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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.bldgs.c9001697
EISBN: 978-1-62708-219-8
Abstract
Corrosion in potable and nonpotable water systems has been well documented in the past, and new research discusses innovations in water treatment and materials that are designed to enhance the quality of a water system, whether commercial or residential. This paper is a collection of five case histories on the failure of copper and steels as used in potable and non-potable water systems. The case histories cover a range of applications in which copper and steel products have been used. Copper and steel pipes are the two most commonly used materials in residential, commercial and industrial applications. The projects that are discussed cover these three important applications. The purpose of presenting this information is to allow the reader to gain an understanding of real life corrosion issues that affect plumbing materials, how they should have been addressed during the design of the water system, and how a water system should be maintained during service. We share this information in the hope that the reader will gain some limited knowledge of the problems that exist, and apply that knowledge in designing or using water systems in day-to day life.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001411
EISBN: 978-1-62708-234-1
Abstract
A welded joint between lengths of 4 in. OD x 13 SWG copper pipe which formed part of a cold-water main failed by cracking over one-third of the circumference. Microscopic examination of the filler metal showed that it had a structure corresponding to a brass of the 60:40 type commonly used for bronze welding. Failure resulted from dezincification of the joint material from the internal side of the tube. Also, a selective attack on the beta phase had occurred. It was evident that the loss in mechanical strength arising from the corrosion had resulted in the development of cracking in service. The filler metal used was not resistant to the conditions to which it was exposed. Copper welding rods as per BS 1077 or a Cu-Ag-P brazing alloy as recommended in BS 699, would have been preferable.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0091293
EISBN: 978-1-62708-234-1
Abstract
Copper piping in a closed-loop water heater system was found to be corroded with MIC and erosion of the weak oxide layer. Investigation (visual inspection, bacterial corrosion cultures, and 20x/400x micrographs) supported the conclusion that the corrosion was caused by microbiological attack, specifically sulfur-reducing bacteria. No recommendations were made.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.homegoods.c9001698
EISBN: 978-1-62708-222-8
Abstract
A residential subdivision near Tampa, FL was constructed in 1984 through 1985. Several sections of copper pipe were removed from one residence that had reported severe leaking. Visual examination revealed extensive pitting corrosion throughout the ID surfaces of the sample. Microscopic evaluation of a cross section of a copper pipe revealed extensive pitting corrosion throughout the inner diametral surfaces of the pipe. Some pits had penetrated through the wall thickness, causing the pin hole leaks. Analysis of a sample of water obtained from the subdivision revealed relatively high hardness levels (210 mg/l), high levels of sulfate ions (55 mg/l), a pH of 7.6 and a sulfate-to-chloride ratio of 3:1. Analysis of corrosion product removed from the ID surfaces of the pipe section revealed that an environment rich in carbonates existed inside the pipe, a result of the hard water supply. It was concluded that pitting corrosion was a result of the corrosive waters supplied by the local water utility. Waters could be rendered non-pitting by increasing their pH to 8 or higher and neutralizing the free carbon dioxide.
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001065
EISBN: 978-1-62708-214-3
Abstract
A 460 mm (18 in.) diam suction line to the main feed water pump for a nuclear power plant failed in a violent, catastrophic manner. Samples of pipe, elbow, and weld materials (ASTM A106 grade B carbon steel, ASTM A234 grade WPB carbon steel, and E7018 carbon steel electrode, respectively) from the suction line were analyzed. Evidence of overall thinning of the elbow and pipe material and ductile tearing of fractures indicated that the feed water pipe failed as a result of an erosion corrosion mechanism, which thinned the wall sufficiently to cause rapid, ductile tearing of the material after its design stress had been exceeded. It was recommended that steel with a higher chromium content be used to mitigate the erosion corrosion potential in the lines and that more rigorous nondestructive (ultrasonic) examinations be performed.