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

1st Edition - August 24, 2015
Editors: Abdel Salam Hamdy Makhlouf, Mahmood Aliofkhazraei
Language: English
Hardback ISBN:
9 7 8 - 0 - 0 8 - 1 0 0 1 1 7 - 2
eBook ISBN:
9 7 8 - 0 - 0 8 - 1 0 0 1 2 6 - 4

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 ele… Read more

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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.

Preface
Chapter 1: Failure analysis of oil and gas transmission pipelines
- Abstract
- 1 Introduction
- 2 Mechanical Damage
- 3 Longitudinal Seam-Weld Defects
- 4 Corrosion
- 5 Fatigue
- 6 Conclusion
Chapter 2: Modern analytical techniques in failure analysis of aerospace, chemical, and oil and gas industries
- Abstract
- 1 Microscopy Techniques
- 2 Chemical and Radiographic Analysis
- 3 Conclusion and Future Outlook
Chapter 3: Methods for assessing defects leading to gas pipe failure
- Abstract
- 1 Introduction
- 2 Macroscopic and Microscopic Aspects of Pipe Failure
- 3 Brittle Fracture in a Pipe Emanating from a Crack
- 4 Assessment of Gouges Using Notch Fracture Mechanics
- 5 Pipe Failure Emanating from Corrosion Defect
- 6 Pipe Failure Emanating from Dents
- 7 Conclusion
Chapter 4: Failure of glass fiber-reinforced epoxy pipes in oil fields
- Abstract
- 1 Introduction
- 2 In-Lab Studies
- 3 In-Service Degradation and Failure
- 4 Conclusion
Chapter 5: Failures and integrity of pipelines subjected to soil movements
- Abstract
- Acknowledgment
- 1 Introduction
- 2 Recent Failures and Lessons Learned
- 3 Mitigation Measures During Operation
- 4 Prevention Measures at the Design Stage
- 5 Conclusion
Chapter 6: Oil field drill pipes failure
- Abstract
- Acknowledgments
- 1 Introduction
- 2 Case 1: In-service Pitting
- 3 Case 2: Surface Oxide Cracking
- 4 Case 3: Hardbanding Failure
Chapter 7: Failure analysis and solution studies on drill pipe thread gluing at the exit side of horizontal directional drilling
- Abstract
- Acknowledgments
- 1 Introduction
- 2 Methodology and Model
- 3 Results and Discussion
- 4 Conclusion and Recommendations
Chapter 8: Causes and conditions for reamer blade balling during hole enlargement while drilling
- Abstract
- Acknowledgments
- 1 Introduction
- 2 Methodology and Model
- 3 Results and Discussion
- 4 Conclusion and Recommendations
Chapter 9: Analysis of reamer failure based on vibration analysis of the rock breaking in horizontal directional drilling
- Abstract
- Acknowledgments
- 1 Introduction
- 2 Methodology and Model
- 3 Results and Discussion
- 4 Conclusion and Recommendations
Chapter 10: Effect of artificial accelerated salt weathering on physical and mechanical behavior of sandstone samples from surface reservoirs
- Abstract
- 1 Introduction
- 2 Experimental Program
- 3 Analysis of Results of the Experimental Program
- 4 Conclusion
Chapter 11: Stochastic failure analysis of defected oil and gas pipelines
- Abstract
- 1 Introduction
- 2 Research Significance
- 3 Time-Dependent Reliability Analysis
- 4 Worked Example
- 5 Conclusion
Chapter 12: Determining the cause of a carbon steel joint failure in a gas flow pipeline production facility
- Abstract
- 1 History and Visual Examination
- 2 Laboratory Evaluation of the Failed “T” Joint
- 3 Failure Analysis Summary
- 4 Conclusion
- 5 Recommendations
Chapter 13: Experimental and numerical investigation of high-pressure water jetting effect toward NPS8 natural gas pipeline integrity—Establishing safety distance perimeter
- Abstract
- 1 Introduction
- 2 Description of the Ruptures Pipe Incident
- 3 Methodology
- 4 Results and Discussion
- 5 CFD Simulation Study
- 6 Experimental and CFD Study on Safety Distance
- 7 Conclusion
Chapter 14: Graphitization in pressure vessels and piping
- Abstract
- 1 Introduction
- 2 Industrial Cases
- 3 Discussion
- 4 Conclusion
Chapter 15: Cases of failure analysis in petrochemical industry
- Abstract
- 1 Methodology
- 2 Cases of Failure Analysis
- 3 Conclusion
Chapter 16: Failure analysis of heat exchanger tubes in petrochemical industry: Microscopic analysis approach
- Abstract
- 1 Introduction
- 2 Case 1: Pitting Corrosion of PTA Equipment From Inappropriate Maintenance Practices
- 3 Case 2: Acidic/Caustic Alternating Corrosion of Ethylene Plant From Operational Mistakes
- 4 Conclusion
Chapter 17: Failure of 17-4 PH stainless steel components in offshore platforms
- Abstract
- 1 Introduction
- 2 Precipitation Hardening Stainless Steels (PH)
- 3 17-4 PH Steel
- 4 Case 1: Failure of Studs and Nuts by Galling
- 5 Case 2: Failure of PSV Spring
- 6 Case 3: Nondestructive Detection of Cracks is Studs of 17-4PH
- 7 Conclusion
Chapter 18: Fracture representation and assessment for tubular offshore structures
- Abstract
- 1 Introduction
- 2 Evaluation of Crack Driving Forces in Tubular Joints
- 3 Damage Mechanics Approach
- 4 Failure Assessment
- 5 Fracture Resistance at the Joint Level
- 6 Fracture Resistance in Structures
- 7 Conclusion
Chapter 19: Manufacturing, testing, and operational techniques to prevent sour service damages
- Abstract
- Acknowledgments
- 1 Introduction
- 2 Case Histories
- 3 Quality Control of Plate Manufacturing Process and Testing Requirements
- 4 Quality Control of Pipe Manufacturing Process and Testing Requirements
- 5 Pipe Specification Selection Criteria and Field Application Quality Control
- 6 Conclusion
Chapter 20: The role of microfractography in failure analysis of machine components and structures
- Abstract
- 1 Development of Microfractography in Failure Analysis
- 2 Corrosion Fatigue Failure in Steam Turbine Blade
- 3 Corrosion Fatigue Failure of Cargo Oil Tank Structural Member in Very Large Crude Oil Carrier
- 4 The Role of Stretched Zone in Unstable Fracture of Hot and Cold Forging Dies for Automotive Components
- 5 Conclusion
Index

