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Failure Analysis: Integrally Geared Compressor Cracked Impeller

The document summarizes an investigation into crack damages found on the impeller blades of a large centrifugal air compressor at a chemical plant in Yeosu, South Korea. Inspections in December 2005 discovered cracks on the stage 1 impeller blades ranging from 5 to 70 mm. Microscopic examination of fracture surfaces and microstructures identified the presence of microvoids and concentrated microvoids at grain boundaries, indicating low cycle fatigue failure. Chemical analysis found the impeller material composition was within specifications. Vibration data showed an increase prior to the impeller damage discovery. Emergency repairs were conducted to promptly resume plant operations while permanent repairs were scheduled.

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Abdulrahman Alkhowaiter
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383 views35 pages

Failure Analysis: Integrally Geared Compressor Cracked Impeller

The document summarizes an investigation into crack damages found on the impeller blades of a large centrifugal air compressor at a chemical plant in Yeosu, South Korea. Inspections in December 2005 discovered cracks on the stage 1 impeller blades ranging from 5 to 70 mm. Microscopic examination of fracture surfaces and microstructures identified the presence of microvoids and concentrated microvoids at grain boundaries, indicating low cycle fatigue failure. Chemical analysis found the impeller material composition was within specifications. Vibration data showed an increase prior to the impeller damage discovery. Emergency repairs were conducted to promptly resume plant operations while permanent repairs were scheduled.

Uploaded by

Abdulrahman Alkhowaiter
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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제8회 정유⋅석유화학 회전기계 설비보전 웤샵

사고사례: 대형 원심압축기 임펠러 블레이드의


크랙손상 원인규명
Case Study: Failure Analysis
on Crack Damages to Impeller Blades
of Large Capacity Centrifugal Compressor
2006. 11. 09.

이 안 성 팀장
회 전 기 계 팀
e-엔지니어링 연구 센터
한 국 기 계 연 구 원
Tel: 042-868-7356, E-mail: aslee@ kimm.re.kr
H.P.: 011-9404-7356
여수 S사 K3공장: Main Critical Workhorse Machines Composition

Gas Expander

0.5S

Steam Turbine

Motor

VS Air Compressor
Stage 1 Impeller
Layout of PTA Air Compressor

5 Stage Centrifugal Air Compressor manufactured by 외국 M사


- Normal Volume (m3/h): 180,000
- Required Power (kW): 23,700
- Total Discharge Pressure: 18.5 barA
Maintenance History of K3 Air Compressor

Month Year Event Inspection Results Remarks


Oct. 1997 Operation started
Oct. 1998 Temporary overhaul No abnormalities
June 2000 Scheduled overhaul No abnormalities
Compressor stage 1 impeller
K3 capacity-up
Feb. 2001 No abnormalities replaced. Capacity up from
modification
160,000 to 180,000 Nm3/h
No abnormalities
Apr. 2003 Scheduled overhaul
(PT inspection)
Oct. 2004 Temporary overhaul No abnormalities
yAir compressor:
- Cracks on stage 1 impeller
Damages found at
- Cracks on pinion gear of
Dec. 2005 Scheduled overhaul air compressor
stage 1-2 rotor
and steam turbine
ySteam turbine: VS side 1st
stage blade bendings
Compressor Stage 1 Impeller: Crack Damages
- Blade cracks occurred practically all over the stage 1 impeller.
- Cracks occurred at 9 out of 14 blades, ranging from Min. 5 to Max. 70 mm.
- Even within one blade, cracks occurred at different radii along its leading edge.

60
mm

70
mm

- Two cracks as large as 60 ~ 70 mm


- Rest of cracks ranges mostly from 5 to 10 mm
Compressor Stage 1-2 Rotor Shaft: Pinion Gear Crack Damages

2nd stage 1st stage


side side
Pinion Gear Crack Damages

50 mm

Gear load side crack damages


occurred at 33 out of 51 teeth
Steam Turbine: Blade Bending and Tip Rubbing Damages

Bending Damages

Tip Rubbing
Damages

0.5S side VS side

Total number of blades: 62


Bent blades: 15 (3 very severe), Tip rubbed blades: 12
Blade Bending and Tip Rubbing Damages

VS
0.5S side
side
Stage 1-2 Rotor Bearings: Babbitt Damages
Emergency Measures taken for Prompt Re-operation of K3 Plant

No. Damage Item Emergency Measures Remarks


Compressor stage 1 The modified failed impeller was The compressor is
impeller temporarily replaced by the old currently running
1 original impeller in stock. under a reduced
capacity. The new
impeller is put on order.
Compressor stage The cracks at the pinion gear Several months later,
1-2 rotor were all grooved-out to stop the repaired rotor shaft
shaft/pinion gear further crack propagations. The was replaced by a
2 whole rotor assembly was low- brand new one. But the
speed balanced. matching bull gear was
Then, the rotor was put-back in not exchanged by new
operation. one.
Steam turbine Without any repair actions on The steam turbine
blades the damaged blades, the turbine rotor will be replaced
3
rotor was put-back in operation at the next scheduled
and is still running now. overhaul.
Compressor stage Damaged bearing babbitts were
4 1-2 bearings re-babbitted by a local
manufacturer.
Detail Observations and Investigations in terms of
Macroscopic and Stereoscopic Examinations

