By. S.

Turcott, Steel Image

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CUI #1 - STAINLESS STEEL BUFFER VESSEL SHELL

Part Type: Buffer Vessel

Service Alkaline polymer solution
80-100ºC at 2-5 bar
Material: ASME SA-240 Grade 321 stainless steel
Failure: Corrosion under insulation (CUI) from water ingress.
Caused chloride stress corrosion cracking (Cl-SCC).
Diagnosis Method: Optical microscopy and EDS analysis

CASE STUDY EXAMPLE FOR POSSIBLE BOOK

An insulated buffer vessel containing alkaline polymer solution began leaking. Removal
of the insulation and efforts to weld repair the leak sites only opened up additional,
undetected cracks within the surrounding area. The vessel comprised of ASME SA-240
Grade 321 stainless steel. It had been in service for fifteen years, located at the coastline
of the Gulf of Mexico and exposed to sea air.

Extensive branched cracks had formed above and throughout a series of stiffener rings
(Figure 1). Cracking was found predominantly on the external surface.

Optical microscopy found the shell wall, ribs and associated welds to contain a high density
of stress corrosion cracks (SCC, Figures 2 and 3). Cracking was confirmed to have
occurred from the external surface. Energy dispersive spectroscopy (EDS) analysis
confirmed the presence of chlorine (Figure 3e). Therefore, cracking had occurred by
chloride stress corrosion crack (Cl-SCC).

No quality issues with the shell material or welds were observed. The shell conformed to
the ASME SA-240 Grade 321 stainless steel requirements and no detrimental phases had
formed during welding. The corrosion cracking was not due to a quality issue.

Failure was attributed to corrosion under insulation (CUI). Chloride stress corrosion crack
(Cl-SCC) requires water to occur. Therefore, the primary cause of external cracking was
due to water/moisture ingress into the insulation. Once water was introduced, combined
with the temperature of operation, corrosion cracking had occurred. The chlorides
contributing to the cracking had likely been introduced through either the sea air or
leaching from the insulation. The support ribs help water collect/pool and are common
sites for CUI damage.

Stainless steel vessels containing extensive Cl-SCC cracking are challenging to repair and
often require replacement.

CUI #1 - Stainless Steel Buffer Vessel Shell Page 1 of 4

 By. S. Turcott, Steel Image
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Cracking occurred above and

throughout stiffener ring

a) Provided Shell Section

b) Cracks highlighted by FPI

Figure 1: Photographs displaying (a) the section of the buffer shell submitted for
analysis and (b) cracks highlighted by fluorescent penetrant inspection.
Cracking had occurred above and throughout the vessel stiffener rings.

CUI #1 - Stainless Steel Buffer Vessel Shell Page 2 of 4

 By. S. Turcott, Steel Image
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Stress Corrosion Cracking

(SCC)

a) Cross-Section #1

Stress Corrosion Cracking

(SCC)

b) Cross-Section #2
c) Section #3, weld, 5x
SCC

SCC

d) Section #3 plate, 5x

Figure 2: Photographs and macrographs displaying the cracks to exhibit classic

stress corrosion crack (SCC) morphologies. Cracking had initiated from
the external surface. As well as within the shell, cracks radiated through
the weld and stiffener ring.

CUI #1 - Stainless Steel Buffer Vessel Shell Page 3 of 4

 By. S. Turcott, Steel Image
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OD Surface

a) B-3200, Loc #1 b) Cross-section, 5x

OD Surface

Cl-SCC cracks propagating

from OD surface
(requires fluid/water and
chlorides on OD surface)
c) Adj Fracture, ~40x

001
e) Crack Tip, EDS
10.0

O
8.0
Counts[x1.E+3]

Cr
6.0
Ni
Fe
Mn Chlorine
4.0 Mn Fe
Cr
Ni Cr
Cl Cr Mn
CFe Ca
2.0 Si Cl Ca Mn Fe Ni
Ca Ni

0.0
d) Crack Tip, 100x 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
keV
Figure 3: (a-d) Photograph and micrographs displaying the cracks to exhibit branched, transgranular
morphologies typical for chloride stress corrosion cracks (Cl-SCC). (e) EDS spectrum
displaying the presence of chlorine which confirmed cracking had occurred by Cl-SCC. Cl-
SCC requires water to occur and therefore, the failure was classified as corrosion under
insulation (CUI) from water ingress into the insulation.

CUI #1 - Stainless Steel Buffer Vessel Shell Page 4 of 4