Handbook of materials failure analysis with case studies from the oil and gas industry:
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| Other Authors: | , |
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| Format: | Book |
| Language: | English |
| Published: |
Amsterdam
Elsevier, Butterworth-Heinemann
[2016]
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| Subjects: | |
| Online Access: | Klappentext Inhaltsverzeichnis |
| Physical Description: | XIX, 430 Seiten Illustrationen |
| ISBN: | 9780081001172 0081001177 |
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| 245 | 1 | 0 | |a Handbook of materials failure analysis with case studies from the oil and gas industry |c edited by Abdel Salam Hamdy Makhlouf, Mahmood Aliofkhazraei |
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Record in the Search Index
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| adam_text | Handbook of Materials Failure Analysis
With Case Studies from the Oil
and Gas Industries
Edited by
Abdel Salam Hamdy Makhlouf and Mahmood Aliofkhazraei
This handbook covers the most common cases of failure and their investigation, analysis, and
possible remedy in the oil and gas industry.
• Introduces readers to modern analytical techniques in materials failure analysis
• Combines foundational knowledge with current research on the latest developments and
innovations in the field
• Includes numerous compelling case studies of materials failure in oil and gas pipelines and
drilling platforms
About the handbook:
This handbook covers analysis of materials failure in the oil and gas industry, where a single failure
can result in devastating consequences for people, wildlife, the environment, and the economy of a
region. The book combines introductory sections on failure analysis with numerous real-world case
studies of pipelines and other types of materials failure in the oil and gas industry, including joint
failure, leakage in crude oil storage tanks, failure of glass fiber-reinforced epoxy pipes, and failure of
stainless steel components in offshore platforms, among others.
Abdel Salam Hamdy Makhlouf is a Professor in the Department of Manufacturing Engineering,
College of Engineering and Computer Science, University of Texas Pan-American, USA.
Mahmood Aliofkhazraei is an Assistant Professor in the Department of Materials Science at the
Tarbiat Modares University. He is an expert in the field of coatings and corrosion science.
Contents
F)
Contributors..........................................................xv
Preface...............................................................xix
CHAPTER 1 Failure Analysis of Oil and Gas Transmission
Pipelines............................................... 1
Brad James, Alexander Hudgins
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 2 Modern Analytical Techniques in Failure
Analysis of Aerospace, Chemical, and Oil
and Gas Industries..................................... 39
Seifollah Nasrazadani, Shokroilah Hassani
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
VI
Contents
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 3 Methods for Assessing Defects Leading to Gas
Pipe Failure.............................................55
Guy Pluvinage, Julien Capelle, Christian Schmitt
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
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
Contents
Vil
CHAPTER 4 Failure of Glass Fiber-Reinforced Epoxy Pipes
in Oil Fields......................................... 91
Guillermina Capiel, Pablo Fayó, Antonela Orofino,
Pablo E. Montemartini
1 Introduction............................................91
2 In-Lab Studies..........................................93
3 In-Service Degradation and Failure...................98
4 Conclusion.............................................101
References.............................................102
CHAPTER 5 Failures and Integrity of Pipelines Subjected
to Soil Movements.................................... 105
Hernán G. Kunert, Aníbal A. Marquez, Pablo Fazzini,
José L. Otegui
1 Introduction...........................................105
2 Recent Failures and Lessons Learned....................108
3 Mitigation Measures During Operation...................113
4 Prevention Measures at the Design Stage................119
5 Conclusion.............................................120
Acknowledgment.........................................121
References.............................................121
CHAPTER 6 Oil Field Drill Pipes Failure..........................123
Gudimella V.S. Murthy
1 Introduction...........................................124
2 Case 1: In-Service Pitting.............................124
2.1 Experimental.......................................126