Damaged stage 1 impeller after Man Turbo had


collected some test samples
General magnified views of the crack-fractured surface

(a) (b)
A series of profile views
(a) (b)
of the fractured surface (I)

(c) (d)

(e)
A series of profile views
(a) (b)
of the fractured surface (II)

(c) (d)

(e) (f)
Stereographic image of the fractured surface,
displaying the separated grain facets
Microstructural Examinations using
Optical Microscope

Sample preparations for


microstructural examinations
Representative microstructures of the material with no etching
for cleanness examination

(a) (b)

(c)
Microstructures of un-etched sample selected adjacent to
main crack (a) and micro cracks (b, c)

(a)

(b) (c)
Microstructures of the base material with etching

(a) (b)
Microstructures of the material, displaying main cracks,
microcracks and formations of microvoids

(a) (b)

(c) (d)
Profile of the hardness measurements
(avg. 392 VHN or 40 HRc)
Microscopic Examinations using SEM and EDS
SEM micrographs showing typical images of (a) grain boundary
facets with microvoids, (b) some residues on grain facets and (c)
cleaved fracture surface containing microvoids

(a) (b)

(c)
SEM micrographs showing (a) clean grain surface and
(b) residue located at grain boundaries and corners

(a) (b)
Spectra of the EDS analyses on (a) clean grain surface,
(b) residue on grain surface, and (c) cleaved fracture surface

(a) (b)

(c)
SEM micrographs showing (a) microvoids and (b) concentrated
microvoids formed at grain boundaries and corners and (c) interior
of the square marked void in (b), taken from the base material

(a) (b)

(c)
EDS spectrum on the square marked void in (b)
A summary of the EDS chemical analysis results
Weight (%)

Fe Cr Ni Mo C O Zn S

Material Bal. 13 4 0.5


specification

Clean grain 80. 15.


4.83
surface 15 02

Residue on grain 19. 4.2 16.8 51. 4.2 1.8


4.8 1.52
surface 27 1 1 54 1 5

Cleaved fracture 80. 16.


Surface 3.47
22 31

Interior of void 81. 14.


4.36
17 47
Time at Impeller Blade Damages and
Compressor Vibration Trend Data
Plot-0
200 VI6101A.PV
● Vibration of compressor stage 1 and 2 pinion shaft 18.094
UM
180
VI6101B.PV
○ Vibration of compressor main drive shaft 16.122
UM
160

140

120

100

80

60

40

20

0
2005-09-01 00:00:00 120.00 Day(s) 2005-12-30 00:00:00
C-6101 VIB C-6101 VIB
Further microscopic observations at the same magnification
for references

(a) (b)
(a) Microstructures of the blade sample taken from the failed modified stage 1 impeller,
having the material specification of X 3 CrNiMo 13 4
(b) Microstructures of the blade sample taken from the original stage 3 impeller, having the
material specification of X 4 CrNi 13 4, which is identical to that of the original
(un-modified) stage 1 impeller
* Man Turbo later confirmed that they are basically the identical material specification.
Figure (a) shows grain sizes of 150~180 µm whereas figure (b) of 50 ~70 µm.
Conclusive Remarks

€ Lots of cracks were found from many blades, 9 out of total 14. Many blades had multi-
cracks along the leading edges at different radii. Thus, the damages were overall aspects.
€ The fracture surface showed a typical pattern of the brittle failure mode, composed of
the intergranular failure of crack initiation and cleavage crack propagation by HCF.
€ Microstructures of the material had many microvoids and even concentrated cracks
mostly at the grain boundaries and corners. The material had a fully martensitic structure
with very coarse grain sizes of 150 ~ 180 µm, appearing un- tempered. Even the hardness
was relatively high of 392 VHN(40 HRc)
€ Comprehensive EDS results indicated that traces of Zn, S an O found at the residues on
the crack surface were only local events, happening to be trapped and deposited from the
service environment and that they would not be any factors on the ‘so called’ impeller
blade damages in hand. The main cause of the damages is concluded as the microvoid
formations at the grain boundaries and corners.
Conclusive Remarks

€ The microvoid formations in the damaged blades may be explained only by the
hydrogen-bearing environment at the impeller of large capacity air compressor. Thus, the
fracture mechanism of the present damages can be further specified as the hydrogen-
induced stress cracking in the combination of hydrogen absorption and brittle
microstructures of the material.
€ To reduce a possibility of the ‘so called’ hydrogen-induced damage, it is often
recommended that the microstructure of the material should be softened. But on the
contrary, the damaged impeller blades had very brittle microstructures with large grain
sizes and high hardness, coupled with no tempering. Therefore, the brittle microstructure
of the material is concluded as the root cause of the damaged modified stage 1 impeller
blades.

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