FAILURE ANALYSIS ON ELBOW TUBE IN PETRO-CHEMICAL PLANT

Hafizal Yazid, Mohd B. Harun, *Shaiful Rizam Shamsudin,

Zaiton Selamat, Shariff Sattar and Muhamad Jalil

Malaysian Institute for Nuclear Technology Research (MINT),

Bangi, 43000 Kajang, Selangor, Malaysia.

*Kolej Universiti Kejuruteraan Utara Malaysia (KUKUM)

01000 Kangar Perlis.

ABSTRACT

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

1. Introduction

Petro-chemical plant has many critical component in which any failure will lead to catastrophy. Every
component has its endurence limit once exceed will lead to the failure. Plant shut down neccissitate
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 study is to analyse
the cause of leakage in one of the elbow tube that was used for liquid chemicals transport. Fig.1 depicts
the component and the leakage area.

Fig. 1: Failed tube due to the present of hole.

The part description are given as follows:

Table 1: Part description

THEME CLASS DETAILS
Elbow pipe material A312 Gr 304
Thickness of Elbow pipe 3.0 mm
Outer diameter 3.5 in. (90mm)
Internal environment medium organic liquid, VCM
External environment medium organic waste liquid plus water
( benzene, chlorofin, EDC, VCM, trace HCL)

The approach adopted was to assess a large hole that appears close to the flange (B). The location of
the hole also close to the weldment region.

2. Experimental Procedures

The failed tube was examined through three methods of investigation namely, visual examination,
spark emission spectrometry for chemical composition and optical and scanning electron microscopy
for microstructural examination. The sample was etched by using Glyceria (10% glycerol, 50 HCl and
30%HNO3) and swabbed with cotton for 2-5 minutes.

3. Results and Discussion

3.1 Visual Examination

Fig 2:The as-received pipe where the leaking part Fig 3:The leaking part exposed after the clamp
of the tube was clamped. was removed. It was seen that the area was
covered with tar to prevent leakage.
 Fig 4: A hole was found after the tar was removed.

1. After removing clamped metal sheet and black tar materials, a large hole was observed near
the weldment area.
2. The hole was almost round in shape and few mm in diameter size.

3.2 Macroscopy

By using a stereomicroscope, macroscopic examination on the interior surface of the pipe revealed a
large hole (Fig.5) and pits (Fig. 6) at the seam weld. Pits also were observed on base metal of the
interior surface (Fig. 7). From Fig. 8, it was observed that the pitting was initiated from interior surface
of the pipe and propagated to the outer surface. Due to the long exposure of the pits to the hot
environmental liquid caused a formation of the hole. A Schematic diagram of longitudinal section of
the tube in Fig. 9 showing the position of a hole in the weld seam on interior surface of pipe .

Seam weld

Pit

Hole

Fig 5: Leaking hole in the weld seam as observed Fig 6: Pit at the weld seam on the interior surface
on interior surface of pipe. of pipe.
 Pit

Inner
Pit O’

O
Outer

Fig 7: Some pits on the base metal of interior Fig 8: Section cut parallel to seam weld and
surface. longitudinal along pipe axis (O-O’ shown in
Fig. 9), showing a pitting in the seam weld
penetrated from inner surface to outer surface.

Leaking hole H’

Weld Seam weld Weld

O O’

H
Fig 9: A Schematic diagram of longitudinal section of the tube showing the position of a hole in the
weld seam on interior surface of pipe. The parts A and B are shown in Fig. 4.
3.2 Metallography

Results of metallography examinations are as follows:

Outer
WM
WM
BM
BM

Inner

Fig. 10: Cross sectional cut H-H’ (Fig. 9) close to Fig. 11. As Fig 10, at higher magnification.
the leaking hole. A pit penetrated from interior Intergranular cracks can be seen at the end of the
surface to outer surface in the seam weld. pit.

Fig. 12: Microstructure of the HAZ close to the Fig 13: Heat-effected Zone (HAZ).
hole.

Fig 14: Optical micrograph on seam Weld shows Fig. 15: Optical micrograph on the Base Metal
a weld structure. (BM). Note the deformation bands and annealing
twins showing that material was cold-worked.
 Fig. 16: One of the pits in the seam weld.

Microstructures from microscopic examination of cut sections through H-H’ (Fig. 9) close to the
leaking hole are shown in Figs. 10-16. The combination of the pitting attack with crack was observed
between the seam weld and base metal (Fig. 11). The structure of the seam weld was significantly
different with the base metal as shown in Figs. 14 and 15. The base metal shows an austenite structure
with some twinning. Some small pits were also observed on interior surface the seam weld, and one of
them is shown as in Fig. 16.

3.3 Electron Microscopy and Microanalysis

Scanning electron micrograph on transverse cross-sectional part at a region closest to the leaking hole
was shown in Fig. 17 and 18. In Fig.18, it was clearly shown the intergranular cracks propagated at the
interface between the seam weld and base metal. The elements presented in the base metal, seam weld
and corrosion product was determined by using an energy dispersive X-ray analyzer (EDX) attached to
the SEM. The microstructure for both base metal and seam metal was different but contain the same
chemical composition as shown by EDX spectrums in Fig. 19 and 20. The base metal and seam metal
consist of Fe, Cr and Ni as a major element. The corrosion in the leaking hole is shown in Fig. 21. The
corrosion product in the hole contains chloride and oxygen elements (Fig. 22).
Fig. 17. Electron micrograph on transverse cross-sectional part at a
region closest to the leaking hole.

Fig. 18, as Fig. 17 but at higher magnification.

Fig. 19: EDX spectrum on base metal

Fig. 20: EDX spectrum on seam Weld

Fig 21. Corrosion product in the hole/crack

Fig. 22: EDX on corrosion product

4. Conclusions

Pitting corrosion had perforated the seam weld. In the presence of chloride in the hot solution, it may
locally attack the alloy causing continuous pitting. In pitting mechanism, once the reaction started,
ferric chloride can be produced and accelerated the pitting corrosion of the seam weld in the pipe. This
happens because when the pit formed, the metal around the pit become cathodic and penetration within
the pit is rapid because the area of effective cathode is very large as compared to the anodic pit. The
pitting attack on the seam weld continuously occurred until it penetrated to outer surface which causing
the leak. In austenitic steel, corrosion resistance of heat-effected zone is reduced by the precipitation of
chromium carbide along the grain boundaries. The depletion of chromium to the grain boundaries
reduces the corrosion resistance of the matrix. In addition to the pitting corrosion of the weld itself, the
base metal which is in contact with the seam weld suffered to stress corrosion cracking driven by
residual welding stresses from weld shrinkage.

5. Recommendation

The leaking pipe should be replaced with seamless tubes of type 304L stainless steel to minimize the
areas requiring welding. The chloride content in the liquid should be controlled to minimize the pitting
corrosion.

Acknowledgement

The authors thank Dr Azali Muhamad; Materials Technology Group Manager, Dr Abd. Nassir Ibrahim;
Industrial Technology Divisional Director and other Materials Technology Group staff for supporting
this work.

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