Failure [Failure [to communicateto communicate] ] Analysis?Analysis?

ASM-NTX MeetingASM-NTX MeetingMichael S. Beaton, PE Michael S. Beaton, PE

18 February, 2010 18 February, 2010

FAILURES of COMMUNICATIONFAILURES of COMMUNICATION

• DESIGN / MATERIAL SELECTIONDESIGN / MATERIAL SELECTION• PURCHASINGPURCHASING• INSTALLATIONINSTALLATION• SUBSTITUTIONSUBSTITUTION• REPAIR / REWORK / REFURBISHMENTREPAIR / REWORK / REFURBISHMENT• APPLICATION / OPERATIONAPPLICATION / OPERATION

DESIGNDESIGN

• SPECIFICATIONSPECIFICATION– SUPPLEMENTARY REQUIREMENTS– A36 STEEL, IMPACT REQUIREMENTS– RETEST OTHERS, DUAL CERTIFY TO

LOWER STANDARD $ $

MATERIAL SELECTIONMATERIAL SELECTION(Purchasing)(Purchasing)

• HYDRAULIC FITTINGHYDRAULIC FITTING• Plasma cut preforms from platePlasma cut preforms from plate• Drill intersecting holes, tapDrill intersecting holes, tap• Leaks at plate midlineLeaks at plate midline $ $

– Centerline segregationCenterline segregation

Indentation number Hardness, HK 200Hardness Conversion,

ROCKWELL

1 565 C51

2 377 C38

3 312 C30

4 301 C29

5 276 C25

6 388 C39

7 220 B94

PURCHASINGPURCHASING• CASTINGSCASTINGS• HEAT TREATMENT REQUIRED (shown HEAT TREATMENT REQUIRED (shown

on drawing)on drawing)• Heat treatment was OMITTED, castings Heat treatment was OMITTED, castings

failed to meet hardness, tensile strength failed to meet hardness, tensile strength requirementsrequirements $ $

• Failure analysis resulted in redesign to Failure analysis resulted in redesign to thicken area where failures had occurredthicken area where failures had occurred

REPAIR (or lack)REPAIR (or lack)

• Heat Recovery Steam GeneratorHeat Recovery Steam Generator• Scheduled Cleaning – skipped Scheduled Cleaning – skipped $$• Copper build-up in systemCopper build-up in system

• Fouling, galvanic corrosion, tube perforationFouling, galvanic corrosion, tube perforation

SUBSTITUTIONSUBSTITUTION

• Natural Gas Processing PlantNatural Gas Processing Plant• Stainless steel and Cupronickel – same Stainless steel and Cupronickel – same

plant, same fabrication shopplant, same fabrication shop• CuNi filler used on stainless steel CuNi filler used on stainless steel $$• COPPER CONTAMINATION CRACKINGCOPPER CONTAMINATION CRACKING

• Ref. Welding Journal, Feb. 2010Ref. Welding Journal, Feb. 2010

DESIGN and INSTALLATIONDESIGN and INSTALLATION

• Welded construction, two heavy plate Welded construction, two heavy plate sections, pipe – joined by weldingsections, pipe – joined by welding

• Needed FULL penetration weldsNeeded FULL penetration welds $ $

FATIGUEFATIGUE

• Repeated or fluctuating stressRepeated or fluctuating stress• Stress below tensile strength of the Stress below tensile strength of the

materialmaterial• Progressive fracture from initiation point(s)Progressive fracture from initiation point(s)

– Often created by aggressive environment or Often created by aggressive environment or sensitizing condition (corrosion, fretting, arc sensitizing condition (corrosion, fretting, arc strikes, weld spatter, strikes, weld spatter, Lack of PenetrationLack of Penetration))

Trinity Metals LaboratoryTrinity Metals LaboratoryQUALITY PHILOSOPHYQUALITY PHILOSOPHY

• QUALITY is a fundamental business strategy for QUALITY is a fundamental business strategy for Trinity Metals Laboratory.Trinity Metals Laboratory.

• Our GOAL is to be the best provider of testing Our GOAL is to be the best provider of testing services in our market in terms of accuracy, services in our market in terms of accuracy, dependability, and value to our customers.dependability, and value to our customers.

• We are committed to providing our customers We are committed to providing our customers with consistently high quality testing services, with consistently high quality testing services, – defect free defect free – on time on time – at competitive prices.at competitive prices.