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FAILURE ANALYSIS OF WELDED STEAM BOILER FLANGE

Conference Paper · November 2015

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 3rd International Conference in Africa and Asia on Welding and Failure Analysis of Engineering Materials,
2-5 November, 2015, Luxor, Egypt

FAILURE ANALYSIS OF WELDED STEAM BOILER FLANGE

Hamed ABDEL-ALEEM, Saad KHODIR, M. NEWISHY

Central Metallurgical R&D Institute, Manufacturing Technology Dept., Helwan, Egypt.

E-mail:hamedaa@gmail.com

ABSTRACT

Steam boiler flange made of carbon steel alloy ASTM A105 was failed at area adjacent
to the welding zone when the operating pressure and temperature suddenly increased over than
designed ones. The failure occurred after 6 years in service. The flange and connected
pipe failed segments was received for failure analysis and data collections. The flange
was subjected to visual examination, non-destructive test, chemical analysis,
microstructure observation, and hardness test. The results of chemical composition
showed the conformity of flange material with the required specifications of ASTM
A105, typically microstructure, hardness values with no abnormalities or creep
indications. Also, the absence of cracks close to the ruptured area is excluding the
possibilities of defective materials or overheating. Macro and micro-structures
examination of the weld joint showed numerous welding defects such as porosity,
lack of fusion and non-metallic inclusion at the boundary line between the root and
filling passes. Apparently the steam boiler flange material fractured due to fatigue
crack. Fine striations within the beach mark of the fractured surface observed by
SEM give a strong indication of fatigue failure. The crack initiated at the edges of
welding defects and proceeded in the flange material due to the fluctuating radial
stresses resulted from increasing and decreasing working pressure during service. A
proper welding techniques carried out by qualified welders are recommended for
prevention of similar failure in the future.

Keywords: Steam boiler flange, carbon steel, welding defects, fatigue failure, proper welding technique, qualified
welders.

INTRODUCTION

Flanges and pipes material used in pressures vessels are made from carbon steel alloys [1]. The
2‫ ״‬piping that connected to the carbon steel flange of steam boiler, failed after six years of service
life when the operating pressure and temperature suddenly increased to 2400psi and 350 0C,
respectively. The normal operating pressure and temperature are 1400 psi and 308 0C. The failure
took place in the flange side near the heat affected zone of weld joint connecting 2‫ ״‬pipe with the
flange. Generally, the major reasons of destruction carbon steel flanges and connected pipes are:
tension-compressions, fatigue, corrosion fatigues and creep damages [2]. The Investigation was
carried out with the aim of determining the root cause of the failure
 3rd International Conference in Africa and Asia on Welding and Failure Analysis of Engineering Materials,
2-5 November, 2015, Luxor, Egypt

EXPERIMENTAL PROCEDURE

The failed flange was subjected to visual examination, non-destructive and destructive tests.
Chemical analysis and ultrasonic thickness measurement were carried out. The chemical analysis
of the failed materials was carried out using an optical emission spectrometer [3-6].
Metallographic examination of the flange material, weld joint and connecting pipe, close to the
failed zone and far from it was carried out. Samples were cut out from the failed flange using
water cooling cutting machine, and then mounded for metallographic preparation. Macro and
microstructures investigations of the samples were carried out using metallographic methods;
mechanical grinding down to 1200 grade emery paper followed by polishing using 0.1µm
agglomerated alpha alumina suspension, rinsed and degreased with acetone, and then etched
using Nital solution for 40 s.

Hardness test was carried out for base metal (BM) of flange, weld metal (WM), and heat affected
zone (HAZ)). The hardness test was carried out in accordance with ASTM standard E92,
standard test method for Vickers hardness of metallic materials and ASTM E384, standard test
for microhardness of materials. Scanning Electron Microscope (FEI model: Quanta FEG-250)
equipped with Energy Dispersive x-ray Spectroscopy (SEM -EDS) analysis was used to examine
the fracture surface whereas EDS was used to make spot chemical analysis at dispersed points,
near and at remote distances from the failed zone and in areas where abnormal morphology in
microstructure was observed.

