Divine Metallurgical US rape Services Pvt. Lt gy 04 a1 " Metals & Alloys Testing Lab cnt @avecaoy con NABL & ISOAIEG 17025-2017 Accredited on’ uremorarcmsce utr 1c509820000070017F Page tof 1 Report No. + DMSPL-20-025362-3 Date ofssue 09-12-2020 customer. M/s. Anand Seamless Tubes Pvt td, Plot No.129/A AnkholPatiya,Chhatral-Kadi Road, Mehsana Received On 05-12-2020 Description. Precess:Cold Draw Process (Failed Sample) Drawn By Party Nature of Sample Final Material Size:25 4omm OD X3.048mm Thk(U- Tubes) Raw Material Size48.3mm OD X5.08mm Thk Specification ASTM A213/213M:2019 Grade 22 ‘Test Name : MICROSTRUCTURE EXAMINATION __Test Method : ASTM £3:11(RA2017) and ASTM £407:07(2015}e1 Test Parameters Results Observation “Microstructure shows partial decarburization region at both the edges of the tube. Microstructure also shows that the grains near to inner ledge ofthe tube are coarser than the core regeion grains Observation at 100 x & 200 x Magnification. E Vilela's Reagent a Note : Image 1 & 2 are takeryat 100 X & image 3is taken at 200 X E sf —————End of Report Tested By \¢ red Signatory Condi Reporting = 4. Sample must be drawn bythe party. The result relate only to the sample submited by the party 2. Any Bart or prt of the Test Report shall not be repreduced, for ths the writen request fo OL is mandatory forthe Customer. 3. Samples are store fr fiteen days from the date of receipt.ate Valttag Divine Metallurgical Cena nner Services Pvt. Ltd. 2 0 " ISO / TEC 17025 : 2017 ‘ULR -71¢509820000070062F Page 1 of 1 Report No. : DMSPL-20-025755-0 Date of Issue : 09-12-2020 Customer, IM/s. Anand Seamless Tubes Put. Ltd Plot No.129/A,Ankhol Patiya,Chhatral-Kadi Road, Mehsana. Received On 08-12-2020 Description, Precess:Cold Draw Proceés (OK Sample) Drawn By Party Nature of Sample Final Material Size:25.40mm OD X 3.048mm Tak(U- Tubes) Raw Material Size:48.3mm OD X 5.08mm Thk Specification ASTM A213/213M:2019 Gragle T22 ‘Test Name : CHEMICAL ANALYSIS Test Method : ASTM £415:2017 _ Requirement % Carbon 0.050-0.15 5% Silicon 0.50 max. ‘% Sulphur (0.025 max. 5% Phosphorus 0.025 max. % Manganese 0.30-0.60, 4% Nickel % Chromium 1,902.60 % Molybdenum 1.026 087-113 Remark: The Result meets the Requirement Tested By Ws Condition of Reporting : 1. Sample must be crawn by the party. The recut relate only to the samole submitted by the party. 2: Saycarter pelle of Ges Tork Rasen Gal tot We reeeena Ie eeDivine Metallurgical oo ervices Pvt. Lt 1% sar rzzgan21 732200108, , star 8 Sei np drticon NABL & ISOAEC 17025-2017 Accredited. on” urements LR -Tc509820000070046F Page 1of 1 Report No. + DMSPL-20-025755-2 Date of Issue : 09-12-2020 Customer. (M/s. Anand Seamless Tubes Pvt.Ltd. Plot No.129/A,Ankhol Patiya,Chhatral-Kadi Road, Mehsana. Received On (08-12-2020 Description Precess:Cold Draw Process (OK Sample) Drawn By : Party Nature of Sample Final Material Size:25.40mm OD X 3.048mm Thk(U- Tubes),Raw Material Size:48,3mm OD X .08mm Thk Specification ASTM A213/213M:2019 Grade T22 Test Name : Hardness Test Test Method : ASTM €384:2017 Equipment :FIE VICKERS HARDNESS TESTER (DMSPL/07/09) Cal. Dt: 30-1un-2020 Sample Hardness in BHN®. ‘Average I/Locaton [346 a7 146 146.33 Requirement | 163-BHN Max nark: The Result meets the Requirement of ASTM A213/213M:2019 Grade T22_ Note : *VPN Converted into BHN End of Report esq __ Tested By Condition of Reporting 1. Somple must be drawn by the party. The result relate only to the sample submited by the party. 