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Case Studies - Field Failures
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Those who don't know history are destined to repeat it. -- Edmund Burke
Case Studies
Paul Sedivy Director – High Purity Products 2505 Foster Avenue P O Box 389 Janesville, WI 53547 [email protected] Direct #800-586-4762 Mobile #608-436-8200
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Widely varied problems, encountered in 25+ years
• All Tubing – No Pipe • All Stainless
• 304L & 316L • Duplex • Nickel • Titanium
• CPI & High Purity Industries
Case Studies
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Bending / Forming
Intrados
Extrados
CLR - Centerline Radius OD/T < 23 to avoid ID tooling RG can help with specifics
Case Studies
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Bending / Forming 4.000” 304/304L
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Case Studies
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Please note grooves
Case Studies
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• Grooves • Sharp stress
concentrators
• Starter Cracks
• Saw cuts
• Burrs
• High cold-work (more stainless is formed) Makes metals ‘notch brittle’
Bends / Forming
Case Studies
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Black Spots in Hygienic
Orbital Tube Welds
Its All About Cleaning
Black Spots
Case Studies
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Black Spots
Near Orbital welds
Case Studies
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Spots in 1. Seamless Tubing 2. Welded Tubing 3. Fittings From Multiple Suppliers
Black Spots
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Rarely found in bead through tube welds.
Consistently found in prepared joints with no ID cleaning.
Black Spots
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Cleaning or removal of ID
particulate just before joint
closure.
Use “Best Practices” when
making orbital welds
Black Spots
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Particulate?
a. Dust, Lint, etc.
Cleaning Cloth Residual (PET)
b. Aerosols (oils)
c. Water Spots
d. Chips (stainless)
Black Spots
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Black Spots
Case Studies
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Black Spots
Case Studies
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Black Spots
Case Studies
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Black Spots
Case Studies
Analysis: FT-IR confirmed PET plastic
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Black Spots
Clean Wipes
Caps / Plugs
Abrasives
Sleeving
Case Studies
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I. PET (Plastic) 1. Abrasives – Nylon, Silicon carbide 2. Black End Caps – Polyethylene 3. Blue End-Caps – Polyethylene 4. Sleeving – Polyethylene 5. Clean Wipes – PET
Black Spots
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Black Spots
White Clean wipes - PET
600 micron size, or 0.024”
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White Clean wipes - PET
10 micron fiber size, or 0.0004”
Black Spots
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Cotton cloth (white) Eliminates melting and adhesion Residue - Non adherent ash
Re-use of PET wipes? Not best practice.
Black Spots
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Case Studies
Solvent Cleaning IPA / water mixture can cause spotting (water).
Concentration > 90% IPA desirable. 70% IPA - Poor practice.
Black Spots
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Black Spots
Case Studies
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Contamination – Cu - LME
Liquid Metal Embrittlement
Case Studies
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Understanding Fatigue Crack – But Why?
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6-Moly used for Bruschetta production
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Understanding
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Tubing can only resist ID Pressure due to its round shape and tension in the wall – aka Hoop Stress!
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Expansion; aka Omega Loops
Δ = Change ΔT*MCLE*L = ΔL 150°F·9.2x10-6·150’ ·12 = 2.48”
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Expansion; aka Omega Loops
**Depth of loop should be twice width
Approx Expansion Capacity
(in) Width of expansion loop
Tube (in) 20 40 60 80 100
1.000 1.5 5
1.250 1 4 8
1.500 0.8 3 6
2.000 2.5 5 8
2.500 2 4 6 8.5
3.000 1.5 3 5 7.5
4.000 1.4 2.5 4.5 6
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Dark Welds
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The Secrets of Stainless Steel The Protective Layer of Oxide
Air
Cr Cr
Cr Cr Cr Cr
Metal (mostly iron)
Cr2O3
Cr2O3
Oxide
Oxide
O2 O2 O2 O2
O2 O2
O2 O2 O2 O2
O2 O2 Air
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Dark
Marginal Alloys can be significantly affected
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Dark
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Dark
What's the fix? Better Cleaning, Better shielding Measure O2 before you weld Nitric Acid paste Neutralize Rinse, rinse Dry
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Case Studies
Dark
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Case Studies
Dark
AWS D18-2 Color Code Chart ASME BPE also has a chart
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Fatigue
Compressor – high pressure, high cycles, hot
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Case Studies
Fatigue
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Case Studies
Fatigue
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Case Studies
Fatigue
To Resist Fatigue Surfaces – Polished?