RESULTS

General views of the received failed flange and connected pipe are shown in Fig.1. It was notice
that the surface of fractured zone is free from deposits and /or corrosion products. Close-up
views of the failed flange are shown in Figs. 2&3. The original fracture zone initiated at the
weld toe of flange side in the area of final filling weld layer as shown in Fig. 2. The
reinforcement of final filling weld layer zone appears slightly thicker than the other remaining
weld metal. Low-magnification examination of the original fracture surfaces (Fig. 3) revealed
the presence of beach marks, indicating that the fractures had originated and propagated by
fatigue [7-10]. The fatigue region of the fracture surface was quite smooth. The remain part of
the fracture surface, corresponding to final, fast fracture, had the typical appearance of brittle
fracture, exhibiting little or no evidence of plastic deformation. No cracks were observed near or
close to ruptured areas. Also, no damage or loss in flange wall thickness (8mm) was observed.
Chemical composition of the received flange, weld metal and connected pipe are given in Table
1 showing conformity of flange material with the required specifications of ASTM A105 given in
Table 2.
3rd International Conference in Africa and Asia on Welding and Failure Analysis of Engineering Materials,
2-5 November, 2015, Luxor, Egypt

Fig. 1 As received steel flange showing the fracture surface.

Fig. 2 Close-up views of the fractured part of flange showing fracture initiation zone.
 3rd International Conference in Africa and Asia on Welding and Failure Analysis of Engineering Materials,
2-5 November, 2015, Luxor, Egypt

The inner surfaces of the axially welded joint of flange and connected pipe are shown in Fig. 4.
Non- acceptable HILO (4mm) was observed in the inner surface of the weld joint. HILO may
cause turbulence action during water or steam flows which in turn induced mechanical stresses
on the weld joint. No pits or other forms of corrosion products were detected at the inner surface
of the flange or connected pipe indicating successful water treating program.

Fig. 3 Close-up views of the fractured part of flange showing fracture initiation zone,
fatigue fracture (beach zone and final fracture surface.

Fig. 4 the internal surface of the weld connecting steel to flange showing non-accepted HILO.
3rd International Conference in Africa and Asia on Welding and Failure Analysis of Engineering Materials,
2-5 November, 2015, Luxor, Egypt
 3rd International Conference in Africa and Asia on Welding and Failure Analysis of Engineering Materials,
2-5 November, 2015, Luxor, Egypt

Fig. 5 As-polished and macrostructure of the welding cross-section showing internal flows at the
boundary line between inter-passes.
The as-polished and etched macrostructures at the cross section of weld joint near origin fatigue
fractured zone (final filling weld layer) are given in Fig. 5. It can be noticed that several welding
defects such as slag inclusion, porosity and lack of fusion were found at the boundary line
between the first and final weld passes confirming the non-soundness of the weld joint.
Microstructures of the above mentioned specimens are given in Figs. 6-7. The base metal (BM)
of the flange material has a ferrite-lamellar pearlite structure typically for alloy ASTM A105
(Fig.7 a). No sign of creep effect and no visible plastic deformation preceding fracture excluding
the possibility of overheating. The structures of the heat affected zones (HAZ) consist of pearlite-
upper bainite and tempered ferrite-pearlite structures as shown in Fig. 7 b and c, respectively.
The microstructure of base metal of connected pipe is acicular ferrite-pearlite structure (Fig. 7d).
The microstructure of the weld metal (WM) of the final layer (Fig. 7e) consists of acicular
ferrite, side plate ferrite and grain boundary ferrite. The structure of the first layer or root pass
(Fig. 7f) consists of annealed ferrite pearlite structures. Grain size of HAZ is coarser near the
fusion line and becomes finer as goes far from it.

Fig. 6 Microstructures of the cross-section of the weld joint showing internal flows.

Scanning electron microscope (SEM) examination of the original fracture surface showed
striations marks indicating that the fractures had originated and propagated by fatigue (Fig. 8).
Energy Dispersive Spectroscopy (EDS) attached to SEM was used to analysis the fracture
surface at original fatigue fracture surface (Fig. 9). The results have shown that aggressive
elements such as Cl , S, Ca, , K & Na are not present. Hardness measurements along the cross-
 3rd International Conference in Africa and Asia on Welding and Failure Analysis of Engineering Materials,
2-5 November, 2015, Luxor, Egypt

section transverse to the welding direction under a load of 9.8N for 15s loading time are given in

Table 3. Hardness values in Vickers are 180 for flange BM, 210 flange HAZ, 220 WM last layer,
195 WM first layers, 205 connected pipe BM and 220Hv for connected pipe HAZ confirming the
soundness of weld joint from creep effect.

Fig. 7 Microstructures of the weld joint showing: (a). flange base metal, (b), (c) heat affected
zone, (d) base metal of connected pipe, (e) cap pass and (f) root pass of the weld.
3rd International Conference in Africa and Asia on Welding and Failure Analysis of Engineering Materials,
2-5 November, 2015, Luxor, Egypt

Fig. 8 SEM image of the original region showing fatigue striations.

