FAILURE ANALYSIS OF SHEARED SHAFT OF A BRINE

RECYCLE PUMP
1

Saleh A. Al-Fozan, Anees U. Malik and Mohammad Al-Hajri

Research and Development Center
Saline Water Conversion Corporation (SWCC)
P.O.Box 8328, Al-Jubail 31951, Saudi Arabia.
E-mail: rdc@swcc.gov.sa
INTRODUCTION

The Manager, Al-J ubail Plants in his letter No. 3226/1648 dated 6/12/2004 and
3221/1/4-560 dated 7/12/2004 addressed to the Manager, R&D Center, Al-J ubail
requested R&D Center to analyze the cause of shearing of brine recycle pump shaft of
C-3 unit #15. The R&D Center decided to take up the necessary investigation.

BACKGROUND

Al-J ubail plants Phase 2 A&B consist of 40 desal units. Each unit operated with two
brine recycle pumps. Pump columns and elbows are fabricated by Ni-resist D2
construction material in all four areas. In C-2 and C-3 the brine recycle pump columns
and elbow were failed by stress corrosion cracking (SCC), while C4 and C-5 brine
recycle pumps were free from damage. The results of investigation had clearly shown
that the .cause of failure was originated from material. Therefore, the columns and
elbows were replaced by 2205 duplex stainless steel, which has better corrosion
resistance properties.

The upper and lower columns and elbow of brine recycle pump (A) of desal #15 were
replaced in 1997. At this time, the pump was overhauled. During the period between
last overhauled and failure, two new rewind motors were installed.

VISUAL INSPECTION OBSERVATIONS
1. Pump was sheared at two locations.
2. Many cracks were found in key area.
3. The failure appeared like fatigue fracture.

1
Issued as Troubleshooting Technical Report No. TSR 3804/05005 in August 2005.
4. Sleeve was found broken to many pieces.

OBSERVATION FROM OPERATION DATA SHEET

1. Unit was tripped or shutdown on 30/10/2004 between 12:00 and 16:00 hours.
2. Unit was restarted between 16:00 and 20:00 hours with one pump only (Pump B)
on the same day.
3. On 31/ 10/2004, between 16:00 and 20:00 hours, the pump B trip again.
4. No information about the reason of second trip was available.
5. Pump A was running without any indication of problems as per plant staff.
6. Pump was not returned to service after the first trip due to the failure.

OBSERVATION FROM VIBRATION RECORDS

1. Pump was overhauled on 1997.
2. From year 1997 until the end of J an 2000 the vibration trend was excellent.
3. On Aug 19, 2000 new rewound motor was installed.
4. The vibrations of new motor were considered to be high.
5. The vibration of coupled motor and pump was slightly high but in acceptable
range.
6. The pump was kept in operation.
7. On 8/9/2002, abnormal sound from water cooling line was recorded.
8. On 1/11/2003 abnormal sound was heard at discharge.
9. Vibrations were in the same range (104 at 1x).
10. On 26/1/2004 new rewound motor was installed.
11. Solo ran vibrations were high.
12. Balancing of motor was carried out.
13. After coupling vibrations of pump was kept as they were before motor
replacement (slightly higher than 102 ).
14. Last vibration reading recorded before incident was on 8/8/2004.
15. Startup with present of T&I was carried out on 31/10/2004, one day after unit
trip. Pump was found noisy and not taken load during test run.
16. Motor was transferred to desal 19 (P-3B), solo run was carried out on 6/11/04 as
per T&I vibration records.
17. A metal piece was found inside motor.
18. T&I recommended internal inspection of the pump by WR#1888619 dated
18/12/2004.

DPT RESULTS

1. Cracks were found at many locations in key position at both sides.
2. One crack was found in groove in sleeve area.

Figure 1 shows the cracks location on the shaft.

SAMPLE PREPARATION FOR METALLOGRAPHIC STUDY

The failed shaft was sectioned at different locations for metallographic studies. Also,
the hardness test was carried out on the cross section of the shaft.

CRACKS IN KEY POSITION AREA

Many cracks were found in the key position. These cracks were concentrated in one
edge area. Figure 2a shows the locations of these cracks at key position area. Figure 2b
shows closer view of the cracks on the shaft.

Two other brine recycle pump shafts were tested by DPT (D-1 P3-B & D-33 P3-B) and
no crack was found as per T&I DPT report.

DISCUSSION

Table 1 shows the chemical analysis of the broken shaft material. The results of
analysis show the shaft material is Austenitic 316 SS. From the closer visual inspection
of the failed parts, many cracks were found in different locations especially in key area.
Also, some pits were found on the shaft surface, which indicate corrosion activities on
the shaft. From the operation data sheet, it appeared that the final stage of failure was
occurred during the start-up of the unit after the trip.

