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Engineering Structural Integrity: research, development and application

FAILURE ANALYSIS ON ELBOW TUBE IN PETRO-CHEMICAL PLANT

*Hafizal Yazid, Mohd B. Harun, Zaiton Selamat, Shariff Sattar and Muhamad Jalil

The elbow tube was found to have leakage. The immediate action was to cover the leakage
region with black tar material and clamped metal sheet to protect the liquid flowing out from
the leakage. However, after long period of operation the leakage still occurs. It was dismantled
from the plant on 10 December 2005. The leakage pipe was sent to MINT Material
Laboratory for investigation on 13 Mac 2006. When the clamp metal sheet and black tar
material was removed, it was found a large hole on the tube. This paper describes the results
of investigation that was performed to determine the cause of the failure.

Keywords: Elbow tube; Leakage; Clamped metal sheet

INTRODUCTION

Plant shut down necessitates immediate repair and maintenance acitivities that cause delay in the
production process and considerable financial losses [1]. Statistical surveys revealed that 48-60%
of failures were caused by overheating and 15-20% were caused by various mode of corrosion [2].
Frequently, both mechanisms are related to one another and present to accelerate the failures. The
objective of this paper is to establish the most probable cause that lead to the failure of elbow tube.

The approach adopted was to assess the failure sample by three modes of investigation,
namely visual examination, chemical composition analysis and microstructural examination. Visual
examination is carried out to have an overall and close-up view of the failed sample. Overall view is
achieved by digital camera. Close-up examination is carried out using stereomicroscope. Chemical
composition is obtained by spark emission spectrometry. Microstructural examination is carried out
by optical and scanning electron microscope. The etchant used was Glyceria.
The details of the failed sample is given as follows:
Elbow pipe material: A312 Gr304
Thickness: 3.0mm
Outer diameter: 90mm
Internal environment medium: organic liquid, Vinyl Chloride Monomer (VCM)
External environment medium: organic waste liquid plus water (benzene, chlorofin, EDC,
VCM, trace HCL)

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 ESIA9
Engineering Structural Integrity: research, development and application
Results and Discussion

Visual Examination

FIGURE: 1 – As received pipe use clamp metal to FIGURE: 2 – Overall view shows the present of hole
avoid leakage. in between the weldment. A and B indicate
the flange position.

Pits
Seam weld Inner

Hole Outer

FIGURE: 3 – Hole between the seam weld and FIGURE: 4 – Cut section along the seam weld
base metal observed observed by stereomicroscope (2x
stereomicroscope (2x magnification). magnification).

Figure 1 and 2 show the condition of the as received pipe and the location of the hole
respectively. It is clearly shown that the hole is close to the weldment on the side of flange B.
Figure 3 shows the present of hole between the seam weld and base metal. Cut section along the
seam weld reveals the origin of the attack. Pitting attack starts from the inner side penetrating to the
outer side of the pipe. This is the evidence that shows problem initially occur in the inner side of the
pipe which contains organic liquid, Vinyl Chloride Monomer (VCM).

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*E-mail address: hafizal@mint.gov.my, Mailing address: Nuclear Malaysia, Bangi, 43000 Kajang, Selangor,
Malaysia. Tel: 603-89250510 Fax: 603-89250907
 ESIA9
Engineering Structural Integrity: research, development and application
Microstructural Examination by optical and scanning electron microscope

Intergranular cracks

Weld Metal

Base
Metal

FIGURE: 5 - Intergranular cracks can be seen at the FIGURE: 6 – Microstructure of HAZ near the pit.
end of the pit.

FIGURE: 7 – Microstructure of seam weld. FIGURE: 8 – Microstructure of base metal. Present of

deformation bands and annealing twins.

Intergranular cracks

FIGURE: 9 – Another spot of intergranular cracks. FIGURE: 10 – Corrosion product in the pit.
Figure 5 shows the present of pit in between the weld metal and base metal. Intergranular
cracks were found at the end of the pit. Combination of pitting attack with crack is clearly observed.
Figures 6, 7 and 8 show the microstructure of heat affected zone (HAZ), seam weld and base metal
respectively. Base metal shows austenite structure with some twinning. Present of deformation

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 ESIA9
Engineering Structural Integrity: research, development and application
bands and annealing twins in the base metal indicates that the material was cold worked. Figure 9
shows another spot of intergranular cracks at higher magnification observed by scanning electron
microscope. Typical corrosion product found in the pit is shown in Figure 10.

Microanalysis Examination by EDX

FIGURE: 11 – EDX spectrum on base metal FIGURE: 12 – EDX spectrum on seam weld

Even the microstructure of base metal

and seam weld is different, the chemical
composition of both are the same as shown
by Figure 11 and 12. Both contain Fe, Cr
and Ni as major element. Microanalysis of
corrosion product proves the present of
chloride and oxygen element as shown in
Figure 13.

Conclusions

Pitting corrosion attack the seam weld

from the inside of the pipe. In addition to
FIGURE: 13 – EDX spectrum on corrosion product that, base metal which is in contact with the
seam weld suffered stress corrosion cracking
that probably be driven by residual welding stresses. It is recommended to replace the pipe with
seamless pipe type 304L stainless steel and to control the chloride content in the medium to avoid
pitting.

REFERENCE LIST

(1) ASM, Case histories in failure analysis, Metals Park (OH): ASM Pub., 1979.
(2) ASM, Failure analysis and prevention, Metals Handbook, 9th ed., vol. 11, Metals Park
(OH): ASM Pub.,1988.

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