Handbook of materials failure analysis : with case studies from the oil and gas industry / edited by Abdel Salam Hamdy Makhlouf, Mahmood Aliofkhazraei ; contributors, Mohammed A. Al-Anezi [and forty-two others].

Format:

Book

Contributor:

Makhlouf, Abdel Salam Hamdy, editor.

Aliofkhazraei, Mahmood, editor.

Al-Anezi, Mohammed A., contributor.

Language:

English

Subjects (All):

Fracture mechanics.

Materials--Fatigue--Case studies.

Materials.

Physical Description:

1 online resource (0 p.)

Place of Publication:

Amsterdam, Netherlands : Elsevier, 2016.

Language Note:

English

Summary:

" Handbook of Materials Failure Analysis: With Case Studies from the Oil and Gas Industry" provides an updated understanding on why materials fail in specific situations, a vital element in developing and engineering new alternatives. This handbook covers analysis of materials failure in the oil and gas industry, where a single failed pipe 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 fibre reinforced epoxy pipes, and failure of stainless steel components in offshore platforms, amongst others. Introduces readers to modern analytical techniques in materials failure analysisCombines foundational knowledge with current research on the latest developments and innovations in the fieldIncludes numerous compelling case studies of materials failure in oil and gas pipelines and drilling platforms

Contents:

Front Cover

Handbook of Materials Failure Analysis With Case Studies from the Oil and Gas Industry

Copyright

Contents

Contributors

Preface

Chapter 1: Failure analysis of oil and gas transmission pipelines

1. Introduction

2. Mechanical Damage

3. Longitudinal Seam-Weld Defects

3.1. Lap-Weld Defects

3.2. Lap-Weld Case Study

3.3. ERW Defects

3.4. Flash Weld Defects

3.5. Submerged-Arc Weld Defects

3.6. Submerged-Arc Weld Defect Case Study

3.7. Shielded Metal Arc Weld Defects

4. Corrosion

4.1. General Corrosion

4.2. Stress Corrosion Cracking

4.3. High-pH SCC Case Study

4.4. Near-Neutral pH SCC Case Study

4.5. Hydrogen-Stress Cracking

4.6. HSC Case Study

4.7. Grooving Corrosion

5. Fatigue

6. Conclusion

References

Chapter 2: Modern analytical techniques in failure analysis of aerospace, chemical, and oil and gas industries

1. Microscopy Techniques

1.1. Optical Microscopy

1.2. Scanning Electron Microscopy

1.3. Focused Ion Beam

2. Chemical and Radiographic Analysis

2.1. Energy Dispersive Spectroscopy

2.2. X-Ray Fluorescence

2.3. X-Ray Diffraction

2.4. Fourier Transform Infrared Spectrophotometry

2.5. X-Ray Photoelectron Spectroscopy

2.6. Radiography

2.7. Neutron Radiography

2.8. X-Ray Radiography

2.9. Gamma-Ray Radiography

2.10. Fluoroscopic Radiography

3. Conclusion and Future Outlook

Chapter 3: Methods for assessing defects leading to gas pipe failure

2. Macroscopic and Microscopic Aspects of Pipe Failure

3. Brittle Fracture in a Pipe Emanating from a Crack

3.1. Cracks in a Pipe

3.2. Fracture Condition of a Cracked Pipe

3.3. Failure Assessment Diagram

3.4. Defect Assessment in a Brittle Cast Iron Pipe

4. Assessment of Gouges Using Notch Fracture Mechanics.

4.1. Gouges in Pipes

4.2. Notch Fracture Mechanics

4.3. Notch Failure Assessment Diagram

4.4. Safety Factor Associated with Defect in Pipe Under Service Pressure

4.5. Two-Parameter Fracture Mechanics

4.5.1. Example of material failure master curve for a steel pipe

4.5.2. Loading path in plane Kap-Tef

5. Pipe Failure Emanating from Corrosion Defect

5.1. Burst Pressure Predicted by Plastic Collapse

5.2. Domain Failure Assessment Diagram

5.3. Application to Corrosion Defect in a Gas Pipe [25]

6. Pipe Failure Emanating from Dents

6.1. Dent: Origin and Description

6.2. Limit of Acceptability of Dent Depth

6.3. Methods to Estimate and Control Dent

6.4. Methods to Estimate and Control Dent+Gouge Defect

7. Conclusion

Chapter 4: Failure of glass fiber-reinforced epoxy pipes in oil fields

2. In-Lab Studies

3. In-Service Degradation and Failure

4. Conclusion

Chapter 5: Failures and integrity of pipelines subjected to soil movements

2. Recent Failures and Lessons Learned

3. Mitigation Measures During Operation

4. Prevention Measures at the Design Stage

5. Conclusion

Acknowledgments

Chapter 6: Oil field drill pipes failure

2. Case1: In-service Pitting

2.1. Experimental

2.1.1. Visual examination

2.1.2. SEM surface studies

2.1.3. Microstructure

2.1.4. Vicker's macrohardness

2.1.5. Chemical composition

2.2. Discussion

2.3. Conclusion and Recommendations

3. Case2: Surface Oxide Cracking

3.1. Experimental

3.1.1. Visual observation

3.1.2. Chemical analysis

3.1.3. Hardness measurements

3.1.4. Mechanical testing

3.1.5. Microstructural characterization

3.2. Discussion

3.3. Conclusion and Recommendations

4. Case3: Hardbanding Failure.

4.1. Experimental

4.1.1. Visual observation

4.1.2. Chemical analysis

4.1.3. Hardness measurements

4.1.4. Mechanical testing

4.1.5. Microstructural characterization

4.1.6. Fractography

4.2. Discussion

4.3. Conclusion and Recommendations

Chapter 7: Failure analysis and solution studies on drill pipe thread gluing at the exit side of horizontal directional dr ...

