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Laboratory Examination of Smelt Spouts
2011 TAPPI PEERS CONFERENCEPortland, Oregon
Craig ReidAcuren Group Inc
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BLRBAC Safe Firing• Inspect spouts every scheduled outage• Replace all spouts at least annually • cut up at least one removed spout to inspect
the water side• Field hydro test new spouts• Never rebuild, repair, or modify a spout• Clean and inspect head tank and collecting
tank annually • Periodically inspect cooling water piping
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BLRBAC SAFE FIRINGcompliance varies
• Spouts not changed annually• Fireside inspection practice varies –
(clean, dry, full access)• Rebuilt spouts used• Water side examination of sacrificial
spout not documented
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MaterialsCarbon steel
– Bare– Thermal sprayed– Chromized– Roll clad with stainless– Roll clad with Alloy 825
Fabricated 304L stainless steel50Cr/50 Ni Cast Dry spouts
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Damage Mechanisms• water side corrosion and/or deposition
• fireside corrosion by smelt
• fireside corrosion by condensed vapor
• fireside thermal fatigue
• fireside rodding damage
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Water SideDefined water passages
– the “CE” Spout– water makes several longitudinal passages– analogous to water flow through a tube
Not so defined water passages– assorted designs– water flow is more or less directly from inlet
to outlet
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“CE” Spout
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SummaryDamage Mechanisms
• water side deposition or corrosion not a factor in damage
• no overheating of either carbon steel or stainless steel
• corrosion of bare carbon steel
• corrosion of carbon steel exposed by loss of thermal spray and chromizing
• thermal fatigue cracking of carbon steel, stainless steel, roll clad plate, and 50 Cr/50 Ni dry spouts
• “mechanical” fatigue cracking of chromized spouts – after four years
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SummaryThermal fatigue
• not found with CE style spouts
• analogous to thermal fatigue of composite smelt spout opening tubes and primary air port tubes
• occurs without corrosion
• driven by smelt side heat flux variations (in dry and water cooled spouts)
• related to cooling water flow pattern in water cooled spouts with “not so defined cooling water passages”
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SummaryThermal fatigue
• No “easy” solution available to boiler operator
• Parallel with ORNL/Paprican research program on composite tube cracking
• Smelt side thermal flux variations inherent in operation
• Spout water passage design expertise resides with suppliers
• Spout water supply system design depends on suppliers
• Operator can monitor and trend cooling water parameters – e.g. flow rate and temperature
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SummaryInspection
• Observed damage occurs without significant water side corrosion or deposition
• Monitor water side by other means than spout sacrifice
• Keep spouts in service by visual inspection, UT thickness, MT or PT for cracking
• If significant damage is found or the type or pattern of damage changes then trigger a water side examination
• Always to a visual inspection with good lighting
• surface preparation is essential for sensitive MT or PT
• “if you ain’t grindin/sandin then you ain’t findin”
• UT thickness must be a scan using a screen display – no point “doinking” by test robots
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CHRONOLOGICAL BACKGROUND
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Powell – “CE” chromized. Service up to 4 years with no deterioration
1990 -1995
Powell – 2 thermal spray and 2 chromized spouts installed. Thermal spray lost after 6 months.
1990
Powell – thermal spray used with mixed success1985 -1989
Powell - “CE” bare - after boiler rebuild spout life decreased from 1 year to 6 months - tide line thinning
1985
Harmac - cast Hastelloy C spout leaked in short service – due to casting defects
1982
Harmac - average spout life 11 months1982
Harmac - average spout life 7 weeks1968
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Mill N – “CE” bare - 2 boilers – no deterioration 2001
Swedish report of a smelt spout leaking incident due to start up overheat . Also mentioned thermal fatigue cracking as a common problem
1997
Powell – started changing chromized annually1995
Powell – 3 new “CE” chromized leaked after 6 months - a 4th spout which had been in service for 2 years did not leak
1995
Harmac – 50Cr/50Ni dry spout trial. Reverted to water cooled.
1993 -1994
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Mill E1 - “CE” bare – no deterioration aside from rodding damage.
2004
Mill C1 - solid 304 – cracking and 25% wall loss at inlet. Plate sensitized at inlet and outlet – maybe from stress relief heat treatment.
2004
Mill G – “CE” rebuilt spouts thermal sprayed -cooling water lost for 3 minutes – ran another week then 3 spouts examined. One showed shallow surface overheating but no loss of spray.
