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Unexpected High-Energy Failure of Type 304L Stainless Steel Piping in the Tail Gas System in Nitric Acid Plant Due to Intergranular Stress Corrosion Cracking (IGSCC)

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Abstract

An incident occurred at a Nitric Acid Plant when a failed 18-in. (457 mm)-diameter 304L stainless steel pipe connecting the Converter to the Tail Gas Catalytic Reactor ruptured. The rupture resulted in thrown fragments and some damage to equipment in the vicinity of the pipe. Normally, pipe operating conditions are about 80 psig (0.55 MPa) and 850–900 °F (454–482 °C), and the nominal thickness of the pipe was 0.180-in. (0.46 mm). This article summarizes the discovery of a very unusual condition of intergranular stress corrosion cracking due to sensitization of the low-carbon stainless steel used in manufacture of the pipe. The lessons learned from this failure investigation are vital to those who use stainless steel in Tail Gas systems.

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Authors and Affiliations

  1. Baker Engineering and Risk Consultants, Inc. (BakerRisk®), 3330 Oakwell Court, Suite 100, San Antonio, TX, 78218, USA

    Daniel J. Benac, Nicholas Cherolis & Mike Hester

  2. LSB Cherokee Nitrogen Plant, Cherokee, AL, USA

    Mike Hester

Authors
  1. Daniel J. Benac
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  2. Nicholas Cherolis
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  3. Mike Hester
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Correspondence to Daniel J. Benac.

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Benac, D.J., Cherolis, N. & Hester, M. Unexpected High-Energy Failure of Type 304L Stainless Steel Piping in the Tail Gas System in Nitric Acid Plant Due to Intergranular Stress Corrosion Cracking (IGSCC). J Fail. Anal. and Preven. 17, 217–227 (2017). https://doi.org/10.1007/s11668-017-0252-0

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  • DOI: https://doi.org/10.1007/s11668-017-0252-0

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