8毫米厚的碳钢(ASTM A 53)排放管在使用中断裂;在一个y形接头焊接处,管汇部分出现了裂纹。调查(目测和照片)证实了管子因疲劳而失效的结论。裂纹起源于焊缝区域的裂缝和凹坑,这些裂缝和凹坑作为应力源,由于尖半径角的设计,产生了很高的局部应力。异常高的结构应力和由泵振动引起的交变应力导致了故障。建议包括改变接头设计,加入大半径角,改善组件的配合,以允许完全焊接渗透。建议采用衬带提高焊接质量,管壁厚度由8 mm增加到9.5 mm。
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引用次数: 0
Cause and Prevention of Fatigue Failures in Boiler Tubing 锅炉油管疲劳失效的原因及预防
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.power.c9001569
S. L. Meiley
This paper reviews several fatigue failures from the waterwall, superheater, and economizer portions of the boiler, their causes and how they were mitigated and monitored. Some cases required simple field modifications by cutting or welding, repair of existing controls, and/or changes in maintenance. Nondestructive inspections by visual, magnetic particle, ultrasonic, and radiographic methods for detecting and monitoring damage are discussed. These failures are presented to provide hindsight that will help others in increasing the success rate for anticipating and analyzing the remaining life of other units.
本文综述了锅炉水冷壁、过热器和省煤器部分的几种疲劳失效,它们的原因以及如何减轻和监测它们。有些情况下需要通过切割或焊接进行简单的现场修改,修复现有的控制,和/或更改维护。讨论了用目视、磁粉、超声和射线照相等方法检测和监测损伤的无损检测方法。这些失败是为了提供后见之明,帮助其他人提高预测和分析其他单元剩余寿命的成功率。
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引用次数: 1
Stress-Corrosion Cracking of an Inconel 600 Safe-End on a Reactor Nozzle 反应器喷嘴上英科乃尔600安全端应力腐蚀开裂
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.power.c0091655
Cracking occurred in an ASME SB166 Inconel 600 safe-end forging on a nuclear reactor coolant water recirculation nozzle while it was in service. The safe-end was welded to a stainless-steel-clad carbon steel nozzle and a type 316 stainless steel transition metal pipe segment. An Inconel 600 thermal sleeve was welded to the safe-end, and a repair weld had obviously been made on the outside surface of the safe-end to correct a machining error. Initial visual examination of the safe-end disclosed that the cracking extended over approximately 85 deg of the circular circumference of the piece. Investigation (visual inspection, on-site radiographic inspection, limited ultrasonic inspection, chemical analysis, 53x metallographic cross sections and SEM images etched in 8:1 phosphoric acid) supported the conclusion that the cracking mechanism was intergranular SCC. No recommendations were made.
核反应堆冷却水再循环喷嘴安全端锻件在使用过程中发生断裂。安全端焊接在不锈钢包层碳钢喷嘴和316型不锈钢过渡金属管段上。在安全端焊接了一个英科乃尔600热套管,并在安全端外表面进行了明显的补焊,以纠正加工误差。对安全端进行的初步目视检查显示,裂纹延伸了大约85度的圆周。调查(目视检查、现场射线检查、有限超声检查、化学分析、53x金相截面和8:1磷酸蚀刻的SEM图像)支持裂纹机制为晶间SCC的结论。没有提出任何建议。
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引用次数: 0
Failure Investigation of Longitudinal Seam Welded Elevated Temperature Header 纵缝焊接高温封头失效研究
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.power.c9001669
J. F. Henry, F. Ellis, J. Alice, J. LaFontaine, P. Orban
As the result of a leak detected in a plate-formed header at PENELEC'S Shawville Unit No. 3, an extensive failure investigation was initiated to determine the origin of cracking visible along the longitudinal weld seam. Fabricated from SA387-D material and designed for a superheater outlet temperature of 566 deg C, the 11.4 cm thick header had operated for approximately 187,000 h at the time of the failure. Discussion focuses on the results of a metallographic examination of boat samples removed from the longitudinal seam weldment in the vicinity of the failure and at other areas of the header where peak temperatures were believed to have been reached. The long-term mechanical properties of the service-exposed base metal and creep-damaged weld metal were determined by creep testing. Based on the utility's decision to replace the header within one to three years, an isostress overtemperature lead specimen approach was taken, whereby failure of a test specimen in the laboratory would precede failures in the plant. These tests revealed approximately a 2:1 difference in life for the base metal as compared to weld metal.
