Leakage on Water Cooling Distribution Pipe in a Hydroelectric Power Plant

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1 23

Journal of Failure Analysis and Prevention

ISSN 1547-7029

J Fail. Anal. and Preven.

DOI 10.1007/s11668-019-00610-4

Leakage on Water Cooling Distribution Pipe in a Hydroelectric Power Plant

M. Nurbanasari, T. S. Purwanto,

R. S. Piliang, T. Kristyadi, E. Saefudin &

Y. Irwan

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1 23

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Journal of Failure Analysis and Prevention

Journal of Failure Analysis and Prevention Editors

Editors

Editor-in-Chief

Elvin Beach, The Ohio State University, Columbus, OH, USA Associate Editors

Adam Boesenberg, Danfoss Power Solutions, Ames, IA, USA

Ryan Haase, Materials Evaluation and Engineering, Minneapolis, MN, USA Joseph Maciejewski, Novelis, Inc., Kennesaw, GA, USA

Vir Nirankari, Exponent, Inc., Natick, MA, USA

Editorial Board

Milo Kral, Board Liaison, University of Canterbury, Christchurch, New Zeland; Mark Barkey, The University of Alabama, Tuscaloosa, AL, USA; Daniel Benac, Baker Risk Engineering, San Antonio, TX, USA; Pierre Dupont, Schaeffler Belgium Sprl/bvba, Dour, Belgium; Margaret Flury, Medtronic, Minneapolis, MN, USA; Brad James, Exponent Inc., Menlo Park, CA, USA; Richard McSwain, McSwain Engineering, Inc., Pensacola, FL, USA; Brett Miller, IMR Test Labs, Louisville, KY, USA; David Moore, Unified Engineering, Aurora, IL, USA; George Pantazopoulos, Elkeme SA, Athens, Greece; Craig Schroeder, Briggs & Stratton, New Berlin, WI, USA; Roch Shipley, Professional Analysis Consulting, Inc., Lisle, IL, USA; Daniel Thomas, Infinity Space, Cambridge, United Kingdom; Dustin Turnquist, Engineering Systems Inc., Englewood, CO, USA; Mary Anne Fleming, Staff Liaison, Senior Content Developer, Journals, ASM International, Materials Park, OH, USA

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3/23/23, 1:38 PM Journal of Failure Analysis and Prevention | Editors

https://www.springer.com/journal/11668/editors?gclid=CjwKCAjwzuqgBhAcEiwAdj5dRu5dGm9YP9HmQf1tSQyx1Y7i4PBrr2CHayAdrOLqJDvLxvv… 2/4

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Journal of Failure Analysis and Prevention

Journal of Failure Analysis and Prevention Volumes and issues Volume 19, issue 2

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Volume 19, issue 2, April 2019

36 articles in this issue

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Failure Analysis of Incoloy 800HT and HP-Modified Alloy Materials in a Reformer

Chris Maharaj, Andres Marquez & Riza Khan Case History---Peer-Reviewed

Published: 20 March 2019 Pages: 291 - 300

Thermal Fatigue Failure of Low-Pressure Turbine Blade in a Low-Bypass Turbofan Engine

R. K. Mishra & S. K. Jha

Case History---Peer-Reviewed

Published: 18 March 2019 Pages: 301 - 307

Failure Analysis of a Cam Gear in the Torquemeter Assembly of a Turboprop Engine

R. K. Mishra, D. Arul Kumaresan ... Vinay Kumar

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3/23/23, 1:42 PM Journal of Failure Analysis and Prevention | Volume 19, issue 2

https://link.springer.com/journal/11668/volumes-and-issues/19-2 2/9

Case History---Peer-Reviewed

Published: 19 March 2019 Pages: 308 - 313

Failure of a Dissimilar Metal Braze in an Expansion Joint

Brett A. Miller, Phillip D. Swartzentruber & Justin T. Barnes Case History---Peer-Reviewed

Published: 22 March 2019 Pages: 314 - 319

Cracking of AISI T22 Reheater Pendant Assembly Tubing of Steam Boiler

B. Erenburg, A. Zilberberg & E. Iskevitch Case-History---Peer-Reviewed

Published: 25 March 2019 Pages: 320 - 327

Product News

News Published: 27 March 2019 Pages: 328 - 330

Industry Updates

News Published: 27 March 2019 Pages: 331 - 336

Professional Resources

News Published: 27 March 2019 Pages: 337 - 342

Training

Calendar Published: 27 March 2019 Pages: 343 - 346

(9)

