Flanges Impact Testing Exemption Assessment

Roberto Robles, M. Muñoz, Antonio Santana
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Abstract

Over the last decade, multiple carbon steel flanges brittle fracture failures have led the industry to issue a global alert on standard ASTM A105 flanges toughness values at temperatures higher than −20°F (−29°C), the minimum temperature allowed by the current editions of ASME B16.5 and ASME B31.3. The ASME BPV VIII Subgroup Toughness penalized these components by assigning the material the UCS-66 Curve A and modified UCS-66(c) to limit the minimum temperature of standard A105 flanges to 0°F (−18°C), unless the flanges have been normalized and manufactured to fine grain practice, after which they can be used down to the temperature permitted by ASME B16.5. In order to determine whether these changes would provide acceptable toughness values, nineteen (19) flanges were purchased from local manufacturers in both as-forged and normalized conditions and were subjected to several tests including charpy testing at various temperatures, McQuaid-Ehn, hardness testing, metallography, grain sizing, and chemical analysis. The results suggest that complying with UCS-66(c) does not necessarily guarantee acceptable toughness results for flanges that were normalized and manufactured to fine grain practice, and this is attributed to low Mn:C ratios and possibly uncontrolled heat treatment procedure. On the other hand, a number of non-normalized standard flanges have been found to provide very low toughness values at temperatures as high as 32°F (0°C), despite the current state of UCS-66(c) allowing use down to a minimum temperature of 0°F (−18°C). In view of the above, this paper discusses and evaluates some of the possible additional technical requirements that users could specify to minimize the risk of brittle fracture on standard ASTM A105 flanges, as well as a number of methods to guarantee better toughness performance in standard flanges.
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在过去的十年中,多次碳钢法兰脆性断裂故障导致行业对ASTM A105标准法兰在温度高于- 20°F(- 29°C)时的韧性值发出全球警报,这是ASME B16.5和ASME B31.3当前版本允许的最低温度。ASME BPV VIII韧性亚组对这些部件进行了惩罚,将材料指定为UCS-66曲线A和修改的UCS-66(c),以将标准A105法兰的最低温度限制在0°F(- 18°c),除非这些法兰已经标准化并制造成细晶粒实践,之后它们可以在ASME B16.5允许的温度下使用。为了确定这些变化是否能提供可接受的韧性值,19(19)个法兰从当地制造商购买,在锻造和正火条件下,并进行了几项测试,包括在不同温度下的夏比测试、McQuaid-Ehn测试、硬度测试、金相学、晶粒尺寸和化学分析。结果表明,符合UCS-66(c)并不一定保证标准化和制造细晶粒实践的法兰的可接受韧性结果,这归因于低Mn: c比和可能不受控制的热处理程序。另一方面,尽管目前的UCS-66(C)允许使用最低温度为0°F(- 18°C),但人们发现许多非正态化标准法兰在高达32°F(0°C)的温度下提供非常低的韧性值。鉴于此,本文讨论和评估了用户可以指定的一些可能的附加技术要求,以尽量减少标准ASTM A105法兰脆性断裂的风险,以及一些保证标准法兰具有更好韧性性能的方法。
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