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 Failure Analysis Case Studies II A Sourcebook of Case
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 FAIZURE
ANAZYSIS
CASE
SZZLDIESII
Edited by
D.R.H. Jones

Pergamon
Failure Analysis
Case Studies I1
 FAILURE ANALYSIS
CASE STUDIES I1
A sourcebook of case studies selected from the pages of
Engineering Failure Analysis 1997-1999

Edited by

D.R.H. JONES
Department of Engineering
University of Cambridge, UK

2001
PERGAMON
An imprint of Elsevier Science
AMSTERDAM - LONDON - NEW YORK - OXFORD - PARIS - SHANNON - TOKYO
ELSEVIER SCIENCE Ltd
The Boulevard, Langford Lane
Kidlington, Oxford OX5 1GB, UK

0 2001 Elsevier Science Ltd. All rights reserved.

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Printed in The Netherlands.
 PREFACE

It is now three years since Elsevier Science published the first book of Failure Analysis Case
Studies selected fiom volumes 1 , 2 and 3 of the journal Engineering Failure Analysis. The book
has proved to be a sought-after and widely used source of reference material to help people avoid
or analyse engineering failures, design and manufacture for greater safety and economy, and
assess operating, maintenance and fitness-for-purpose procedures. In the last three years,
Engineering Failure Analysis has continued to build on its early success as an essential medium
for the publication of failure analysis cases studies and papers on the structure, properties and
behaviour of engineering materials as applied to real problems in structures, components and
design.

Failure Analysis Case Studies I1 comprises 40 case studies describing the analysis of real
engineering failures which have been selected from volumes 4, 5 and 6 of Engineering Failure
Analysis. The case studies have been arranged in sections according to the specific type of
failure mechanism involved. The failure mechanisms covered are overload, creep, brittle
fracture, fatigue, environmental attack, environmentally assisted cracking and bearing failures.
The book constitutes a reference set of real failure investigations which should be useful to
professionals and students in most branches of engineering. My sincere thanks go to the authors
of the case studies for finding the time to communicate their experiences to the wider world for
the benefit of us all.

D.R.H. Jones
May 2001
 vii

CONTENTS

Preface ......................................................................................................................................................... v

Overload failures

Bursting of a silo
R. Kieselbach .............................................................................................................................................. 3
Shear failure of a road-vehicle steering shaft
J.H. Cleland and D.R.H. Jones .................................................................................................................. 11
Breakup of the firewall between the B and C modules of the Piper Alpha
platform - I. Analysis by hand calculation
A.C. Palmer ............................................................................................................................................... 19
Failure of a flexible pipe with a concrete liner
M. Talesnick and R.Baker ........................................................................................................................ 31
Torsional failure of a wire rope mooring line during installation in deep water
C.R. Chaplin .............................................................................................................................................. 45

Creep failures

Type I11 creep cracking at main steam line welds

K.G. Sedman, J.C.Thornley and R.M. Griffin ......................................................................................... 63
Creep failure of a spray drier
P. Carter .................................................................................................................................................... 73
Catastrophic failure of a polypropylene tank Part I: primary investigation
P.R.Lewis and G.W Weidmann ............................................................................................................... 79
Catastrophic failure of a polypropylene tank Part 11: comparison of the DVS 2205
code of practice and the design of the failed tank
G.W. Weidmann and P.R.Lewis .............................................................................................................. 97

Brittle fracture

Investigation of the M V Kurdistan casualty

S.J. Garwood ........................................................................................................................................... 117
Investigation of failed actuator piston rods
T.F. Riitti and E.J. Wentzel ..................................................................................................................... 139
Premature failure of prestressed steel bars
A. Valiente and M. Elices ....................................................................................................................... 147
Premature fracture of a composite nylon radiator
P.R. Lewis ............................................................................................................................................... 157
 ...
Vlll

Fatigue

Catastrophicfailure of a raise boring machine during underground reaming operations

A. James .................................................................................................................................................. 175
Fatigue failure of the de Havilland Comet I
P.A. Withey ............................................................................................................................................. 185
Low-cycle fatigue of titanium 6A1-4V surgical tools
H. Velasquez, M. Smith, J. Foyos, F. Fisher. O.S. Es-Said and G. Sines............................................... 193
Failure analysis and experimental stress analysis of a threaded rotating shaft
R.B. Tait .................................................................................................................................................. 199
An investigation of the failure of low pressure steam turbine blades
N.K. Mukhopadhyay, S. Ghosh Chowdhury, G. Das, I Chattoraj, S.K. Das and
D.K. Bhattacharya................................................................................................................................ 211
Vibration-induced fatigue failure of an impulse line
K.R. Al-Asmi and A.C. Seibi.................................................................................................................. 225
Malfunctions of a steam turbine mechanical control system
J.H. Bulloch and A.G. Callagy................................................................................................................ 235
Fatigue failure of hold-down bolts for a hydraulic cylinder gland
C. Tao, N. Xi, H. Yan and Y. Zhang....................................................................................................... 241
Analysis of a vehicle wheel shaft failure
J. Vogwell ............................................................................................................................................... 247
Fatigue failure analysis of a leg press exercise machine
P.J.Vernon and T.J Mackin ..................................................................................................................... 255
Failure analysis of rubber fuel pipes in aero-engines
G. Fu ........................................................................................................................................................ 267