2. Any part or parts ofthe Test Report shall not be reprosuced, forth, the writer request to DLS Ks mandatory forthe Customer: Somesiciien aoe chalk tay Wada dane tase aaa ceCol al st, Vale Divine Metallurgi eee Services Pvt. Lt sat raza ago, 1792 v0 , 3 sia, pdr con, Metals & Alloys Testing Lab sezanseavoeatras con Tose | NABL& ISO-IEG 17025-2017 Accredited oN. urexsaeroisKs al 8 ‘ULR -1509820000070009F Page 1 of 1 Report No. + DMSPL-20-025755.3, Date of Issue : 09-12-2020 ‘Customer. M/s. Anand Seamless Tubes Pvt. Ltd. Plot No.129/A,Ankhol Patiya,Chhatral-Kadi Road, Mehsana. Received On (08-12-2020 Description = Precess:Cold Draw Process (OK Sample) Drawn By Party Nature of Sample Final Material Size:25.40mm OD X 3.048mm THk(U- Tubes), Raw Material ize:48.3mm OD X 5.08mm Thk Specification 2 ASTM A213/213M:2019 Grade T22 ‘Test Name : MICROSTRUCTURE EXAMINATION ‘Test Method : ASTM £407:07(2015)e1 and ASTM E3:11(RA2017) Equipment : OLYMPUS METALLURGICAL MICROSCOPE Gx41 (DMSPL/09/01) Observation Microstructure shows ferrtic grains Observation a 100% & 00x Etchant. 2%6Nital . Tira "Note : Image 1s taken at 100 X & Image 2 is takenat 500 X magnification. m End of Report—————- Tested By | Condition of Reporting : 1. Sample must be drawn by the part. The result relate only to the sample submited by the party 2. Any part or parts ofthe Test Report shall not be reproduced, forth, the writen request to OLS is mandatory forthe Customer 3.Sampes are store for Fiten days from the date of recepDivine Metallur; cal " Services Pvt. Lt 1807 TBC 170252017 REPORT ON FAILURE ANALYSIS OF TUBE 25.40MM OD X 3.048 MM THK X 4500MM LEG LENGTH-(U TUBES)-SA- 213 GRADE T22 NAME: ANAND SEAMLESS TUBES PVT.LTD. CHHATRAL.Divine Metallurgical i" Services Pvt. Lt 1S0/ TEC 17025: 2017 Contents © 4 Gopal tual ste, valor BRS. sin, ms 3245 8173 289 9179200 107, sa1ae2re aes BS sven preteen sexnseutrsey em (ON ursmecrerromes Sr.No, PARTICULARS "AGENO. INTRODUCTION _ DETAILS OF COMPONENT METHODOLOGY ADOPTED [40 ‘ANALYSIS OF COMPONENT 4.1 VISUAL EXAMINATION 4.2 CHEMICAL COMPOSITION ANALYSIS 4.3 METALLOGRAPHIC EXAMINATION 4.4 HARDNESS MEASUREMENT {TECHNICAL BSCUSSION | CONCLUSION. RECOMMANDATIONS 80) [ENCLOSURES (TEST REPORTS)Divine Metallurgical ° Ses bomen " Services Pvt. Lt 1 ss raze ar a0 109, Sian 5 sire pst cn Accredited by NABL_ _accourts@divinelaboratory com ISO/IEC 17025 2017 on” vremaorrenses 1.0 INTRODUCTION : 4 M/S ANAND SEAMLESS TUBES PVT.LTD. CHHATRAL had requested vide email dated 02/12/2020 ‘to DMSPL to carry out root cause analysis of failure of tube sample supplied to their client M/S L & T: HED. The failure come to notice after material supplied to client& before taken to use in service. It was a premature failure of low alloy seamless tubes. They wanted DMSPL to study the case of the failure from following point of view: 1) to find out the root cause of failure 2) to suggest remedial measures to be taken to avoid similar failures in future The case of failure was investigated considering, 1) the input data provided by M/S ANAND SEAMLESS TUBES PVT.LTD. CHHATRAL 2) the failed samples submitted