2. Methodology and Model

2.1. Analysis of Construction Conditions

2.2. Material Tensioning and Make-Up and Break-Out Tests

2.2.1. Material tensioning tests

2.2.2. Make-up and break-out tests

2.2.3. Control equation of thread connection

2.2.4. Connecting thread 3D FEM

3. Results and Discussion

3.1. FEM Verification

3.2. Effects of Insufficient Make-Up Torque

3.3. Effect Analysis of Bending Moment

3.4. Improvement Measures

3.5. New Drill Pipe Thread Design

3.6. Comparison of Bending Strength

3.7. Comparison of Flexural Rigidity

3.8. Comparison of the Shoulder Sealing

4. Conclusion and Recommendations

Chapter 8: Causes and conditions for reamer blade balling during hole enlargement while drilling

2.1. Physical Model

2.2. Mathematical Model

2.2.1. Governing equations of continuous flow

2.2.2. Equation for cuttings removal

2.2.3. Discrete particle hard sphere model

2.3. Simulation Conditions

2.4. Numerical Model and Computation

2.5. Restrictive Conditions

3.1. Flow Pattern Discussion

3.2. Discussion of the Causes of Reamer Blade Balling

3.3. Measures to Reduce Balling

3.4. Optimizing the Reamer Blade Hydraulic Structure

3.5. The Influence of Nozzle Type and Angle

3.6. Parameter Optimization.

4. Conclusion and Recommendations

Momenclature

Greek Symbols

Chapter 9: Analysis of reamer failure based on vibration analysis of the rock breaking in horizontal directional drilling

2.1. Reamer-Rock Contact with Mathematical Model

2.2. Drucker-Prager Rock Strength Criterion

2.3. Basic Assumptions

2.4. Petrophysical Parameters

2.5. Meshing and Boundary Conditions

3.1. Reamer Lateral, Axial, and Torsional Vibration Characteristics

3.2. Pullback Force on the Reamer Lateral Vibration

3.3. RPM on the Reamer Lateral Vibration

3.4. Selection of Reasonable Construction Parameters

3.5. Engineering Applications

Chapter 10: Effect of artificial accelerated salt weathering on physical and mechanical behavior of sandstone samples from ...

1.1. Geological Setting

1.2. Salt Weathering Effect

2. Experimental Program

2.1. Mineralogical Characterization

2.2. Experimental Procedures for Artificial Accelerated Salt Weathering Tests

2.3. Experimental Procedures for Physical Tests

2.4. Experimental Procedures for Mechanical Tests

3. Analysis of Results of the Experimental Program

3.1. Physical Behavior

3.2. Mechanical Behavior

Chapter 11: Stochastic failure analysis of defected oil and gas pipelines

2. Research Significance

3. Time-Dependent Reliability Analysis

3.1. Background

3.2. Methods for Time-Dependent Reliability Analysis

3.2.1. First Passage Probability Method

3.2.2. Monte Carlo Simulation Method

3.3. Gamma Process Model

3.3.1. Maximum-Likelihood Estimation

3.3.2. Method of Moments.

3.4. Comparison of Reliability Analysis Methods

4. Worked Example

Chapter 12: Determining the cause of a carbon steel joint failure in a gas flow pipeline production facility

1. History and Visual Examination

2. Laboratory Evaluation of the Failed ``T´´ Joint

3. Failure Analysis Summary

3.1. Physical Evaluation of the Cracked Site of the ``T´´ Joint

3.2. Chemical Composition Examination

3.2.1. FeCO3 corrosion predominates in natural gas pipes

3.3. The Metallographic Examination

3.4. Surface Examination Using SEM-EDS and Macrograph Images

5. Recommendations

Chapter 13: Experimental and numerical investigation of high-pressure water jetting effect toward NPS8 natural gas pipeli...

2. Description of the Ruptures Pipe Incident

3. Methodology

4. Results and Discussion

4.1. Experimental Study

4.1.1. Properties of the impacted surface

4.1.2. Dispersion of pipe thinning rate

4.1.3. Pressure distribution for nozzle jetting source

4.1.4. The zero effect for nozzle jetting system at certain distance

5. CFD Simulation Study

5.1. Determination of the Pressure-Distance Curve for Various Nozzles Sizes

5.2. Jet Flow Pattern and Abrasion Behavior on the Pipe Test

6. Experimental and CFD Study on Safety Distance

6.1. Analysis on Pipe Distance with CFD and Experimental Result

Chapter 14: Graphitization in pressure vessels and piping

2. Industrial Cases

2.1. Case1: Welded Joint in a Superheated Steam Tube

2.2. Case2: Longitudinal Welded Joint of Distillation Tower of a Catalytic Cracking Unit

2.3. Case3: Water Wall of Steam Boiler

2.4. Case4: Aligned Graphite in Steam Pipe

2.5. Case5: Outlet Superheater Steam Pipe

3. Discussion

4. Conclusion.

References.

Notes:

Description based upon print version of record.

Includes bibliographical references at the end of each chapters and index.

Description based on online resource; title from PDF title page (ebrary, viewed November 27, 2015).

ISBN:

9780081001264

0081001266