Environmental attack

Failure of austenitic stainless steel components used in nitrogen oxide plant

V.M.J. Sharma, A.K. Jha, P. Ramesh Narayanan, S. Arumugham and T.S. Lakshmanan ..................... 277
Corrosion of central heating systems
D.R.H. Jones ........................................................................................................................................... 285
Crevice corrosion of 3 16L caused by chloride partition in water-butanone mixtures
J.H. Cleland ............................................................................................................................................. 301
Type I pitting of copper tubes from a water distribution system
P.J.L. Fernandes ...................................................................................................................................... 307
Corrosion of flexible waveguides
D. Papatheodorou, M. Smith and O.S. Es-Said....................................................................................... 3 13
Failure of automobile seat belts caused by polymer degradation
J.M. Henshaw, V. Wood and A.C. Hall .................................................................................................. 317
Oxidation failure of radiant heater tubes
K.B. Yoon and D.G. Jeong...................................................................................................................... 33 1

Environmentally assisted cracking

Sustained load crack growth leading to failure in aluminium gas cylinders in traffic
J.W.H. Price, R.N. Ibrahim and D. Ischenko .......................................................................................... 345
Hydrogen-assisted stress-corrosion of prestressing wires in a motonvay viaduct
L. Vehovar, V.Kuhar and A. Vehovar ................................................................................................... 357
 ix

Failure analysis of camer chain pins

G.A. Slabbert, J.J. McEwan and R. Paton............................................................................................... 365
Unusual cases of weld-associated cracking experienced in a high temperature
catalyst reduction reactor
M.L. Holland ........................................................................................................................................... 373
Hydrogen cracking of ferritic stainless steel thermal storage tanks
S. Konosu and T. Nakaniwa.................................................................................................................... 383
Hydrogen embrittlement failure of hot dip galvanised high tensile wires
N.K. Mukhopadhyay, G. Sridhar, N. Parida, S. Tarafder and V.R. Ranganath ...................................... 393

Bearing failures

Contact fatigue in rolling-element bearings

P.J.L. Fernandes ...................................................................................................................................... 409
An air crash due to fatigue failure of a ball bearing
I. Salam, A. Tauqir, A. U1 Haq and A.Q. Khan ...................................................................................... 415
Failure analysis of a condensate pump shaft
A.M. Lancha, M. Serrano and D. Gdmez Briceiio .................................................................................. 425

Author Index ........................................................................................................................................... 443

Overload failures
Failure Analysis Case Studies II
D.R.H. Jones (Editor)
0 2001 Elsevier Science Ltd. All rights reserved 3

BURSTING OF A SILO

R. KIESELBACH
Failure Analysis of Metals,Swiss Federal Laboratories for Materials Testing and Research,
Oberlandstrasse 129, CH-8600 Dlfbendorf, Switzerland
(Received30 Augmf 1996)

Abstract-This paper describes the bursting of a large silo on a farm, which caused considerable environmental
damage and cost. The cause was misuse of the silo for vegetable slurry instead of for feed for livestock, and
overfilling the silo. 0 1997 Elsevier Science Ltd. All rights reserved.

Key words:silo, failure, rupture, hydrostatic pressure

1. INTRODUCTION

Most of the accidents in connection with silos are due to suffocation or gas poisoning of the farmers
entering a silo. Some are also caused by the explosion of methane, which is produced by fermentation
of the forage. Cases of bursting or explosion are, nevertheless, rather rare.
In the present case, three identical silos had been built on a farm, each with a diameter of 6 m
(20 ft) and a height of nearly 25 m (80 ft). The hull of the vessels was made of steel plates measuring
1.4 x 2.68 m, and the thickness of the sheets vaned from 5.7mm at the bottom to 2.4 mm at the
top. All in all, the silo consisted of 16 rings and one base ring. The individual sheets had been
protected against corrosion by enamelling, and were joined by bolts and nuts. The joints were
protected against corrosion by a special kind of mastic. The total capacity of a silo was approximately
630 m3.
Since the farm no longer had any use for the silos, they were rented to a feed company for the
storage of feed for pigs. The slurry was delivered in tank cars and pumped into the silo. The silo
was filled up repeatedly in the following months. Finally, a few minutes after a delivery, when the
tank car had just left the site, the silo burst and spilled its contents, a slightly sour slurry. The
collapse of the top of the silo also damaged the next, still empty silo, which buckled and also
collapsed partially. The spilled slurry caused considerable environmental damage in addition to the
cost of the silos and the cost of the interruption to service. According to the lorry driver, the silo
had been, at that time, approximately three-quarters full, and the manhole lid had not been fastened,
but only laid loosely on its flange.

2. INVESTIGATIONS AND TESTS PERFORMED

2.1. Visual inspection
The site of the accident was visited and the following observations could be made (see Figs 1-3).
Silo 3 had failed and was severed above the seventh ring (counted from the bottom), where a
reinforcement ring was attached. A zone, four rings high, had been separated, and hung partially
on the silo, partially on the ground. The contents of the silo had spilled for approximately 30 m in
a semicircle uphill and 200 m downhill. The pasture had been destroyed, the slurry being slightly
sour after lactic acid fermentation.
The detached rings were separated into several pieces, and were in some places still immersed in
a pool of slurry, such that it was difficult to make out where the pieces had belonged. Failure had
Reprinted from Engineering Failure Analysis 4 (l),49-55 (1997)
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