at DMSPL along with good quality sample from same batch to help in comparing test result This report contains the finding of the failure. DETAILS OF THE COMPONENT: ‘Tube size: 25.40mm OD X 3.040 mm Thickness X4500 mm leg length (U Tubes). Specification:SA213 GRADE T22 These U-tubes were manufactured by a cold drawing process and proper heat treatment and supplied after due inspection almost 2 months ago. However, earlier last week when the client (L&T HED) opened the boxes for insertion of these tubes into the equipment they ‘observed small cracks on the ends of the tube. (Picture is attached for reference at below) CLIENT: M/S LBVT -HED, P.O.No. 041011953/VINOD PATIL DATED 21/01/2020 FOR Qty $06 Nos. Material drawn in three cycle with heat treatment from raw material of size 48.3mm O.D. x 5.08 mm Thk. 1st Draw:42.20mm 0.0 xX 3.56 mm Thk: 37.34% Reduction 2nd Draw:33.40mm O.D X 3.30 mm Thk: 27.78% Reduction 3rd Draw:25.400mm 0.0 X 3.10 mm Thk: 30.40% Reduction, Heat Treatment cycle Followed: Normalising 900°C & Tempering 800°CDivine Metallurgical ern Services Pvt. Ltd. 1 cot rzeo et 79200 03, ‘ai ozzrezons 1 ice orestalcam, & Accredited by NABL euntsBavelorioy cm ISO / IEC 17025 : 2017 ON rower Photo of Failed Tube as intimated by customer.Divine Metallurgical 9 horeetmeness " Services Pvt. Ltd. 1 sarrzanzo. 179201003 inwzames 1 Gee, sprain, Accredited by NABL zoster ISO / TEC 17025 : 2017 Cn remo ereT 2.0 METHODOLOGY ADOPTED The failure was investigated based on the common principles of analysis of failure of a metal component, Viz- 1) Testing and Measurement of sample: 4) Visual examination of failed component: ) Chemical composition analysis of the failed components as well as good component ) Metallo graphy examination. 4) Hardness Measurement of tube 2) Compilation and Analysis of the Data. 3) Formulation of Conclusion. 4) Recommendations. 2.1 VISUAL EXAMINATION. The Visual examination of the failed component shows longitudinal crack with zigzag pattern and branching.Divine Metallurgical ° SS own sera Services Pvt. Lt 91732249291 792280103, ‘sien 3 dren. moet ‘Accredited by NABL Scaredonmeteesy an ISO/IEC 17025 : 2017 cn remateerees 2.1 CHEMICAL COMPOSITION ANALYSIS ‘The chemical composition analysis of the component was carried out to know the material used is as per specification. Test Report no. 20-025362-0 dated 05/12/2020 sample taken from failed ‘component shows Material found to be confirmed to required specification-ASTM A 213 GRADE 122. Test report No. 20-025755-0 dated 09/12/2020 sample from good quality tube shows ‘material confirmed to the required specification. No any Significant difference noticed in chemical composition as compared to failed with good quality sample. 2.2 METALLOGRAPHIC EXAMINATION. |A) The Metallographic examination of the component were carried out to know the ‘microstructure phases present. / formation of detrimental phases during manufacturing process /service use. Test report no. 20-025755-3 dated 09/12/2020 for good sample shows ferrtic grains& Test report No. 20-025362-2 dated 09/12/2020 shows polygonal ferritic grains with the presence of some dark, globular/elliptical micro voids at grain boundary and in grain scatter globular alloy carbide- may be due to spheroidization. ‘500 X (Failed Component)Divine Metallurgical ° S.23,r09 cee Services Pvt. LU sar rmzzan ago 0172200109, " zr 3 3 wre spsrestnal on Metals & Alloys Tes Sezspwoeatra oon NABL & ISO-IEG 17 a ON uretuscerotats '500 x (Failed Component) 1100 X (Failed Component) 8) The Micro structure of component shows that component have been exposed to higher temperature for longer time. As such, globular carbide& voids has been formed which is detrimental to the component. 