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 |  موضوع: كتاب Handbook of Materials Failure Analysis With Case Studies from the Oil and Gas Industry السبت 10 مارس 2018, 10:34 pm | |
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Handbook of Materials Failure Analysis With Case Studies from the Oil and Gas Industry
Edited by
Abdel Salam Hamdy Makhlouf
Mahmood Aliofkhazraei
ويتناول الموضوعات الأتية :
CHAPTER
Failure analysis of oil and gas
transmission pipelines 1
Brad James, Alexander Hudgins
Exponent, Menlo Park, California, USA
CHAPTER OUTLINE
1 Introduction . 1
2 Mechanical Damage . 3
3 Longitudinal Seam-Weld Defects . 6
3.1 Lap-Weld Defects .8
3.2 Lap-Weld Case Study .9
3.3 ERW Defects .12
3.4 Flash Weld Defects 14
3.5 Submerged-Arc Weld Defects 14
3.6 Submerged-Arc Weld Defect Case Study 15
3.7 Shielded Metal Arc Weld Defects .20
4 Corrosion . 21
4.1 General Corrosion .22
4.2 Stress Corrosion Cracking .22
4.3 High-pH SCC Case Study 23
4.4 Near-Neutral pH SCC Case Study 24
4.5 Hydrogen-Stress Cracking .24
4.6 HSC Case Study .28
4.7 Grooving Corrosion .31
5 Fatigue 33
6 Conclusion . 36
References 36
CHAPTER
Modern analytical
techniques in failure analysis
of aerospace, chemical, and
oil and gas industries
2
Seifollah Nasrazadani*, Shokrollah Hassani
Engineering Technology Department, University of North Texas, Denton, TX, USA*
BP America Inc., Houston, TX, USA
CHAPTER OUTLINE
1 Microscopy Techniques 39
1.1 Optical Microscopy .39
1.2 Scanning Electron Microscopy .40
1.3 Focused Ion Beam .41
2 Chemical and Radiographic Analysis . 42
2.1 Energy Dispersive Spectroscopy 42
2.2 X-Ray Fluorescence 44
2.3 X-Ray Diffraction 45
2.4 Fourier Transform Infrared Spectrophotometry 46
2.5 X-Ray Photoelectron Spectroscopy .47
2.6 Radiography 49
2.7 Neutron Radiography 50
2.8 X-Ray Radiography .51
2.9 Gamma-Ray Radiography 52
2.10 Fluoroscopic Radiography .53
3 Conclusion and Future Outlook 53
References 53
CHAPTER
Methods for assessing
defects leading to gas
pipe failure 3
Guy Pluvinage, Julien Capelle, Christian Schmitt
ENIM (LaBPS), Metz, France
CHAPTER OUTLINE
1 Introduction . 56
2 Macroscopic and Microscopic Aspects of Pipe Failure . 58
3 Brittle Fracture in a Pipe Emanating from a Crack 59
3.1 Cracks in a Pipe .59
3.2 Fracture Condition of a Cracked Pipe .60
3.3 Failure Assessment Diagram .61
3.4 Defect Assessment in a Brittle Cast Iron Pipe .64
4 Assessment of Gouges Using Notch Fracture Mechanics . 65
4.1 Gouges in Pipes .65
4.2 Notch Fracture Mechanics 66
4.3 Notch Failure Assessment Diagram 68
4.4 Safety Factor Associated with Defect in Pipe Under Service
Pressure 68
4.5 Two-Parameter Fracture Mechanics .70
4.5.1 Example of Material Failure Master Curve for a Steel Pipe 70
4.5.2 Loading Path in Plane Kap-Tef 71
5 Pipe Failure Emanating from Corrosion Defect 71
5.1 Burst Pressure Predicted by Plastic Collapse 73
5.2 Domain Failure Assessment Diagram .76
5.3 Application to Corrosion Defect in a Gas Pipe .77
6 Pipe Failure Emanating from Dents 78
6.1 Dent: Origin and Description .78
6.2 Limit of Acceptability of Dent Depth 79
6.3 Methods to Estimate and Control Dent .80
6.4 Methods to Estimate and Control Dent+Gouge Defect .83
7 Conclusion . 86
References 88
CHAPTER
Failure of glass fiber
reinforced epoxy pipes
in oil fields 4
Guillermina Capiel*,, Pablo Fayo´*, Antonela Orofino*,, Pablo E. Montemartini*,
