51312-01217-FAILURE OF DUPLEX STAINLESS STEEL VALVES IN EFFLUENT WATER SERVICE IN A CRUDE OIL PROCESSING FACILIT

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Product Number: 51312-01217-SG

ISBN: 01217 2012 CP

Author: Abdul Razaaq Al-Shamari

Publication Date: 2012

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Failure of Duplex Stainless Steel Valves in Effluent Water Service in a Crude Oil Processing Facility Abdul Razzaq Al-Shamari Inspection & Corrosion Team Kuwait Oil Company Ahmadi Kuwait. Abdul Wahab Al-Mithin Inspection & Corrosion Team Kuwait Oil Company Ahmadi Kuwait. Amer Jarragh Inspection & Corrosion TeamKuwait Oil Company Ahmadi Kuwait. G. Santhosh Kumar Inspection & Corrosion Team Kuwait Oil Company Surya Prakash Inspection & Corrosion TeamKuwait Oil Company Ahmadi Kuwait Abstract Poor quality control during the manufacturing stage of process components can sometimes occur resulting in sub-standard products which may go unnoticed for years till a problem occurs. These non-conformances may lead to accelerated corrosion induced failures which in turn lead unscheduled shutdowns production loss environmental contamination as well as health and safety hazards. This paper highlights the premature and unexpected failure of three motor operated valves (MOV) of different sizes made of duplex stainless steel which were in effluent water service in a crude oil processing facility. These valves were in operation for only three years and consisted of (1) a 16-inch diameter Gate Valve (Suction line of effluent water feed pump); (2) a 10-inch diameter Gate Valve (Suction line of effluent water feed pump) and (3) a 36-inch diameter Gate Valve (Discharge header of pump). The failure investigation revealed that in all three cases the valve materials were subjected to improper heat treatment during the component fabrication stage resulting in substandard quality of the materials and consequent poor corrosion resistance. Key words: Duplex Stainless steel Heat Treatment Effluent Water Quality Control Leaks Weld Cracking