Events

Calendar Published: 01 April 2019 Pages: 347 - 349

An Extended FMECA Method and Its Fuzzy Assessment Model for Equipment Maintenance Management Optimization

Ling Wang, Yangfen Gao ... Xiai Chen Technical Article---Peer-Reviewed

Published: 08 February 2019 Pages: 350 - 360

Failure Analysis of an Automobile Coil Spring in High-Stress State

Shuaijiang Yan, Qingxiang Wang ... Guodong Cui Technical Article---Peer-Reviewed

Published: 01 February 2019 Pages: 361 - 368

Acquiring and Sharing Tacit Knowledge in Failure Diagnosis Analysis Using Intuitionistic and

Pythagorean Assessments

Mohammad Yazdi

Technical Article---Peer-Reviewed

Published: 01 February 2019 Pages: 369 - 386

Mixed-Mode Stress Intensity Factor Estimation of Inclined Cracks in an Unnotched Round Bar

S. Suresh Kumar & M. E. Aniruthan Technical Article---Peer-Reviewed

Published: 12 February 2019 Pages: 387 - 393

(10)

Failure Analysis of a Four-Way Flange Cracking in a KQ65 Wellhead Christmas Tree

Ji-ming Zhang, Xiqiang Wang ... Ping Du Technical Article---Peer-Reviewed

Published: 04 February 2019 Pages: 394 - 401

Stress Analysis and Fatigue Life Assessment of a Piston in an Upgraded Engine

Mohsen Najafi, Hadi Dastani ... Salim Pirani Technical Article---Peer-Reviewed

Published: 05 March 2019 Pages: 402 - 411

Leakage on Water Cooling Distribution Pipe in a Hydroelectric Power Plant

M. Nurbanasari, T. S. Purwanto ... Y. Irwan Technical Article---Peer-Reviewed

Published: 30 January 2019 Pages: 412 - 417

Failure Analysis of Additively Manufactured

Polyester Test Specimens Exposed to Various Liquid Media

Israel A. Carrete, Diego Bermudez ... David A. Roberson Technical Article---Peer-Reviewed

Published: 04 February 2019 Pages: 418 - 430

Application of Casting Simulation in Failure Analysis of Impeller

Yudha Pratesa, Badrul Munir & Suryadi Najamuddin Technical Article---Peer-Reviewed

Published: 08 February 2019 Pages: 431 - 437

(11)

Failure Analysis of the Tubes in a Methanol Synthesis Tower

S. W. Liu, W. Z. Wang ... L. P. Guan Technical Article---Peer-Reviewed

Published: 19 February 2019 Pages: 438 - 444

Reliability Analysis of Type III Gas Storage Vessel Under Pressure Loading

A. Ghouaoula, A. Hocine ... Rami Suleiman Technical Article---Peer-Reviewed

Published: 22 March 2019 Pages: 445 - 452

Failure Analysis of Secondary Superheater Tube in a 600-MW Coal Power Plant

M. Nurbanasari, H. Abdurrachim & M. M. Prihadi Technical Article---Peer-Reviewed

Published: 18 March 2019 Pages: 453 - 460

On the Critical Assessment into Damage Behavior of a WC–Co Hard Metal Alloy Used in the Form of Rock Drill Bits

Saurabh Dewangan

Technical Article---Peer-Reviewed

Published: 18 March 2019 Pages: 461 - 470

Failure Analysis of Additive Manufactured Fiber- Reinforced Thermoplastics

Siddharth M. Nayak, P. Balachandra Shetty ... G. R. Viraj Technical Article---Peer-Reviewed

Published: 18 March 2019 Pages: 471 - 475

(12)

Photoelastic Stress Analysis of Crankpin Fillets of a Crankshaft

Riad Ahmad, Ahmad O. Hasan & Hani Al-Rawashdeh Technical Article---Peer-Reviewed

Published: 18 March 2019 Pages: 476 - 487

Evaluation of Failure and Repair of the Jebba and the Shiroro Hydroelectric Power Stations

C. T. Thomas, O. Ogunbiyi ... B. J. Olufeagba Technical Article---Peer-Reviewed

Published: 21 March 2019 Pages: 488 - 495

PCA-I and AHP Methods: Unavoidable Arguments in Accident Scenario Classification

Hefaidh Hadef & Mébarek Djebabra Technical Article---Peer-Reviewed

Published: 21 March 2019 Pages: 496 - 503

Analysis of Low-Pressure Turbine Nozzle Guide Vane Failure in an Aero Gas Turbine Engine: A Computational Approach

