Failure analysis of weld cracking in wax oil cracking unit

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis Pub Date : 2025-02-27 DOI:10.1016/j.engfailanal.2025.109467

Hongbin Xie , Xianrui Zou , Fangfang Zhang , Xianjing Lu , Fang Zhang , Liuyi Huang , Fengping Zhong , Mao Cheng , Xuebin Wang , Jiabin Liu , Guoping Ling

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引用次数: 0

Abstract

Pressure piping systems are a crucial component in chemical plants. However, pressure piping and its accessories in chemical plants are exposed to complex service environments, and defects in piping materials and welding further increase the risk of failure. This study analyzes the cracking failure of a drain valve in a paraffin oil cracking unit of a petrochemical enterprise. The location of the crack is the weld between the guide valve and the branch pipe, which is a full-penetration butt joint, employing a welding process of GTAW for the root pass and SMAW for the cover passes. Inspection and analysis revealed that stress concentration caused by defects on the inner wall of the valve, combined with sulfide corrosion in the medium, were the reasons for crack initiation. The cracks propagated under variable loads, and porosity defects in the weld seam and heat-affected zone accelerated the crack propagation rate, ultimately leading to corrosion fatigue failure of the valve. After analyzing the failure mechanism and process, we propose improvement suggestions.

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来源期刊

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.