Figure 3 shows the location of shearing in bearing area. The accumulation of corrosion
product can be clearly seen in the sheared area. This corrosion initiated in sheared area
due to the non-availability of protective film due to the shearing. Figure 4 shows the
failed shaft after removal from its location.

The material was evaluated for any change in general specifications. The chemical
analysis of shaft shows typical Austenitic 316 SS material, which is as per design. The
microstructure did not show any abnormality. Also, the hardness of material does not
show any deterioration of material as shown in table (2). From these results it is evident
the material was not directly responsible for this failure.
From the visual inspection, some pitting was observed on the shaft surface. Figure 5
shows these pits. The EDX analysis was carried out to investigate the origin of the pits.
Figure 6 shows the results of the EDX analysis, the chloride ions were found in the pits.
This indicates the initiation of corrosion process in the shaft area. The corrosion would
have initiated during the operation and/or during long or short shut down. Figure 7a &
b show the closer view of the one face of the failed fracture. The fracture shows typical
fatigue failure. The crack initiation was located in bearing key area. This area could be
classified as crevice area.

Failure Mechanism
The failure mechanism could be divided into three stages namely:
Crack initiation.
Crack propagation.
Shaft sheared.

Crack initiation
The location of the failed area is considered to be suitable for corrosion and cracking
due to the presence of crevices, the pitting initiation could be started in the beginning
followed by crack initiation. Due to the presence of stress concentration area and
rotation stresses, the crack could be initiated from the pit area.

Crack propagation
Due to the rotation and vibrations along with cracking, the crack was propagated as a
result of the fatigue phenomenon.

Shaft sheared
The last step of failure occurred due to the huge stresses induced to the shaft. The huge
stresses could be attributed to the reverse rotation of the shaft inducted by backflow.

Cracks on key area

Many cracks were found in the keys area of BRP P3-A. Some of these cracks were
found deeply penetrated. The dye penetration test (DPT) of the two pump shaft of desal
#1 & 33 was carried out to investigate the extent of problem in other pumps. As per the
attached DPT result sheets, no crack was found in both the shafts.

As per design the key should fit well in the groove. If there is any looseness then the
key will hit the key groove specially during startup and shutdown which appear to be
the main reason responsible for initiation of these cracks.

Possibility of Crevice Corrosion
The possibility of localized corrosion particularly crevice attack on 316L shaft may
arise due to its relatively poor protection in presence of duplex stainless steel discharge
column pipe which is more cathodic. This case is reverse to the previously used pumps
where Ni-Resist casing used to provide cathodic protection to 316L shaft.

CONCLUSIONS

1. The combined action of environment, geometry and stresses caused the crack
initiation. The propagation stage resulted by corrosion fatigue. The final stage
resulted by mechanical stresses.
2. The cracks on the key area could be due to the looseness of key installation in key
groove.

RECOMMENDATIONS

1. Care to be taken by operation during startup of brine recycle pump by ensuring
closing of discharge valve of down pump to avoid back flow from running pump.
2. All brine recycle pump shafts must be inspected by DPT during routine
maintenance.
3. The pump motors must be internally inspected.
4. It is advised that RDC should be assigned to carry out compatibility studies by
using duplex stainless steel as stationary parts with austenitic stainless steel as
rotary parts.

REFERENCES

1. Handbook of case histories in failure analysis, ASM, volume 2, 1993.
2. Metal handbook, volume 11, Failure analysis and prevention, 9
th
edition, 1986.



Table 1. Shaft Material Analysis

Elements Chromium
(Cr)%
Nickel
(Ni)%
Molybdenum
(Mo)%
Manganese
(Mn)%
Silica
(Si)%
Iron
(Fe)%
Compositions 17.7 11.5 2.1 1.6 0.3 bal
Standard 16-18 10-14 2-3 2 1 bal




Table 2. Hardness Values of Broken Shaft

Location Hardness Value (BHN)
From Edge to shaft center 200 158 150 140 145
Near from key area 165 165 162 165 169





















































Figure 1. Cracks Location on Shaft Surface as detected by visual examination







Top view
Side view




































Figure 2. Cracks location on shaft key area













Bearing
Bearing

















Figure 3. Broken shaft located in bearing area























Figure 4. Closer view of first rupture in the shaft
























Figure 5. Pitting corrosion on the shaft surface







































































Figure 6. EDX profile of pit on the shaft surface











0 5 10 15 20
Energy (keV)
0
10
20
30
40
50
cps
C
O
Fe
Na
Mg
Al
Si
Mo
Cl
Ca
Cr
Cr
Fe
Fe
Ni







































Figure 7. Closer view of one face of shaft fracture

A
B
Crack initiation