1

OMIFCO PROJECT SPONSORS

OOC

Oman Oil Company S.A.O.C, Oman

(50 % shareholder)

KRIBHCO -

Krishak Bharati Cooperative Limited, India

(25 % shareholder)

IFFCO

Indian Farmers Fertiliser Cooperative Limited, India

(25 % shareholder)

PROCESS UNITS
(i)

(ii)

Total installed capacity

Ammonia

11,90,000 MT/year

Urea

16,52,000 MT/year

Plant

Capacity

Licensor

Ammonia*

2 x 1750 MTPD

M/s Haldor Topsoe

Urea**

2 x 2530 MTPD

M/s Snamprogetti

For CO2 removal system, the process licensor : M/s Giammarco Vetrocoke

** For Urea granulation, the process licensor : M/s Hydro Fertiliser Technology

FAILURE ANALYSIS
COMMON

OF

SUCTION LINE WELD

JOINT

OF HP AMMONIA PUMPS OPERATING AT 23 BAR

IN
UREA PLANT.

y Site Photograph that indicates weld

the pipe has broken and snapped off
location during operation

joint
from

at
its

Investigation by
TCR Advanced Engineering Services Pvt. Ltd., Vadodara, INDIA

Visual

Examination

Low Magnification Examination

Wet Fluorescent Magnetic Particle Inspection ( WFMPI )

Chemical Analysis

Scanning Electron Microscopy ( SEM ) Analysis

Energy Dispersive Spectrum ( EDS ) analysis

Microstructure Examination ( Metallography )

Tensile Test

Impact Test

Hardness Test

Micro - Hardness Test

Micro Hardness Profile Measurement

6

Visual Examination

y Rust marks in the area

y
OMIFCO - Oman

adjacent to the weld of

painted pipeline.
ID surface of the pipe looks
blackish brown indicating
general form of corrosion.
Fracture surface is flat and
in transverse direction. At
one location weld material had
peeled off.
The counterparts of the
failed joint displaced offcentre.
Weld joint failed from the
HAZ region as well as
from the weld region.
8

y view near fast fracture surface.

y The weld bead had come out on either side of the pipe, Some

pitting/dent marks are seen on ID.

y Rust marks are noticed on the fracture surface.
y No thinning or deformations observed at the failed location.
y At all region fracture surface displayed flat surface with coarse
striations.
OMIFCO - Oman

LOW MAGNIFICATION EXAMINATION

10

y low magnification view at the

fracture surface.
y Multiple origins are observed
from OD as well as ID Surface.

11

y Indicates that the fracture has

taken place precisely at the
fusion zone and perhaps
moved into the weld.
y ID surface shows general form
of corrosion having blackish
grey color.

12

y Photographs at low magnification( 33 X ) shows multiple origins

in form of ratchet marks.

y Presence of corrosion products observed at the cracked

surface.

13

y The fracture surface is fully covered with adherent corrosion

deposits.

y Photographs indicates that initial crack movement is in fatigue

mode.

14

NON - DESTRUCTIVE TEST

15

y Photograph indicates the

ID surface Weld HAZ

view in WFMPI (Wet
Fluorescent Magnetic
Particle Inspection) tested
condition.

y Secondary Transverse

Hairline Cracks were

observed at HAZ.
y No other defects
observed either at OD
or at ID.

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CHEMICAL ANALYSIS

pipe specimen and weld zone.

It conforms to the material specification

A 333 Gr. 6

17

SCANNING ELECTRON MICROSCOPY ( SEM )

18

y SEM reveals crack

initiation in fatigue
mode and movement in
peripheral direction in
high cycle fatigue
mode.
y corrosion marks on the
fracture surface.
y crack propagated under
combined influence of
corrosion and fatigue.

19

ENERGY DISPERSIVE SPECTRUM ( EDS ) ANALYSIS

20

Energy Dispersive Spectrum ( E D S )

Elements

% age

Oxygen

37.22

Sodium

1.31

Magnesium

0.87

Silicon

0.93

Chlorine

1.07

Calcium

0.87

Iron

57.74

Result of EDS Analysis.