Composite Materials, Institute of Materials Science and Technology (INTEMA), University of Mar
del Plata and National Research Council, Mar del Plata, Argentina*
Chemical Engineering Department, University of Mar del Plata, Mar del Plata, Argentina
CHAPTER OUTLINE
1 Introduction . 91
2 In-Lab Studies 93
3 In-Service Degradation and Failure 98
4 Conclusion . 101
References 102
CHAPTER
Failures and integrity of
pipelines subjected to soil
movements 5
Herna´n G. Kunert*,, Anibal A. Marquez*,{, Pablo Fazzini, Jose´ L. Otegui}
University of Mar del Plata, Mar del Plata, Argentina*
GIE S.A., Failure Analysis Division, Mar del Plata, Argentina
INTEMA-CONICET, Mar del Plata, Argentina{
Y-TEC (YPF—CONICET), Ensenada, Argentina}
CHAPTER OUTLINE
1 Introduction . 105
2 Recent Failures and Lessons Learned 108
3 Mitigation Measures During Operation . 113
4 Prevention Measures at the Design Stage 119
5 Conclusion . 120
Acknowledgment 121
References 121
CHAPTER
Oil field drill pipes failure 6
Gudimella V.S. Murthy
Materials Science and Technology Division, CSIR-National Metallurgical Laboratory,
Jamshedpur, Jharkhand, India
CHAPTER OUTLINE
1 Introduction . 124
2 Case 1: In-Service Pitting . 124
2.1 Experimental .126
2.1.1 Visual Examination . 126
2.1.2 SEM Surface Studies 126
2.1.3 Microstructure 128
2.1.4 Vicker’s Macrohardness . 130
2.1.5 Chemical Composition 130
2.2 Discussion .130
2.3 Conclusion and Recommendations 131
3 Case 2: Surface Oxide Cracking 131
3.1 Experimental .132
3.1.1 Visual Observation . 132
3.1.2 Chemical Analysis . 132
3.1.3 Hardness Measurements 132
3.1.4 Mechanical Testing 132
3.1.5 Microstructural Characterization 134
3.2 Discussion .137
3.3 Conclusion and Recommendations 139
4 Case 3: Hardbanding Failure . 139
4.1 Experimental .140
4.1.1 Visual Observation . 140
4.1.2 Chemical Analysis . 140
4.1.3 Hardness Measurements 142
4.1.4 Mechanical Testing 143
4.1.5 Microstructural Characterization 144
4.1.6 Fractography 145
4.2 Discussion .151
4.3 Conclusion and Recommendations 151
Acknowledgments 151
References 152
CHAPTER
Failure analysis and solution
studies on drill pipe thread
gluing at the exit side of
horizontal directional drilling
7
Xiao-Hua Zhu
School of Mechanical Engineering, Southwest Petroleum University, Chengdu, China
CHAPTER OUTLINE
1 Introduction . 153
2 Methodology and Model 155
2.1 Analysis of Construction Conditions .155
2.2 Material Tensioning and Make-Up and Break-Out Tests .157
2.2.1 Material Tensioning Tests . 157
2.2.2 Make-up and Break-out Tests . 158
2.2.3 Control Equation of Thread Connection 160
2.2.4 Connecting Thread 3D FEM 161
3 Results and Discussion . 161
3.1 FEM Verification 161
3.2 Effects of Insufficient Make-Up Torque 162
3.3 Effect Analysis of Bending Moment .162
3.4 Improvement Measures .166
3.5 New Drill Pipe Thread Design 167
3.6 Comparison of Bending Strength .168
3.7 Comparison of Flexural Rigidity .168
3.8 Comparison of the Shoulder Sealing 170
4 Conclusion and Recommendations . 172
Acknowledgments 172
References 172
CHAPTER
Causes and conditions for
reamer blade balling during
hole enlargement while
drilling
8
Xiao-Hua Zhu
School of Mechanical Engineering, Southwest Petroleum University, Chengdu, China
CHAPTER OUTLINE
1 Introduction . 175
2 Methodology and Model 177
2.1 Physical Model 177
2.2 Mathematical Model .178
