ML20140B603
| ML20140B603 | |
| Person / Time | |
|---|---|
| Site: | Braidwood  |
| Issue date: | 01/23/1986 |
| From: | Gallo J ISHAM, LINCOLN & BEALE |
| To: | Callihan A, Cole R, Grossman H Atomic Safety and Licensing Board Panel |
| References | |
| CON-#186-823 ALAB-143, OL, NUDOCS 8601270055 | |
| Download: ML20140B603 (70) | |
Text
I f
^
fP j ISHAM, LINCOLN & BEALE-COUNSELORS AT LAW it20 CONNECTICUT ACNUE N W e jylf H0 egpAS gy@ty,/h b
towAno s isHAv ist2 teor UU iefs % C hh . [ L tw,cAGo orFict TH8E E FIRST NAT ONAL PL AIA ROBER T T. LINCOLN 1872 1889 witLIAM G BEALE. 1885 4 23 CHI LU i 80602 0F ha ~ -,,,t TEtEx e u
,1986 0JAnkhC Herbert Grossman, Esq., Chairman Dr. Richard F. Cole Administrative Law Judge Administrative Law Judge Atomic Safety and Licensing Atomic Safety and Licensing Board Board U.S. Nuclear Regulatory U.S. Nuclear Regulatory Commission Commission Washington, D.C. 20555 Washington, D.C. 20555 Dr. A. Dixon Callihan Administrative Law Judge 102 Oak Lane Oak Ridge, TN 37830 Re: In the Matter of Commonwealth Edison Company (Braidwood Station, Unity 1 and 2, Docket Ncs. 50-456 and 50-457 U Gentlemen:
In accordance with the disclosure requirements of the McGuire decision, in the matter of Duke Power Company (William B. l McGuire Nuclear Station, Units 1 and 2) ALAB-143, 6.AEC 623 (1973), I am enclosing two reports that are relevant to Intervenors Rorem, et al. subcontention item ll.C. The reports are (i) an Evaluation of Pitting Corrosion of A106B Steel Pipe by Professor Danyluk, and (ii)
Metallurgical Testing of Pipe Samples Per Consultant Specification No. 121 by Taussig Associates, Inc. _
Sincerely,
. , " . i. i . . ,,/
' Joseph Gallo One of the Attorneys.for Commonwealth Edison Company JG/ kit cc: Service List Enclosures 8
I
!e i ,. . . a m,.... m n , . .
1
')
y STEVEN DANYLUK Ph. D. i Associate Professor of Materials Science and Engineering l 4647 Fairview Avenue
$UaIMENcivlL ENGINEERING. Downers Grove, IL 6N15 MECH ANICS. A METALLURGY Novembsr 26, 1985
$$,+e,'i$.oua oi:i u:
Mr. Corwyn Berger Taussig Associates. Inc.
P. O. Box 1427 Skokie, Illinois 60076
Dear Mr. Berger:
I have completed my evaluation of the pitting corrosion of the chemically cleaned and not chemically cleaned A106B steel pipe which is scheduled for use in the Braidwood Nuclear Power Project. This evaluation included: a review of report No.
60493-1-May 15, 1985, on site inspection of piping in storage and service, and supervision and evaluation of subsequent metallographic examination of pipe cross-sections performed by Taussig personnel.
There is no evidence to suggest that the chemical cleaning was overly aggressive.
The surface morphology of the chemically cleaned pipe that had been corroded is not substantially different from the not chemically cleaned or new pipe. All pipe showed surface irregularities and depressions. The chemically cleaned and cor-roded pipe contained shallow pits not unexpected in carbon steel. Neither the pitted regions nor the corrosion products from these regions exhibit any unusual morphology based on the pit shape or chemistry, so there is no reason to expect that the chemically cleaned pipe would corrode more rapidly than the not checi-cally cleaned pipe. I have also evaluated the general service conditions to which the steel pipe will be subjected and, in my opinion, these conditions are rela-tively mild as, for example, compared to those in the Chemical Process industry which routinely uses this grade of pipe. My field experience of corrosion prob-less in the Power and Chemical Process industries has shown that the chemically cleaned pipe may continue to be used when the design calls for A106 grade B steel pipe.
I have enclosed a brief summary of my evaluation on which these recommendations are based.
l l
Yours truly, ,
k Steven Danyluk Associate Professor mgk s y
enclosure '
i l l
~
.ft -
(
Evaluation of Pitting Corrosion of A106B Steel-Pipe
- 4
'l Steven Danyluk Associate Professor i
University of Illinois at Chicago
. and High Tech Materials Research Corporation
- w November 1985 h
t a
1 l
- Submitted to Taussig Associates, Inc.'
I i
f l
t Summary Carbon steel pipe, ASTM A106 Grade B, with nominal sizes of 2,1 1/2,1, 3/4,1/2 and 3/ 8-in. which had been stored outdoors in 1977 in an uncov-ered condition at the Braidwood Nuclear Power Project were found in 1981 to be corroded. The pipe was chemically cleaned at that time to remove the corrosion product. After chemical cleaning, the pipe was stored indoors in a warehouse from which material was withdrawn for installa-tion until 1984 when localized pitted regions were found on the OD and ID of the pipe in storage. The remaining pipe was then removed from the warehouse and stored in secured, covered trailors. A number of wall thickness measurement specimens were also stored in a warehouse. Vari-ous random sections of this pipe in the chemically cleaned and not chemically cleaned state were examined to determine if the chemical cle-aning had exacerbated the corrosion.
This report summarizes the visual, metallographic and corrosion product analysis that was accomplished of various sizes of this pipe in the var-ious conditions. The corrosion product ' morphology and chemistry are what is expected of normal oxidation of carbon steel. No unusual chem-1stry was found to suggest that the chemically cleaned pipe would corrode at a higher rate than the not chemically cleaned pipe.
Visual Examination A site visit to the Braidwood plant was made on September 4,1985. Pipe
( 3/ 8-in. size) that had been exposed to atmospheric conditions since 1977 was examined. In addition, various sizes of pipe stored in secured, covered trailors since 1981 were also examined. Ferthermore, chemically cleaned pipe (2-in. size) that had been installed subsequent to chemical cleaning and removed due toia normal re-route had been exa-mined. All the chemically cleaned and stored pipe showed no unusual corrosion behavior. The wall thickness measurement specimens mentioned above did not exhibit unusual corrosien behavior. ,
Meta 11onrachic Evaluation -
Metallographic cross-sections of 2-in. chemically cleaned corroded pipe and 3/ 8-in. not chemically cleaned, corroded pipe (8-year atmospheric exposure history) revealed no unusual properties. The pits were wide and shallow and evidence of localized crevice corrosion was not found.
New pipe also exhibited surface depressions which are the precursors of pits of similar geometry to the corroded pipe, and the chemically cle-aned and corroded pipe. The scale from inside1 pits was discolored as expected of Fe2O3 In addition, the scale was ' cracked and had spalled from the parent metal as expected. Theimaximue pit depth of the 3/ 8-in.
pipe wrapped in bundles and exposed to atmospheric conditions since 1977 was measured by Taussig personnel to be 0.016 in, while a typical pit depth ranged from 0.006 and 0.008 in. These' pit depths are not exces-sive considering an exposure time of 8 years.
(
?
-4 i
Corrosion Product Analysis The corrosion product of chemically cleaned pipe was investigated by Taussig personnel by: wet chemical analysis of the removed scale, energy dispersive analysis (EDI) in conjunction with scanning electron microscopy (SEM), and pH evaluation. The wet chemical analysis revealed the expected oxide chemistry of Fe20 3 with trace amounts of Mn02 , Ca0, K2 0, Nacl and SiO2 while the EDI analysis revealed elements that corre-lated well with the wet chemical analysis. The Mn, Ca, K, Na and Si fcund in the chemical analysis of the corrosion scale are most like'.y a result of the chemical cleaning process while the trace amounts of chlo-rine and phosphorous are probably the result of sample cuttini, and handling. The pH of water in contact with the corrosion scale ret ealed a value of 6.0. This indicates that there were negligible soluble chlo-rides and sulfides in the scale. Since the corrosion scale chemistry of this chemically cleaned pipe does not reveal any unusual chemistry, its corrosion is not expected to be different from the not chemically cle-aned pipe.
Recommendation The pit configuration in the chemically cleaned pipe was not different from the not chemically cleaned pipe. The pits were broad and shallow and not expected to exacerbate subsequent corrosion. There is no reason to expect that the chemically cleaned pipe would corrode at a faster rate than the not chemically cleaned pipe or new pipe given that all other conditions are the same. The chemically cleaned pipe may continue to De used in applications where A106B steel pipe is normally recom-mended.
l l
l
v ' "P -
4
- - - . . , _ , _ , s l
i '
l M y- .
am -s n '
t i
Metallurgical Engineers 1
i
' r 3
- Report No. 60493-2/ August 27, 1985 l
1 SARGENT & LUNDY 55 East Monroe Chicago, Illinois 60603 Attention: Mr. Charles F. Beck i
( )
1 p e
.I O
i i
i i i 9
1 i
.l i
l l
l l
l
.- -. 3 k -
ig .
A . , . . _ . p Metallurgical Engineers is3orrontagenoaa . so.e.m.noiseco77 . i 3:2676 2ico Report No. 60493-2/ August 27, 1985 SARGENT & LUNDY 55 East Monroe Chicago, Illinois 60603 Attention: Mr. Charles F. Beck SUBJECT Metallurgical Testing of Pipe Samples Per Consultant Specification No. 121.
9 0 BACKGROUND:
A total of 67 pipe samples were submitted to our laboratory for metallurgical testing in accordance with Sargent & Lundy Consultant
, Specification No. 121. These pipes were received from Commonwealth Edison Company at the Braidwood Station on pipe sample transmittals from M.A. Gorski and represented various sizes from 1/2" to 2" diameter. Most of the submitted pipes had been pickled and reportedly displayed indications of corrosion and rusting. Twenty of the pipe samples were identified as new. The purpose of the testing was to determine if the corrosion or pickling had caused a significant degradation of the pipe properties.
Consultant Specification 121 required nine tensile and chemical tests on pipes of various sizes to determine if it conformed to the requirements of ASTM A106-75a. Burst tests were to be performed on both new and corroded pipe in 1/2" and 2" diameters. Bend tests were requested on various size pipes to evaluate its ductility.
Samples of good and corroded pipe in 1/2" and 2" diameters were also to be subjected to fatigue tests. Metallurgical and corrosion tests were requested to evaluate the severity of corrosion ~ and the composition of the corrosion residue. The sample identification, size and heat numbers, as marked by Commonwealth Edison, are shown in Table 1. Photograph 1 is an illustration of the visual appearance gf new and corroded pipe.
