AMPP Store - Individual Conference Papers

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Failure Analysis of Paints and Coatings for Transmission & Distribution (T&D) Pipeline and Utility Structures Case Studies

Product Number: 41215-940-SG

Author: Mehrooz Zamanzadeh, George T. Bayer

Publication Date: 2015

$20.00

In this paper failure analysis methodology will be applied to the principal mechanisms by which paints and coatings fail during service; with specific application to case studies involving T&D pipelines and utility structures. The case studies will apply standard failure analysis techniques to determine the primary causes and modes of failures.

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Failure Analysis of Reactor Effluent Air Cooler (REAC) in a Hydrocracker Unit

Product Number: 51314-3730-SG

ISBN: 3730 2014 CP

Author: Surajit Ghosal

Publication Date: 2014

$0.00

A major fire in a Reactor Effluent Air Cooler (REAC) of the Hydrocracker Unit (HCU). Visual inspection was made on the failed portion. Metallurgical investigation, macrostructural and microstructural analysis, Scanning Electron Microscopy, and Energy Dispersive x-ray Spectroscopy was conducted on the failed air cooler.

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Failure Analysis On A Carbon Steel Pulsation Dampener In Glycol Service Using Statistical Fractography Highlights A Stress Corrosion Cracking Contribution

Product Number: 51322-17774-SG

Author: Bruce Cowe, Hervé Marchebois, Gustavo Gimenes, Laurent Ponson, Nicolas Auvray

Publication Date: 2022

$20.00

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.

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Failure Analysis On A Super Duplex Stainless Steel Tube Material Before And After Slow Strain Rate Testing In Sour Conditions - Part 1: SCC Susceptibility

Product Number: 51322-17998-SG

Author: Wenle He, Raveendra Siriki, Jerry Lindkvist

Publication Date: 2022

$20.00

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.

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Failure Cases Of Super Duplex Stainless Steel Pump Components

Product Number: 51322-17689-SG

Author: Janardhan Rao Saithala, Amjad Kharusi, Mohammed Ghafri, Ossama Mohammed, Abdul Majeed, Manish Kulkarni, Talal Nabhani

Publication Date: 2022

$20.00

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

Product Number: MPWT19-14360

Author: Rashed Alhajri, Yousef Alrayes, Fahad Alhindas, Ghassan Bahamden

Publication Date: 2019

$0.00

During the construction of a 56km long 16 in. carbon steel sour gas pipeline, repetitive surface
preparation failures were detected during visual inspection of pipeline girth weld internal surface prior to
coating application. Such failures represented 67% of the total pipeline girth welds and were manifested
by excessive sharp-edges at the root pass. To identify the failure causes, an investigation was
performed through reviewing the pipeline, fabrication and coating application specifications and
procedures, quality control records and performing an extensive visual inspection through an advanced
video robotic crawler on all pipeline girth welds made. Upon investigation analysis, the failures were
caused by sharp-edges in the root pass which were attributed to improper practices during
manufacturing, field fabrication and pre-coating quality control. The failure analysis indicated that the
mechanized Gas Metal Arc Welding process, with the parameters used, was not suitable for internal
girth weld coating application. In addition, a more stringent requirement should be applied to the
acceptable pipe-end diameter tolerance and pre-coating quality control to ensure absence of similar
premature surface preparation failures. The pre-coating quality control can be improved through
utilization of robotic laser contour mapping crawler for precise detection and sizing of unsatisfactory
surface weldment defects, including sharp edges.

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Failure Investigation: Field Sampling and Communication to Maximize the Effectiveness of Laboratory Analysis

Product Number: 41214-825-SG

Author: Rick Huntley, Cindy O’Malley

Publication Date: 2014

$20.00

An accurate and comprehensive coating failure analysis often hinges not only on the quality of the field investigation and the laboratory analysis but also on effective communication between the field analyst and the forensic laboratory. Several steps can be taken during a field investigation to ensure that samples of coating removed for laboratory analysis fairly represent the condition of the coatings and give the forensic laboratory the best possible chance of discovering the root cause of the coating failure.

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Failure of 24” Common Crude Piping and Formation of Iron Sulfides Due to the Influence of Sulfate & Iron Reducing Bacteria and Methanogens

Product Number: 51322-17545-SG

Author: Yousef Khuraibut

Publication Date: 2022

$20.00

A leak suddenly occurred at the 24-inch common crude piping from the separators heading to the degassing boot inlets and the wet crude tanks in an oil gathering center. The initial observations showed the leak was due to a deep isolated pit and localized corrosion. Additional inspections by manual ultrasonic thickness (UT) and long range ultrasonic thickness (LRUT) measurements for the 24” common crude line showed similar deep isolated pits (up to 70% thickness reduction) scattered across the length of the 1100 meter piping.

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Failure of a Vaned Diffuser in a Sour Gas Compressor

Product Number: 51317--9073-SG

ISBN: 9073 2017 CP

Author: Vishwas Gadgil

Publication Date: 2017

$20.00

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.

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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: 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.

Individual Conference Papers

Association for Materials Protection and Performance