David
Linden
is
President of D.H.Linden
Associates, Inc. He has
37 years of experience in
the turbo machinery
industry. Mr. Linden has
worked at a number of
Original
Equipment
Manufacturers including
Conmec Inc., Dover,
Dresser
Rand
Co.,
General Electric Co.,
Ingersoll Rand Co. and
Westinghouse Electric
Corp.
Mr.
Linden
specializes in the areas of Turbomachinery design and
reliability. Mr. Linden graduated with a BSME from
Rutgers University. He is the author/coauthor of ten
technical papers for various ASME and Turbomachinery
Symposiums. Mr. Linden is a member of ASME, ASTM,
NACE and a contributor to the API 687 Rotor Repair subcommittee.
ABSTRACT
One of the primary causes of flow path failures in
industrial axial flow compressors has been attributed to or
is related to corrosion damage. Over the years, a number
of corrosion mitigations have been utilized by various
manufacturers and users. This paper summarizes several
long term monitoring and assessment programs that
evaluated the effectiveness of the mitigation steps and
makes recommendations for future operation. The
monitoring programs included detailed metallurgical
analyses of corroded stator and rotor blades, material
captured in inlet filter pads, flow path deposits and
corrosion coupons. The hardware was examined at
various run time intervals that ranged between 2 to 12
years. When possible, corrosion damage was mapped and
quantified. The hardware was then returned to service and
94
CORROSION:
Compressor flow path corrosion can be divided into two
basic types; General and Localized.
- General Corrosion is a uniform corrosion in which the
metal corrodes at a fairly constant rate over the entire
surface of the part.
- Localized Corrosion is where only a small area of the
metal surface is affected, although the rate of corrosion
in this small area is often very high. Examples of
localized corrosion include inter-granular corrosion,
stress corrosion cracking, pitting and crevice corrosion.
95
MATERIALS:
Trade
Name
Typical
Industry
Specification
Nominal
Chemistry
Alloy steel
(Disc
Material)
403/410
SS
AMS 6414
AISI 4340
Fe, 1.8Ni,
0.8 Cr, 0.25
Mo
AMS 5611
AMS 5609
Fe, 12 Cr
420 SS
AMS 5621
300 SS
321/347
15-5
AMS 5645
AMS 5646
AMS 5658
17-4
AMS 5643
Carpenter
Custom
450
Irrubigo
AMS 5763
Fe, 13 Cr,
0.35, C
Fe, 18 Cr,
10 Ni
Fe, 15 Cr, 5
Ni, 4 Cu
Fe, 17 Cr, 4
Ni, 4 Cu
Fe, 15 Cr, 6
Ni, 1.5 Cu
A-286
AMS 5735
Inconel
718
AMS 5663
Titanium
AMS 4928
N/A
Relative
Corrosion
Resistance
Fe, 25 Cr, 5
Ni
Fe, 25 Ni,
15 Cr, 2 Ti
Ni, 19 Cr 17
Fe, 5
Cb,3Mo
Ti, 6 Al, 4 V
1
5
3
3
3
4
4
4
5
96
97
Minimum
Maximum
Typical
weight. %
weight. %
(average)
Sodium
2
19
5
Aluminum
1
21
8
Silicon
0
35
10
Sulfur
22
68
32
Chlorine
2
26
10
Potassium
0
5
2
Calcium
0
8
3
Iron
6
68
42
Copper
0
10
1
Zinc
0
12
1
Table #4 Deposit Analysis Results Weight Percent
98
99
1
2
3
4
5
6
7
8
9
10
Run #1
403 SS
Run #2
CC 450
Run #3
Titanium
Mils
Micron
Mils
Micron
Mils
Micron
10
22
17
11
10
3
3
2
1
0.5
250
560
430
280
250
76
76
50
25
13
3
8
6
4
5
1
2
0.5
-
76
200
150
102
127
25
50
13
-
2
2.4
2.3
2
1
-
50
61
58
50
25
-
100
101
102
10
103
11
104
12
105
13
106
REFERENCES:
Angello, L., 2005, Axial compressor Performance
Maintenance Guide Update, EPRI Technical Guide
1008325
a.
b.
c.
d.
of
the
e.
f.
g.
h.
i.
14