TEST RESULTS:
Tension Testing:
1 The pipe samples identified as TS-1 through TS-9 were first subjected to tensile tests. Flat reduced section tensile test specimens were cut and machined from pipes TS-1 through TS-4 which represented 1-1/2" and 2" diameter pipes. This machining was performed in accordance with ASTM A370. The remaining five specimens were of diameters 1" and under and were tested in full cross section.
All nine specimens were tested with no preparation on the inside or outside diameters. All of the tests were per formed in accordance with ASTM E8. The test of TS-4 failed to meet the elongation requirements. A retest was performed in full section on TS-53 which is of the same heat number and' size. This retest is i allowed by ASTM A106, Section 17. Insufficient material from TS4 did not allow its testing in full section. A full section retest was also performed on TS-2 of the same 1-1/2" diameter as a comparison between reduced. and full section specimens in 1-1/2" diameters. The results of these tests are shown in Table II.
, o Report No. 60493-2 Page 2 Sargent & Lundy Except for TS-4 the test results shown in Table II meet the requirements specified by ASTM A106-75a for both full section and reduced section specimens, including the retest for Heat (/JD1571 using specimen TS-53 in lieu of TS-4. The Grade B material requires a minimum tensile strength of 60,000 psi. and a minimum yield strength of 35,000 psi. The elongation minima are shown in Table II. All nine specimens exceeded the minimum elongation requirements.
Chemical Analysis:
The nine pipe sections subjected to tensile testing were also subjected to chemical analysis. All of the samples were analyzed for 15 elements to verify conformance to A106 and to identify'any possible contaminants or unusual alloying additions. ASTM A106 specifies analysis of only 5 elements; carbon, manganese, phosphorus, sulfur and silicon. These tests were performed in accordance with ASTM A751. The results of this testing suggested that several specimens might contain silicon contents below specification limits. To investigate and verify this condition, a round robin retest program was established at our laboratory and at Chicago Spectro Services Laboratory. The results are shown in Table III. The results of these tests conform to the chemical requirements of ASTM A106-75a with no evidence of significant amounts of contaminants or unusual alloying elements.
Burst Testing:
Four tube samples, TS-10, TS-20, TS-30, and TS-40, were subjected to burst testing at Pittsburgh Testing Laboratories facilities in Pittsburgh, Pennsylvania. The ends of the 4' lengths of pipe were closed by welding or threading and plugging. A nipple was attached to one end to permit pressurizing the pipe with water.
Each of the four pipes were pressurized with water until rupture of the pipe occurred. The water pressures required to rupture the pipes are shown in Table IV. Illustrations of the appearance of these fractures are shown as Photographs 2 through 4.
.o o Report No. 60493-2 Page 3 Sargent & Lundy The burst test results revealed a slight decrease in the pressure sustained by the corroded pipe as compared to the new pipe.
These variations may be expected due to differences in wall thickness between different pipes. ASTM allows for variations in wall thickness of 12.5%. All four of the test pressures exceed the minimum hydrostatic pressure specified in ASTM A530 Section 5 (3900 psi. for 2" diameter and 7400 psi. for 1/2" diameter). The visual appearance of the fracture of Sample TS-30 was slightly different from that observed in the other three pipes. Three pipes displayed a single linear fracture while TS-30 displayed a linear failure with fractures continuing at approximately 45 at each end. This condition is most likely due to minor residual stresses incurred during normal manufacture of the pipe and would not be expected to have any relation to the pitting or corrosion on TS-30. All of the tested pipe exceeded the minimum hydrostatic pressure specified by ASTM A530.
Bend Testing:
Nine pipe samples, TS-36 and TS-60 through TS-67, were subjected to bend testing. Each pipe was bent over a die with a diameter equal to or less than five times the nominal pipe diameter. (It should be noted that Section 11 of A106 normally requires p,pe to be bent over a die of 12 times the nominal pipe diameter; specially ordered close coiling pipe is required to be bent over a die of 8 times the pipe diameter. The testing of the submitted pipe was more severe than either of these requirements.) This testing was performed at Wallace Machines facilities at 1800 W. Cornelia, Chicago. The bending was continued through an arc of 90 or more. No preparation was performed on any parts of the pipes prior to bending. No internal mandrel was used during any of the tests. A summary of the ' test results are shown in Table V. The visual appearance of the convex surfaces of the nine pipe samples are shown as Photographs 5 and 6.
Examinations of the bent pipes were performed by a qualified Level III Visual Examiner. The visual examination of all bend tests revealed no indications of any cracks or other open defects on the nine pipe samples. These test results meet the bend requirements of ASTM A106.
l' i
Report No. 60493-2 Page 4 Sargent in Lundy Fatigue Testing:
Twenty pipe samples were subje ted to fatigue testing at Materials Research Laboratory in Glenwood, Illinois. The 1/2" and 2" diameter pipes represented both the new and corroded condit:.ons. No surf ace
~
treatments or preparations were performed prier to testing. The load controlled fatigue tests were performed in 4 point bending (R= -1). With the 2" setup shown in Photograph 7, L=24 and A=8.
For the 1/2" diameter pipe L-12 and A=4. L is the distance between the two outside loading points and A is the distance between adjacent loading points. All tests were performed at room temperature with results as shown in Table VI.
The test results are tabulated in Figures 1 and 2 with comparison to results reported by A.R.C. Markl, " Fatigue Testing of Piping Components", Trans. ASME, April 1952, Page 289. All of the failures oceurred at one of the two center span loading points with the exception of the 1/2" corroded pipe. Five of the six specimens of 1/2" corroded pipe f ailed approximately midway between the loading points in the area of constant moment. The method of four point bending exposes greater areas of the pipe to the fatigue stresses than other methods of fatigue testing. In four point bending fracturing may occur at almost any location between or at the loading points.
The graph of the test results shown in Figure 1 reveals the 2" samples to be within the results expected by Markl. The results of the 1/2" diameter pipe shown in Figure 2 is generally above the results expected by Markl. A copy of the Materials Research Laboratory report is attached as an appendix to this report.
Macro-etch Testing:
Macro-etch testing was to be performed on the nine pipe samples i used for bend testing. Due to a delay in the shipment of these samples from Braidwood it was agreed between Taussig Associates and Commonwealth Edison Company that the ten pipes specified for corrosion evaluation, TS-50 to TS-59 would be used. A full section of each pipe was cut to a length of approximately 1/2".
The cut face of each section was sanded to a suitable fineness for macro-etch testing. These specimens were placed in hot hydrochloric acid solutions as required by ASTM E381. After a suitable exposure time, the specimens were removed, rinsed, and dried. Illustrations of the visual appearance of these macro sections are shown as Photographs 8 through 13.
Report No. 60493-2 Page 5 Sargent & Lundy Visual examination of the macro-etch sections revealed all ten samples to display uniform structures with no evidence of inherent defects or weld seams. Several samples displayed evidence of some wall thickness variations. (Such variations are allowed by ASTM A106, however measurements of these wall thicknesses are outside the scope of Sargent & Lundy Consultant Specification 121.) None of the sections displayed indications of laps, cracks, laminations, segregation, or other irregularities. Though no requirements are specified by A106 for macro-etch testing, these results are typical of expected macro-etch samples for ASTM A106 type materials.
QX Analysis:
The surfaces of pipes TS-50 through TS-59 were all subjected to EDX analysis. Analyses were performed in the pitted areas on both the outside and inside diameters of all ten pipes. Using an ISI-40 scanning electron microscope, a 15 key electron beam was
. used to cause emission of characteristic x-rays. Energy dispersion x-ray (EDX) techniques were used to obtain semi-quantitative I chemical analyses of the examined surfaces. The results of these tests are shown in Table IX. Illustrations of the EDX spectra obtained from the examined samples are shown as Photographs 24 through 30.
The results of these analyses revealed iron to be the primary constituent in the pitted areas. Numerous other elements were identified in trace amounts. The most common trace elements were found to be aluminum, sulfur, and silicon. It may be estimated that each of these elements are in concentrations of less than 5%. The limit of detection is estimated to be approximately .1 to .5% for most elements. The results had good correlation with .
the results of the deposit analysis. It should be noted that EDX analysis is insensitive to elements of atomic numbers less than
, 10 including hydrogen, oxygen, and carbon.
Only sample TS-57 displayed significant amounts of a secondary element. Phosphorus was found in greater than nornally expected i amounts on both the 0.D. and I.D. of this sample. The phosphorus may be remnants of iron phosphate or zine phosphate used as a l lubricant during drawing operations. These materials may also ;
inhibit corrosion during pickling operations and may explain the '
limited corrosion observed on this sample during metallographic examination.
c Report No. 60493-2 Page 6 Sargent & Lundy pH Testing:
A drop of deionized water was placed on the outside surfaces of pipes TS-52 TS-54, and TS-58. The water was spread to form a film. After approximately 5 minutes , a piece of pH paper was used to evaluate the acidity of the water. The deionized water was found to have a pH of 6.0. The water on the pipe surfaces exhibited the exact same color indicative of 6.0 pH. The pH paper used positively identifies changes of 0.4 pH and should be e capable of distinguishing changes of 0.2 pH. This testing indicates that the sulfur and chlorine on the pipe surface are not in sufficient quantity or are not adequately chemically active to
, cause significant amounts of sulfuric or hydrochloric acids to be formed when exposed to water and would therefore not be expected to cause any significant reduction in the life of the tubing.
Meta 11ographic Examination:
Meta 11ographic cross sections were cut from the ten pipe samples used for macro-etch testing. These sections represented the full wall thickness of each pipe from the outside diameter to the inside diameter. All ten sections were mounted in bakelite colds
, to facilitate grinding and polishing to a .05 micron finish. A metallurgical microscope was used to examine the cross sections
, at magnifications of up to 1000X. A solution of 17. Nital was applied to the specimens to provide clear definition of their microstructures.
All ten of the examined sections displayed microstructures typical i of low carbon pipe products such as ASTM A106. The 2" and 1-1/2" diameter samples displayed microstructures of pearlite and accicular ferrite. This may indicate these pipes were hot worked. The smaller diameter pipes generally displayed more equiaxed ferrite and pearlite indicative of a cold worked and annealed product.
, Both methods are acceptable means of forming per ASTM A106. Some partial decarburization was detected on the outside surfaces of several of the tubes extending to depths of up to .006". The inside diameter of sample TS-5.' exhibited a layer of total decarburi-zation approximately .0025" thick. A small lap was observed on the inside circumference of T5-53 which cay be ceas44ered-normal .4 and-not- rejectionable. These decarburized layers may not be y C j5-considered unusual or excessive for this type of product. No g' c evidence of inherent metallurgical defects were observed in any , .,
of the examined sections such as excessive inclusions, cracks, '
laps, laminations, or seams. Illustrations of the microstructures [u >r',',
and surface appearances of these metallographic sections are shown i .i..
as Photographs 14 through 23.
m_
Report No. 60493-2 Page 7 Sargent & Lundy Some pitting was observed on the surfaces of most of the metallo-graphic cross sections. These corrosion pits were relatively broad and shallow. The maximum depth of these pits was measured and are shown in Table VII. The most severe corrosion was observed on the outside diameter of sample TS-58. Most of the outside surface had corroded and only isolated areas of the original outside diameter of the as-manufactured pipe were identified. In general the nine sections displayed only isolated areas of pitting.