D. Arul Kumaresan & R. K. Mishra Technical Article---Peer-Reviewed

Published: 19 March 2019 Pages: 504 - 510

Tensile and Fatigue Analysis of 3D-Printed Polyethylene Terephthalate Glycol

Grzegorz Dolzyk & Sungmoon Jung Technical Article---Peer-Reviewed

Published: 26 March 2019 Pages: 511 - 518

(13)

Mechanical Behavior and Evaluation of Dented Pipe Caused by Cylindrical Indenter

Chunyu Yu, Binquan Qiu ... Jie Zhang Technical Article---Peer-Reviewed

Published: 25 March 2019 Pages: 519 - 535

Degradation of Polycarbonate Properties Under Thermal Aging

Sonya Redjala, Rabah Ferhoum ... Said Azem Technical Article---Peer-Reviewed

Published: 20 March 2019 Pages: 536 - 542

Finite Element Failure Analyses of Structural Steel Solid and Perforated Tension Coupons

K. K. Adewole & F. A. Olutoge Technical Article---Peer-Reviewed

Published: 25 March 2019 Pages: 543 - 550

Nondestructive Testing of Wire Ropes Based on Image Fusion of Leakage Flux and Visible Light

Juwei Zhang & Shilei Wang Technical Article---Peer-Reviewed

Published: 28 March 2019 Pages: 551 - 560

Buckling Failure Analysis of Hydraulic Cylinder Rod on the Flap Institutions for Power Catwalk

Qiaolei Sun, Zheng Chen ... Yiliu Tu Technical Article---Peer-Reviewed

Published: 28 March 2019 Pages: 561 - 569

(14)

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Erosion of an Arrow-Type Check Valve Duo to Liquid–Solid Flow Based on Computational Fluid Dynamics

Xiaodong Zhang, Yongsen Chen & Wenwu Yang Technical Article---Peer-Reviewed

Published: 27 March 2019 Pages: 570 - 580

Ultimate Failure of Defective Pipelines Reinforced with Composite Repair Systems

Rumu Chen, Jinshui Qiu ... Ganglu Ren Technical Article---Peer-Reviewed

Published: 29 March 2019 Pages: 581 - 589

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(15)

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(16)

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T E C H N I C A L A R T I C L E — P E E R - R E V I E W E D

Leakage on Water Cooling Distribution Pipe in a Hydroelectric Power Plant

M. Nurbanasari.T. S. Purwanto.R. S. Piliang.T. Kristyadi. E. Saefudin._{Y. Irwan}

Submitted: 23 April 2018 ÓASM International 2019

Abstract This paper reported the investigation of leakage occurred on the water cooling distribution pipe in a 175 MW hydroelectric power plant. The pipe has been used around 2 years. The pipe has a function to flow through the cooling water from penstock to the heat exchanger. The leakage of the pipe caused the system was shut down and impacted on economic losses. Nondestruc- tive, chemical, mechanical and metallography tests were carried out in this investigation. Based on chemical composition, hardness and microstructure analysis confirmed that the pipe was made of low-carbon steel and met with the standard of ASTM A595 grade A, which is suitable for water pipeline. Nondestructive inspection found that the surface of inner wall of the pipe experienced erosion–

corrosion and from metallography analysis, it is strongly evidenced that the leakage occurred on the base metal due to the severe erosion–corrosion at the localized area. The severe erosion–corrosion occurred was induced by the elbow of the pipe and the excessive root penetration causing flow turbulence and continuing to progressive wall thinning of the pipe.

Keywords Excessive root penetration Erosion–corrosionTurbulent

Water cooling distribution pipe

Introduction

Hydroelectric power plant uses hydropower as the main driving force on power generation systems. The potential energy of water is converted to mechanical energy by turbine and is coupled with generator to produce the electricity [1]. There are some major components that are required in hydroelectric power plant, such as reservoir and dam, inlet gates, fore bay, penstock, turbine and generator.

One of the supporting components that play an important role in hydroelectric power plant is water cooling distribution pipe in the power house. The water cooling distribution pipe drains off the cooling water from penstock to oil cooler and generator cooler heat exchanger. The pipe is located in a closed area and protected from the sun, has low working temperature and is usually made of steel.

The steel pipes in water distribution system have been used widely for more than five centuries [2]. However, there are some problems that often occur in the steel pipes.

