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Failure Analysis of Cracked Reducer Flange

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Abstract

A cracked reducer flange was analyzed for the cause of the failure. The flange was carefully cut to obtain samples for metallographic, X-ray, and scanning electron microscopy (SEM) Examinations. The examinations revealed that the introduction of chloride ions in the operational service led to pitting corrosion in the inner surface of the flange. Chloride ion inclusions were probably the result of chemical contaminations, i.e., cleaning chemicals’ contamination during shutdown of the operation. The introduction of corrosion pits caused unexpected load stress intensification and cracking of the flange. Consequently, stress corrosion cracking emanated from the pits under the influence of chloride attack and operational pressure. Then the cracks propagated in a transgranular manner, in the radial direction of the flange, until the final failure occurred.

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Authors and Affiliations

  1. Materials Science Lab, Department of Advanced Systems, KISR, P.O. Box 24885, 13109, Safat, Kuwait

    Khaled Habib

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  1. Khaled Habib
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Correspondence to Khaled Habib.

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Habib, K. Failure Analysis of Cracked Reducer Flange. J Fail. Anal. and Preven. 10, 480–485 (2010). https://doi.org/10.1007/s11668-010-9389-9

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  • DOI: https://doi.org/10.1007/s11668-010-9389-9

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