PENELEC公司的Shawville 3号机组在板形封头中检测到泄漏,因此开始了广泛的故障调查,以确定纵向焊缝可见裂缝的起源。由SA387-D材料制成,设计用于过热器出口温度为566摄氏度,11.4厘米厚的集箱在故障发生时已经运行了大约187,000小时。讨论的重点是对从故障附近的纵缝焊件和箱头的其他区域取出的船样进行金相检查的结果,这些区域被认为已经达到了峰值温度。通过蠕变试验测定了服役暴露母材和蠕变损伤焊缝金属的长期力学性能。根据公用事业公司在一到三年内更换集管的决定,采用了等应力过温铅样品方法,即实验室测试样品的失败将先于工厂的失败。这些测试显示,与焊接金属相比,母材的寿命相差约2:1。
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引用次数: 0
Investigation of Turbine Disc Cracking by Field Metallography 汽轮机盘裂的现场金相分析
Pub Date : 2019-06-01 DOI: 10.31399/asm.fach.power.c9001666
A. Cervoni, M. Clark
Stress-corrosion cracking of low-alloy steel turbine discs has emerged as a generic concern in nuclear generating stations. An investigation that made extensive use of field metallographic techniques to examine suspected cracking in such a component is described. The crack position, and its relationship to surface topographic features, were examined and recorded by magnetic rubber and high-resolution dental rubber replicating materials. Corrosion deposits on keyway surfaces and within the crack were collected with acetate foil replicas applied and then stripped from the keyway surfaces. Microstructural details were revealed by the use of field metallographic preparation techniques and replicated by acetate foil for examination with optical and scanning electron microscopes. It was possible by these techniques to establish the cracking mechanism as stress corrosion possibly related to chloride or sulphate ion steam contaminants. Subsequent sectioning and conventional metallography confirmed both the validity of the conclusions and the replication techniques.
低合金钢涡轮盘应力腐蚀开裂已成为核电站普遍关注的问题。本文描述了一项广泛使用现场金相技术来检查这种部件中可疑裂纹的调查。利用磁性橡胶和高分辨率牙科橡胶复制材料检测并记录了裂纹位置及其与表面形貌特征的关系。用醋酸箔复制品收集键槽表面和裂纹内的腐蚀沉积物,然后从键槽表面剥离。利用现场金相制备技术揭示了其微观结构细节,并用乙酸箔复制,用于光学和扫描电子显微镜的检查。通过这些技术可以确定开裂机理为应力腐蚀,可能与氯化物或硫酸盐离子蒸汽污染物有关。随后的切片和常规金相学证实了结论和复制技术的有效性。
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引用次数: 0
Failure Analysis of Brass Tubes 黄铜管失效分析
Pub Date : 1997-02-01 DOI: 10.31399/asm.fach.power.c9001521
S. Lawrence, R. Bodnar
Admiralty brass (Alloy C44300) cooling tubes which were part of a heat exchanger in a turbogenerator that provided electricity to a manufacturing plant failed. A mixture of non-recirculating city and “spring pit” water flowed through bundles of tubes to cool the oil in which they are immersed. However, a problem developed when several of the brass tubes cracked transversely, allowing cooling water to mix with the oil. The presence of a tensile stress, intergranular cracks, and a corrosion product suggested the tube failures resulted from stress-corrosion cracking. The main corrosion product was cupric hydroxychloride. In addition to switching to a more corrosion-resistant alloy, extreme care should be taken in the manufacturing of the replacement tube bundles to avoid imparting any residual tensile stresses in the tubing. Analyses of city and spring-pit water were recommended also, to determine which contained the least-harmful corrosive chemicals.
