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Failure of a Vaned Diffuser in a Sour Gas Compressor

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Failure of a diffuser (with vanes, made from material P265GH) is investigated. The gas compressor was in service for over 10 years. The gas contained both CO2 and H2S. Relative humidity of the gas was 100 %. It was found that the diffuser was fractured in 3 locations.

Product Number: 51317--9073-SG
ISBN: 9073 2017 CP
Author: Vishwas Gadgil
Publication Date: 2017
Industry: Oil and Gas Production
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Failure of a vaned diffuser in a sour gas compressorDr.ir. V.J. Gadgil Ing. P. MartiniusPower and Gas Division Siemens Netherlands N.V.Industrieplein 1 7553 LL Hengelo The NetherlandsOil and gas is a highly competitive industry. Maintenance and service play an important role in the operation of a gas field. Upstream equipment must be able to handle gas from a production well. In many cases along with hydrocarbons the gas contains other components such as CO2 H2S and water in liquid or vapor form. It is well known that the these are corrosive in nature and more so in combination with each other. There is extensive literature on the corrosivity of CO2 and H2S and their synergy (12). ISO 15156 (parts 1-3) have established guidelines which are accepted worldwide in choosing material resistant to cracking in H2S environment.In this article a failure of a vaned diffuser in a gas compressor is investigated. The gas compressor was in service for over 10 years. The gas contained both CO2 and H2S with partial pressure of 0.44 bar and 0.63 bar each on the suction side. Relative humidity was 100 %. It was found that the two halves of the diffuser was fractured through and through in 3 places. Material of the component was investigated using emission spectroscopy. The fracture surfaces were investigated with optical microscopy and analytical SEM. Fracture surfaces showed evidence of brittle fracture. In some areas there were fatigue striations. Metallographic investigation of the fractures reveal intergranular cracking. Microstructure was consistent with a rolled plate. The origin of the cracks was from initial pitting corrosion. Elemental Sulphur analyzed with EDX was found to have been deposited on the fracture surfaces and at other locations. Hardness of the steel was well within specifications. Residual stress was measured using X-Ray diffraction in two directions. Results of the various investigations are presented. Possible cause of the failure is discussed at length. Remedial actions are discussed. Finally conclusions drawn from the investigations are presented.

Key words: Diffuser, Gas compressor, failure, sour gas, failure investigation, hydrogen embrittlement

Failure of a vaned diffuser in a sour gas compressorDr.ir. V.J. Gadgil Ing. P. MartiniusPower and Gas Division Siemens Netherlands N.V.Industrieplein 1 7553 LL Hengelo The NetherlandsOil and gas is a highly competitive industry. Maintenance and service play an important role in the operation of a gas field. Upstream equipment must be able to handle gas from a production well. In many cases along with hydrocarbons the gas contains other components such as CO2 H2S and water in liquid or vapor form. It is well known that the these are corrosive in nature and more so in combination with each other. There is extensive literature on the corrosivity of CO2 and H2S and their synergy (12). ISO 15156 (parts 1-3) have established guidelines which are accepted worldwide in choosing material resistant to cracking in H2S environment.In this article a failure of a vaned diffuser in a gas compressor is investigated. The gas compressor was in service for over 10 years. The gas contained both CO2 and H2S with partial pressure of 0.44 bar and 0.63 bar each on the suction side. Relative humidity was 100 %. It was found that the two halves of the diffuser was fractured through and through in 3 places. Material of the component was investigated using emission spectroscopy. The fracture surfaces were investigated with optical microscopy and analytical SEM. Fracture surfaces showed evidence of brittle fracture. In some areas there were fatigue striations. Metallographic investigation of the fractures reveal intergranular cracking. Microstructure was consistent with a rolled plate. The origin of the cracks was from initial pitting corrosion. Elemental Sulphur analyzed with EDX was found to have been deposited on the fracture surfaces and at other locations. Hardness of the steel was well within specifications. Residual stress was measured using X-Ray diffraction in two directions. Results of the various investigations are presented. Possible cause of the failure is discussed at length. Remedial actions are discussed. Finally conclusions drawn from the investigations are presented.

Key words: Diffuser, Gas compressor, failure, sour gas, failure investigation, hydrogen embrittlement

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