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| موضوع: كتاب Handbook of Materials Failure Analysis With Case Studies from the Oil and Gas Industry السبت 10 مارس 2018 - 21:34 | |
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أخوانى فى الله أحضرت لكم كتاب 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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