2.2 Discussion.........................................130
2.3 Conclusion and Recommendations.....................131
3 Case 2: Surface Oxide Cracking.........................131
3.1 Experimental.......................................132
3.2 Discussion.........................................137
3.3 Conclusion and Recommendations.....................139
4 Case 3: Hardbanding Failure............................139
4.1 Experimental.......................................140
4.2 Discussion.........................................151
4.3 Conclusion and Recommendations.....................151
Acknowledgments........................................151
References.............................................152
VIII
Contents
CHAPTER 7 Failure Analysis and Solution Studies on Drill
Pipe Thread Gluing at the Exit Side of
Horizontal Directional Drilling.......................................153
Xiao-Hua Zhu
1 Introduction............................................153
2 Methodology and Model...................................155
2.1 Analysis of Construction Conditions.................155
2.2 Material Tensioning and Make-Up and Break-Out Tests.... 157
3 Results and Discussion..................................161
3.1 FEM Verification....................................161
3.2 Effects of Insufficient Make-Up Torque.............162
3.3 Effect Analysis of Bending Moment..................162
3.4 Improvement Measures...............................166
3.5 New Drill Pipe Thread Design.......................167
3.6 Comparison of Bending Strength.....................168
3.7 Comparison of Flexural Rigidity....................168
3.8 Comparison of the Shoulder Sealing.................170
4 Conclusion and Recommendations........................ 172
Acknowledgments.........................................172
References..............................................172
CHAPTER 8 Causes and Conditions for Reamer Blade Balling
During Hole Enlargement While Drilling..................175
Xiao-Hua Zhu
1 Introduction............................................175
2 Methodology and Model...................................177
2.1 Physical Model......................................177
2.2 Mathematical Model.................................178
2.3 Simulation Conditions..............................182
2.4 Numerical Model and Computation....................182
2.5 Restrictive Conditions.............................183
3 Results and Discussion..................................184
3.1 Flow Pattern Discussion.............................184
3.2 Discussion of the Causes of Reamer Blade Balling...186
3.3 Measures to Reduce Balling.........................186
3.4 Optimizing the Reamer Blade Hydraulic Structure....187
3.5 The Influence of Nozzle Type and Angle.............190
3.6 Parameter Optimization.............................192
4 Conclusion and Recommendations..........................195
Acknowledgments.........................................197
References..............................................197
Contents
IX
CHAPTER 9 Analysis of Reamer Failure Based on Vibration
Analysis of the Rock Breaking in Horizontal
Directional Drilling.....................................199
Xiao-Hua Zhu
1 Introduction.............................................199
2 Methodology and Model....................................202
2.1 Reamer-Rock Contact with Mathematical Model..........202
2.2 Drucker-Prager Rock Strength Criterion..............202
2.3 Basic Assumptions...................................203
2.4 Petrophysical Parameters............................203
2.5 Meshing and Boundary Conditions.....................203
3 Results and Discussion...................................204
3.1 Reamer Lateral, Axial, and Torsional Vibration
Characteristics......................................204
3.2 Pullback Force on the Reamer Lateral Vibration......207
3.3 RPM on the Reamer Lateral Vibration.................208
3.4 Selection of Reasonable Construction Parameters.....209
3.5 Engineering Applications............................211
4 Conclusion and Recommendations...........................212
Acknowledgments..........................................213
References...............................................214
CHAPTER 10 Effect of Artificial Accelerated Salt Weathering
on Physical and Mechanical Behavior of
Sandstone Samples from Surface
Reservoirs...............................................215
Marco Ludovico-Marques, Carlos Chastre
1 Introduction.............................................215
1.1 Geological Setting...................................215
1.2 Salt Weathering Effect............................. 217
2 Experimental Program.....................................217
