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WULC - 14 - 1100-C V Venugopal OMIFCO Failure Analysis of HP Ammonia Pumps Suction Line Weld Joint
WULC - 14 - 1100-C V Venugopal OMIFCO Failure Analysis of HP Ammonia Pumps Suction Line Weld Joint
OOC
KRIBHCO -
IFFCO
PROCESS UNITS
(i)
(ii)
11,90,000 MT/year
Urea
16,52,000 MT/year
Plant
Capacity
Licensor
Ammonia*
2 x 1750 MTPD
Urea**
2 x 2530 MTPD
M/s Snamprogetti
For CO2 removal system, the process licensor : M/s Giammarco Vetrocoke
** For Urea granulation, the process licensor : M/s Hydro Fertiliser Technology
FAILURE ANALYSIS
COMMON
OF
JOINT
joint
from
at
its
Investigation by
TCR Advanced Engineering Services Pvt. Ltd., Vadodara, INDIA
Visual
Examination
Chemical Analysis
Tensile Test
Impact Test
Hardness Test
Visual Examination
y
OMIFCO - Oman
10
11
12
surface.
13
deposits.
mode.
14
15
y Secondary Transverse
16
CHEMICAL ANALYSIS
17
18
19
20
% age
Oxygen
37.22
Sodium
1.31
Magnesium
0.87
Silicon
0.93
Chlorine
1.07
Calcium
0.87
Iron
57.74
21
MICROSTRUCTURE EXAMINATION
( METALLOGRAPHY )
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23
25
TENSILE TEST
Tensile Test results meet the requirements of ASTM A 333 Gr.6
Gr.6.
26
HARDNESS TEST
General hardness was measured at different locations.
Gr.6.
27
normal trend.
Values at OD and ID are little on higher side as slight cold deformation
is given during pipe making.
The lower values at crack tip and fracture surface indicate that the
welded joint had slight inherent stresses which were relieved after the
fracture.
Location I D
Origin of Crack
At Crack Tip
At Fracture Surface
OD
Core
ID
29
SUMMARY
30
y
y
y
y
y
y
y
y
31
32
33
CONCLUSIONS
34
y
y
y
y
Visual Examination clearly indicates that the fracture has taken place in
transverse direction perpendicular to the pipe axis.
The failure has taken place both from weld and HAZ.
From Visual and Low Magnification Examination multiple origin of the
cracks all over the circumference starting from both OD as well as ID.
The pipe is exposed to the sea water atmosphere and the paint had
peeled off at some places near welding and corrosion has taken place.
Both SEM Analysis and Optical Metallography confirm that the failure is on
account of high cycle fatigue assisted by corrosion.
The cracking has taken place in the weld and HAZ zone as seen in WFMPI
and Optical Metallography. All the cracks are filled with corrosion
products. Even the secondary cracks seen on the fracture surface were
having corrosion fatigue nature.
35
Pipe has been supported especially at elbow joint where the change in
the direction of the Liquid Ammonia takes place. Pipe line connecting
the pump, hence some vibrations induced on it. In this case the vibration
stresses induced appear more severe in nature.
The surface corrosion in form of tiny pits has provided favorable sites for
stress concentration to take place both from OD and ID.
The humid salty marine atmosphere provided the climate for corrosion to
take place.
The prevailing vibrations on the pipe line induced the fluctuating
stresses.
Thus, naturally the most vulnerable site for corrosion fatigue damage to
take place is weld and HAZ
y
y
y
36
CAUSE OF FAILURE
37
y All other vulnerable weld joints may be evaluated with WFMPI, and
38
the
Flexibility Analysis of the Line from the Ammonia Receiver ( V
105 ) to the Ammonia Booster Pump ( P 105 A/B ) and from the
discharge of Ammonia Booster Pump ( P 105 A/B ) to the suction
of HP Ammonia Pump ( P 101 ).
The report indicate that there is no over stressing at any point in
the pipe line and no alarming forces and moments at the restrain
points.
Also engaged M/s ELECTROWATT ENGINEERING , Muscat to carry
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