2.2.1 Governing Equations of Continuous Flow 179
2.2.2 Equation for Cuttings Removal 180
2.2.3 Discrete Particle Hard Sphere Model . 180
2.3 Simulation Conditions 182
2.4 Numerical Model and Computation 182
2.5 Restrictive Conditions .183
3 Results and Discussion . 184
3.1 Flow Pattern Discussion 184
3.2 Discussion of the Causes of Reamer Blade Balling 186
3.3 Measures to Reduce Balling 186
3.4 Optimizing the Reamer Blade Hydraulic Structure 187
3.5 The Influence of Nozzle Type and Angle .190
3.6 Parameter Optimization 192
4 Conclusion and Recommendations . 195
Acknowledgments 197
References 197
CHAPTER
Analysis of reamer failure
based on vibration analysis
of the rock breaking in
horizontal directional drilling
9
Xiao-Hua Zhu
School of Mechanical Engineering, Southwest Petroleum University, Chengdu, China
CHAPTER OUTLINE
1 Introduction . 199
2 Methodology and Model 202
2.1 Reamer-Rock Contact with Mathematical Model .202
2.2 Drucker-Prager Rock Strength Criterion 202
2.3 Basic Assumptions .203
2.4 Petrophysical Parameters 203
2.5 Meshing and Boundary Conditions .203
3 Results and Discussion . 204
3.1 Reamer Lateral, Axial, and Torsional Vibration Characteristics 204
3.2 Pullback Force on the Reamer Lateral Vibration 207
3.3 RPM on the Reamer Lateral Vibration 208
3.4 Selection of Reasonable Construction Parameters .209
3.5 Engineering Applications 211
4 Conclusion and Recommendations . 212
Acknowledgments 213
References 214
CHAPTER
Effect of artificial
accelerated salt
weathering on physical
and mechanical behavior
of sandstone samples from
surface reservoirs
10
Marco Ludovico-Marques*, Carlos Chastre
Barreiro School of Technology, Polytechnic Institute of Setu´bal, Lavradio, Portugal*
Department of Civil Engineering, FCT, Universidade NOVA de Lisboa, Lisboa, Portugal
CHAPTER OUTLINE
1 Introduction . 215
1.1 Geological Setting 215
1.2 Salt Weathering Effect 217
2 Experimental Program . 217
2.1 Mineralogical Characterization 217
2.2 Experimental Procedures for Artificial Accelerated Salt
Weathering Tests .219
2.3 Experimental Procedures for Physical Tests 221
2.4 Experimental Procedures for Mechanical Tests .222
3 Analysis of Results of the Experimental Program 223
3.1 Physical Behavior .223
3.2 Mechanical Behavior 225
4 Conclusion . 231
References 232
CHAPTER
Stochastic failure analysis
of defected oil and gas
pipelines 11
Mojtaba Mahmoodian, Chun Q. Li
Royal Melbourne Institute of Technology, Melbourne, Australia
CHAPTER OUTLINE
1 Introduction . 235
2 Research Significance 237
3 Time-Dependent Reliability Analysis 238
3.1 Background .238
3.2 Methods for Time-Dependent Reliability Analysis 239
3.2.1 First Passage Probability Method . 240
3.2.2 Monte Carlo Simulation Method . 242
3.3 Gamma Process Model .243
3.3.1 Maximum-Likelihood Estimation 245
3.3.2 Method of Moments . 246
3.4 Comparison of Reliability Analysis Methods 246
4 Worked Example 247
5 Conclusion . 252
References 253
CHAPTER
Determining the cause of
a carbon steel joint failure
in a gas flow pipeline
production facility
12
Abdel S.H. Makhlouf*, Ahmed Z. Farahat
Manufacturing and Industrial Engineering Department, College of Engineering and
Computer Science, University of Texas Rio Grande Valley*
Central Metallurgical Research and Development Institute, CMRDI, Helwan, Cairo, Egypt
CHAPTER OUTLINE
1 History and Visual Examination . 257