2.1 Mineralogical Characterization.......................217
2.2 Experimental Procedures for Artificial Accelerated Salt
Weathering Tests.....................................219
2.3 Experimental Procedures for Physical Tests..........221
2.4 Experimental Procedures for Mechanical Tests........222
3 Analysis of Results of the Experimental Program..........223
3.1 Physical Behavior....................................223
3.2 Mechanical Behavior.................................225
4 Conclusion...............................................231
References...............................................232
X
Contents
CHAPTER 11 Stochastic Failure Analysis of Defected Oil
and Gas Pipelines......................................235
Mojtaba Mahmoodian, Chun Q. Li
1 Introduction...........................................235
2 Research Significance..................................237
3 Time-Dependent Reliability Analysis....................238
3.1 Background.........................................238
3.2 Methods for Time-Dependent Reliability Analysis....239
3.3 Gamma Process Model................................243
3.4 Comparison of Reliability Analysis Methods.........246
4 Worked Example.........................................247
5 Conclusion.............................................252
References.............................................253
CHAPTER 12 Determining the Cause of a Carbon Steel
Joint Failure in a Gas Flow Pipeline Production
Facility...............................................257
Abdel S.H. Makhlouf, Ahmed Z. Farahat
1 History and Visual Examination.........................257
2 Laboratory Evaluation of the Failed “T” Joint..........259
3 Failure Analysis Summary...............................260
3.1 Physical Evaluation of the Cracked Site of the
T Joint............................................260
3.2 Chemical Composition Examination...................261
3.3 The Metallographic Examination.....................263
3.4 Surface Examination Using SEM-EDS and
Macrograph Images..................................263
4 Conclusion.............................................264
5 Recommendations........................................264
References.............................................266
CHAPTER 13 Experimental and Numerical Investigation of
High-Pressure Water Jetting Effect Toward NPS8
Natural Gas Pipeline Integrity—Establishing
Safety Distance Perimeter..............................267
Zulkifli A. Majid, Rahmat Mohsin, Tan F. Long
1 Introduction...........................................268
2 Description of the Ruptures Pipe Incident..............270
3 Methodology............................................272
4 Results and Discussion.................................275
4.1 Experimental Study.................................275
Contents
XI
5 CFD Simulation Study.......................................279
5.1 Determination of the Pressure-Distance Curve for
Various Nozzles Sizes.................................280
5.2 Jet Flow Pattern and Abrasion Behavior on the
Pipe Test..............................................281
6 Experimental and CFD Study on Safety Distance..............282
6.1 Analysis on Pipe Distance with CFD and
Experimental Result....................................283
7 Conclusion.................................................289
References................................................289
CHAPTER 14 Graphitization in Pressure Vessels and Piping............291
Heloisa C. Furtado, Ivan U. Perez, Tito L. da Silveira,
lain L. May
1 Introduction...............................................291
2 Industrial Cases...........................................293
2.1 Case 1: Welded Joint in a Superheated Steam Tube......293
2.2 Case 2: Longitudinal Welded Joint of Distillation
Tower of a Catalytic Cracking Unit.....................294
2.3 Case 3: Water Wall of Steam Boiler....................294
2.4 Case 4: Aligned Graphite in Steam Pipe................296
2.5 Case 5: Outlet Superheater Steam Pipe.................299
3 Discussion.................................................301
4 Conclusion.................................................303
References................................................303
CHAPTER 15 Cases of Failure Analysis in Petrochemical
Industry..................................................305
Juan M. Salgado-Lopez, Carlos Rubio-Gonzalez
1 Methodology................................................305
2 Cases of Failure Analysis..................................308
2.1 Case 1: Fatigue Induced by Changes in Manufacturing
Without Appropriated Engineering Knowledge.............308
2.2 Case 2: SCC Due to H2S in Austenitic Stainless Steel.311
2.3 Case 3: Pitting Due to a Poor Slope in a Pipeline.....316
