Urvesh Vala,
Anunad Mishra,
- Head, Material Engineering & Technology, L&T Energy Hydrocarbon Engineering Limited, Gujarat, India
- Engineer, Material Engineering Technology, L&T Energy Hydrocarbon Engineering Limited, Gujarat, India
Abstract
A failure analysis investigation was carried out on a high-temperature studded pipe used in a convection module for heat recovery in an oil and gas refinery application after leakage was detected during pre-commissioning hydrotesting. The investigated pipe was manufactured from AISI 316H austenitic stainless steel, and carbon steel studs had been joined to its outer surface by high-frequency resistance welding. Two leaks were reported in the pipe under investigation, and a sample containing one leaking region was removed for detailed examination. The failed sample was examined by visual inspection, dye penetrant testing, optical emission spectroscopy, stereomicroscopy, metallographic sectioning, scanning electron microscopy, and energy-dispersive spectroscopy. The leak was associated with a longitudinal crack that propagated through the pipe wall thickness and exhibited a predominantly intergranular morphology. Metallographic examination further showed that one end of the crack was located at a lack-of-fusion region between the stud and the external surface of the pipe. Localized bulging and heat tint were also observed in the damaged zone. A copperish-colored matter was observed along the crack surfaces during optical examination, and EDS analysis later confirmed the presence of copper both on the opened fracture surface and along the internal crack surfaces in cross-section. Based on the combined metallographic, fractographic, and elemental evidence, the failure was attributed to an intergranular decohesion mechanism consistent with liquid metal embrittlement of austenitic stainless steel by copper during the stud welding stage, likely assisted by local overheating. Further investigation into the source and transfer route of copper contamination was strongly recommended.
Keywords: AISI 316H; studded pipe; hydrotest leakage; intergranular cracking; copper contamination; liquid metal embrittlement; SEM; EDS; failure analysis.
[This article belongs to Journal of Catalyst & Catalysis ]
Urvesh Vala, Anunad Mishra. Catalyst-Driven Degradation and Failure Analysis of Intergranular Cracking in 316H Studded Pipes under Refinery Heat Recovery Conditions. Journal of Catalyst & Catalysis. 2026; 13(01):-.
Urvesh Vala, Anunad Mishra. Catalyst-Driven Degradation and Failure Analysis of Intergranular Cracking in 316H Studded Pipes under Refinery Heat Recovery Conditions. Journal of Catalyst & Catalysis. 2026; 13(01):-. Available from: https://journals.stmjournals.com/jocc/article=2026/view=244322
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Journal of Catalyst & Catalysis
| Volume | 13 |
| Issue | 01 |
| Received | 18/04/2026 |
| Accepted | 20/04/2026 |
| Published | 30/04/2026 |
| Publication Time | 12 Days |
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