Presence of Oxygen, Sodium, Magnesium, Chlorine, and Calcium

confirm that the corrosion is induced by the salty marine

atmosphere.

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MICROSTRUCTURE EXAMINATION
( METALLOGRAPHY )

22

y corrosion fatigue cracking

having trans-granular nature

of propagation.
y It is having mild branching
nature.
y Matrix is banded ferrite
and pearlite.
y crack observed adjacent to
fracture surface on pipe
indicating another origin of
fatigue crack.

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ycorrosion damage entering the metal surface from the pitting

like surface damage at weld location.

y Matrix is ferrite dendrites with carbides.

y It also indicates corrosion fatigue crack moving precisely

along the fusion zone of the weld.

y The nature of crack is trans-granular.

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EDS ANALYSIS AFTER METALLOGRAPHY

EDS Analysis carried out after metallography inside the crack.
The presence of Oxygen, Sulphur and Chlorine on OD crack

confirm that it is a corrosion product induced by marine

atmosphere.

Presence of Oxygen, Sodium, Sulphur and Calcium at ID crack

indicates that there is a water based corrosion product.

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TENSILE TEST
Tensile Test results meet the requirements of ASTM A 333 Gr.6

for tensile properties.

V NOTCH CHARPY IMPACT TEST

V notch charpy test was carried out on the sample drawn at ()56 C.
Impact Test results meet the requirement of ASTM A 333

Gr.6.

26

HARDNESS TEST
General hardness was measured at different locations.

Hardness results meets with the requirements of ASTM A 333

Gr.6.

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MICRO - HARDNESS TEST

Micro-hardness test conducted at different locations. indicating a

normal trend.
Values at OD and ID are little on higher side as slight cold deformation
is given during pipe making.
The lower values at crack tip and fracture surface indicate that the
welded joint had slight inherent stresses which were relieved after the
fracture.
Location I D

Micro - Hardness in VPN @ 100 gm

Load

Origin of Crack

196 , 212 , 213

At Crack Tip

194 , 198 , 207

At Fracture Surface

191 , 186 , 209

OD

207 , 209 , 208

Core

170 , 168 , 172

ID

207 , 215 , 213

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MICRO - HARDNESS PROFILE

y The result of micro-hardness profiled is shown in table.
y The profile does not indicate any severe abnormality. Values at weld

and HAZ are on slightly higher side.

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SUMMARY

30

y
y
y

y
y

y
y
y

The butt weld joint failed circumferentially during the service

after 39 months of operation in February 2008.
The pipe material is ASTM A 333 Gr. 6. The pipe dimensions were
8 X Sch. 20.
A Leak was observed from the same weld joint during first week of
Sept., 2007 and again in the first week of Jan., 2008 and the same
was arrested by injecting sealing compound using clamp.
Visual Examination indicates complete snapping of the pipe at the
failure location from the weld joint.
Circumferential corrosion damage is seen near to the failure
location where the paint has peeled off precisely at the region of
clamp.
Fracture has occurred perpendicular to longitudinal direction
and in a single plane from the weld / HAZ region.
Fracture surface comprises of both fatigue and brittle nature.
Low Magnification View confirms cracking both from OD and ID
and in the weld zone near Weld HAZ.

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SEM Analysis confirms that the cracking is a typical fatigue

damage starting both from ID and OD and Assisted by mild
corrosive atmosphere.
Crack movement is in combined influence of high cycle fatigue
and corrosion mode.
Secondary cracks were also noticed on the fracture surfaces
which were also having corrosion fatigue nature along with
corrosion products.
EDS Analysis confirms that the corrosion damage on fracture
surface is due to salt
containing
Moisture from marine
atmosphere.
Overall microstructure of weld metal, HAZ and parent metal is
normal and acceptable for the service.
Pitting like corrosion damage at OD surface.