Sample TS-57 exhibited the least pitting and it may have been due to normal processing and production techniques rather than the pickling treatment. None of the examined sections displayed evidence of other surface conditions such as intergranular or grain boundary attack, stress corrosion cracking, or indications
=
of embrittlement. The results of the metallographic examinations revealed microstructures typical of ASTM A106 material though no specific requirements are stated in the specification.
Deposit Analysis:
Sections from the tubes identified as TS-50 through TS-59 were submitted to
Dearborn Chemical in Lake Zurich,
Illinois. Samples of loose scale on the outside diameter of these samples were obtained by using scotch tape. Because of the relatively small 8
amount of sample obtained by this method, only semi-quantitative chemical analyses were performed on the individual samples. To
' obtain a quantitative analysis, all of the scale obtained from
, the ten tubes was combined for a composite analysis. The results of this x-ray fluorescence testing is shown in Table VIII.
, In general, the scale samples were found to have iron as the primary constituent with trace amounts of manganese, calcium, chlorine, and silicon. The most unusual sample would be TS-57 which displayed minor amounts of zinc, manganese, calcium, sulfur, silicon, phosphorus and lead. A composite sample was obtained by combining all the scale removed from the ten pipes. It was found 8 to be 83% iron. No measurable amounts of chlorine were identified.
The elements which were identified by these analyses may be con-sidered relatively inert and would not be expected to cause additional corrosion.
Report No. 60493-2 Page 8 Sargent & Lundy CONCLUSIONS:
The tensile and chemical results from corroded pipes TS-1 through TS-9 all conformed to the requirements of ASTM A106-75a, grade B.
The outside surfaces of the tensile specimens were not machined or otherwise prepared which indicates the effects of the corrosion in tension may be negligible. The burst tests resulted in slightly lower values for the corroded pipes but all values exceeded the minimum hydrostatic test pressure specified by A530. The corroded g pipes TS-36 and TS-60 through TS-67 were subjected to bend tests and exhibited no. defects af ter bending over a more severe diameter
, than required for specially ordered close coiling material.
i The fatigue tests were peformed in four point bending on 2" and 1/2" diameters in both the new and corroded conditions. The results were compared to those expected by Mark 1 and good correlation was found. The corroded pipes displayed slightly lower test results but were within the range expected by Markl for the 2" and above the expected range for the 1/2" pipes. The corrosion may have caused a small degradation of fatigue properties but has not brought it below the values expected by Markl. The decrease may be due to differences in the actual wall thicknesses rather than any effect of corrosion or pitting.
The macro-etch testing revealed corroded pipes TS-50 through TS-59 to have structures typical of A106 with no indications of significant
. defects. The metallographic cross sections of these same pipes exhibited broad shallow pits apparently due to corrosion. No other effects of corrosion were observed including stress corrosion cracking, intergranular corrosion or embrittlement. The micros truc-tures were typical of low carbon steels with no evidence of microscopic defects.
Analyses of corrosion deposits of samples TS-50 through TS-59 indicated iron as the primary conr,tituent. The other elements of 6 the corrosion were present at relatively low concentrations.
These elements included manganese, silicon, calcium, aluminum, chlorine and sulfur. No unusual differences were observed between the deposit analyses performed on debris from the pipe surface and EDX analyses performed in pitted areas.
On 3 corroded pipes, '
exposing the pitted outside pipe surface to water caused no significant change in pH and would not be expected to cause any I
Report No. 60493-2 Page 9 Sargent & Lundy significant reduction in the life of the tubing. This indicates that the sulfur and chlorine present in the pit areas may not be active or capable of producing significant amounts of hydrochloric or sulfuric acids.
Based upon the above test results it appears that the corrosion of the submitted samples may have generally caused a slight decrease j in properties but meet or exceed the requirements of expected values for the specified materials. In view of the acceptable test results we may expect this material to perform in a similar manner to ASTM A106 material which has not been pickled with no significant degradation of service lifetime.
e Respectfully submitted, N
Mark A. Hineman Senior Metallurgical Engineer 8 TAUSSIG ASSOCIATES, INC.
t MAH:lc s
e 4
i
Table 1 Sample Summary Actual Size / Test Test ID No. Schedule Condition Heat No. Designation Performed TS-1 2" S/80 2 KD6751 Tens./ Chem. Tens./ Chem.
TS-2 1 1/2" S/80 2 HD7760 Tens./ Chem. Tens./ Chem.
TS-3 2" S/160 2 273088 Tens./ Chem. Tens./ Chem._
TS-4 1 1/2" S/80 2 JD1571 Tens./ Chem. Tens./ Chem.
TS-5 1" S/80 2 KD7115 Tens./ Chem. Tens./ Chem.
TS-6 1/2" S/80 2 KD6830 Tens./ Chem. Tens./ Chem.
TS-7 3/4" S/80 2 JD1570 Tens./ Chem. Tens./ Chem.
1 TS-8 3/4" S/160 2 KD7589 Tens./ Chem. Tens./ Chem.
TS-9 1/2" S/160 2 KC3423 Tens./ Chem. Tens./ Chem.
TS-10 2" S/80 1 U71443 Burst Burst TS-11 2" S/80 1 U71443 Fatigue Fatigue TS-12 2" S/80 1 U71443 Fatigue Fatigue TS-13 2" S/80 1 U71443 Fatigue Fatigue l' TS-14 2" S/80 1 U71443 Fatigue Fatigue TS-15 2" S/B0 1 U71443 Fatigue Fatigue TS-16 2" S/80 1 U71443 Spare Spare TS-17 2" S/80 1 U71443 Spare Spare TS-18 2" S/80 1 U71443 Spare Spare TS-19 2" S/80 1 U71443 Spare Spare TS-20 1/2" S/80 1 270431 Burst Burst i TS-21 1/2" S/80 1 270431 Fatigue Fatigue TS-22 1/2" S/80 1 270431 Fatigue Fatigue
, TS-23 1/2" S/80 1 270431 Fatigue Fatigue TS-24 1/2" S/80 1 270431 Fatigue Fatigue TS-25 1/2" S/80 1 270431 Fatigue Fatigue TS-26 1/2" S/80 1 270431 Spare Spare TS-27 1/2" S/80 1 270431 Spare Spare i TS-28 1/2" S/80 1 270431 Spare Spare TS-29 1/2" S/80 1 270431 Spare Spare TS-30 2" S/80 2 KD6751 Burst Burst TS-31 2" S/80 2 KD6751 Fatigue Fatigue TS-32 2" S/80 2 KD6751 Fatigue Fatigue
, TS-33 2" S/80 2 KD6751 Fatigue Fatigue TS-34 2" S/80 2 KD6751 Fatigue Fatigue TS-35 2" S/80 2 KD6751 Fatigue Fatigue TS-36 2" S/80 2 KD6751 Bend Bend TS-37 2" S/80 2 KD6751 Spare Spare TS-38 2" S/80 2 KD6751 Spare Spare TS-39 2" S/80 2 KD6751 Spare Spare TS-40 1/2" S/80 2 KD6830 Burst Burst TS-41 1/2" S/80 2 KB6830 Fatigue Fatigue TS-42 1/2" S/80 2 KD6830 Fatigue Fatigue
Table 1 Page 2 Actual Size / Test Test ID No. Schedule Condition Heat No. Designation Performed TS-43 1/2" S/80 2 KD6830 Fatigue Fatigue TS-44 1/2" S/80 2 KD6830 Fatigue Fatigue TS-45 1/2" S/80 2 KD6830 Fatigue Fatigue TS-46 1/2" S/80 2 KD6830 Spare Spare TS-47 1/2" S/80 2 KD6830 Spare Spare TS-48 1/2" S/80 2 KD6830 Spare Spare TS-49 1/2" S/80 2 KD6830 Spare Spare TS-50 2"S/80 2 KD6751 Corrosion corrosion, Macro /
l Micro Test TS-51 1 1/2" S/80 2 HD7760 Corrosion Corrosion, Macrc Micro Test TS-52 2" S/160 2 273088 Corrosion Corrosion, Macrc Micro Test TS-53 1 1/2" S/80 2 JD1571 Corrosion corrosion, Macrc Micro, Tension TS-54 1" S/,80 2 KD7115 Corrosion Corrosion, Macrc Micro Test TS-55 1/2" S/80 2 KD6830 Corrosion Corrosion, Macrc Micro Test TS-56 3/4" S/80 2 JD1570 Corrosion Corrosion, Macrc Micro Test g TS-57 3/4" S/160 2 KD7589 Corrosion Corrosion, Macrc Micro Test TS-58 1 1/2" S/160 2 HD7760 Corrosion Corrosion, Macrc
! Micro Test
. TS-59 1" S/160 2 KD7115 Corrosion Corrosion, Macrc Micro Test TS-60 1 1/2" S/80 2 HD/760 Bend Bend i TS-61 2" S/160 2 273088 Bend Bend TS-62 1 1/2" S/80 2 JD1571 Bend Bend TS-63 1" S/80 2 KD7115 Bend Bend TS-64 1/2" S/80 2 KD6830 Bend Bend TS-65 3/4" S/80 2 JD1570 Bend Bend
, TS-66 3/4" S/80 2 KD7589 Bend Bend TS 1/2" S/160 2 KC3423 Bend Bend Condition 1 - New pipe Condition 2 - Corroded & Pickled (see note)
Note: All condition 2 pipe may not be corroded or pickled. This pipe was selected from the population of pipe that was corroded and pickled. Not all heats of this population were pickled.
Table II Tensile Test Results kcds_r:__
c . 3 u; - c ' W 9 5-TS-1 TS-2 TS-3 TS-4 Width, in. .503 .496 .494 .496 Thickness, in. .214 .184 .334 .195 Area, sq. in. .1076 .0912 .1649 .0967 Tensile Strength, psi. 72,800 81,200 70,400 83,300 Yield Strength, psi.
(0.21 Offset) 47,200 60,800 36,400 59,400 1 Elongation, in 2" 25.5 28 38.5 20.5 V: L *. j ( .' '.' : 'I ...- .
