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Meeting Materials Science & Technology 2019
Symposium Failure Analysis: Industry Specific Failures
Presentation Title Avoidable and Non-avoidable Failures in Power Plants
Author(s) Fahmida Hossain, Veda-Anne Ulcickas
On-Site Speaker (Planned) Veda-Anne Ulcickas
Abstract Scope Many of the causes of Power Plant failures are widely known but still not avoided. For some cases, environmental factors are less obvious and cause unexpected failures. 1) Unexpected failure of a Waste Heat Recovery Unit (WHRU). The unit failed prematurely in six months. The root cause of the failure was corrosive attack of the tube ends at the tube sheet weld joints at the exhaust outlet due to sulfuric acid. Gas entering the Heat Exchanger (HE) was ~873F and gas exiting was ~350F. It is well-known that HE operating temperatures should be outside the dew point (~300oF) of sulfuric acid. 2) Unexpected failure of HRSG LP carbon steel economizer tubes due to SCC in three years. Ammonium nitrate salts on the OD of the finned tubes was the likely aggressive species. This is a known environment to cause SCC of carbon steel tubes.

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Adhesive-wood Interactions in Relation to Failure in Bonded Wood Products from Centimeter to Nanometer Scale
Avoidable and Non-avoidable Failures in Power Plants
Carbonyl Index Depth Profiling via Micro FTIR and FPA Detection
Case Studies in Failure Analysis of Tinplate Containers for Food Packaging
Coating Cases: Failure & Prevention
Comparing Inherent Damping Capability of Additively Manufactured Stainless 316L and Inconel 718
Cracking of a Heavy Dump Tractor Trailer Resulted from the HDG Process
Cutting Inserts Wear Monitoring in AISI 1045 Dry Longitudinal Turning through Cutting Forces: a Case Study
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Doomed ! Parts That Have Made It through Quality Control That Shouldn’t
Failure Analysis of a Ceramic Seal in a Fluid Rotary Joint for an Aerospace Application
Failure Analysis of a Combine Wheel Motor
Failure Analysis of a Corroded SCUBA Tank
Failure Analysis of a Second-stage Turbine Disk Rupture
Failure Analysis of a Waste Heat Recovery Boiler Thermally Coupled to Ammonia Oxidation Reactor
Failure Analysis of Industrial Products and Components: From Identification to Process Based Approach
Failure Analysis on Cracked Outlet Nozzles (2 off) from a Regeneration Gas Heater Economizer
Failure of Beet Planter Support Wheel Kingpins
Failure of Polycrystalline CT Blade Fir Trees and the Role of Carbide Morphology
Failure of Underground ABS Dry Compressed Air Piping
Fan Blade Fatigue Fractures in CFM56-7B Engines
Helicopter Main Rotor Servo Disconnect Failure Due to Self-locking Nut Reuse
Hydrogen Embrittlement Case Studies: Contributions from Material Processing
Inadequate Weld Repair and Rupture of a Pressure Vessel
Investigation of a Helicopter Accident Where Cyclic Control Was Lost Due to Improper Maintenance
Oil Heater Tube Failure due to Excessive Unintended Carburization
Overview of NTSB Commercial Space Investigations
Polymer Failures: Case Histories
The Identification of Plastic Additives in a Failure Analysis Investigation
The Little Plane that Could: Failure Analysis of a Robust Turbine Engine
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Tube Leaks in Black Liquor Recovery Boiler
When a Butterfly Flaps Its Wings: Failure Analysis of a Hydrostatic Axial Piston Pump Control Module Component
Why Threaded Plastic Couplings Fail in Service

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