Handbook of Materials Failure Analysis with Case Studies from Oil and Gas Indust
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Edited by
Abdel Salam Hamdy Makhlouf
Mahmood Aliofkhazraei
Butterworth Heinemann is an imprint of Elsevier
The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, UK
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Copyright # 2016 Elsevier Ltd. All rights reserved.
CHAPTER
Failure analysis of oil and gas
transmission pipelines 1
Brad James, Alexander Hudgins
Exponent, Menlo Park, California, USA
CHAPTER OUTLINE
1 Introduction ......................................................................................................... 1
2 Mechanical Damage ............................................................................................. 3
3 Longitudinal Seam-Weld Defects ........................................................................... 6
3.1 Lap-Weld Defects .................................................................................8
3.2 Lap-Weld Case Study ...........................................................................9
3.3 ERW Defects .....................................................................................12
3.4 Flash Weld Defects ............................................................................14
3.5 Submerged-Arc Weld Defects ..............................................................14
3.6 Submerged-Arc Weld Defect Case Study ..............................................15
3.7 Shielded Metal Arc Weld Defects .........................................................20
4 Corrosion ........................................................................................................... 21
4.1 General Corrosion ...............................................................................22
4.2 Stress Corrosion Cracking ...................................................................22
4.3 High-pH SCC Case Study ....................................................................23
4.4 Near-Neutral pH SCC Case Study ........................................................24
4.5 Hydrogen-Stress Cracking ...................................................................24
4.6 HSC Case Study .................................................................................28
4.7 Grooving Corrosion .............................................................................31
5 Fatigue .............................................................................................................. 33
6 Conclusion ......................................................................................................... 36
References .............................................................................................................. 36
CHAPTER
Modern analytical
techniques in failure analysis
of aerospace, chemical, and
oil and gas industries
2
Seifollah Nasrazadani*, Shokrollah Hassani†
Engineering Technology Department, University of North Texas, Denton, TX, USA*
BP America Inc., Houston, TX, USA†
CHAPTER OUTLINE
1 Microscopy Techniques ...................................................................................... 39
1.1 Optical Microscopy .............................................................................39
1.2 Scanning Electron Microscopy .............................................................40
1.3 Focused Ion Beam .............................................................................41
2 Chemical and Radiographic Analysis ................................................................... 42
2.1 Energy Dispersive Spectroscopy ..........................................................42
2.2 X-Ray Fluorescence ............................................................................44
2.3 X-Ray Diffraction ................................................................................45
2.4 Fourier Transform Infrared Spectrophotometry ......................................46
2.5 X-Ray Photoelectron Spectroscopy .......................................................47
2.6 Radiography ......................................................................................49
2.7 Neutron Radiography ..........................................................................50
2.8 X-Ray Radiography .............................................................................51
2.9 Gamma-Ray Radiography ....................................................................52
2.10 Fluoroscopic Radiography .................................................................53
3 Conclusion and Future Outlook ............................................................................ 53
References .............................................................................................................. 53
CHAPTER
Methods for assessing
defects leading to gas
pipe failure 3
Guy Pluvinage, Julien Capelle, Christian Schmitt
ENIM (LaBPS), Metz, France
CHAPTER OUTLINE
1 Introduction ....................................................................................................... 56
2 Macroscopic and Microscopic Aspects of Pipe Failure ......................................... 58
3 Brittle Fracture in a Pipe Emanating from a Crack ................................................ 59
3.1 Cracks in a Pipe .................................................................................59
3.2 Fracture Condition of a Cracked Pipe ...................................................60
3.3 Failure Assessment Diagram ...............................................................61
3.4 Defect Assessment in a Brittle Cast Iron Pipe .......................................64
4 Assessment of Gouges Using Notch Fracture Mechanics ....................................... 65
4.1 Gouges in Pipes .................................................................................65
4.2 Notch Fracture Mechanics ..................................................................66
4.3 Notch Failure Assessment Diagram ......................................................68
4.4 Safety Factor Associated with Defect in Pipe Under Service
Pressure ............................................................................................68
4.5 Two-Parameter Fracture Mechanics .....................................................70
4.5.1 Example of Material Failure Master Curve for a Steel Pipe ..............70
4.5.2 Loading Path in Plane Kap-Tef ....................................................71
5 Pipe Failure Emanating from Corrosion Defect ...................................................... 71
5.1 Burst Pressure Predicted by Plastic Collapse ........................................73
5.2 Domain Failure Assessment Diagram ...................................................76
5.3 Application to Corrosion Defect in a Gas Pipe .......................................77
6 Pipe Failure Emanating from Dents ...................................................................... 78
6.1 Dent: Origin and Description ...............................................................78
6.2 Limit of Acceptability of Dent Depth ....................................................79
6.3 Methods to Estimate and Control Dent .................................................80
6.4 Methods to Estimate and Control Dent+Gouge Defect ...........................83
7 Conclusion ......................................................................................................... 86
References .............................................................................................................. 88
CHAPTER
The role of
microfractography
in failure analysis of
machine components
and structures
20
Ryuichiro Ebara
Institute of Materials Science and Technology, Fukuoka University, Fukuoka-city, Japan
CHAPTER OUTLINE
1 Development of Microfractography in Failure Analysis ........................................ 411
2 Corrosion Fatigue Failure in Steam Turbine Blade .............................................. 412
3 Corrosion Fatigue Failure of Cargo Oil Tank Structural Member in Very
Large Crude Oil Carrier ..................................................................................... 414
4 The Role of Stretched Zone in Unstable Fracture of Hot and Cold Forging
Dies for Automotive Components ....................................................................... 416
5 Conclusion ....................................................................................................... 420
References ............................................................................................................ 422