TS-5 TS-6 TS-7 TS-8 TS-9 Outside Diameter, in. 1.300 .834 1.050 1.051 .851 Inside Diameter, in. .932 .532 .727 .592 .485 Area, sq. in. .6445 .3198 .4508 .5922 .3916 Tensile Strength, psi. 68,900 68,800 69,0000 71,400 65,400 Yield Strength, psi.
(0.21 Offset) 47,600 45,700 45,500 51,800 47,900 1 Elongation, in 2" 45 34 45.5 41 38.5
_ ... ,: .i Retests: TS-2 TS-53 Outside Diameter, in. 1.880 1.880 Inside Diameter, in. 1.485 1.487 Area, sq. in. 1.043 1.037 Tensile Strength, psi. 78,000 81,300 Yield Strength, psi.
(0.2% offset) 58,700 59,700 1 Elongation, in 2" 36 37.5 Requirements of ASTM A106-75a, grade B:
Tensile Strength 60,000 minimum Yield Strength 35,000 minimum 1 Elongation, in 2" For Full Section Tests 30 For Reduced Section Tests E= 48t + 15.00 (TS-1: 25.3 min.)
(TS-2: 23.8 min.)
(TS-3: 30.0 min.)
(TS-4: 24.4 min.)
Y' [09, l VL Y]' D T%4 b P E l its st)$ T l
TABLE III Chemical Analysis TS-1 TS-2 TS-3 TS-4 TS-5 TS-6 TS-7 TS-8 TS-9 Carbon .20% .21% .23% .23% , .19% .21% .20% .217. .20%
Manganese .72 .89 .81 .86 .80 .87 1.05 .97 .63 Phosphorus .008 .014 .005 .011 .013 .017 .015 .015 .010 Sulfur .015 .013 .007 .013 .014 .020 .017 .017 .018 Silicon .10 .11 .17 .14 .12 .12 .11 .11 .17 Cickel <.01 <.01 <.01 .02 <.01 .01 .02 .03 .01 Chromium .03 .04 .01 .04 .03 .04 .04 .04 .04 Molybdenum <.01 <.01 <.01 .01 <.01 <.01 .01 .01 .01 Copper .03 .02 .02 .04 .02 .04 .06' .06 .03 Lead <.005 <.005 <.005 <.005 <.005 <.005 <.005 <.005 <.005 Aluminum <.005 <.005 .043 <.005 <.005 <.005 <.005 <.005 <.005 Tia <.005 .005 <.005 <.005 <.005 <.005 <.005 <.005 <.005 Vcnadium <.005 <.005 <.005 <.005 <.005 <.005 <.005 <.005 <.005 Ciobium <.005 <.005 <.005 <.005 <.005 <.005 <.005 <.005 <.005 Boron <.0005 <.0005 <.0005 <.0005 <.0005 <.0005 <.0005 <.0005 <.0005 Titanium <.005 <.005 <.005 <.005 < 005 <.005 <.005 <.005 <.005 Grade 8 ASTM A106-75a requirements: Carbon Maximum 0.30 Manganese 0.29 - 1.06 Phosphorus Maximum 0.048 Sulfur Maximum 0.058 Silicon Maximum - 0.10
. s*
l};',',1v'on
Table IV Burst Testing Sample Size Condition Maximum Pressure, psi.
TS-10 2" sch 80 New 15,300 TS-20 1/2" sch 80 New 29,800 TS-30 2" sch 80 Corroded 14,200 TS-40 1/2" sch 80 Corroded 26,300 Minima per ASIM A530 2" sch 80 - 3,900 psi. for nominal size 1/2" sch 80 - 7,400 psi for nominal size Hydrostatic Pressure (P) = 2St/D Where S = pipe wall stress (60% of minimum specified yield strength) t= wall thickness (nominal value used)
D= specified outside diameter
Table V Bend Testing 1
Test Die Diameter
~
Pipe Size Sample Diameter Ratio
- Results 2" sch 80 TS-36 8" 4 No defects 2" sch 160 TS-61 8" 4 No defects 4
1 1/2" sch 80 TS-60 5-1/2"" 3.7 No defects 1 1/2" sch 80 Tf-62 5-1/2" 3.7 No defects 1" sch 80 TS-63 4-1/4" 4-1/4 No defects 3/4" sch 80 TS-65 3" 4 No defects 3/4" sch 160 TS-66 3" 4 No defects 1/2" sch 80 TS-64 2-1/2" 5 No defects 1/2" sch 160 TS-67 2-1/2" 5 No defects
- Diameter Ratio = (Die Diameter)/(NPS Pipe Diameter) e
TABLE VI 4-Point Bend Fatigue Tests of 2" and 1/2"-
Schedule 80 Pipe @ Room Temperature Measured OD Measured ID Nominal l 2 Actua1 Reversals to Heat No. Specimen No. (in.) (in.) Stress (iksi) Stress (iksi) Failure U71443 TSil-1 2.390 1.935 50.0 47.53 10.833 New TS13-1 2.390 1.935 37.5 35.65 55,918 2"-Schedule 80 TS12-1 2.390 1.935 30.0 28.52 102,898 TS13-2 2.390 1.935 27.5 26.14 270.207 ,
TS12-2 2.390 1.935 25.0 23.76 992,305 KD6751 TS32-1 2.370 1.940 50.0 50.74 3,820 i Corroded TS31-1 2.365 1.920 37.5 37.30 28,489 2"-Schedule 80 TS31-2 2.365 1.920 30.0 29.85 77,661 TS32-2 2.370 1.940 25.0 25.37 262,997 TS33-1 2.370 1.940 20.0 20.30 825,591 270431 TS21-2 .840 .545 80.0 79.87 659 New TS22-1 .840 .545 60.0 59.90 9,885 1/2"-Schedule 80 TS22-3 .840 .545 52.5 52.43 61,616 TS23-1 .840 .545 47.5 47.41 160,670 4
TS22-2 .840 .545 40.0 39.94 959.592
- KD6830 TS41-1 .836 .546 60.0 61.12 4.735 Carroded TS41-2 .836 .546 52.5 53.49 14,510 1/2"-Schedule 80 TS42-1 .836 .546 47.5 48.38 25,303 i
TS42-2 .836 .546 40.0 40.75 87.626
. TS43-1 .836 .546 30.0 30.56 651,337 4
TS43-2 .836 .546 28.0 28.51 835,593 I
Nominal stress based on ASTM specified dimensions 2
1 Actual stress based on measured dimensions.
l 1
1
I FOUR-POINT BEND FRTIGUE TESTS OF 2"-5CH. 80 PIPE e RT i '
I I I s ,I I l I I I I I i
, s .
- 50 N - 's o HERT =U71443 (NEW CONDITION)-
N - 0 's e HERT =KD6751 (CORRODED COND.)
l M w
N -
N,
's i 's 4 l 40 - N, ,
's ' e -
.t N - e e ,?*e
! 35 - -
s- s , Ne,84 -
t m s%-s i m N,
! E 30 - N
- e 's -
i G 's
! C4,,ee>- 's 25 -
- Cg 'N -
i u
5 N -
N,
's -
s N
{ 20 -
s
- I I I I I I I I 'Is 1 I ;
3 . ' * ' ' ' ' '
10' 10' 10' -
c ,
l- REVERSALS TO FRILURE ,
(NF1 4.
] Fig. 1 Fatigue resulta comparing "new" and " corroded" groups of 2" diameter pipe.
1 Strens calcuintion based on netual aire.
\
! FOUR-POINT BEND FATIGUE TESTS OF 1/2"-5CH.80 PIPE o RT -
i l
l 80 'N s' s 1 I I I I I I I I o HEAT m270431 (NEW CONDITION)
I I N
i 'M N- s 'e,'hg'#of
- HERT =KD6830 (CORRODED COND.)
- y 60 - -
s -4 s -
s 's s i 1 50 - - \ - -
ci s - ~
l m y )$Js ,'
40 -
's, -
e - '
4 -
m 35 -
s, s -
- s, 's, a 30 - '
a -
N N- -
1 a s N, i
O e
25 - -
's - s 's * -
., N- s j
i 20 'N -
- ; [ [ l l [ l l l [ sj l l
! 10' 10' 10' ' ' '
10' REVERSALS TO FAILURE [NF) l.
)i Fig. 2 Fatigue resulta comparing "new" and " corroded" groups of 1/2" diameter pipe. Strens calculation bnned on actual aire.
4
! .e
9 Table VII Maximum Pit Depth Maximum Pit Depth Sample Size Outside Diameter Inside Diameter TS-50 2" sch 80 .004 .0015 TS-51 1-1/2" sch 80 .006 .002 TS-52 2" sch 160 .008 .00l*
TS-53 1-1/2" sch 80 .008 .003 TS-54 1" sch 80 .006 .005 TS-55 1/2" sch 80 .006 .004 r
TS-56 3/4 sch 80 .008
.002 TS-57 3/4" sch 160 .002 .00l*
TS-58 1-1/2" sch 160 .008 .008 TS-59 1" sch 160 .004 .006 4
e
- Less Than i
e
Table VIII ',
Deposit Analysis
~
TS-50 TS-51 TS-52 TS-53 TS-54 TS-55 TS-56 TS-57 TS-58 TS-59 Composite Zinc as ZnO Trace None None None None None Trace Minor None Trace 'None Copper as Cu0 None None None None None, None None None Trace None None Nickel as NiG None None None None None None None None None None None Iron as Fe 0 3 Major Major Major Major Major Major Major Minor + Major Major 83 Manganese as MnO Trace Trace Trace Trace None Trace Trace Minor Trace Trace 1 Chromium as Cr 0 3 None None None None None None None None None None None Tin as SnO None None None None None None None None None None None Titcnium as Tio, Trace None None None None None None None None None 1 Aluminum as A1 0 3 None None None None None None None None None None None Calcium as Ca0 Trace Trace Trace Trace Trace Trace Trace Minor Trace Minor 2 Magnesium as NgG Trace None None None None None Trace None None None 2 Strontium as Sr0 None None None None None None None None None None None Barium as Ba0 None None None None None None None None None None None Sodium as Na,0 None None None None None None None None None None None Potcssium as K,0 Trace None Trace Trace None Trace Trace Trace Trace Trace . None
-Chleride as Nacl Trace Trace Trace Trace None Trace Trace Trace Trace Trace None Sulfate as SO 3- Trace None None None None None None Minor None None 1 T:tol Phosphorus cc P 30 5(3) None None None None None None None Minor None None None Silica as SiO Trace Trace Trace Trace Trace Trace Trace Minor Trace Trace 3 Carbonate as CO, None ---- ---- ---- ---- ---- ---- ---- ---- ----
None venadium as V,05 None None None None None None, None None None None None Lead as PbO None None None None None None None Minor None None None Arsenic as AS,0, None None None None None None None None None None None s-
Table IX
. EDX Analysis TS-50 TS-50 TS-51 TS-51 TS-52 TS-52 ID OD ID OD ID OD Major Fe Fe Fe Fe Fe Fe Minor Traces Si Ti S S S Si (In Decreasing S Ca K Si Al S Concentrations) Cu Si Mn Al Si Al K Al Cu Mn Mn Ca Ca S Al K Cu Mn
. Mn K Si Ca Cl Cl Al Mn P Cu K K Na C1 Cr Ca Zn Cr Cu Ni TS-53 TS-53 TS-54 TS-54 TS-55 TS-55 TS-56 TS-56 ID OD ID OD ID OD ID OD Major Fe Fe Fe Fe Fe Fe Fe Fe Minor -
Traces Al Si S Si Si Si S S (In Decreasing S S Al S Al Al Si Si Concentrations) Si Al Si Ca S S Al Ca Cu Ca Cu K Mn Mn Mn K Mn Mn Mn Mn Cr Ca K C1 Ca C1 Cl Al Ca K Zn Al K K Cr Cr Zn Cr Ca Mn Na K C1 C1 C1 Cu
. C1 Ca P TS-57 TS-57 TS-58 TS-58 TS-59 TS-59 ID OD ID OD ID OD Major Fe Fe Fe Fe Fe Fe Minor P P Traces Zn Zn S Si Cu Si
- ; (In Decreasing Mn Ca S S S Ca Concentrations) Al Si Al Cu Si S S S Mn Al Mn Al S K K Ca Al K Cr Mn Cu Mn K Cl K Al K Ca Mg Ca C1 C1 C1 Mn
! Cr P
. , _ _ . - , . - . . _ = _ - . . - - . _ . .-. -
s 4
Table IX Page 2 4
Explanation of Symbols:
j Fe - Iron 3
Si = Silicon S = Sulfur 4 - Cu = Copper
! K = Potassium
!' Ca - Calcium Mn = Manganese 4
A1 = Aluminum I Na = Sodium i Cr = Chromium
- Ti - Titanium
.f { C1 = Chlorine j P = Phosphorus r Zn = 2ine Mg - Magnesium i
4 I
4 t
i f
1 f 5
e i
i
e
- i f
t t
t Photographs: No. 1 l
e t
i :. t i
' . r i >
- .-2. w :_ ,.w me, t
m%
Y M.- . am. . &jY-l 3.k ,x %~ ,
n .
