Joint Investigation Results Stress Corrosion Cracking of Compressed Gas Valves and Fittings
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1 Annotated Summary of Discussion Joint Investigation Results Stress Corrosion Cracking of Compressed Gas Valves and Fittings Labor/Industry Overview Briefing 19 September 2011 Charleston, WV
2 January May June August September Joint Investigation Chronology
3 Stress Corrosion Cracking is a mechanicalchemical process that results when even a very small pit forms in a metal under stress. The concentrated stress extends a crack from the pit by alternate corrosion and stress failure. The stress responsible is predominately residual concentrated along the grain boundaries from non-uniform cooling, casting defects and machining.
4 Separation of Nut Securing Nipple Jan 2011
5 Failed Valve Fitting on Right
6 Top of Failed Valve Nut
7 Separated Top and Base of Valve Nut
8 Crack in Valve Body That Had Not Yet Failed
9 Crack in a Nut That Had Not Yet Failed
10 Crack in Valve Body That Had Not Yet Failed
11 Crack in a Fitting That Had Not Yet Failed
12 Signs of Corrosion Contrast w/ Original Yellow Brass on Valve Nut Brownish-White Corrosion Residue & Reddish Cooper Deposits
13 Stress Corrosion Cracking is Microscopic in Early Stages Micrograph of Corrosion Pit Showing Crack Development
14 Example of Corrosion on Valve Body
15 Zinc Energy Dispersive X-ray Spectrometer Analysis of Corrosion Product
16 Atomic Structure of Brass Cooper and Zinc
17 SEM Image of Zinc Oxide Formation in Brass Matrix
18 In Dezincification, the zinc in the brass alloy is selectively converted to zinc-oxide creating pits that decrease alloy strength and rending it porous. The cooper is redeposited on the surface of the brass creating an anode allowing two corrosion mechanisms to operate simultaneously chemical and galvanic.
19 SEM of Porous Surface Deposits
20 There are three types of dezincification; intergranular, layer, and pitting (loss of material in the local area) with the latter being the most serious.
21 Corrosion Pit Approaching 2/1000 of an Inch
22 SEM Showing Crack Developing From Corrosion Pit
23 SEM Showing Corrosion Pit Origin and the Developed Crack
24 Polished Cross-Section of Intergranular Crack
25 SEM of Intergranular Corrosion in Fitting Not Yet Failed Corrosion Voids Following the Grain Boundaries
26 Microgram of Crack Formation in Fitting Not Yet Failed
27 Solution? Manufacturers required to provide specifications and testing of materials used in their valves and fittings. The specification limit brass alloys to those containing no more than 15% zinc or an other proven dezincification-resist metals.
28 CAG Valve Nipple and Nut Specifications
29 Significance of Pitting Depends on Thickness of Metal Examples of Non-Compliant Fittings
30 Solution? Adhere to Compressed Gas Association specifications.
31 Regulatory Note An emergency shelter shall be constructed such that it will be protected under normal handling, provide for rapidly establishing and maintaining an internal shelter atmosphere and provide proof of current approval for all items and materials subject to MSHA approval. (WV Code )
32 Regulatory Note Until breathable air, air-monitoring, and harmful gas removal components approved by MSHA mine operators may comply with the Federal Mine Safety and Health Act (Mine Act) by: (1) Using breathable air, air-monitoring, and harmful gas removal components that are grandfathered for use until December 31, 2013 (MSHA Program Information Bulletin No. P10-21, December 9, 2010)
33 Regulatory Note a refuge alternative structure that has been approved and is in service or components that have been approved and are in use, but require replacement due to damage, must be replaced with a unit or components that meet the requirements of the final rule. (Federal Register /Vol. 73, No. 251 /Wednesday, December 31, 2008 /Rules and Regulations, p )
34 Next Steps WV and MSHA to Issue Notices re: Refit Identify units require immediate action Take corrective action on problems Complete Part 7 MSHA approvals Manufacture new valves & fittings Complete plans for refit Refit problems first followed by others Complete all by 31 December 2013
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