 3rd International Conference in Africa and Asia on Welding and Failure Analysis of Engineering Materials,
2-5 November, 2015, Luxor, Egypt

DESCUSIONS
The results obtained showed that material conformity to ASTM A105, typically microstructure
and hardness values with no abnormalities or creep indications, excluding the possibilities of
overheating. Absence of cracks close to the ruptured area excludes the possibility of defective
overstressed flange material. Apparently the flange fractured due to fatigue cracks that initiated
at location near or at the toe (high stress concentration area) of the weld due to presence of
welding defects. Macro and micro-structures examination (Figs. 5, 6) of the weld joint showed a
numerous welding defects at the boundary between first and last passes at the finial filling weld
layer as shown in Fig. 2. The crack initiated at the toe of the weld and proceeded in the flange
material due to the fluctuating radial stresses resulted from increasing and decreasing working
pressure during service. Energy-dispersive spectroscopy of the fracture surface revealed only
carbon, silicon, manganese, oxygen and iron. Fine striations within the beach mark areas of the
fractured flange observed by SEM give a strong indication of fatigue failure. Final fracture
occurred when the operating pressure suddenly exceeded (2400psi) ultimate tensile strength of
the flange material which has lower hardness values than the connected pipe material (Table 3).

Fig. 9 SEM and EDS analysis of the original fracture surface.

Generally, fatigue fracture is a result of repetitive fluctuating stress causing fracture well below
the yield strength of the steel flange. Factors required for fatigue fracture include a sufficiently
high tensile stress, a sufficiently large variation in applied stress, and a sufficient number of
cycles of applied stress [6, 7]. Fatigue fractures are promoted by stress concentrations areas such
as notches, welding toe, sharp corners, keyways, dents, gouges, laps, folds, flakes, and tensile
residual stresses arise from punched holes, heat treatment, welding, and so on. Visible beach
marks indicate the location of the fracture initiation site. Beach marks are produced when
 3rd International Conference in Africa and Asia on Welding and Failure Analysis of Engineering Materials,
2-5 November, 2015, Luxor, Egypt

oxidation at the crack tip propagating under an alternating stress is interrupted from time to time,
for example, working pressure varied during service. Also, visible beach marks are generated
when non-steady-state loading occurs or with rapid changes in loading, for example, boiler
turned on and shutdown.

In ductile structural materials as in this case of flange steel material, crack propagation is by
microvoids coalescence, and the crack path becomes perpendicular to the tensile axis. The
correlation between striation spacing and tensile load has been well established, where one
striation represents one fatigue load cycle. Striation spacing increases with increasing maximum
tensile loading. There was an evidence of weld defects such as lack of fusion, slag inclusion and
porosity present in the section in the weld metal near weld toes in the area of final filling weld
metal. The fatigue cracks propagated until there was insufficient cross section of the steel flange
to support the increasing working pressure (2400psi) than designed ones (1400psi). The
morphology of the fracture suggests the cracking propagated under radial tensile stresses.

CONCLUSIONS AND RECOMMENDATIONS

Based on the results obtained in this investigation, the failure of flange steel could be attributed
to fatigue failure due to improper welding operation of flange to connected pipe. Porosity, lack
of fusion and non-metallic inclusion near or at the welding toe could be the primary causes for
the crack initiation and propagation resulting in fatigue failure in the area of cap pass. It is highly
recommended to apply a proper welding procedure with the corresponding WPS, PQR and to be
carried out by qualified welders. Non destructive testing should be applied after welding.

REFRENCES
[1] Meng-bin L, Kewei G, Chaur-jeng W, Alex A V. Failure analysis of the oil transport spiral welded pipe. Eng Fail
Anal 2012; 25:169-74.
[2] T. B. William. ASM International Course 0335, Principles of Failure Analysis, Lesson 3: Ductile and Brittle
Fracture, Page 61- 63.
[3] ASTM E3 – 01 Standard Guide for Preparation of Metallographic Specimens, ASTM International, 2004.
[4] Metals Handbook; Welding and Soldering, ASM. Vol. 6 (2002).
[5] Metals Handbook; Welding and their Weldability. AWS Vol. 4 (1982).
[6] Metals Handbook; Failure Analysis and Prevention, ASM. Vol. 11(2002).
[7] Davis, J.R. (1998), Principles and Procedures of Fractography in Metals Handbook, Desk Edition, 2nd Edition,
ASM International, pp 1238-1247.
[7] Rao, P. N., Manufacturing Technology, McGraw Hill Publisher.
[8] Yong Bai and Qiang Bai (2005),Subsea Pipelines and Risers, Elsevier Inc, USA.
[9] Dhooge. A. and Deleu E, Susceptibility of Brittle Fracture of Flanges in ASTM A105, Research Center of
Belgian Welding Institute (BWI).

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