Failure analysis of S30408 pipe cracking and preventive measures

BACKGROUND: The feed pipeline made from 30408 stainless steel of a new unit leaked during the air pressure test. OBJECTIVE: The present work aims to examine the specific cause of pipeline cracking, and providing effective approaches to avoid similar failures. METHODS: Macroscopic inspections of the cracked pipe defects were made on site immediately after leakage. Mechanical properties and hardness of specimens machined from the failed pipe were tested. In addition, microscopic analyses including material composition, microstructure observation and crack morphologies of the failed part were performed to get detail information. Composition of the feed raw material was also analyzed to identify whether it had been contaminated by corrosive elements or not. RESULTS: No impurity composition was found in the feed raw material. The element constituents, yield strength, tensile strength and hardness of the cracked pipe fulfill standard requirements. A number of scratches and defects with a size of several microns were found on the inner wall of the leaked pipe, and they were believed to be formed at the perforation step during pipeline processing. Liquation cracks were found at the pipeline butt weld joint, and they laid hidden dangers for the safety and steady operation of the pipeline. CONCLUSION: The overall analysis results indicated the pipeline leakage during air pressure test was caused by cracks initiated around inner wall defects, which sabotaged the bearing capacity of the pipe by wall thickness reduction and stress concentration. Therefore, improving the inner wall surface quality at the perforation step may help to avoid such failure. The metallurgical effect and weld stress caused during the welding process promoted the initiation and propagation of liquation cracks. The tendency of welding hot crack formation could be reduced by taking strict composition control of the welding rod and adopting reasonable welding parameters.