Documente Academic
Documente Profesional
Documente Cultură
(2014) 14:303–306
DOI 10.1007/s11668-014-9813-7
CASE HISTORY—PEER-REVIEWED
Abstract The root cause of corrosion of a pump impeller in failures, it is important to select proper materials that are
a cooling water system is investigated. The impeller material appropriate for operating parameters, system concerns, and
was made of ductile cast iron. The pump failure was extended pump life. To avoid future failures, root cause
encountered after eight months of operation. A detailed visual analysis is performed to uncover problems leading up to
examination, microstructure examination, and water analysis equipment failure [5–9]. In the present investigation, the
were carried out to ascertain the probable cause of failure. pump impeller in a PVC manufacturing plant failed after
Finally, the obtained results infer that the solid-particle con- 8 months in service. Finding root cause of this premature
taining fluid flow was responsible for erosion–corrosion in the failure was urgently required to avoid further financial and
impeller failure. production loss. The failed impeller body was a ductile cast
iron ASTM A536 grade 65-45-12 material. This impeller was
Keywords Erosion–corrosion Pump impeller used to pump cooling water at a peripheral speed rate of 150
Cast iron Ductile iron Failure fps.
Centrifugal pumps are used in various industrial applications To investigate the cause of material degradation, sections
such as coolant recirculation, condensate transport, drainage, were selected to verify the micro- and macro-structure of the
and boiler feed applications. The most important components impeller, the chemical composition, and the hardness value.
of centrifugal pumps are the impeller, casing, pump shaft, and The sections were taken judiciously from various locations
bearing. The basic working principle of the centrifugal pump throughout the impeller body, including the areas of thinning
is that the impeller rotates, which in turn creates pressure at the at the pumping chamber and the impeller blades. The mac-
inlet of the impeller, and this pressure helps in sucking fluid roscopic examination of the sections from the failed impeller
surrounding it. The fluid is pushed radially along the impeller areas was performed visually at low magnification with the
to the casing, and thereafter, the casing collects the fluid and it aid of a stereo microscope to determine if patterns could be
is pumped out through a discharge nozzle [1, 2]. A significant recognized indicating the metal loss mechanism. The deposit
percentage of pump failures in process industries is due to was removed from the corroded surface using a glass bead
high flow velocities and sand particles trapped in the system, blasting method to examine the surface underneath it. A
along with a corrosive environment causing combined ero- chemical analysis was carried out on the impeller material to
sion–corrosion failure [3, 4]. To avoid premature pump verify that the material chemistry meets the appropriate
specification. An examination of the chemical composition of
corrosion products on the failed impeller surface was per-
P. Sharma (&)
formed using an energy dispersive X-ray (EDX) system
Research & Development, Buckman, 1256 N McLean Blvd,
Memphis, TN 38108, USA attached with a scanning electron microscope (SEM). Small
e-mail: pankaj26may@gmail.com; psharma@buckman.com specimens were cut and prepared for metallographic
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304 J Fail. Anal. and Preven. (2014) 14:303–306
Visual Examination
Fig. 3 Macrograph of the failed impeller showing (a) deposits, and
(b) pits after removing the deposits
The damaged impeller was visually examined. All the
observations made in this investigation suggest that the
cause of damage to the impeller was mainly attributed to examinations were performed using stereo microscope to
the erosion–corrosion of the impeller. The photographs obtain a closer view of the corroded features. The corroded
(Figs. 1a, b, 2) show that the material locally was worn area shows an orange-color compound, possibly rust,
away entirely from the impellor blade surface. Macro which might have formed after the impeller was exposed to
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304 J Fail. Anal. and Preven. (2014) 14:303–306
Visual Examination
Fig. 3 Macrograph of the failed impeller showing (a) deposits, and
(b) pits after removing the deposits
The damaged impeller was visually examined. All the
observations made in this investigation suggest that the
cause of damage to the impeller was mainly attributed to examinations were performed using stereo microscope to
the erosion–corrosion of the impeller. The photographs obtain a closer view of the corroded features. The corroded
(Figs. 1a, b, 2) show that the material locally was worn area shows an orange-color compound, possibly rust,
away entirely from the impellor blade surface. Macro which might have formed after the impeller was exposed to
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J Fail. Anal. and Preven. (2014) 14:303–306 305
air and after being separated from the system (Fig. 3a). Chemical Analysis
Inspection of the pitted area using stereo microscope shows
that the pits are horseshoe shaped. It can also be seen that A chemical analysis of the impeller was performed which
the entire impeller surface, including pumping chamber provided the results shown in Table 1. It was understood
and impeller blade, contains thinning and perforations. The from the chemical composition that the material was duc-
corroded areas showed a pattern of localized attack and tile cast iron. The results confirm that the composition of
deep grooves with directional features. The macroscopic
examination revealed an erosion pattern after sandblasting
the deposit from the interior surface as seen in Fig. 3b.
Microstructural Examination
Hardness Results
The hardness tests were carried out on the cross section of the
sample at different distances from the failure. The Brinell
hardness value of the impeller material ranged from 164 to
172 BHN. The hardness tests indicate mechanical properties
are consistent with the properties of the impeller [8].
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306 J Fail. Anal. and Preven. (2014) 14:303–306
Table 1 Chemical composition of the impeller material obtained from EDS analysis
Composition, wt.%
Element C Si Mn P Fe
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