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<p>This study focuses on the failure analysis of a super duplex stainless-steel piping located on the first pass pump discharge side of a desalination plant. A root cause failure analysis approach was employed, incorporating various laboratory-based testing including optical metallography, scanning electron microscopy, and EBSD analysis. The investigation revealed that the primary failure mechanism was chloride-induced pitting corrosion, exacerbated by forming a detrimental <i>σ</i>-phase in the ferrite phase. The <i>σ</i>-phase precipitates created chromium-depleted zones, reducing the material’s pitting resistance. Corrosion was particularly severe in the heat-affected zones and along the toe of circumferential welds. Corrosion testing with the simulated environment of desalination confirmed the reduced corrosion resistance of the pipe spool. Recommendations to mitigate similar failures include stringent control of heat treatment during manufacturing to prevent <i>σ</i>-phase precipitation, ensuring a balanced ferrite/austenite ratio, ferrite testing, and corrosion test to ensure the material’s reliability.</p>

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Root Cause Failure Analysis of Pump Discharge Line

  • 期刊论文

  • 发表日期：

    2025年4月16日

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  • Awais Manzoor,
  • Osama Saleem,
  • Ronald Abbas,
  • Shoaib Ahmed

摘要

This study focuses on the failure analysis of a super duplex stainless-steel piping located on the first pass pump discharge side of a desalination plant. A root cause failure analysis approach was employed, incorporating various laboratory-based testing including optical metallography, scanning electron microscopy, and EBSD analysis. The investigation revealed that the primary failure mechanism was chloride-induced pitting corrosion, exacerbated by forming a detrimental σ-phase in the ferrite phase. The σ-phase precipitates created chromium-depleted zones, reducing the material’s pitting resistance. Corrosion was particularly severe in the heat-affected zones and along the toe of circumferential welds. Corrosion testing with the simulated environment of desalination confirmed the reduced corrosion resistance of the pipe spool. Recommendations to mitigate similar failures include stringent control of heat treatment during manufacturing to prevent σ-phase precipitation, ensuring a balanced ferrite/austenite ratio, ferrite testing, and corrosion test to ensure the material’s reliability.