Failures metallurgical

S.R. Paterson, T.A. Kuntz, R.S. Moser and H. Vaillancourt, Boiler Tube Failure Metallurgical Guide, TR-102433, Electric Power Research Institute, 1993. 

When casing is being retrieved because of casing failure it is imperative to future prevention of such failures that a thorough metallurgical study be made. Every attempt should be made to retrieve the failed portion in the as-failed condition. 

Failure analysis using modern techniques such as finite element stress analysis and fracture mechanics Metallurgical and weld analysis Chemical engineering and process capability Quality assurance... 

The trainee will visit other departments in the head office to learn about the supporting facilities which are available such as non-destructive testing, metallurgical and failure analysis, hazard analysis and quality assurance. Emphasis is laid on safety, i.e. the integrity and safety of the plant in operation and on the surveyor s own personal safety. It is important that the trainee understands the techniques involved, particularly the limitations of their application. 

The Alclad alloys have been developed to overcome this shortcoming. Alclad consists of a pure aluminum layer metallurgically bonded to a core alloy. The corrosion resistance of aluminum and its alloys tends to be very sensitive to trace contamination. Very small amounts of metallic mercury, heavy-metal ions, or chloride ions can frequently cause rapid failure under conditions which otherwise would be fully acceptable. When alloy steels do not give adequate corrosion protection—particularly from sulfidic attack—steel with an aluminized surface coating can be used. 

Ruptures or Internal Vessel Explosions - An catastrophic opening of a container (i.e., tank, vessel or pipe), commonly from overpressure or metallurgical failure, resulting in the immediate release of its contents. 

Level controller allowed cold liquid to enter pipe causing metallurgical failure of 1.57 inch pipe connection to a feed drum released vapors ignited by furnace 14 Fatalities, 22,892,000 loss... 

Massive metallurgical weld failure of liquid propane tank... 

Metallurgical failure of buried pipeline that spread into process area, lack of automatic plant process El Vs. 6 Fatalities, 54,000,000 loss and resulted 30% reduction in crude oil sales until facility replaced. 

Abqaiq, Saudi Arabia, Production Facility, Explosion/Fire Metallurgical failure of pipeline 53,700,000 loss... 

Metallurgical failure of laminated reactor vessel released vapors. 

Dhaka, Bangladesh, Chemical Plant, Explosion Metallurgical failure of pipe weld 70,000,000 loss... 

Aluminum compressed air cylinder safety has been an important issue in recent years. Safety procedures regarding the use, care and maintenance of compressed air cylinders have been in placed to ensure the public safety. Many attentions have been paid especially so-called sustained-load cracking (SLC) failures. SLC is a metallurgical anomaly that occasionally develops in high-pressure cylinders made generally from aluminum alloys. 

A total of 17 pipe failures and soil samples were studied by metallurgical and analytical evaluation and the following points have been noted. 

The reactor failed without an adequate check on why (metallurgical failure). 

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