Putting surfaces in compression Shot blasting Peening
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Fumes
Drying action & condensation Most common modes of uncontrolled
failures
What are concentrations? Solubility limits!
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Fumes
Drying action & condensation If you can smell bleach (sodium
hypochlorite – NaClO
It’s concentrated bleach
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Fumes
Drying Action & Condensation Preventive actions Rinse often and completely Avoid foams Great ventilation Cleaning is good
Corrosion Inhibitors
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Fumes Dirt on top Drip-lines to bottom
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Fumes
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Fumes
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MIC SRB – Sulfur Reducing Bacteria MRB – Manganese Reducing Bacteria Every MIC case in stainless has been SRB 1. Cavernous pits 2. Sulfur in the corrosion by product 3. Terraced features 4. Stagnant Conditions 5. Often well water
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MIC
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MIC
Tube had a rotten egg smell
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MIC
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MIC
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MIC
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MIC
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MIC
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1. Dissolving metal – corrosion damage (most of what we see)
2. Precipitation of metals out of solution – typically very visible (Rouging)
Corrosion-by-products a. Often oxidized
b. Sulfides
c. Chlorides
1&2 often (>90% of time) happen near each other.
Corrosion
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SRB with S
MIC
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Case Studies
Tubes within tubes Think air bubbles Think collapse from thermal fatigue Splashing up onto hot tube Will cause inner tube to Fold & Collapse
Nested Tubes
Excessive temperature Thermal fatigue - high stresses - deformation Drying action
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Case Studies
Vertical exchangers
Corrosion at top of exchanger! Cant get the last bit of air out! Hot & Cold Splashing and drying Thermal fatigue “Safe Ending” – Better alloy for last 3’
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Transverse section of intermediate tube near through wall cracking. Please note significant axial cracking from the tube ID toward the OD. Here imagine heat from OD and cooling from ID
Nested
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Case Studies
Orbital Welds
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Case Studies
Orbital
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Case Studies
Orbital
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Case Studies
Pitting
Pitting is typically cause by Chloride ions May be present as
Salts NaCl, MgCl, KCl Acids – HCl Bleach Solutions - Sodium hypochlorite – NaClO
Three things to be aware of:
1. Cl concentration 2. pH 3. Temperature
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Case Studies
Pitting Neutral water Crevices are BAD Stainless Steel likes clean
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Case Studies
Guidelines
Sports Drinks
Pasteurize then bottle => Pits & cracking What are your chloride concentrations? What is your pH? Electrolytes
NaCl, MgCl, KCl
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Case Studies
SCC – Stress Corrosion Cracking
Same Tube
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Case Studies
SCC – Stress Corrosion Cracking
Tends to occur in same environments as pitting (Chlorides), only at higher temperatures
May start as pitting, cracking may begin once
stresses are high enough
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Case Studies
SCC – Stress Corrosion Cracking
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Case Studies
SCC – Stress Corrosion Cracking
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Case Studies
SCC – Stress Corrosion Cracking
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Case Studies
SCC – Stress Corrosion Cracking
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Case Studies
SCC – Stress Corrosion Cracking
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Duplex alloys are a good value
SCC – Stress Corrosion Cracking
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Nickel Content (wt. %) Nickel Content (wt. %)
SCC – Stress Corrosion Cracking
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ASTM G36 MgCl2 Solution Boiling at 155℃ Time to Cracking (hr)
2 hr 304L or 316L
25 hr 2205 (Duplex)
150 hr 4565
500 hr 2507 (Super Duplex)
1,000 + hr - No cracking, discontinued N08367 (6XN)
E-Brite, 29-4C, 439 + Indicates no cracking
SCC – Stress Corrosion Cracking
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Case Studies
Steel Defects
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Case Studies
Guidelines
1. Stainless likes flow - 5fps or more a) Fowling means more flow is needed! b) Flow induced erosion is rare c) Faster Flow => turbulent flow => cleaning
2. Minimize stagnant time
3. Much damage can occur during
a) Upsets b) Start-ups and shutdowns
4. Avoid drying action
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Case Studies
Thank you!