It has been reported that the steel pipe often suffers from wall thinning and any leaks in a pipe wall after use for several months due to many of erosion and corrosion problems [3–6]. This current paper intends to repot the failure analysis of the leakage on water cooling distribution pipe in a 175 MW hydroelectric power plant, which has been operated for more than 25 years. About 80 m³/s of river water is converted to electrical power in the power plant using vertical shaft of Francis turbine coupled with generator. Unfortunately, the river water quality is not good due to pollution, which comes from among others fish farming, domestic sewage, industrial and agricultural wastes. The leakage was often occurred during the opera- tion and located near to the welded joint of the pipe. A M. Nurbanasari (&)T. S. PurwantoR. S. Piliang

T. KristyadiE. SaefudinY. Irwan

Department of Mechanical Engineering, Institut Teknologi Nasional, Jl. PHH. Mustapha 23, Bandung 40124, Indonesia e-mail: meilinda@itenas.ac.id

123

https://doi.org/10.1007/s11668-019-00610-4

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comprehensive investigation was carried out to prevent the same failure in the future.

Methodology of Investigation

Visual inspection was performed to determine the location of the leaks, and then the leaking pipe was sectioned for further investigations. Figure1 shows a leak point at installed water cooling distribution pipe.

The methods for investigation consisted of nondestructive and destructive inspection, namely:

a. Dye penetrant based on ASTM E165 [7].

b. Chemical composition was carried out to verify the leaking pipe using optical emission spectroscopy (OES-Master Pro-Oxford Instrument).

c. Metallographic analysis was performed on optical microscopy (Nikon Epiphot). Scanning electron microscopy (SEM) equipped with EDS was also used and conducted on a JEOL 610-LA operated at 20 kV.

SEM–EDS analysis was also carried out to study the scale and corrosion deposit. Preparation for metallographic samples followed standard metallographic techniques. The etchant of 3% nital was applied to the samples to reveal the microstructures.

d. Hardness was measured on a Vickers hardness tester with a load of 200 g and dwelling time 15 s. Average

hardness value was obtained from six times measurement.

Results and Discussion

Verification of Pipe Material

The chemical composition of leaking pipe, which is pre- sented in Table1, confirmed that the pipe was of low- carbon steel composition and satisfied with the standard of ASTM A 595 grade A [8]. The average hardness of the investigated pipe was 134 HV. The microstructure of the leaking pipe (Fig.2) consisted of ferrite and little amount of pearlite.

Leaking Investigation

Dye penetrant was carried out on leaking area of the pipe.

The stages of the cutting process of the leaking pipe to collect the sample for dye penetrant are shown in Fig.3.

Figure3shows the investigated leaking pipe (a) and the sample with leaking area was cut from the pipe (b). Visual inspection found that the inner surface of the pipe experienced corrosion and there were scale deposit and some localized erosion–corrosion marks were also observed (c).

Dye penetrant testing was conducted on the outer surface

Fig. 1 The leaking point of water cooling distribution pipe in installed condition

Table 1 The chemical composition of the leaking pipe (wt.%)

Remarks C (max) Si (max) S (max) P (max) Mn Fe

ASTM A595-grade A [8] 0.015–0.25 0.04 0.03 0.04 0.30–0.90 Balance

Leaking pipe 0.04 0.01 0.01 0.02 0.28 Balance

Fig. 2 Microstructure of the leaking pipe

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of the pipe to determine the leaking location and the result exhibited clearly evidence of leaking, as shown by arrow (d).

It is believed that the leak observed in Fig.3d was ini- tially from the inner surface and propagated to the outer surface of the pipe. For confirmation, the sample was cut into two sections at the leak location, as shown by the dashed line in Fig.4.

The sample number 1 was for SEM–EDS analysis to investigate the scale and corrosion deposit on pipe inner surface. The sample number 2 was for microstructure analysis to find out the cause of the leakage, and the result is shown in Fig.5.

Figure5shows the microstructure of the three different zones, namely base metal, heat-affected zone (HAZ) and weld metal that were observed by optical microscopy.

Figure5 gives strong evidence that the leakage was initiated from the inner surface of the pipe and occurred not on the welded joint but on the base metal. The welded joint used V-groove with single-pass welding and resulted weld beads on the inner and outer surface of pipe. Figure5also shows there is a difference in thickness of base metal between the left and right side of the weld metal. The thickness of base metal on the right side of weld metal in Fig.5 refers to the normal wall thickness of the pipe (7 mm), while the thickness of base metal on the left side of the weld metal was reduced sharply. A maximum

thickness reduction was observed in the region where pinhole leaks had occurred (note that the water flow is from right to the left as indicated by yellow arrow in Fig.5).