4 * \
%T _--?.=
! i i
g h3h_W,=~f,y4 #
h Q5~k ! !
C-v
? d
%y-&~s?. .. . j !
n
_f5% h .
"e; e.
~.- i
?
h m_;>r - l t q 4 l
! t !
l I r
,i i
. s
[
An illustration of the visual appearance of corroded and new pipe. l The top pipe, TS-38, is a 2" schedule 80 sample which has been !
pickled and displays a corroded appearance. The pipe at the !
bottom of the photograph, TS-19, is a 2" schedule 80 pipe in the !
new condition. !
i I
i 4 !
I I
i 4
i
No. 2 l
i
- t.
- l
~*'
gW$i.ikal a e l l - -u9 -
p.'
.L - ~n .
'%+ S.-
2
, -- 4At_c.A? s .- ,.
. r y : T..-y .e .
-fb e- ., ::,,
T. M
- A
- Y s
- -.3 , .w.
n -,db4 i
-woc j .,
9&c~ -
i .
i
! ..- - p w.gj. w- Aa. w q'n.. .
M g- ih C . ,
if
- - ! ,=29~44W s. . 94 1, .
M=
-* J i ,?~
]
l l . . . . . - - .
I 4
)
i '
i 8
t 1
i I Illustration of the visual appearance of the fractures of pipes
.and TS-40 (top). These 1/2" schedule 80 pipes were I l TS-20 (bottom)by steadily increasing water pressure on the inside i burst tested of the pipes.,
i 1
! l h
\
l i
i I .-- .- . ..
-m,
--.,-m--y--. - . . - - . . . - - , - . . . , . - - . w,w -w w.-.....mm-wyy.n.-ym--+w,-y,w, ,w-e-y,--ww--m-u--w-
No. 3 I
l '
%~ ~
l
- 4. . .,
S .
M. I
_. ex ' !
i I
a l
I An illustration of the fracture appearance of the 2" schedule 80 pipe identified as TS-10 after burst testing.
- ,, - - _ . , y - ..,..T~_.,. ,,-..,_.-,..,_--_m,-_ _.---...,.-y .-, , - - - - va-- ,-,
No. 4 i
l I
. Ml
.$: ~ ,5$9,~:*=
s .~:-Q~ h ,...
jh; 3d? . ' 2$h?!* . '
I ~$ ..
E l
- t' -5.,.b e .:4- ,,
,t -
s w";,
s s. -***s.
-( ,t w:3.,: .*. '**NL& +
'i
.(
- - : 2..%
o ,, se +- es - ;..
1 i
'/ 7.;4,M. g.h2" i
W R* ~
5
- 1. ,
s A
This photograph displays the appqarance of the 2" schedule 80 pipe, TS-30, af ter burst testing.*Ms fracture displays a dif ferent appearance from those shown in Photographs 2 and 3,tt, gm... %
a hkN kO IMQ t MW W ** W
--w - - - - - -
m,, 39,.,y__ , _ _ , . _ . - - ew-,.,e,._ w._ _ _ _ _
No. 5
_E::: :.M_.:..m ;. . .
l
W~~~-
%.L G--=f,f $, k, nWm. ~a..
-~EY
,r_r --
~ ~
s n .
mW W ?:, - l s _ .
r_r p : m .- -.
w i.
f - .
\ -
4 I
l
! An illustration of the convex surfaces of three pipes after bend testing. These pipes are identified as TS-62 TS-60, and TS-61 from top to bottom. No evidence of any cracks or defects were observed in these samples after bending.
i l
l
- , . - - - - - . - . - - - ._m -,y_,
, , , , , - , 9 q , - . - -_.p.
No. 6
- V'; _
^
, q%. -
c ,
g% ; 4 ..Y.s -
ms'
_gi.ivt %Av hWM%3J.)w
, mm . e *l, h 2[ ,1 . , -N -
l-&.
~ '
s' f*1A --] Q _
l i
, An illustration of the convex surf aces of the five smaller diameter pipes after bend testing. These samples are TS-63 through TS-67 sequentially from top to bottom. No evidence of any defects were observed on these convex surfaces after bending.
l l
l
_-__=_~n_-- . _ - , . . - . . - . - - , - . _ , - _ . _ . - . _ _ _ . _ _ _ . . . . _ _
No. 7 Y
,e . ,
'~ :. ..agk,.
.. -.f
~
'y ? ?l5.l th L'g ,. & l h' f] . '.) E;.i. 2.
~
...d;f# ! ,
)
I .
d - l -" if 4 $$?$i?lpl
- ^ " l
- j. '
-~
- - I ' ,
10
~ - - - -
g' _ _ . . ]l I
i A photograph of the f atigue testing set-up used by Materials Research Lab. on the 2" schedule 80 pipe.
i
-p
l
) .
f . .
i f
I No. 8 l
l l
l e,-l,i. V t+f 3" I . k . k'sM y ."
h.(
- R . f.k} I l '
.G<g ? f?f ~.3.,.W ; V : *s ui, tf,.-c
- v. - - t. .u
. z , ,.:. ~
y 1 _-
w
" .E. .^' f; . . kh1, j. -[- u
.. m. . :
.m.~.,-~.-
T. -
. 't.( , _
- - 2~..'
.' u ;. R. .
. '. g' <. ,
2.- . ,c ... ,
g .,
p ..-
s
. _-4~%'
- t.
- > T *
- .- (n
~ : ;4: .h
..? 's - ' ; . i .-
'g, J ,
. ..(t..
,; .. . 4. #".
i
. ["f .
M $, . ' - M, A w, y' . [ [j ' 14-_ 1
. s, . c. ' w q.e .. -
- c . .- > ,
. s, 2 . ....e.,..
<. 3 . . .. . .. .
s- . .__s -
8.. , , ' .. - .mg- . .; p. - . ,
- s 4, :. ,; ' , ?. 3.
( T . Ji #* .
,e
, f
..u .,' , C . .. a{. -
~--+**g :kpfgis , E M',yh.4lN # ' ' 'Q % @ ~
a I
t*
a
?
, I 1
I An illustration of the macro-etch section from Sample TS-50.
I i
l l
i
I No. 9
, i e
. i
~ ~
- [ - t
- 34. ,
?.
gg*:n .o s g
~;; ~ g:
s
~~*'* , #~ "w h? . . . .',. ' . .'
. ; l.",f jGy .
....+.-
-:20
-.. m .
- ?,.Q ,
\
.1 -.
A e ps# ,
s ,. .,
_g v p. .:
l e,y,
,v .
j
'' "E ;
., _ _h -
@ .. * ' -N ,
. ." iEM ,' .': "g. 3 )
e='i' . ^ - -
Mvw 2r c~. : .- -
i y - -s ?. 7.m,
'...-. . , . ;:^- . . t ,. 3 i 5 -*:
a he,s. . =$ ,%~-. . ,,
no sg - ~ ...... . . T... yv -
t
, ..._, 2 3. v. s. -
.2A m ; . ;< ., .
_. ,:. s%
~ 2 . , g - . .,
. _ . . *g__ - . , . . . J. t
,;. + fWr L_ . .;g ' s l
i g, _ . _ _ . _ _ - _ . . _ _ - .
l I
V l
)
i l
1 I l L i l l l
l i
I Examples of the visual appearance of the macro-etch sections f rom j Pipes TS-51 (left) and TS-54 (right). ,
1 l
l )
i l I
i l
l l
l I
l i
__ .- _ -_- _-_----_-.~_.--
l No. 10 h c g
+ f 2f2h )j[ I II)._Nh ' ,[ ) ',
! ,j.' ~hQi~.C
%.2 ' '
n- *(
,.% -4 4. $.._, Jtiss '.8 ,
di:^? G . e.Q ! $.2
.qa
.,;-. - m +
, _s
. ; . .,4 -
A, ' "4.
.3 ..
d-
-) _ l% _' 4[ _ - ,A j
m b g-y;;*;; v ..
- n + -
, .r
-y , :_
- " e,g.
- \ ;;+
9:
^$* *p-Q4 $g v ,Qg". ~ ~:. . ... r .z.+ sw+: dt y
'p n- - .
~
Gi fi Q.u L;/j' -r > ;.
$gh1 5
-r - :: - _& _ .. . .: ? s p. , W _ . . f ..
a -
I L
4 5
A photograph of the macro-etch section from Pipe TS-52.
..,---,_.._-.._,...-.--...--,--..,,-,.,-nn.,,. . , - - - - . , - . , _ , , - - .
l i
No. 11 i
1 l
l i
L em e"n ,
..+
4 m h,o. ..s
.T v..g. ._ \ ..