2.3 HARDNESS MEASUREMENT. The Hardness measurement were carried out at failure and away from failure on the sample to check the heat treatment condition/presence of detrimental phases ‘The test report no. 20-025362-1 DATED 05/12/2020.Mardness values found to be satisfactory and within range. However, hardness value at decarburisation and near crack region found( 130 BHN) to be lower than bulk hardness of 163 BHN (AVE) which shows softening has been occurred in the local area of component Test report No. 20-25755-2 dated09/12/2020 shows hardness value 146.33BHNDivine Metallurgical ee ee " Services Pvt. Ltd. A strona av T2910 inane PE sie = shoomaen 180 /IEC 17025 :2017 cw wremacorarenoce 5. TECHNICAL DISCUSSION: The failure of the component may be attributed to the following factors. Fallure due to discrepancy in composition can be ruled out & not contributing in our To summarize, the failure mechanism includes Presence of voids, the spheroidization of alloy carbides, and the coarsening of precipitate along grain boundary. There is also loss of angularity and creep void formation along the grain boundary leading to inter-granular cracking. A few globular/elliptical/near-globular diffused shaded islands of variable size can also be found. These are perhaps globular carbide present due to spheroidization under high-temperature exposure. ‘The presence of dark voids leads to void coalescence along the grain boundary, resulting in crack formation. The region close to microcrack also revealed that interconnected voids that were generated during/ after manufacturing process. These voids area signature of creep damage developing at elevated temperature. 6. CONCLUSION: ‘The Test Results of all metallurgical parameters, Hardness parameters, Surface Examination and its analysis Indicates that the failure of the tube is attributed to void formation, de-carburisation, & carbide formation at grain boundary phenomenon which has rendered material failure. 7.RECOMMENDATIONS : = It is recommended that care should be taken to avoid formation of voids, globular alloy carbide & de-carburization due to overheat exposure during ‘manufacturing processing including quality of raw material = Raw material and final product inspections should be carried out meticulously avoiding any human error (UT,VDI,DP,ECT) INVESTIGATED BY : V.H.KAKANI AND TEAM OF DMSPL SegerDivine Metallurgical ° iaetire emaaa Services Pvt. Lt Ss 917928920401 79728010 ea Accredited by NABL sanOananrenycos 180 / TEC 17025 2017 on’ vexceoarrsoe utr -1¢509820000069376F Page 1 of Report No. DMsPt-20-025362-0 Date of ssue: 05-12-2020 customer M/s. Anand Seamless Tubes Pt td Plot No.129/A,AnkholPatya,Chhatral-Kadi Road, Mehsana Received On 05-12-2020 Description Precess:Cold Draw Process Drawn By Party Nature of sample Final Matera iz:25.4omm OD X3,048mm Thk(U- Tubes) Raw Material Size:48. 