2.4 Case 4: Failure in Brass Tubes Due Contamination
of the Internal Fluid..................................317
2.5 Case 5: Creep and Internal Corrosion in High
Chromium Steel (Overheating)...........................323
3 Conclusion.................................................327
References................................................328
XII
Contents
CHAPTER 16 Failure Analysis of Heat Exchanger Tubes
in Petrochemical Industry: Microscopic
Analysis Approach.......................................................329
Zhen-Guo Yang, Yi Gong
1 Introduction............................................330
2 Case 1: Pitting Corrosion of PTA Equipment From
Inappropriate Maintenance Practices.....................331
2.1 Background..........................................331
2.2 Failure Analysis...................................332
2.3 Discussion.........................................338
2.4 Conclusion.........................................340
3 Case 2: Acidic/Caustic Alternating Corrosion of Ethylene
Plant From Operational Mistakes.........................341
3.1 Background..........................................341
3.2 Failure Analysis....................................343
3.3 Conclusion..........................................351
4 Conclusion..............................................351
References..............................................352
CHAPTER 17 Failure of 17-4 PH Stainless Steel Components
in Offshore Platforms. .................................353
Sérgio S.M. Tavares, Joaquim S. Corte, Juan M. Pardal
1 Introduction............................................353
2 Precipitation Hardening Stainless Steels (PH)...........354
3 17-4 PH Steel...........................................355
4 Case 1: Failure of Studs and Nuts by Galling............359
5 Case 2: Failure of PSV Spring...........................363
6 Case 3: Nondestructive Detection of Cracks is Studs of
17-4PH..................................................366
7 Conclusion............................................ 367
References..............................................369
CHAPTER 18 Fracture Representation and Assessment for
Tubular Offshore Structures.............................371
Xudong Qian
1 Introduction............................................371
2 Evaluation of Crack Driving Forces in Tubular Joints....373
2.1 Domain Integral Approach............................373
2.2 y] Approach.........................................376
3 Damage Mechanics Approach...............................377
3.1 Gurson Model...................................... 377
3.2 Continuum Damage Mechanics..........................379
Contents xiii
4 Failure Assessment..................................... 381
4.1 Failure Assessment Diagram...........................381
4.2 Validations..........................................382
4.3 Specific Failure Assessment Curves for Tubular Joints.384
5 Fracture Resistance at the Joint Level...................385
6 Fracture Resistance in Structures........................388
7 Conclusion...............................................388
References...............................................389
CHAPTER 19 Manufacturing, Testing, and Operational
Techniques to Prevent Sour Service Damages...............393
Mohammed A. Al-Anezi, Tariq A. Al-Ghamdi,
Waleed L. Al-Otaibi, Saad M. Al-Muaili
1 Introduction.............................................393
2 Case Histories...........................................396
2.1 SOHIC Failures.......................................396
2.2 Procurement of Substandard HIC-Resistant Pipe........398
2.3 Defective Pipe Seam Weld.............................400
3 Quality Control of Plate Manufacturing Process and
Testing Requirements.....................................402
3.1 Quality Control of Plate Manufacturing Process.......402
3.2 Testing Requirements of Plates and Coils.............403
4 Quality Control of Pipe Manufacturing Process and
Testing Requirements.....................................404
4.1 Quality Control of Pipe Manufacturing Process........404
4.2 Testing Requirements of Line Pipe....................406
5 Pipe Specification Selection Criteria and Field
Application Quality Control..............................406
5.1 Pipe Specification Selection Criteria................406
5.2 Field Application Quality Control....................407
6 Conclusion...............................................408
Acknowledgments..........................................409
References...............................................409
CHAPTER 20 The Role of Microfractography in Failure
Analysis of Machine Components and
Structures..............................................................411
Ryuichiro Ebara
1 Development of Microfractography in Failure Analysis.....411