海军部黄铜(C44300合金)冷却管失效,该冷却管是为制造厂提供电力的涡轮发电机热交换器的一部分。非再循环的城市水和“泉坑”水的混合物流经成束的管道,以冷却浸入其中的石油。然而,当几根黄铜管横向开裂时,一个问题出现了,这使得冷却水与油混合在一起。拉伸应力、晶间裂纹和腐蚀产物的存在表明管的失效是由应力腐蚀开裂引起的。腐蚀产物主要为羟基氯化铜。除了使用更耐腐蚀的合金外,在制造替代管束时还应格外小心,以避免在油管中留下任何残余的拉伸应力。还建议对城市和泉水进行分析,以确定哪一种含有危害最小的腐蚀性化学物质。
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引用次数: 0
Stress-Corrosion Cracking of Admiralty Brass Condenser Tubes 海军黄铜冷凝器管的应力腐蚀开裂
Pub Date : 1993-12-01 DOI: 10.31399/asm.fach.power.c0091807
A. Howell, D. Kendall
Failures occurred in admiralty brass condenser tubes in a nuclear plant cooled by freshwater. About 2500 tubes had to be replaced over a span of six years. Investigation (visual inspection, chemical analysis, water chemistry (for both intake and outfall), and corrosion products in the operating system and on test coupons exposed to the operating environment) supported the conclusion that the failure was caused by microbe-initiated SCC. No recommendations were made.
在用淡水冷却的核电站中,海军黄铜冷凝器管发生故障。在六年的时间里,大约有2500根管子需要更换。调查(目视检查、化学分析、水化学(进水口和出水口)、操作系统中的腐蚀产物以及暴露在操作环境中的测试片)支持了故障是由微生物引发的SCC引起的结论。没有提出任何建议。
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引用次数: 0
Reactor Cooling Water Expansion Joint Bellows: The Role of the Seam Weld in Fatigue Crack Development 反应堆冷却水膨胀节波纹管:焊缝在疲劳裂纹发展中的作用
Pub Date : 1992-12-01 DOI: 10.31399/asm.fach.power.c9001682
S. West, D. Nelson, M. Louthan
The secondary cooling water system pressure boundary of Savannah River Site reactors includes expansion joints utilizing a thin-wall bellows. While successfully used for over thirty years, an occasional replacement has been required because of the development of small, circumferential fatigue cracks in a bellows convolute. One such crack was recently shown to have initiated from a weld heat-affected zone liquation microcrack. The crack, initially open to the outer surface of the rolled and seam welded cylindrical bellows section, was closed when cold forming of the convolutes placed the outer surface in residual compression. However, the bellows was placed in tension when installed, and the tensile stresses reopened the microcrack. This five to eight grain diameter microcrack was extended by ductile fatigue processes. Initial extension was by relatively rapid propagation through the large-grained weld metal, followed by slower extension through the fine-grained base metal. A significant through-wall crack was not developed until the crack extended into the base metal on both sides of the weld. Leakage of cooling water was subsequently detected and the bellows removed and a replacement installed.
萨凡纳河反应堆二冷却水系统压力边界包括利用薄壁波纹管的膨胀节。虽然成功地使用了三十多年,但由于波纹管卷曲中出现了小的周向疲劳裂纹,因此偶尔需要更换。一个这样的裂纹最近被证明是由焊接热影响区液化微裂纹引起的。裂纹最初在轧制和接缝焊接的圆柱形波纹管截面的外表面打开,当弯曲的冷成形使外表面处于残余压缩状态时,裂纹被关闭。然而,波纹管在安装时被拉伸,拉伸应力重新打开了微裂纹。这种5 ~ 8晶粒直径的微裂纹是通过韧性疲劳过程扩展的。最初的扩展是通过大晶粒焊缝金属的相对快速的扩展,随后是通过细晶粒母材的缓慢扩展。直到裂纹扩展到焊缝两侧的母材时,才出现明显的穿壁裂纹。随后检测到冷却水泄漏,拆除了波纹管并安装了新的波纹管。
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引用次数: 0
期刊
ASM Failure Analysis Case Histories: Power Generating Equipment
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