Portions of the weld root were observed to be protruding into the inner wall of the pipe at localized area, and erosion was observed close to weld metal region. The wall thickness of the weld metal was around 8 mm. Due to turbulence and excessive water velocity, the passive corrosion-protective film has been repealed in some areas,

Fig. 3 The investigated sample was taken from the leaking pipe (for letters, see the text)

Fig. 4 The leak location was divided into two sections (for number, see text)

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causing erosion–corrosion of the pipe wall, thinning of the pipe wall and finally leaked at a certain point. The mechanism of turbulence is described in Fig.6.

Figure6 shows the illustration of turbulent mechanism occurred in the leaking pipe. Elbows are critical parts in industrial piping system due to their probability of failure [9]. When water passed through an elbow, the pressure will drop and it became turbulent. The weld bead protrusion caused a recirculation zone on the inner radius of an elbow (Fig.6a) and generated a dead zone (Fig.6b). As a result, a localized wear spot on the dead zone had occurred and furthermore experienced erosion very fast and finally leaked [10]. Hence, it can be concluded that the main cause of the leaked was due to severe erosion–corrosion at the dead zone. The severe erosion–corrosion was initiated by flow disturbance, which was induced by the elbow and

poor welding quality simultaneously, namely excessive root penetration resulting weld protrusion on the internal surface of the pipe. Qualitative analysis of SEM–EDS on three different areas is shown in Fig.7.

The EDS spectra of deposit areas (number 1 and 2 in Fig.7) exhibit the presence of sulfur; meanwhile, there is no peaks of sulfur on the base metal (area number 3 in Fig.7). These results suggest that scale deposits contained solid sulfur. EDS analysis also shows the peaks of oxygen on deposit scale areas (number 1 and 2 in Fig.7). This is not surprising, as the feed water of the power plant is from the river that never completely pure and can contain solutions of many gases, e.g., O₂, N₂, CO₂, H₂S and others [11, 12]. Hence, it indicates that the quality of water has changed chemically and biologically due to fish farming, domestic sewage, industrial and agricultural wastes.

Fig. 5 Microstructure analysis of leakage on sample number 2

Fig. 6 Illustration of leaks on the pipe due to turbulent flow

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Fig. 7 Qualitative SEM–EDS results on three different areas:

(a) area 1, (b) area 2 and (c) area 3

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Conclusions and Recommendation

On the basis of the aforementioned data, the conclusions can be drawn as follows:

1. The material pipe was in good agreement with the standard of ASTM A595 grade A, which is suitable for piping and pipeline.

2. The leakage of the pipe occurred on the base metal and was initiated from the inner wall and due to the elbow of the pipe and excessive root penetration causing turbulent flow and severe erosion–corrosion.

3. The scale deposits on the inner wall of the pipe contained sulfur and oxygen, which indicated indi- rectly that the water of the river has already contaminated due to fish farming, domestic sewage, industrial and agricultural wastes.

Recommendation

It is suggested that the leakage on the water cooling distribution pipe can be avoided by performing the welding procedure specification. The excess root penetration must be also considered and shall be limited to the lesser of 1/8 in. or 25% of the nominal wall thickness of the component being joined [13].

References

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2, 19–23 (1980)

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8. ASTM A595/A595M – 14, Standard Specification for Steel Tubes, Low-Carbon or High-Strength Low-Alloy, Tapered for Structural Use(ASTM International, West Conshohocken, 2014) 9. E.S. Firoozabad, B.G. Jeon, H.S. Choi, N.S. Kim, Failure crite- rion for steel pipe elbows under cyclic loading. Eng. Fail. Anal.

66, 515–525 (2016)

10. N.A. Barton, Erosion in elbows in hydrocarbon production systems: review document, research report 115. Health & Safety Executive (2003)

11. A. Rao,Chemistry of Water(New Age International, New Delhi, 2008)

12. H. Ramos, A.B. Almeida, M. Portela, H.P. Almeida,Guideline for Design of Small Hydropower Plants (Western Regional Energy Agency and Network and Department of Economic Development-Energy Division, Belfast, 2000)

13. Engineering Standards Manual ISD 341-2,ASME B31.3 ‘‘Process Piping: Acceptance Criteria’’ (The American Society of Mechanical Engineers, New York, 2006)

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