- . .v
- -.2 -..e - - -
,,~ 'g .
l,. I, .I,[ [i-X
-sigj } j.k l
,E *7 _ .. e. . , {l
- T g " '
t' 53 t' ?' .+;
.)
xw w, pe.La .~
. . +. .v .
.3 f.e
~
? *- M ~ ._.'( .. m@ .- .
-hW c
.y h
2 ~n $Qy
.Q.Q* -.. . i.* .e ' ; . .. ,
? ..j.- s. .' .,i, , 4 Kgg.9- L ,. . . .
. . _ l
..e.
w.
. ~g<. , . .
i 2 .. , . , .. .
. .. s. ,
..n . , . -~ ..,g. ;
- v. h M _ ._;. . .
?_
- e. I ,
027 T *df 4 0 -' -
\
1 b5 Wf _
+*f
\ , - - . - - ._
1 f
s s ,
l l
Examples , of the macro-etch sections from Pipes TS-53 (left) and E
TS-57 (right).
l l
l l
l
l J l i l No. 12
~.
~
- . ~ r _ ,
yv. ' ~~ , '. -
,- . ;ic.gr. $ ;_.. ,
,.,- ~
37, ,e .w- -
?
.9 a .-
. g-p-
M g .yt . w. : , y 5 p~ ~s -
.y,. ,
t - --
- g. e . *
- - 4L} O ) . . ..
n
' sk 1
%l*
+ ,'t. :
l ; - . -
, . ;' ay W' -
~- ,
- f." , ,7 E.2 , si=
~
y, i ,
- v
- }
S 1
,g .
t k. h.:& .
- IT i Jpg.; ^
l W ( :y. . . '.y. , .- . . . . - '. .~.
< ~r:. ., ~ . .
._ .y .
gw ht A ' .
-~
f =g 1
- .s- :s
_'".f ',c K ',LJ '. , ,,_ , .
l w3 Y ar+. 1
-- y' j..% e[%p 4 "",4 n uw. w :=. -. ,:.
. %.3;;. -
1 j
j
.xy
. ,;;s 8 -
t -w M <. , - ... ,rl f I
-gr y ,;'. .c;- ' - . -
. :. , .,y_ _
~. .
- _ l
. l
_ I r
The visual appearance of the macro-etch sections from Pipes TS-58 (left) and TS-55 (right).
l
No. 13 l
l l
., -m e g. " -: - _. % .
f, I l
(. , ! J ' .' i - { ?~ h gg C gymy; 2.'
- 3. - - - Q3 T 2 ~e .h: -
#?.:l- r- -. m
, . x ,......%. . -1e .:. 3 j?t' w :
,t yr.'7'.: : ' he . mg = . -
Q: -
=~,g.
w: . -
.- 4
'c -
,:N
,f' -
a ,
."L _ _. -
.>.:~A i ,
.f . J r t Ey ,,
l l I" s E h*., ', bf's " . ^,1 .
~
.? : .g. ,
~~
L, r... _ . ' . -Y-e- ,- .. x --: . y . .(( .< Y, .
>- ' E g e;[-
,,['
m.p ~ ' -c .+ :%; , 1 i.. . .,p'% J
.'g u _ v - 1.7 ,Q w ~ ase ~> ~ ~ ' ^ ~
.3 i.
; =
,k e
.. :3,%: .:ea-:.
- U ys ,p. .
- v. :
- %-^~.s;gf:;yu.
,y _- ~ , g s _ 'T-~.~.
. s ..
- n. ._ - . .
I 9 1 A photograph of the macro-etch sections from Pipes TS-56 (left) and TS-59 (right).
l No. 14 s j;. a . 4 R4 asM^) ' e-..,, k ' 4 ~
M ;
.kh.-
kb ? bi4:0 FR46 Y'
-w A k s
.i. .
[MredAL & N i I 4 $;'% NE' E - #. ,
$2 h2 i . _ . 1b s ') Y.u N h
i I !
. l
] Magnification: 100X Etchant: 17. Nital l A typical example of the microstructure and surface appearance along the inside diameter of Pipe TS-50.
- .- _a
i . No. 15
~ - , . . -._ 4 -
jR@g3". -~ ; : -
?. f.'
.- . ; - 2
('
. . ' ' ., 2 Tr % rF .. l~.'N ':,
f'.
~
. ? f,';I ,_ 3. .
Ek hM MY .w ~- . r- v
.; y ;_?>-
~ ~ ~ ~ ~
g . .?;-
~ t .-f- ]
. .- - - -.,;. . x ..
E
~ , i ' , 't *
I- '2,
.v),! t{ .g.
.. h$u(h0h- #4'h'a,Ng?f.I ibIkbW'G . .
$Ns.A.Y2$8554$-h*iW*:kE?$ '.%z$p $N N?
T/. W8." 'k,*h,,kf.W
?~
l , I f i l l p Magnification: 100X Etchant: 17. Nital An illustration of an area of severe pitting on the outside diameter of TS-51. This is not a typical area.
~
y- - w- y ,e---
No. 16 l L* % ,, f.
~
,N. s Cy 8
- I p .*[ N M p, /g
%Dg?h.C h[7.. b, %;igy? y *y. ;
W^$$U *s=tyhh llff ^ l
~ . }
R $. .: -
~
{. ~
..~
l I , i l 3 Magnification: 100X Etchant: 1% Nital I An example of the microstructure and surface appearance along the inside diameter of Pipe TS-52. A layer of total decarburization is shown at the outside surf ace with very little pitting or corrosion. The indentation in the surface was caused during the forming of the tube and is not due to corrosion. l
- - - - . . - - . _ _ - _ . . _ _ _ _ . _ _ _ _ _ _ _ _ _z_L
No. 17
~
, p1p _. .
Y e.
'.T.; A [gg E - g T. ,.. :;. _:; .
." [ ( [ -#D f.
['- ,-<w- .
-'.w7'i y
', ~ } ;
...-y...- , ,. .; . s - .>
,g' e $y.=W ~ ;= ..
;w
; 5 4. ,- . l
- y. ,
p g. '* -[ yre mCWf a.- o, ., 4 Y N -, '. '
#, ,,..g'
. . m t:.Tg '.
'" ,~l,' 9,..: -
g I
+;- -
~.p:? wh .g,g,..'V n 14: g g ..~; - ~
. ,;~ . -
Ng rg - , n < n - tf -:- ^.9, ,.
. =. c, . ,
q ,. m..
.- a. ..
.*N S,a .,e .
(. p; _s9 ,4 g,4 o..f... %.
, . - , -n ' :
n ?- = L
%--a - h '.$ p> . : v4g9c LW ..
\,
i k 3 ,,- 2).k<. .. .,'..w%.p E.s- $,w*s, }w:,. t. ;. A-t m.- 4: W g. # qCw. h2 . n 4. l . n.:. s $ Nn ? Nhi? 4 s , .-m.ln ,. n.+.5
. - e4
- a. +... %
'R ! . .
D%^I 'M M
'M. . .>h.y'_d3* *l 2. h>J IN-t? kD. }f-t i
I
- I l
l l t
, hegnification: 100X Etchant: 17. Nital l
l An example of severe pitting near a lap on the outside diameter of Pipe TS-53. 1 1
.I o G !
No. 18
- i I
I i
?'
' f
-l s '
.. f. -
J 2
~
^ifu . 4 d ... '
i .u; : ,i
- s. n-C p , IV. *..
L..*!. 'R. , Y 4/kN'h I #.I .h . , ff a [ s N'$
?--~- I
. h.r$$$ R. k : g(d@@ *! I g* -
N65k
. ~
~
nay.. ~a t.. 4
/
*f.$. $
?i @$ .ET'scM'Os$y$d 55!h
~r/N2/ P'Q f,f h k p , f .c :,e-m'.d*v i
n Q wp: s1,
*y;;~ q::x:::.;. o : ;45$2.. .;,.gy3{
T.'yn.:?,.~.A :.c.?lt',f , &wu.s .?.p 9N.:.L? s;3j;M.w.c
.. .w. nxg..c .- s ., q:r ~ .25 1,.,cc ... - '
-> u .s. c ,~6 t%,., a .M_g '
-(!QY',gh?2
' . '.2 :n' h o :M a. % y;*+Q.",4.:-:?p%e$$.+F'Bg%'x
. .W.f. Wyx..: te.m .c.J;. : R~. y /gl~?W*
&+ .d % '.ts lbsu 4
i- . - t 1 i I o i l
' Magnification: 50X Etchant: 17, Nital An area of unusually severe pitting observed on the outside diameter of Pipe TS-54.
1 1
- - , - p --
y ----*-..---m-.,-+,2. - - *---r- w-w--e-c----- .y ywww-.-.--.e--e---,w,..m- .w _-e-._m_
No. 19 l i 1
^
, . l. . t
[ ' 3 I .... [ . Y ;#2
$'. .~-
!I
. cy .
'hk 7
Nr {
^ ,, T Dk [E ,
F.,
' t;
- . );rs;.rp3D ev i * ,
g -~uas q4,. -
,A l I .,,4tp . w.
'6., '
=
, i L N;m 6 l
I e Magnification: 50X Etchant: 17. Nital This photograph illustrates the microstructure and surf ace condition at the outside diameter of TS-55.
1 No. 20 I l I I I i '
\
\ n:
....c o; t
',p<ts K , '
... -j ;4
- z s.v./c r:..
, l h nj;)'lls.Rilp%s
, .h . . . g '-.
n : I , . . , v. + ;e .
.M, ,. 4 -[.[s v. f,
.. -
- J.h ., , ,g a d VA- '
. i
.~l4.,.y A kC. .~,*J. . r.o, h..g.1 .
.'f1$ 'k h. $E Y'Y. .
l
.F.s . Gl.y...1.:-!;\
.:j 6 ,-
;.gudSpDPfis.4? i p.YS .'@
#f4 1 W.4 t-T'@7%4.$'.*N,4..GC, h? y:?y.IM.9.u .
5,4/s:v'i.t. ' " ' 4 v. 7 ...>. u x ,:p .e-L<..v=.. ,,e f E .a 3
..ry
- e.- :.
%~,,'t h%w.v., -
. r .. . . .1,g+g c-an. si . - .u
< M <.'M6 i:$ Gli&": .k.M d,w'$1$:s.}';.tt. i .v !. e . w s. :. .n.
' Q' j .
. ..[.- ;
d i Magnification: 100X Etchant: 17. Nital An illustration of the largest pit observed on the outside diameter of the metallographic section of TS-56. These pits were generally isolated with a smooth and regular surface between pits. i i l l
No. 21 l l l
)
l i I p.r ~. u,
- u. : S..: ;
\
.. ~ .-
n~ rp:y'. 1
' ~
Nh..ngr"n!p..?,
-= e b/hh
.. t.
i 8 ..- ~#:#.ays, :x .6,.nu.r., s. t _..x%, . :~ ,. v v...,r j,,. l
.v. :e.