2 Laboratory Evaluation of the Failed “T” Joint 259
3 Failure Analysis Summary . 260
3.1 Physical Evaluation of the Cracked Site of the “T” Joint 260
3.2 Chemical Composition Examination .261
3.2.1 FeCO3 Corrosion Predominates in Natural Gas Pipes . 261
3.3 The Metallographic Examination 263
3.4 Surface Examination Using SEM-EDS and Macrograph Images 263
4 Conclusion . 264
5 Recommendations 264
References 266
CHAPTER
Experimental and
numerical investigation of
high-pressure water jetting
effect toward NPS8 natural
gas pipeline integrity—
Establishing safety
distance perimeter
13
Zulkifli A. Majid, Rahmat Mohsin, Tan F. Long
UTM-MPRC Institue for Oil and Gas, Universiti Teknologi Malaysia (UTM),
Skudai, Johor, Malaysia
CHAPTER OUTLINE
1 Introduction . 268
2 Description of the Ruptures Pipe Incident 270
3 Methodology 272
4 Results and Discussion . 275
4.1 Experimental Study 275
4.1.1 Properties of the Impacted Surface 275
4.1.2 Dispersion of Pipe Thinning Rate . 277
4.1.3 Pressure Distribution for Nozzle Jetting Source 278
4.1.4 The Zero Effect for Nozzle Jetting System at Certain Distance . 279
5 CFD Simulation Study 279
5.1 Determination of the Pressure-Distance Curve for Various
Nozzles Sizes 280
5.2 Jet Flow Pattern and Abrasion Behavior on the Pipe Test .281
6 Experimental and CFD Study on Safety Distance . 282
6.1 Analysis on Pipe Distance with CFD and Experimental Result 283
7 Conclusion . 289
References 289
CHAPTER
Graphitization in pressure
vessels and piping 14
Heloisa C. Furtado*, Iva´n U. Pe´rez, Tito L. da Silveira{, Iain L. May}
Electrical Research Center, Rio de Janeiro, Brazil*
Universidad Industrial Santander, Bucaramanga, Colombia
TSEC Integridade Estrutural Ltda, Rio de Janeiro, Brasil{
Metallurgical Consulting Services Ltd., Saskatoon, SK, Canada}
CHAPTER OUTLINE
1 Introduction . 291
2 Industrial Cases . 293
2.1 Case 1: Welded Joint in a Superheated Steam Tube 293
2.2 Case 2: Longitudinal Welded Joint of Distillation Tower of a Catalytic
Cracking Unit 294
2.3 Case 3: Water Wall of Steam Boiler .294
2.4 Case 4: Aligned Graphite in Steam Pipe .296
2.5 Case 5: Outlet Superheater Steam Pipe .299
3 Discussion . 301
4 Conclusion . 303
References 303
CHAPTER
Cases of failure analysis in
petrochemical industry 15
Juan M. Salgado-Lo´pez, Carlos Rubio-Gonza´lez
Centro de Ingenier?´a y Desarrollo Industrial, Quere´taro, Me´xico
CHAPTER OUTLINE
1 Methodology 305
2 Cases of Failure Analysis 308
2.1 Case 1: Fatigue Induced by Changes in Manufacturing Without
Appropriated Engineering Knowledge .308
2.2 Case 2: SCC Due to H2S in Austenitic Stainless Steel .311
2.3 Case 3: Pitting Due to a Poor Slope in a Pipeline 316
2.4 Case 4: Failure in Brass Tubes Due Contamination of the
Internal Fluid .317
2.5 Case 5: Creep and Internal Corrosion in High Chromium
Steel (Overheating) 323
3 Conclusion . 327
References 328
CHAPTER
Failure analysis of heat
exchanger tubes in
petrochemical industry:
Microscopic analysis
approach
16
Zhen-Guo Yang, Yi Gong
Department of Materials Science, Fudan University, Shanghai, China
CHAPTER OUTLINE
1 Introduction . 330
2 Case 1: Pitting Corrosion of PTA Equipment From Inappropriate
Maintenance Practices . 331
2.1 Background .331
2.2 Failure Analysis .332
2.2.1 Visual Observation . 332
2.2.2 Materials Examination 334
2.2.3 Process Media Detection 334
