Determining the root causes of failure in low toughness carbon steel fittings, flanges and piping

Challenge

Failure of commercially available ASTM/ASME carbon steel (CS) fittings, flanges, and piping due to low toughness is a recurring problem.

Chemistry, fabrication approach, heat treatment, and the use of 100% recycled steels are likely contributing factors, but the underlying root cause is unknown, and existing industry standards are insufficient to prevent the issue.

Solution

• Test commercially available fittings and flanges
• Analyze results and present findings to industry and 
• Interpret results to determine root cause(s) of low toughness. 

Benefits

A guideline, when applied, can significantly increase safety, reliability, and quality. This will reduce the costs resulting from low toughness components.

Value

One company reported having incurred >USD100M direct cost due to delays associated with replacement of thousands of flanges in a single new construction project. 

A failure in an existing plant can cost >USD1M per day in lost production. Subsequent investigations, inspections, and replacements can cost much more.