,. .s ..
,n.v
- 4. s : ,
.., 2 .
e.> f- .
. . . e,*,,
.:x
. i. . k ;;.,.:.~.. .
;.y. .r.
ru <>u . 3 vs.: I .. -Cs
- .s r s.v : :
- .%:.a.,} &'tWo.
.Jc'.sLw,..::..p:f'?yM,g.s.ea..
..7 t j.Y-l;$$YW'C$f? y .es n
.m f w s ,'f,hf'$-$'Le E@f?&,s
.v
/c v .:
..h. ,
. h b'E.'.
-,;f l L.
I i T I I l l l e Magnification: 100X Etchant: 17. Nital l An example of the outside diameter of Pipe TS-57. Later testing revealed this pipe to have been subjected to a zinc coating and phosphate treatment which would resist the effects of corrosion.
~ . - - . - - - - - - . . . - - , ~ . - - . . ~ . -
l I No. 22 (vy-:x -M I l
. M' h h .'J
- u. .. p%.. ,. s 4,yl ,
.'; 3,$-4
?-S i [.Atw4 $ y:%i.:&,M+ .
( L.* s i. 4 ' 14 s., x . ., 3- n.shw.
.s c ?-
t.s<h.,:isg% (p m -c.::r?;<
~.
- v 2 tr.o.#
vf'#1.:. e g 6y76 et J. (dt. .s;j}p' 8 95 %- .... %Y <
#. y , i-
Y ,Vi pY'.M *g 0(.%'2;E r s b'O S f 'f;f. 7 .*:-?
g , l *i. .
?)
- .*5 Ja .'V.4b,c / . g TN a s[.f*,e'.~2 .s
*+ %r a p' , . ,. '
s ,~' - . t.+Q.
- s. .s.t' y:r ,g?e g. nf 6 4= . *.<s".5 ; P, ? Q:. e $ :+}.;
$$hDT?d$.v}<dQQ .5 ? 3 @ $ $.+ s&,F'*.
%'Lfn- '
b -. -
'S'.9 i %%re'BM.?;Wl&RiE4db?%. f"bWM_. 5 e t
.l I i ' e l Magnification: 50X Etchant: 17. Nital An example of a typical area on the outside diameter of Pipe . TS-58. l i I i I i i i
._- . _ - - - _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ - , _ _ _ _ _ . . , _ __ . , _ . . , _ _ . ,,. ~
l No. 23 l I 9d';g.~;%ys .:, % :6. ~. l,i.'Nh.T'A.5%.
-s w.V&. . r ,/.t,N'
, W -
.s; .o . .%q
.r.p* b3Ds%q, Ms.m. N.:. c*:< s G;a..< , : ,
- p.wv -!
I :.y
* .~ i:c .r,...ir,..
.,. - . i. . Y4 e
6 ' f /.'
'. 4* . .r.d ..jA);:v, .v
. .g .4 -
l t :'a .r := .
.W-:- .;~c %..h n is- g &g. w $..
.m..cy~
-p p.t j .4 cc?.~.;,,~g u,
. - Q.: c.?.U,.,s ...LW.n . ,, a ;y ' &-
h.' , .* : $i;f# 3Q v r);;t )o. w"'9 6 p ^. '.f@. y'$fQ>.. L'.ij ~.'4
,. e .e -4 i /,t.>i
. < J a, w .,.!,c3 - 'f.n& gTf.d
'a. 'iv>, , . ,g,
! 1
* :y : *i ' ~%. 6i- r.*,.& . . >. Y 4 r.
.st -
. 1
,g -4:g s...'.i'r&. f,?
. .t g g, ,4,s"
,,. s,. .
./.ger s.C.\c g y p;&?.g.
v.G1
.,g . e' c ,
l 1- - -- I 1 l l e l Magnification: 100X Etchant: 17. Nital ! A photograph of the microstructure and surface condition displayed by the outside diameter of Pipe TS-59.
l . I No. 24 t
]
.; ;..c, _
\ **
,, . h f
'2 . -
4+v[r .
,6 M ,D, -
e u
- .-.. . .ss .. . .. >.. y :
e
< - a >
._.,u ~ - ~ :
. A. .
. -) . y 'X A.- -
. Lt% ., % s. g $ '**
..g r. -..
. < . ~
I . .
; ~. . .:
- 4 :
~ . . : (-in-:s :af _
, Q . ,, -
i _. 4 .- *
; ~ - '
. f~s
~ '~ .
- 7
-,' ' t . p.
n . a e, s I g., K, . i.'W 2- -1..A.
' s ;
i _.
-~
.e c n.: :' .
-- .' l r -_
, - ' * .. . ~
8~ -m. . M ,.- ~ ;
+
. ;. ;, ;... a-r ";
.1 ..
1.. - . =~ g
. 4sp . , .
.r,-- r 7, ,. v ; i .: ,..
~
~_. . s:. .. , -
a
..r.
- n .._ . ..
e . ki;a
- &::t, , ; ,'. .
.: 4 5
g f i - l l i i I An example of an EDX spectrum obtained on the inside diameter of i TS-50. The highest peak near the center of the photograph is due to iron but a secondary manganese peak has been identified. The relative peak heights indicate the approximate concentration of i 1 each element. i l I l
--- - . - ~ - - - _ _ _ _ . _ _ _
e e # No. 25 i. l i f' . - %'x * , ,, . J.' ._. - a-
, me -
o~ .. . '.- ~.~. { _'
. . , e-a>+",*"..
... u. . 1. .- . - - .
~8
( I, I et
, ,t, $ $t t
- m. B e f.t. ,,.
)
. c.9 ,8 r
=
R. , if.;.-Ay4h y e .- ' i 5' j V. Q Typ3 .. ]. 9.- [ }- 4e _ . l .; s . 3,
- ..r.
-.S
. 5 .- -. ..
e - .,e g-1 w-. . w.g- , , , .. y'- - ._ ..
- z
-t
.w .4 . . ,,: ..n.. .j ( ; _. ; .
'f:1 a .
--s.
.;,, 4 f ,..-; c =- '
*: - w
,v .
3 ..
% y - . ,. z.,
, .. . .. [ ~ _ ~,
*?~
. s. . . .
-.g
~-
- . - p-m...- . ., . , 7 s ' ' ' -
- , 57 ' i 7;_
-9 .
, . . = g g', v ,
~
- f,-
l
.'eAi.
. .e s:me g7
- . . ' . .. . ..'.e~ .
_ . _ _ . _ _ . _ _ _ _ _ . _ _ _ _ . l a I 1 i i l I a i e j An illustration of an EDX spectrum obtained from the outside diameter I of TS-52. Again the high iron peak has been incorrectly identified l as manganese. Much smaller amounts of the other elements are also
- shown near the left of the photograph.
i \
I l No. 26 l l l l ._ . I 1 i
. a.
. s* , - gr . .. -
s ,1 , i
- e. ....
,.s .s\ .. ...
t:
. . .. ...,, sz.e ,
p _.-
- .ii .. .*
a.s i,a j ., s : v f , .
~
I 4 , I~ :
, . A'9., %.
$... .5N.-iC+ ..
c m'- . ,.,. ,.f. y- , e s.
, a.:
, p ..
4 .* g g . . . . t .
. . - c l _
- . c. .
I n .
. - 4w , , -
i-z .
. a. " t' .:
.. M.A ,4 s.;- t j
- : s5 . ,, ,, . .
j s 4 -,J f - ' i l 1 -.2, A.' s, .. .
} l I
I l l l 4 i I i I I i I L i i l I An example of an EDX spectrum obtained from the inside diameter of l Pipe TS-53. l l
l l No. 27 I
. 4 's y
~~
I ( ,. .- ... .-
- .. ~ .i..ss.
l ., n ie y
'4 "* 'I ' I, '
~
I I ...se se . i r
- L- e a
-e64 ga3
&$CC tt
-' N -
}
.. f 9 g"^-
~ "f' ~ .
m s_ l
) i; ,'. .'." - -t s .l j P~ 1 s
,. n -
f 4 . '
.n 74
,d -
4 I
'dr f j
) . y ~# .y J ; 7 .
-r -
e; _4.._,, _r-7
'hp
..v -' . -
, ' Q..q 9 ',/ . .
. -W % - P
- - w. .. ,, :. * ,
'K _ * ~ - . p,
; ~ .* , s . *
;- - . g . . .
t
- . . s . . . . .- -
l l t .- -
~a,- - ,
- ,' .y .
- h --
- ~ ~ -
g ~. . _. h:. N . _> ,
. . . h. 3 .
L 1 t I I. 1 l This EDX spectrum was obtained from the inside diameter of Pipe TS-55. 1 I _- ____m___.-.-~_m.e-,_-
4 l I l i No. 28
.. . - .. : - t .
>><=***0. ,,,.
- r. " . u .Lu .-. .u ,-
. . e e e. -
i c .. g' . 3 s I%. - ; ,
' 7,* .y [ b ..
i l l - 1 , , . . , - 1
- . 4 L ,
l l
.lO1 &
~~ hee- t . .
u t ' s I i ' l l
' An EDX spectrum obtained from the outside diameter of Pipe TS-56. l The vertical scale of this spectrum has been increased to enhance '
the lower concentration elements. The iron peak in this photograph greatly exceeds the vertical scale. 1 l l l l i l
s 1 , I Materials Research _ s. Laboratory, one science Road , h ea C d e 312 lpc, Glenwood, Illinois 60425 e Local telephone 755 8760 e Chicago telephone 785-4020 s February 18, 1985 MRL Job #6-14180
' P.O. #10775 t
Mr. Mark Hineman Taussig Associates, Inc. 7530 Frontage Road Skokie, IL 60077 i
Dear Mr. Hineman:
Lengths of 1/2" and 2" diameter schedule 80' pipe, supplied by you,'
- have been tested in fatigue. It was the purpose of these tests to co: pare the fatigue properties of the " normal" and " corroded" surfaces \
on these four lots of pipe. Load controlled fatigue testing was carried out in four point bending (R -1) in a setup as shown in Fig. 1. TMe 2" setup (1 - 24", a - 8") is pictured and the 1/2" setup was similar except that 1 - 12" and a 4". These room d eeperature3 and tegts were run at stresses expected to produce failures bhtveen 10
?
10 cycles. and are The results of these tests are collected in Table 1 g pictted in Figs. 2 through 7 These figures are plots based on stresses calculated on this schedule 80 p;pe using both nominal pipe All results are also cocpared to dinensions and/or actual dimensions.
