Failure Analysis of Condenser Tubes - MP Dec. 2012
Failure Analysis of Condenser Tubes - MP Dec. 2012
Failure Analysis of Condenser Tubes - MP Dec. 2012
Material Evaluation
The tube material chemical composi-
tion was veried, and it conforms to the
chemical composition requirements for
inhibited admiralty brass stated in ASTM
B43-09.3 Inhibited admiralty brasses are
copper-zinc alloys noted for their im-
proved corrosion resistance to low-velocity
freshwater and seawater, and hence are
selected for condenser and heat exchanger
tubing in these environments.4
62 MATERIALS PERFORMANCE December 2012 NACE International, Vol. 51, No. 12
M AT E R I A L S S E L E C T I O N & D E S I G N
FIguRE 1
Metallographic Examination
Cross sections of the tube samples
were prepared for metallographic ex-
amination (Figure 3). The tubes outside
diameter (OD) surfaces were covered
with a continuous layer (tarnish lm),
typically 10 m thick. Obviously, the
cracks had started locally from the tubes Diagram of a typical water-cooled surface condenser.
OD at oxides-attributed sites and propa-
gated intergranularly (Figure 4). More- FIguRE 2
over, the cracks were completely lled
with oxides. The presence of multiple
cracks running near each other at the
cracking region may suggest that the ap-
plied stress had been relatively low. Inter-
estingly, localized dealloying (plug de
zincication) was found at the tubes OD
surfaces.
Scanning electron microscope/energy
dispersive x-ray (SEM/EDX) analysis Transverse cracks observed on the condenser tube samples.
showed that the products formed inside
the cracks were composed mainly of cop- FIguRE 3
per oxides (Figure 5). Traces of Mg, Al,
Si, Ca, Cr, Mn, C, Cl, Na, and Ni were
also detected inside the cracks. It is also
worth noting that considerable iron con-
centration was found in the layer formed
on the tubes OD surfaces.
Water Analysis
Steam condensate samples from both
condensers were collected and analyzed.
The pH of the condensate varied from
7.5 to 8.5. The water analysis also
conrmed the presence of ammonium
(the maximum concentration detected
was 0.2 ppm). Chloride was also found
(~0.8 ppm).
Results
These ndings clearly indicate that the
condenser tube failures were caused by
ammonia (NH3) stress corrosion cracking
(SCC). Indeed, brasses containing 20 to
40% Zn (admiralty brass) are highly sus- Intergranular cracks and localized dezincication on the tube cross sections.
ceptible to SCC that can be induced by Note the oxides formation in the cracks. As polished.
FIguRE 1
small amounts of NH3.5 It has been docu- addition, NH 3 and ammonium com- Conclusion
mented that very small concentrations of pounds are sometimes used as constitu- The failure analysis concluded that the
NH3 (1 ppm or less) can lead to SCC in ents of the steam treatment program. condenser tube cracks were caused by
copper and copper alloys.6 Ammonium NH3 dissolves in the water lm that forms NH3 SCC.
can be produced when nitrogen oxides on the tubes and produces concentrations
react with brass surfaces. Nitrogen oxides signicantly higher than those of the bulk Recommendations
may be introduced into the condenser water. It is also well recognized that the The steam condensate pH, ammo-
due to leaking of air into the system.7 In presence of an oxidizer such as oxygen in nium, and dissolved oxygen levels in
64 MATERIALS PERFORMANCE December 2012 NACE International, Vol. 51, No. 12
M AT E R I A L S S E L E C T I O N & D E S I G N