Analysis of pipe failure for the Great Plains Coal Gasification Plant

• Main Authors: Keiser, J.R., Mayotte, J.R. ), Dias, O.C. )
• Language: unknown
• Published: 2022
• Subjects: 01 COAL; LIGNITE; AND PEAT; 36 MATERIALS SCIENCE; CARBON STEELS; RUPTURES; CARBONIC ACID; CORROSIVE EFFECTS; CARBON DIOXIDE; COAL GASIFICATION PLANTS; CORROSION; DESIGN; FAILURE MODE ANALYSIS; IRON CARBONATES; METHANATION; PIPES; PRESSURE EFFECTS; SCALING; TEMPERATURE EFFECTS; VELOCITY; WATER; ALLOYS; CARBON COMPOUNDS; CARBON OXIDES; CARBONATES; CHALCOGENIDES; CHEMICAL REACTIONS; FAILURES; HYDROGEN COMPOUNDS; INDUSTRIAL PLANTS; INORGANIC ACIDS; IRON ALLOYS; IRON BASE ALLOYS; IRON COMPOUNDS; OXIDES; OXYGEN COMPOUNDS; STEELS; SYSTEM FAILURE ANALYSIS; SYSTEMS ANALYSIS; TRANSITION ELEMENT COMPOUNDS; Carbonic acid
• Online Access: http://www.osti.gov/servlets/purl/7092714; https://www.osti.gov/biblio/7092714; https://doi.org/10.1016/1044-5803%2894%2990077-9; https://doi.org/10.1016/1044-5803(94)90077-9

The rupture of a carbon steel elbow in the methanation area of the Great Plains Coal Gasification Plant resulted in a fire and plant shutdown. The failure was investigated by personnel from Oak Ridge National Laboratory and ANG Associates, the plant operators. These studies consisted of an on-site inspection and extensive laboratory examination that included optical metallography, x-ray fluorescence, x-ray diffraction, chemical analyses, and electron spectroscopy for chemical analysis (ESCA). It was concluded that operation of a heat exchanger under off-specification conditions contributed to higher than design temperatures, lower than design pressures, and higher than design concentrations of carbon dioxide and water in the exit line from a condensate separator. Together, these conditions produced high levels of carbonic acid and higher than design velocities resulting in severe corrosion of the carbon steel. 9 refs., 7 figs., 2 tabs.