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Corrosion Found in The Boiler and Feed Systems
Corrosion Found in The Boiler and Feed Systems
systems
Corrosion and tube failure caused by water chemistry
Metals obtained from their oxide ores will tend to revert to that state. However , if on
exposure to oxygen the oxide layer is stable , no further oxidation will occur. If it is
porous or unstable then no protection is afforded.
Direct chemical-higher temperature metal comes into contact with air or other gasses
(oxidation, Sulphurisation ) Electrochemical-e.g. Galvanic action , hydrogen evolution ,
oxygen absorption
For hydrogen absorption to occur no oxygen needs to be present, a pH of less than 6.5
and so an excess of free hydrogen ions is required.
The Protective film of hydrogen gas on the cathodic surface breaks down as the hydrogen
combines and bubbles off as diatomic hydrogen gas.
Boiler corrosion
Cases found in water tube blrs where due to alternating cyclic stresses set up in tube
material leading to a series of fine cracks in wall. Corrosive environment aggravates.
Trans crystalline
more in depth: Occurs in any location where cyclic stressing of sufficient magnitude are
present
Common in wall and supht tubes, end of the membrane on waterwall tubes, economisers,
deaerators . Also common on areas of rigid constraint such as connections to inlet and
outlet headers
Other possible locations and causes are in grooves along partially full boiler tubes (cracks
normally lie at right angle to groove ), at points of intermittent stm blanketing within
generating tubes, at oxygen pits in waterline or feed water lines, in welds at slag pockets
or points of incomplete fusion , in sootblower lines where vibration stresses are
developed , and in blowdown lines.
It can however be found in water tubes , suphtr and reheat tubes and in stressed
components of the water drum.
The required stress may be applied ( e.g. thermal, bending etc. ) or residual ( e.g.
welding)
Boiler steel is sensitive to Na OH , stainless steel is sensitive to NaOH and chlorides
A large scale attack on the material is not normal and indeed uncommon. The
combination of NaOH , some soluble silica and a tensile stress is all that is required to
form the characteristic intergranular cracks in carbon steel.
DNB
Deposition
Whitish highly alkaline deposits or sparkling magnetite may indicate a corrosion sight.
To eliminate this problem either the stresses can be removed or the corrodent. The
stresses may be hoop stress( temp', pressure) which cannot be avoided bending or
residual weld stresses which must be removed in the design/ manufacturing stage.
Avoidance of the concentrations of the corrodents is generally the most successful. Avoid
DNB , avoid undue deposits prevent leakage of corrodents, prevent carryover.
Caustic corrosion
More in depth:
Generally confined to
Depression are often filled with corrosion products that sometimes contain sparkling
crystals of magnetite.
Iron oxides being amphoteric are susceptible to corrosion by both high and low pH
enviroments.
High pH substances such as NaOH dissolve the magnetite then attack the iron.
However at increased rates the rate of bubble formation may exceed the flow of rinsing
water , and at higher still rate, a stable film may occur with corrosion concentrations at
the edge of this blanket.
The magnetite layer is then attacked leading to metal loss.
The area under the film may be relatively intact.
ii), Deposition
A similar situation can occur beneath layers of heavy deposition where bubbles formation
occur but the corrosive residue is protected from the bulk water
prevention's
Hydrogen attack
If the magnetite layer is broken down by corrosive action, high temperature hydrogen
atoms diffuse into the metal, combine with the carbon and form methane. Large CH-3
molecules causes internal stress and cracking along crystal boundaries and sharp sided
pits or cracks in tubes appear.
more in depth: Generally confined to internal surfaces of water carrying tubes that are
actively corroding. Usually occurs in regions of high heat flux, beneath heavy deposits, in
slanted and horizontal tubes and in heat regions at or adjacent to backing rings at welds or
near devices that disrupt flow .
Chelant corrosion
Concentrated chelants ( i,e. amines and other protecting chemicals) can attack magnetite ,
stm drum internals most susceptible.
A surface under attack is free of deposits and corrosion products , it may be very smooth
and coated with a glassy black like substance
Horse shoe shaped contours with comet tails in the direction of the flow may be present.
Alternately deep discrete isolated pits may occur depending on the flow and turbulence
The main concentrating mechanism is evaporation and hence DNB should be avoided
Pure water contains equal amounts of hydrogen and hydroxyl ions . Impurities change the
balance . Acidic water has an excess of hydrogen ions which leads to hydrogen
evolution.See previous notes on Hydrogen Evolution
For hydrogen absorption to occur no oxygen needs to be present, a pH of less than 6.5
and so an excess of free hydrogen ions is required.
The Protective film of hydrogen gas on the cathodic surface breaks down as the hydrogen
combines and bubbles off as diatomic hydrogen gas.
May occur due to heavy salt water contamination or by acids leaching into the system
from a demineralisation regeneration.
Localised attack may occur however where evaporation causes the concentration of acid
forming salts . The mechanism are the same as for caustic attack. The corrosion is of a
similar appearance to caustic gouging
Prevention is the same as for caustic attack . Proper maintenance of boiler water
chemicals is essential
Vigorous acid attack may occur following chemical cleaning . Distinguished from other
forms of pitting by its being found on all exposed areas
Very careful monitoring whilst chemical cleaning with the temperature being maintained
below the inhibitor breakdown point. Constant testing of dissolved iron and non ferrous
content in the cleaning solution should be carried out.
After acid cleaning a chelating agent such as phosphoric acid as sometimes used . This
helps to prevent surface rusting , The boiler is then flushed with warm water until a
neutral solution is obtained.
Oxygen corrosion
In an operating boiler firstly the economiser and feed heater are effected.
In the event of severe contamination of oxygen areas such as the stm drum water line and
the stm separation equipment
In all cases considerable damage can occur even if the period of oxygen contamination is
short
Bare steel coming into contact with oxygenated water will tend to form magnetite with a
sound chemical water treatment program.
However , in areas where water may accumulate then any trace oxygen is dissolved into
the water and corrosion by oxygen absorption occurs( see previous explanation )
Oxygen Absorption
One special type is called pitting were metal below deposits being deprived of oxygen
become anodic . More common in horizontal than vertical tubing and often associated
with condensers.
The ensuing pitting not only causes trouble due to the material loss but also acts as a
stress raiser
The corrosiveness of the water increases with temperature and dissolved solids and
decreases with increased pH
Aggressiveness generally increases with increased O2
During normal operation the environment favours rapid repair of these cracks. However,
with high O2 prescience then corrosion may commence before the crack is adequately
repaired.
Graphitization
Cast iron , ferrous materials corrode leaving a soft matrix structur of carbon flakes
Dezincification
Brass with a high zinc content in contact with sea water , corrodes and the copper is
redeposited. Inhibitors such as arsenic , antimony or phosphorus can be used , but are
ineffective at higher temperatures.
Tin has some improving effects
Exfoliation (denickelfication)
Normally occurs in feed heaters with a cupro-nickel tubing ( temp 205oC or higher)
Very low sea water flow condensers also susceptible.
Nickel oxidised forming layers of copper and nickel oxide
Ammonium corrosion