3mm OD X S.08mm Thk Speciation ASTM A213/213M:2019 Grade 22 Test Name : CHEMICAL ANALYSIS Test Method : ASTM £415:2017 Result Requirement % Carbon 0.10 0.050-0.15 % Silicon 033 (0.50 max. Sulphur 0.005 . 0.025 max, 9% Phosphorus 010 0.025 max. % Manganese 02 0.30-0.60, % Nickel 0.024 % Chromium 23, 1.90-2.60 % Molybdenum 1.020 0.87.1.13 ‘Remark: The Result meets the Requirement of ASTM A213/213M:2019 Grade T22 End of Report————- Tested By C— Condition of Reporting : 5 Sample mus be ran By he party. The result reat nyt the sample subted y the pay. 2: Any part or parts ofthe Test Report shall not be reproduced, for this, the written request to DLs mandatory for the Customer.Divine Metallurgical 9 ASteetieeeeetenss Services Pvt. Ltd. 91782208 9179220100, " inueesom NABL & ISO-IEC 17025-2017 Accredited oh -uransraercrts uur -1¢509820000069237F Page Lof Report No. 5 OMSPL-20-025362-1 Date of sue : 05-12-2020 Customer. IM/s. Anand Seamless Tubes Pvt. td. Plot No.129/A,Ankhol Patiya,Chhatal-Kad Road, Mehsana Received On 05-122020 Description. 1 Precess:Cold Draw Process Drawn By Party Nature of Sample: Final Material Size:25 40mm OD X 3.088mm Thk(U- Tubes) Raw Material Size:48, 3mm OD X5,08mm Thk Specification ASTM A213/213M:2019 Grade T22 ‘Test Name : Hardness Test Test Method : ASTM €384:2017 Equipment : FIE VICKERS HARDNESS TESTER (DMSPL/07/09) Cal. Ot: 30-Jun-2020. [Sample Hardness in BHN® ‘Average 10/tocaton = | 163 162 168 162.67 Requirement | 163-BHN Max ‘Remark: The Result meets the Requirement of ASTM A213/213M:2019 Grade T22_ ‘Note : *VPN Converted into BHN Tested By aa ~-nEnd of Report: Condition of Reporting : sample must be dawn by the party, The result relate only to the sample submitted by the party. 2 Any Bort or ports ofthe Test Report shal not be reproduced, or tis the written request to DLS is mandatory for the Custome! oe sates deine ter eens dah let dena aDivine Metallurgical 9 ei hows 2 Services Pvt. Lt SS ssrmznr , " ‘saz 1 ovenin, reorstnaon Metals & AHloys Testing ‘Scareadvreeay on NABI & ISO-IEC 17025-2017 Accredited on ursvarcwrs ‘LR -7€509820000070008F Page 1 of 1 Report No. + DMSPL.20-025362-2 Date of lssue : 09-12-2020 Customer, (M/s. Anand Seamless Tubes Pvt. Ltd. Plot No.129/A,Ankhol Patiya,Chhatral-Kadi Road, Mehsana. Received On 05-12-2020 Description Precess:Cold Draw Process (Failed Sample) Drawn By Party Nature of Sample Final Material Size:25.40mm OD X 3.048mm Thk(U- Tubes) Raw Material Size:48.3mm OD X 5.08mm Thk Specification ASTM A213/213M:2019 Grade T22 ‘Test Name : MICROSTRUCTURE EXAMINATION ‘Test Method : ASTM €407:07(2015)e1 and ASTM €3:11(RA2017) Equipment : OLYMPUS METALLURGICAL MICROSCOPE GX41 (DMSPL/09/01)_ Test Parameters Observation. “Microstructure shows polygonal feritic grains withthe presence of some dark, globular/eliptcal micro voids. Observation at 100 X & 500 X Etchant. ae ntal c “Note : Image tis taken at 100 X & image 2 is taken at S00 X magnification. End of Report————— vend" | Condition of Reporting : 1. Semple must be drawn by the party. The result relate only to the sample submitted by the party 2: Any part or parts ofthe Test Report shallot be reproduced, for ths, the writen request f0 BUS is mandatory forthe Customer, 3. samples are store for fiten days from the date of receipt