' the results reported in Fig. 4 of " Fatigue Tests of Piping Components",
by A. R. C. Markl. Trans. ASME, APR.1952, p. 289. s i Failures were, in all cases except for the 1/2" corroded pipe, located at one of the two center span loading points. This was anticipated ::ince the maximum stress occurs here and an additional - gripping stress is also present. g Of the six specicens of 1/2" corroded pipe run f ailu-e occurred in five specimens, away from the loading points into the area of constant coment (stress) in the center of the span. Very truly-you-s, i (r _
<~
Q. { J. E. O'Donnell F.. s. d JEO:smb I Encis.
I g APPENDIX 1 1 Material Research Laboratory Report 1. L
?.
l e i l l
l 1 i l 1 u 6 No. 30 a i i , i
. . i l
, I l j
,- i l
-. 3 . 1. . A , . .,
> . p .. .
o, .in. . .u .t. ..o - i..** = .
. t==
4
~
\.; . . ,
g w ,
< i
, ~ ,
g 1
/ ,
5
. n-->', .y * ' '
.,.,y_, Y,
,f
.s e -
* - ..v
. y.
j Y g .
. g s i
i 1. i f 1 f i e An EDX spectrum of the outside diameter of Pipe TS-58. i l l l l 4 N l1
. = l 4
i i l i No. 29 l ) l ! l
. i i
' i j
=
.. . , , , r, .
l
. . . - =
r
. _? .J'- 2 l
x -l
- l
,r .
b .i;I.a- ; icy . % > [
., x+ . A--r ,
3 n Jg_ _ y;.e .-
- T : s . ;; ._; '.~
I A i
. I I
This example of the spectrum obtained from the inside diameter of TS-57 shows relatively high phosphorus and zine concentrations. This suggests the presence of a zine coating with a phosphate treatment. l
e TABLE 1 4-Point Bend Fatigue Tests of 2" and 1/2"- Schedule 80 Pipe O Room Temperature . Measured OD Measured ID Nominal Actual 2 Reversals to Heat No. Specimen No. (in.) (in.) Stress (iksi) Stress (iksi) Failure U71443 TS11-1 2.390 1.935 50.0 47.53 10,833 New TS13-1 2.390 1.935 37.5 35.65 55,918 2"-Schedule 80 TS12-1 2.390 1.935 30.0 28.52 102,898 i TS13-2 2.390 1.935 27.5 26.14 270,207 TS12-2 2.390 1.935 25.0 23.76 992,305 KD6751 TS32-1 2.370 1.940 50.0 50.74 3,820 Corroded TS31-1 2.365 1.920 37.5 37.30 28,489 2"-Schedule 80 TS31-2 2.365 1.920 30.0 29.85 77,661 TS32-2 2.370 1.940 25.0 25.37 262,997 TS33-1 2.370 1.940 20.0 20.30 825.591 270431 TS21-2 .840 .545 80.0 79.87 659 New TS22-1 .840 .545 60.0 59.90 9,885 1/2"-Schedule 80 TS22-3 .840 .545 52.5 52.43 61,616 TS23-1 .840 .545 47.5 47.41 160,670 TS22-2 .840- .545 40.0 39.94 959,592 KD6830 TS41-1 .836 .546 60.0 61.12 4,735 Corroded TS41-2 .836 .546 52.5 53.49 14,510 1/2"-Schedule 80 TS42-1 .836 .546 47.5 48.38 25.303 TS42-2 .836 .546 40.0 40.75 87,626 < TS43-1 .836 .546 30.0 30.56 651,337 TS43-2 .836 .546 28.0 28.51 835,593 I Nominal stress based on ASTM specified dimensions (see Table 2). Actual stress based on measured dimensions. .
Msta:ata , , Rasesrcn Lecoratory. Inc. i 8 TABLE 2 ASTM Nominal Dimensions and Properties for Schedule 80 Pipe 4 Nominal Outside Inside 1 Diameter (in.) Diameter (in.) Dia=eter (in.) (in.4) 1/2 .840 .546 .020 i 1 2 2.375 1.939 .868 I i 1 I 4 1 1 i
Matenals *
- Researen Laboratory.
Inc. l l l l V ^ ,. ..
~ . '4-:.w I
/ _w W?.-
- .g ,... ...
k .
.x pn er, -
j M .^ 4g et ' ' ^
')
, fx L '
r , 4,3 jf. , ,, . _e e, . _2 11 ;
. _ F4 ~ ; '. _ _ t [
(
.~_ ,, - .
', U-Z ..
l
. 'l n N ;..
t 4
.,-%;l @N.e} . l
(- - .
. i k '
,y. ,,
.g - .
; 'q .. y; Q, ,~ g- .a ; ;
i -- *' - '
' 4. .
O ' i',f , ~ l , ,\_ \ p' 7,. .-j . . , , l 1 Fig. 1 Four point bending fatigue setup in closed loop i servo-controlled testing machine. Two inch pipe i setyp shown. i i l 4 i i
G
?$E -
ai; 89 % FOUR-POINT BEND FATIGUE TESTS OF 2"-SCH. 80 PIPE e RT I I 's ,I I I I I I I I
', s 50 N, o 's o HERT =U71443 (NEW CONDITION) -
- N, 's e HERT =KD6751 (CORRODED COND.)
' 'N,
's, N 40 N -
'I%,,,v 1 N s a 35 -
's 's k*t4q -
l0 a: N s N o
's 30 -
- 's -
In N
"%,, , N o
'ss -
e, a s E 25 -
%,7 s a
'se N -
E 0
's - -
s. z N, 's l 20 - s I I I I I I I I 1s 1 2 . ' ' ' 5 ' ' ' ' 10' 10 10' ! REVERSALS TO FRILURE [NF) Fig. 2 Fatigue results comparing "new" and " corroded" groups of 2" diameter pipe.
- Stress calculation based on nominal size.
I
f 55 - E _sil H% FOUR-POINT BEND FATIGUE TESTS OF 2"-SCH. 80 PIPE e RT . I I l s ,I I I I I I I I
- s 50 N, 's o HERT =U71443 (NEW CONDITION)-
j N - o 's -
- HERT =KD6751 (CORR 00E0 COND.)
, .-. s i M % - N 4 4 40 - ',
' ' s's*e ' c,",o ,
. 1 -
s M 35 - - s Nf% N 9
- J tn N, 's E 30 '
- n s
's ~ -
m N, a cy%,'s#r N, i a 25 - N - i o *h IN, J bs C e N, 's
- N, ,
j 20 - - s ! l I I I I I I i 1s i I . 2 4 7 5 ' ' ' 10' 10 10' REVERSALS TO FRILURE (NF) Fig. 3 Fatigue results comparing "nei.:" and " corroded" groups of 2" diameter pipe. { Stress calculation based on aci.ual size. 1
!$E -
_ i t ', H "r i i FOUR-POINT BEND FATIGUE TESTS OF 1/2"-SCH. 80 PIPE e RT ! I I N. s I I I I I I I I I I I 80 '
'. ' o HERT #270431 (NEW CONDITION) s
- HEAT mK06830 (CORRODED COND.)
Y 60 - - s s ,
) 's, e
's fo '**n't r&
50 - -
' '*si
' m ,
!O 40 -
- s. , ,
a:: s. s. G 35 - s. . ' s. , % J 30 - c2,'*Deg % '% ~ T z Pk]y s, s, s - s, r ' ' -
- o 25 -
s . -. z ' s.
' s. -
- 20 ; j j l l l l l l 1 1 'sj 1 1 i
1 3 gs 2 . ' 10' 10' 10' REVER5RLS TO FRILURE (NF) Fig. 4 Fatigue results comparing "new" and " corroded" groups of 1/2" diameter pipe. Stress calculation based on nominal size.
. . - . ,- - - .--.._ . -. .. __ ~ - .
1 . ! gw e' _i!! *
?? g:
4 E FOUR-POINT BEND FATIGUE TESTS OF 1/2"-SCH.80 PIPE o RT .
- I 'N- s 1 I I I I I I I I I I 80 o HERT m270431 (NEW CONDITION)
's , 'e,, !q
] ; '
-
- HERT =KD6830 (CORRODED COND.)
s m - s o,, or @
- y 60 - -
s -
's '
s s ' 1 ' ' - 50 - - s + s m
** peas (g,,uf s ,
i y 40 - s
's, s
! x 's - 's - - i e 35 - i m s s a N 's - - I 30 - - s s
- a 's -
s a ! y 25 - 's. 's, - s 20 ; j l [ i ; i j ; ; s3 i i 1 10' 10' 10' 10' ! REVER5RLS TO FRILURE (NF)
- Fig. 5 Fatigue results cornparing "new" and " corroded" groups of 1/2" diameter pipe. Stress calculation based on actual size.
i l l l. t
EiE ' , _&i"
- 89 0 i
1 FOUR-POINT BEND FATIGUE TESTS OF 2" RND 1/2"-SCH. 80 PIPE o RT . f I I M, I I I I l- 1 I I I I I 80 s
's o HERT #U71443 (NEW CONDITION)
~
- '
- HERT mKD6751 (CORRODED COND.)
' ' #* (% ,'#
$i 60 -
s -
,s ,
s, HERT #270431 (NEW CONDITION) s . HERT mKD6830 (CORRODED COND.T s s 1 50 - N - o s s ' m %',,) , -
!O 40 -
m @*'& s . - s M 35 -
's. N, 's, N. '
' o -
a! 30 - - s s E 's, 's, r 25 - ' -
* 'e s -
a s z 's
's -
. 20 ; I j j l l l l l l 'sj 10' 2 ' ' 10' la' ' ' ' 10' REVERSALS TO FRILURE (NF1 i Fig. 6 All fatigue data on 1/2" and 2" diameter pipe. Stress calcuation based on nominal stre.
J 3 Ja
~
! ! *r
- 5 ?854 n r u.
FOUR-POINT BEND FRTIGUE TESTS OF 2" RND 1/2"-SCH. 80 PIPE e RT . l N, I I I l l l l l 1 I I 80 s, y o HERT mu71443 (NEW CONDITIONT-
- HERT mKD6751 (CORRODED COND.1 g 's, ' s 4.,"f
' o,
- HERT m270431 (NEW CONDITION) y 60 -
s -- HERT mKD6830 (CORRODED COND-i s 1 50 - N - o s
** peg *%
$ 40 -
*Ed's, 's, -
e s, s, - 35 - s, s, - m s, s, g 30 - s, a s s ti C 25 - N - s N es
's, N
20 ; ; ; ; 'sj - i l l l l l l l 10' 10' ' 10' ' ' ' 10' REVERSALS TO FRILURE (NFl Fig. 7 All fatigue data on 1/2" and 2" diameter pipe. Stress cniculation based on actual sire.}}