2003
Mill G – “CE” bare – upper side of cooling tube thinned inside furnace – one small weep. Speculated due to refractory issues
2003Mill N – “CE” bare - 2 boilers – no deterioration 2002
Mill D – “CE” bare – thinning and leak in discharge end cooling tube
2002
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Mill S2 – Dry spouts – full thickness loss2008
Mill E- Dry spouts – thermal fatigue cracking2008
Mill A – roll clad 304L plate – thermal fatigue cracking in 304L entered carbon steel
2007
Mill N - “CE” chromized – 3 years – chromized loss at discharge lip on one spout due to rodding damage – 20% wall loss on exposed carbon steel
2007
Mill S1 – “CE” chromized – chromized lost on upper side of cooling tube inside furnace – exposed tube thinned
2006
Rebuilder - 5 carbon steel spouts after 1 year – no deterioration
2006
Mill N – “CE” chromized – no deterioration2004
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Rebuilder – 2 year examination of the 5 carbon steel spouts examined in 2006 – thermal fatigue at inlet, thinning at outlet end plate
2008
Mill H – “CE” thermal spray with 50Cr/50Ni – 1 year - widespread spray loss but no loss of exposed carbon steel - upper side of cooling tube thinned inside furnace similar to mills G and S – may not have been sprayed
2008
Mill D – bare carbon steel – thermal fatigue cracking to 75% of wall near discharge end on the two right side spouts - cracking coincided with cooling water discharge chamber. Left side spouts no cracking
2008
Mill C1 – solid 304L with weld overlay at inlet and discharge - thermal fatigue cracking to 50% of wall
2008
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Mill D – bare carbon steel – thermal fatigue cracking all 4 spouts – 40 to 80% of trough wall. Cracking coincided with cooling water discharge chamber
2009
Mill A – roll clad alloy 825 plate – thermal fatigue cracking in alloy 825 did not reach carbon steel after 12 months service
2009
Mill C1 – solid 304L – 9 months - thermal fatigue cracking to 70% of wall at smelt inlet – shallower cracking along trough
2009
Mill C3 – solid 304L (same design as Mill C) – no cracking
2009
Mill C2 – bare carbon steel – two variants – 12% wall loss on inlet end plate –okay for multi year use - weld overlay could be used to extend life
2009
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Mill S1 – “CE” bare – 13 months. No corrosion –10 grams/ft2 maximum DWD
2010
Mill D – bare carbon steel – thermal fatigue cracking to 50% of wall near discharge end on the rightmost spout only - cracking coincided with cooling water discharge chamber.
2010
Mill C4 – “CE” bare – 2 years. Thinned. Max. loss 0.110” from 0.250” original. 87 – 99 grams/ft2 DWD in high heat flux channels.
2010
Mill T – carbon steel. Transverse thermal fatigue by in place PT. No lab exam.
2009
Mill H – “CE” chromized – 11 months – 40% of chromized layer on outlet end cooling tube corroded at tide line. No exposed carbon steel.
2009
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Mill D – bare carbon steel – thermal fatigue cracking to 80% of wall near discharge end on the 2nd spout from right side only - cracking coincided with cooling water discharge chamber. Spout allegedly stress relieved.
2011
Mill N – “CE” chromized – 4 years – three spouts on one side found leaking on shutdown PT. Replaced. The spouts on other side cracking ground on and left in place.
2010
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Mill D – 2002 – Bare “CE” – one yearwater leak at smelt outlet
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Damage mode – General thinning
Smelt inlet end
Smelt outlet end
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Mill G – 2003 – Bare “CE”
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THERMAL SPRAYED SPOUTS
Mill H – one year
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Chromizing
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Chromizing
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ChromizingPowell River – 1995 – 6 months
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Suspected cause of failure was overheating – not accepted by mill
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1997 Swedish Incident
• Subatmospheric cooling water• Start up with low smelt and start up burners to
maintain steaming• Hot smelt corroded inside ends of spouts• Smelt sucked into hole in one spout• Internal explosion in spout - then new smelt
sucked in and another explosion – explosions repeated several times a minute
• Cooling water ejected from spout into furnace • Hot water ejected out over dissolving tank roof
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• Furnace ESP’d• Silver Lining:“no thermal fatigue cracks found in spout
troughs which is a frequent trouble of spouts here in Sweden”
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Mill H 2009
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Chromizing
• Spouts left in service with annual PT• Cooling water leaks found at four year
inspection• Suspected “mechanical fatigue”• Three leaking spouts replaced• Three non-leaking spouts left in place
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Water leaking from cracks
Water leaking from cracks
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WATER SIDE EXAMINATION
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DWD Measurement
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Mill C1 – 2008 Solid 304L with Weld Overlay – 1 Year
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Smelt Inlet End
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Butt Weld in Trough
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Weld Overlay at Smelt Outlet End
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Cross Section of Crack Adjacent to Weld Overlay
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Crack at Surface
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Crack Tip
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Crack Adjacent to Weld Overlay Broken Open
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Crack SurfaceThere are Clear Fatigue Striations
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Mill C1 – 2009 Solid 304L– 9 Months
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Trough at Smelt Outlet End
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Mill D – 2008 – Bare carbon steel
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Mill D – 2011 – Bare carbon steel
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Mill A – 2007 – 304L Clad Plate
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Mill A – 2009 – Alloy 825 Clad Plate12 months
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825/carbon steel interface
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Mill E – 2008 – Dry Spout
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Mill S2 – 2008 – Dry Spouts
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Proverbs 3:5
Trust in suppliers with all thine heart and lean not unto thine own understanding