Failure Investigation of Cracks in Bolted Flange

Cracks were observed on the outer diameter of the bolted flanges of a number of large control valves in high temperature service. An investigation was launched to determine the cause of cracking and propose corrective action. Metallurgical failure analysis and finite element analysis techniques were used to investigate the fracture, and concluded that the failures occurred due to thermal fatigue. A structural assessment performed on a cracked flange concluded that the cracks do not have an adverse effect on the integrity of the flange and it was concluded that the cracked flanges could be safely returned to service.