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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.
Heater Treaters are designed for the removal of emulsifies and unwanted salts from crude oil. This paper will discuss a case study completed on two heater treaters that exhibited premature failure after 8 months in service, involving an extensive fire with a subsequent loss of production.Multiple cracking on the mitrated elbow welds, on the flanges to shell circumferential weld and a collapsed tube were observed in the heating section, after the treater went out of service. Visual inspection, metallurgical analysis, physicochemical analysis of the formation water, corrosion deposits analysis and stress analysis were completed to identify the root cause of the failure. Results indicated that the accumulation of deposits from the reservoir water and a low level of crude oil due to the reduction in production caused high thermal cyclic stresses on critical welded areas in addition to a localized overheating on the collapsed tube.
The application of corrosion resistance alloys such as 25% Cr super duplex stainless steel (25Cr SDSS) has expanded in the oil & gas industry recently as new technologies made it feasible for Oil and Gas operators to invest in high sour and corrosive fields. 25Cr SDSS material is often used in critical applications such as piping, rotating equipment, coolers, and instrument components etc. SDSS materials are well known for the 50/50 austenite (γ) and ferrite (α) microstructure which provides the combination of corrosion resistance and high-performance mechanical properties.
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A cold-worked carbon steel pulsation dampener located on a glycol circulation pump failed catastrophically in service. The two parts of the failed dampener were projected several tens of meters across the offshore facility. The failure was investigated initially using traditional metallurgical techniques, but this failed to reach a conclusive failure mechanism.
Standards NACE(1) MR0175 / ISO(2) 15156-31 have temperature-H2S-Cl-pH limits for safely using duplex stainless steels based on their Pitting Resistance Equivalent Number (PREN) of subcategory such as duplex stainless steel (DSS, PREN 30-40, Mo>1.5%) and super duplex stainless steel (SDSS, PREN 4045), temperature-pH domain of stress corrosion cracking (SCC) resistance can be used for material evaluation and provided by using slow strain rate testing (SSRT) screening in sour testing conditions2.