2.2.4 Microscopic Analysis 336
2.3 Discussion .338
2.4 Conclusion 340
3 Case 2: Acidic/Caustic Alternating Corrosion of Ethylene Plant
From Operational Mistakes 341
3.1 Background .341
3.2 Failure Analysis .343
3.2.1 Visual Observation . 343
3.2.2 Materials Examination 344
3.2.3 Process Media Detection 344
3.2.4 Microscopic Analysis 346
3.2.5 Discussion 350
3.3 Conclusion 351
4 Conclusion . 351
References 352
CHAPTER
Failure of 17-4 PH
stainless steel components
in offshore platforms 17
Se´rgio S.M. Tavares*, Joaquim S. Corte, Juan M. Pardal*
Universidade Federal Fluminense – Escola de Engenharia, Rua Passo da Pa´tria,
Nitero´i, Rio de Janeiro, Brazil*
Universidade Federal do Rio de Janeiro, COPPE, Programa de Engenharia
Metalu´rgica e Materiais, Rio de Janeiro, Brazil
CHAPTER OUTLINE
1 Introduction . 353
2 Precipitation Hardening Stainless Steels (PH) 354
3 17-4 PH Steel 355
4 Case 1: Failure of Studs and Nuts by Galling 359
5 Case 2: Failure of PSV Spring . 363
6 Case 3: Nondestructive Detection of Cracks is Studs of 17-4PH 366
7 Conclusion . 367
References 369
CHAPTER
Fracture representation
and assessment for
tubular offshore structures18
Xudong Qian
Department of Civil and Environmental Engineering,
National University of Singapore, Singapore
CHAPTER OUTLINE
1 Introduction . 371
2 Evaluation of Crack Driving Forces in Tubular Joints . 373
2.1 Domain Integral Approach 373
2.2 Approach 376
3 Damage Mechanics Approach . 377
3.1 Gurson Model 377
3.2 Continuum Damage Mechanics .379
4 Failure Assessment . 381
4.1 Failure Assessment Diagram .381
4.2 Validations 382
4.3 Specific Failure Assessment Curves for Tubular Joints .384
5 Fracture Resistance at the Joint Level 385
6 Fracture Resistance in Structures 388
7 Conclusion . 388
References 389
CHAPTER
Manufacturing, testing,
and operational
techniques to prevent sour
service damages
19
Mohammed A. Al-Anezi, Tariq A. Al-Ghamdi, Waleed L. Al-Otaibi,
Saad M. Al-Muaili
Saudi Aramco, Dhahran, Saudi Arabia
CHAPTER OUTLINE
1 Introduction . 393
2 Case Histories 396
2.1 SOHIC Failures 396
2.2 Procurement of Substandard HIC-Resistant Pipe 398
2.3 Defective Pipe Seam Weld 400
3 Quality Control of Plate Manufacturing Process and Testing Requirements . 402
3.1 Quality Control of Plate Manufacturing Process .402
3.2 Testing Requirements of Plates and Coils .403
4 Quality Control of Pipe Manufacturing Process and Testing Requirements 404
4.1 Quality Control of Pipe Manufacturing Process 404
4.2 Testing Requirements of Line Pipe 406
5 Pipe Specification Selection Criteria and Field Application Quality Control 406
5.1 Pipe Specification Selection Criteria 406
5.2 Field Application Quality Control .407
6 Conclusion . 408
Acknowledgments 409
References 409
CHAPTER
The role of
microfractography
in failure analysis of
machine components
and structures
20
Ryuichiro Ebara
Institute of Materials Science and Technology, Fukuoka University, Fukuoka-city, Japan
CHAPTER OUTLINE
1 Development of Microfractography in Failure Analysis 411
2 Corrosion Fatigue Failure in Steam Turbine Blade 412
3 Corrosion Fatigue Failure of Cargo Oil Tank Structural Member in Very
Large Crude Oil Carrier . 414
4 The Role of Stretched Zone in Unstable Fracture of Hot and Cold Forging
Dies for Automotive Components . 416
5 Conclusion . 420
References 422
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