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Several industrial applications including the chemical industry and oilfield technology involve frequently halide-containing streams at elevated temperatures, that challenge the pitting corrosion resistance of metallic materials. Pitting susceptibility becomes not only a reject criterion for materials selection during the design stages of engineering components used in these applications. It also constitutes a significant limiting factor to the service life of these components once in service. Therefore, the characterization of the pitting corrosion resistance of metallic materials including the influence that operational factors can have on material’s susceptibility is crucial.
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Microbial influenced corrosion is a type of corrosion caused by microorganisms attached to the metal surface or by their activity. The first one who noted the MIC was Gaines in 1910 [1], followed by research about the graphitization of cast irons in anaerobic soils in 1934 [2]. Nowadays, attention to MIC problems increased significantly.
The power plant is a natural gas-fired, combined cycle plant with three combustion turbines and a single steam turbine. A large stainless steel surface condenser is used to condense steam off of the turbine, and provide high purity steam condensate return to the boiler system. The steam condenser was put into service approximately 15 years ago. This plant takes makeup water for its open recirculating cooling tower water system from a river location that is inland from an ocean coastal area.
Transfer of Zn from hot-dipped and mechanically galvanized steel bolting to stainless steel by exposing a 304L stainless steel/Galvanized bolting assembly to temperatures in the range 205°C to 537°C for one hour to simulate an industrial fire scenario.
Weld overlay has been successfully used to mitigate high temperature corrosion issues in coal-fired boilers since the1990s, such as in waterwall and superheater/reheater area. Weld overlay is typically applied in shop or field by using Gas Metal Arc Welding (GMAW) process for boiler waterwall application, and the overlay welding is performed in vertical down welding mode (3G welding position) in subcritical and supercritical boiler waterwall applications. With the rapid development of coal-fired boiler market in China, ultra-supercritical boilers are becoming the dominated boiler type which often has spiral waterwall design. Most of ultra-supercritical coal-fired boiler waterwall consists of CrMo steel tubes, which could suffer severe high temperature corrosion attack after the installation of low NOx burners. It is expected that weld overlay could provide a long-term high temperature corrosion protection for ultra-supercritical boiler waterwall based on previous weld overlay study and application experience. However, for the spiral waterwall with inclined tube design, its field overlay welding is highly challenging and significantly different from typical vertical boiler waterwall overlay welding. The challenge and difference include welding position, welding sequence, welding parameters, and overlay properties, etc. This paper presents a successful field application of 309L stainless steel and 622 Ni-based alloy weld overlay on the spiral waterwall of an ultra-supercritical coal-fired boiler, including the welding development, simulation, and experience of overlay welding on the inclined tubes, along with the characterization of the weld overlay applied.
Stainless steels and Ni-base alloys are often considered as construction materials in applications where highly corrosive conditions are expected. High levels of halides, low pH and high temperatures are factors that often contribute to the selection of such materials.
Ten different alloys have been included in this work, representing a range of highly alloyed stainless steels and Ni-base alloys. The purpose has been to evaluate the corrosion resistance of stainless steels with alloying content in the 6Mo range or higher, and competing Ni-base materials. The austenitic grade N08904 and two super-duplex grades have also been included for reference.
Stainless steel is selected for use in the municipal waterworks industry because of its inherent corrosion resistance properties. Designers oftentimes overlook the associated problems with coupling stainless steel with carbon steel metals. When these materials are electrically connected and placed into aqueous environments (immersion service) accelerated corrosion of the anodic carbon steel metal is initiated.
The temperature dependence of the pitting corrosion resistance of a number of stainless steels, Fe-Cr-Ni and Fe-Cr-Ni-Mo materials in a series of high-temperature high-pressure chloride solutions, with or without addition of various (inhibitive) anions: SO4=, HCO3-, PO43-, OH-, etc.