2 Corrosion Fatigue Failure in Steam Turbine Blade.........412
XIV
Contents
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
Index.....................................................................423
|
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| genre | 1\p (DE-588)4522595-3 Fallstudiensammlung gnd-content |
| genre_facet | Fallstudiensammlung |
| id | DE-604.BV042721373 |
| illustrated | Illustrated |
| indexdate | 2024-07-10T07:08:10Z |
| institution | BVB |
| isbn | 9780081001172 0081001177 |
| language | English |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-028152556 |
| oclc_num | 957698164 |
| open_access_boolean | |
| owner | DE-703 DE-83 |
| owner_facet | DE-703 DE-83 |
| physical | XIX, 430 Seiten Illustrationen |
| publishDate | 2016 |
| publishDateSearch | 2016 |
| publishDateSort | 2016 |
| publisher | Elsevier, Butterworth-Heinemann |
| record_format | marc |
| spelling | Handbook of materials failure analysis with case studies from the oil and gas industry edited by Abdel Salam Hamdy Makhlouf, Mahmood Aliofkhazraei Amsterdam Elsevier, Butterworth-Heinemann [2016] XIX, 430 Seiten Illustrationen txt rdacontent n rdamedia nc rdacarrier Stoffeigenschaft (DE-588)4192147-1 gnd rswk-swf Material (DE-588)4169078-3 gnd rswk-swf Finite-Elemente-Methode (DE-588)4017233-8 gnd rswk-swf Fehleranalyse (DE-588)4016608-9 gnd rswk-swf Ermüdung (DE-588)4127718-1 gnd rswk-swf Bruchfestigkeit (DE-588)4139715-0 gnd rswk-swf 1\p (DE-588)4522595-3 Fallstudiensammlung gnd-content Material (DE-588)4169078-3 s Fehleranalyse (DE-588)4016608-9 s DE-604 Bruchfestigkeit (DE-588)4139715-0 s Ermüdung (DE-588)4127718-1 s Stoffeigenschaft (DE-588)4192147-1 s Finite-Elemente-Methode (DE-588)4017233-8 s 2\p DE-604 Makhlouf, Abdel Salam Hamdy (DE-588)1077051247 edt Aliofkhazraei, Mahmood (DE-588)1058846957 edt Digitalisierung UB Bayreuth - ADAM Catalogue Enrichment application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=028152556&sequence=000003&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Klappentext Digitalisierung UB Bayreuth - ADAM Catalogue Enrichment application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=028152556&sequence=000004&line_number=0002&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis 1\p cgwrk 20201028 DE-101 https://d-nb.info/provenance/plan#cgwrk 2\p cgwrk 20201028 DE-101 https://d-nb.info/provenance/plan#cgwrk |
| spellingShingle | Handbook of materials failure analysis with case studies from the oil and gas industry Stoffeigenschaft (DE-588)4192147-1 gnd Material (DE-588)4169078-3 gnd Finite-Elemente-Methode (DE-588)4017233-8 gnd Fehleranalyse (DE-588)4016608-9 gnd Ermüdung (DE-588)4127718-1 gnd Bruchfestigkeit (DE-588)4139715-0 gnd |
| subject_GND | (DE-588)4192147-1 (DE-588)4169078-3 (DE-588)4017233-8 (DE-588)4016608-9 (DE-588)4127718-1 (DE-588)4139715-0 (DE-588)4522595-3 |
| title | Handbook of materials failure analysis with case studies from the oil and gas industry |
| title_auth | Handbook of materials failure analysis with case studies from the oil and gas industry |
| title_exact_search | Handbook of materials failure analysis with case studies from the oil and gas industry |
| title_full | Handbook of materials failure analysis with case studies from the oil and gas industry edited by Abdel Salam Hamdy Makhlouf, Mahmood Aliofkhazraei |
| title_fullStr | Handbook of materials failure analysis with case studies from the oil and gas industry edited by Abdel Salam Hamdy Makhlouf, Mahmood Aliofkhazraei |
| title_full_unstemmed | Handbook of materials failure analysis with case studies from the oil and gas industry edited by Abdel Salam Hamdy Makhlouf, Mahmood Aliofkhazraei |
| title_short | Handbook of materials failure analysis with case studies from the oil and gas industry |
| title_sort | handbook of materials failure analysis with case studies from the oil and gas industry |
| topic | Stoffeigenschaft (DE-588)4192147-1 gnd Material (DE-588)4169078-3 gnd Finite-Elemente-Methode (DE-588)4017233-8 gnd Fehleranalyse (DE-588)4016608-9 gnd Ermüdung (DE-588)4127718-1 gnd Bruchfestigkeit (DE-588)4139715-0 gnd |
| topic_facet | Stoffeigenschaft Material Finite-Elemente-Methode Fehleranalyse Ermüdung Bruchfestigkeit Fallstudiensammlung |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=028152556&sequence=000003&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=028152556&sequence=000004&line_number=0002&func_code=DB_RECORDS&service_type=MEDIA |
| work_keys_str_mv | AT makhloufabdelsalamhamdy handbookofmaterialsfailureanalysiswithcasestudiesfromtheoilandgasindustry AT aliofkhazraeimahmood handbookofmaterialsfailureanalysiswithcasestudiesfromtheoilandgasindustry |