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Tensile Test results and Charpy V Notch Impact Test at (-)56

C results were satisfactory.

Micro Hardness Values indicated normal trend in their

variation. Slightly higher hardness observed at HAZ but which
is normal.

Micro Hardness profile was also normal.

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CONCLUSIONS

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y
y
y
y

Visual Examination clearly indicates that the fracture has taken place in
transverse direction perpendicular to the pipe axis.
The failure has taken place both from weld and HAZ.
From Visual and Low Magnification Examination multiple origin of the
cracks all over the circumference starting from both OD as well as ID.
The pipe is exposed to the sea water atmosphere and the paint had
peeled off at some places near welding and corrosion has taken place.

Optical metallography indicates pitting like damage on OD surface of the

pipe.

Both SEM Analysis and Optical Metallography confirm that the failure is on
account of high cycle fatigue assisted by corrosion.

The cracking has taken place in the weld and HAZ zone as seen in WFMPI
and Optical Metallography. All the cracks are filled with corrosion
products. Even the secondary cracks seen on the fracture surface were
having corrosion fatigue nature.

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HAZ microstructure shows slight inclination towards having some internal

stresses which is reflected from micro-hardness values.

Pipe has been supported especially at elbow joint where the change in
the direction of the Liquid Ammonia takes place. Pipe line connecting
the pump, hence some vibrations induced on it. In this case the vibration
stresses induced appear more severe in nature.

The surface corrosion in form of tiny pits has provided favorable sites for
stress concentration to take place both from OD and ID.
The humid salty marine atmosphere provided the climate for corrosion to
take place.
The prevailing vibrations on the pipe line induced the fluctuating
stresses.
Thus, naturally the most vulnerable site for corrosion fatigue damage to
take place is weld and HAZ

y
y
y

36

CAUSE OF FAILURE

The failure has taken place on account of fatigue cracking

assisted by corrosion initiated at weld and HAZ both from OD and

ID.

The prevailing marine atmosphere, the vibration stresses during

service and the surface corrosion that acted as stress

concentration site resulted as corrosion fatigue.

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RECOMMEDATIONS BY M/s TCR Advanced Engg.

Services Pvt., Ltd., Vadodara, INDIA

y Stress Analysis of pipe line both from fluid dynamics as well as

transmitted vibrations from pump.

y Quality of the painting on the pipe surface especially near welded

joint has to be improved to avoid peeling and subsequent

underneath corrosion damage.

y All other vulnerable weld joints may be evaluated with WFMPI, and

In-Situ Metallography for preventive measure.

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ACTIONS TAKEN BY OMIFCO

Engaged M/s Project & Development India Limited to carry out

the
Flexibility Analysis of the Line from the Ammonia Receiver ( V
105 ) to the Ammonia Booster Pump ( P 105 A/B ) and from the
discharge of Ammonia Booster Pump ( P 105 A/B ) to the suction
of HP Ammonia Pump ( P 101 ).
The report indicate that there is no over stressing at any point in

the pipe line and no alarming forces and moments at the restrain
points.
Also engaged M/s ELECTROWATT ENGINEERING , Muscat to carry

out similar stress Analysis.

The report also indicate that stresses are within the allowable
limits and hence, failure of welding in the piping is not due to
overstressing of piping.
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MOST PROBABLE CAUSE

y Finally, it is concluded that this failure might be
due to corrosion , material defect and internal
stresses owing to welding joint.
y The stresses may have developed on welding due to
injection of sealing compound & clamping.

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FUTURE COURSE OF ACTIONS BY OMIFCO

y To carry out WFMPI or Fluorescent Dye Penetrant Testing and in

Situ Metallography of other vulnerable weld joints for preventive

measure on available opportunity.
y Quality of painting on the pipe surface especially near welded joint

shall be shall be improved to avoid peeling and subsequent

underneath corrosion damage.

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