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Failure of Cast Duplex Stainless Steel Valves Due to Improper Microstructure

Product Number: 51324-20759-SG

Author: K. Ravindranath; B. Al-Wakaa; A. Ali; Ahmad Al-Swaha; Salem Al-Qahtani

Publication Date: 2024

$40.00

Cast duplex stainless steels are popularly used in the petroleum industry due to their good corrosion resistance and mechanical properties. One of the applications of cast duplex stainless steels in the petroleum industry is in the manufacture of valves in corrosive service. The good properties of duplex stainless steels are attributed to their balanced microstructure containing austenite and ferrite phases. The balanced microstructure in the duplex stainless-steel components is achieved by the optimum heat treatment and manufacturing process. Improper cooling during manufacturing or accidental exposure of the component to high temperatures can induce the precipitation of secondary phases in the microstructure of duplex stainless steel, which can seriously influence the corrosion resistance and mechanical properties. The paper deals with the failure investigation of the first-generation cast duplex stainless steel valves that failed in a short duration of service. The microstructure of the failed valve was characterized by optical and scanning electron microscopy. The effect of the microstructure on the mechanical properties was assessed by hardness measurements, tensile testing, and impact toughness testing. The study indicated that the properties of the duplex stainless-steel valves were affected due to the precipitation of secondary phases and the root cause of the failure was embrittlement caused by the precipitated secondary phases.

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Failure of Heat Exchanger Cooling CO2 from a Pre-Combustion Unit

Product Number: 51323-19402-SG

Author: Sivuyile Funani, Abhijit Saha, Abdulaziz Al-Meshari

Publication Date: 2023

$20.00

About a month after commissioning, a decrease in pH of the cooling water in the plant was observed. This meant that CO2 has leaked into the cooling water in one of the coolers. Two months after commissioning, about 15% of tubes in one cooler downstream of the reactor were plugged after inspection results showed that they have leaked.

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Failure of In-Service Stainless-Steel Chemical Storage Tanks Fasteners and Gaskets – A Case Study

Product Number: 51323-18790-SG

Author: Hamad Salem Al-Ajmi, A/Rahman Al-Ghamdi, Tariq Kamshad, Yousef Bahbahani, Salem Al-Qahtani, Manickavasagan Sabesan, Bakheet Al-Yami

Publication Date: 2023

$20.00

Wafra Joint Operations is in the west central part of the Kuwait-Saudi Arabia Neutral Zone. The oilfield produces light and heavy oil and exports it to its various customers after processing. Upstream field consists of various Sub Centres where crude, oil and water being separated, and the separated crude transported to the main gathering centre for further processing in two different trains. The produced water being disposed/injected via water disposal and injection facilities after treatment.

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Failure Of In-Service Stainless-Steel Chemical Storage Tanks Fasteners And Gaskets – A Case Study

Product Number: 51322-18105-SG

Author: A/Rahman Al-Ghamdi, Yousef Bahbahani, Manickavasagan Sabesan, Tariq Kamshad, Salem Al-Qahtani, Bakheet Al-Yami

Publication Date: 2022

$20.00

The Joint Operation (J.O) Wafra Oilfield is in the west central part of the Kuwait-Saudi Arabia Neutral Zone. The Wafra oilfield produces light and heavy oil and export it to its various customers after processing. Upstream field consists of various Sub Centres where crude, oil and water being separated, and the separated crude transported to the main gathering centre for further processing in two different trains. The produced water being disposed/injected via water disposal & injection facilities after treatment.

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Failure of Pipeline Internal Girth Weld Coating Surface Preparation: Investigation and Case Study

Product Number: MECC23-20165-SG

Author: Rashed Alhajri; Yousef Alrayes; Yasser Alsubhi

Publication Date: 2023

$20.00

Pipelines have primarily been developed for the oil and gas business as well as building domestic water networks. To ensure the quality and longstanding pipelines, inspection and quality during design, construction and operations are of prime importance. During construction, pipe manufacturing and field fabrication represent the major cornerstone of a construction quality program.

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Failure On Heater Treater Tubes - Case Study

Product Number: 51322-17586-SG

Author: Roxanna Alvarez

Publication Date: 2022

$20.00

Heater Treaters are designed for the removal of emulsifies and unwanted salts from crude oil. They purpose is to facilitate the oil and water separation by breaking emulsions by means of increasing the temperature of the oil, reducing its density and viscosity. A heater treater is a 3-phase separator vessel, equipped with fire tubes, that utilizes heat and mechanical separation devices to facilitate the separation of oil-water emulsions.

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Failures with Duplex Stainless Steels (DSS) In Hydroprocessing REACs - Update on Latest API Survey

Product Number: MECC23-20094-SG

Author: Gerrit M Buchheim; David E Moore

Publication Date: 2023

$20.00

2205 Duplex Stainless Steel (DSS) UNS S31803 has been used in refinery hydroprocessing unit reactor effluent air coolers (REACs) since the mid 1980’s (1). 2205 was selected due to its good resistance to ammonium bisulfide (NH4HS) corrosion and perceived resistance to chloride stress corrosion cracking because it was an economical choice when compared to higher nickel alloy alternatives such as Alloy 825 or Alloy 625.