Abdel Salam Hamdy Makhlouf

Professor Abdel Salam Hamdy Makhlouf is the Vice President of Integrated Mechanical Material Corrosion Consulting (IM2C), Texas, USA, and a Full professor at Central Metallurgical Research and Development Institute. He has 26 years of experience working in R&D with a blend of both industrial and academic leadership as a Professor of Materials Science, and Advanced “nano-bio” Manufacturing Engineering, and Materials Engineering Consultant. He is the recipient of numerous national and international prizes and awards including the Humboldt Research Award for Experienced Scientists, at Max Planck Institute, Germany; Fulbright, NSF, and Dept. of Energy Fellowships, USA; Shoman Award in Engineering Science; and the State Prize of Egypt in Advanced Science and Technology. His research has focused on five critical areas: Energy, Health, Environment, Advanced manufacturing, Advanced materials. Dr. Makhlouf has published over 200 journal articles, as well as 17 books and handbooks for Springer and Elsevier on a broad range of cross‐disciplinary research fields including advanced multifunctional materials, nanotechnology, smart coatings, corrosion, biomaterials, waste/water treatment, and materials for energy applications. Dr. Makhlouf has served as both a Senior Editor and board member of many international journals, as well as reviewer for several international funding agencies in USA, Germany, UK, Qatar, Belgium, EU, Kazakhstan. He is a Consultant/Reviewer for several universities worldwide.

Affiliations and expertise

Vice President & Engineering Consultant, Integrated Mechanical Material Corrosion Consulting (IM2C), Texas, USA, Professor, Central Metallurgical Research and Development Institute, Cairo, Egypt

Mahmood Aliofkhazraei

Mahmood Aliofkhazraei is assistant professor in the department of materials science at the Tarbiat Modares University, where he also earned his master's degree and Ph.D. in corrosion and protection of materials. Dr. Aliofkhazraei has authored over 60 scientific publications on nanostructured coatings and thin films and has received numerous scientific awards, such as Khwarizmi award. He was selected among the 10 top best nanotechnologists in his country.

Affiliations and expertise

Assistant Professor, Department of Materials Science, Tarbiat Modares University, Tehran, Iran