Many of these DSS REACs have remained in service successfully, with some in service for more than 30 years.

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Fast-Acting And Persistent Post-Hydrotest Corrosion Inhibitors For Newly Constructed Oil Pipelines

Product Number: 51321-16901-SG

Author: Hitesh Bagaria; Moshood Adewale; Rob Gutierrez; Jeanne O'Neal; Jennifer Sargent; Nimesh Patel; Trevor Place

Publication Date: 2021

$20.00

Pressure testing is a standard practice used to validate the condition of new pipelines (prior to wet commissioning) and may also be used to revalidate the integrity of older pipelines. Since water is the primary medium for pressure testing, the process has been termed hydrostatic testing or hydrotesting. While the low cost, accessibility and environmental impact are primary drivers for use of water, the inherent corrosiveness of water poses an asset integrity challenge.

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Faster Qualification Testing for SSPC Paint 47

Product Number: 51324-21089-SG

Author: Sean Fowler; William Tobin; David Duecker; Andy Francis

Publication Date: 2024

$40.00

This study investigates the possibility of reducing the testing time required to qualify paints to the SSPC Paint 47 specification. Using specimens from the original study conducted to develop the test requirements, the irradiance of the UV exposure was increased to see if the 4000 hour results could be replicated in 2000 hours or less. Although final data was not available at the time of writing, data from 1000 hours of the higher irradiance exposure correlated very well with the 2000 hour exposure data from the original study.

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Fatigue and Fracture Resistance of Different Line Pipe Grade Steels in Gaseous H2 Environment

Product Number: 51324-21101-SG

Author: Milan Agnani; Chris San Marchi; Joseph Ronevich

Publication Date: 2024

$40.00

The existing natural gas (NG) pipeline network is being considered to transport pure gaseous hydrogen (GH2) or blends of NG and GH2 for domestic and industrial energy needs, in an effort to reduce global CO2 emissions. The toughness and ductility of ferritic steels are reduced in the presence of GH2. In order to assess the viability of GH2 gas distribution via NG pipeline networks, it is necessary to understand the fatigue and fracture response of the materials in the network, including the various pipeline steels. Hydrogen-assisted fatigue crack growth (FCG) and fracture behavior of five different modern line pipe grade steels (X52, X70, X80, X100, and X120) were evaluated in high-purity GH2 at pressure of 210 bar, where the tensile strength increases with grade, X120 displaying the highest strength. The X52 and X70 steels feature ferrite with small amounts of pearlite in the microstructure. The X80 steel has a combination of polygonal and acicular ferrite, whereas the X100 and X120 steels contain fine ferritic and bainitic microstructures. The different pipeline steels exhibit similar accelerated FCG rates in the presence of GH2, irrespective of the strength and microstructural constituents. A significant reduction in the fracture resistance is observed for all the steels in GH2 as compared to air, although elastic-plastic fracture (J-R) behavior is maintained in GH2. Contrary to FCG rates, hydrogen-assisted fracture is affected by the microstructure and strength of the steel; higher strength steels exhibit lower fracture resistance and lower tearing modulus, analogous to the generally expected trends in air. Selected fracture surfaces are analyzed to rationalize the influence of microstructure and strength on hydrogen-assisted fracture of this class of steels.

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Fatigue and Static Crack Growth Rate of Cr-Mn Stainless Steel in Aerated Brine Simulating Drilling Applications

Product Number: 51323-19152-SG

Author: Ashwini Chandra, Helmuth Sarmiento Klapper, Ramgopal Thodla

Publication Date: 2023

$20.00

Directional drilling tools for oil and gas exploration is one industrial application where Manganese (Mn)-stabilized austenitic stainless steels with different amounts of other alloying elements like Chromium (Cr), Nickel (Ni) and Molybdenum (Mo) have found extensive use in spite of the demanding requirements in terms of mechanical properties and corrosion resistance. The limited resistance of this type of austenitic stainless steels to environmentally assisted cracking (EAC) in hot chloride (Cl-)-containing environments is well known. Chloride-bearing environments at elevated temperatures are not uncommon in drilling operations and can indeed challenge the EAC-resistance of CrMn-stainless steels

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Fatigue Crack Initiation In Zr-2.5Nb Tested In Heavy-Water At 300°C

Product Number: ED22-17233-SG

Author: H.M. Nordin, A.J. Phillion, Q. Wang, M. Lenzi, H.Yu, T.M. Karlsen

Publication Date: 2022

$20.00

Pressure tubes, manufactured from Zr-2.5Nb, are used within a CANDU power reactor to contain the fuel bundles and coolant forming the primary pressure boundary in the core with an expected operating lifetime of 25 years. As part of the Canadian Standards Association (CSA) fitness-for-service requirements for pressure tubes, flaws or stress risers that potentially lead to cracks cannot exist in pressure tubes in operating reactors. Flaws may include: fuel bundle scratches, crevice corrosion marks, fuel bundle bearing pad fretting flaws and debris fretting flaws.

AMPP Conference Papers

Association for Materials Protection and Performance