Fitness-for-Service (FFS) Assessment based on API RP579 Section 3 - Lessons learnt from Historical Equipment

Failures
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Lesson learnt from Historical
Equipment Failures
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Session Agenda
Fatigue and fracture case studies
Other failure mechanism case studies
Statistic on Oil and Gas failure rates
Fitness-for-Service (FFS) Assessment based on API RP579 Section 3 - Lessons learnt from Historical Equipment
Failures
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Failure Case Studies
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Kings Bridge
Fitness-for-Service (FFS) Assessment based on API RP579 Section 3 - Lessons learnt from Historical Equipment
Failures
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Fawley Storage Tank
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MV Kurdistan Tanker
Fitness-for-Service (FFS) Assessment based on API RP579 Section 3 - Lessons learnt from Historical Equipment
Failures
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Origin of failure in Kurdistan Tanker
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Alexander L. Kielland Platform
Fitness-for-Service (FFS) Assessment based on API RP579 Section 3 - Lessons learnt from Historical Equipment
Failures
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Fatigue cracking in brace D6 of
Alexander L. Kielland Platform
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Cockenzie Boiler Drum
Fitness-for-Service (FFS) Assessment based on API RP579 Section 3 - Lessons learnt from Historical Equipment
Failures
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Union Oil Amine Absorber Tower
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Summary of fatigue and fracture case
studies
Union Oil
Cockenzie
Keilland
Kurdistan
Fawley
Kings
Bridge
John
Thompson
Subcritical
growth
Fabrication Service Test Residual Secondary
member
Main
structure
Temp.
significant
Low
toughness
Defect Repair Weld Stress Initiation site Case
Fitness-for-Service (FFS) Assessment based on API RP579 Section 3 - Lessons learnt from Historical Equipment
Failures
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Corrosion failure
A section of a 30 inch
oil transit pipe line
burst in an oilfield
10,000 to 15,000
barrels of oil leaked
over a large area of a
gathering station
A subsequent fire and
explosion occurred
Source of leak a
830mm long split in
the 6 oclock position
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Corrosion failure
View of resulting damage from explosion and fire View of resulting damage from explosion and fire
Fitness-for-Service (FFS) Assessment based on API RP579 Section 3 - Lessons learnt from Historical Equipment
Failures
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Corrosion failure
Burst pipe sample set to Burst pipe sample set to
TWI TWI
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Corrosion failure
TWI asked to determine the cause of failure
in 30 inch pipe
Investigation approach:
Initial examination and photography
Measurement of wall thickness in damaged
region (AUT)
Sectioning of region close to split
Chemical analysis, hardness testing,
fractographic examination, Metallographic
examination, mechanical testing
Engineering assessment
Fitness-for-Service (FFS) Assessment based on API RP579 Section 3 - Lessons learnt from Historical Equipment
Failures
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Corrosion failure
Nominal thickness 9.8 mm
Minimum measured thickness 3.2 mm
Rupture tear
AUT thickness mapping T AUT thickness mapping T- -scan mode scan mode
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Corrosion failure
Metallurgical investigation determined
corrosion result of coal tar paint break
down
Resulting exposed area too great for
cathodic protection system
Failure initiation at several sites which
propagated to coalesce to a unstable single
split
Fitness-for-Service (FFS) Assessment based on API RP579 Section 3 - Lessons learnt from Historical Equipment
Failures
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Corrosion failure
Questions which remained were:
Was the pipe originally code compliant
Was the flaw fit-for-service
A code and a fitness-for-service assessment
were conducted
The code evaluation showed that the
pipeline was compliant with ASME B31.4
and not compliant with ASME B31.3
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Corrosion failure
Burst pressure was evaluated using BS7910
appendix G and B31.G
Material properties taken from from the
failed pipe e.g. yield stress
BS 7910 procedure based on UTS properties
B31.G procedure based on yield properties
Fitness-for-Service (FFS) Assessment based on API RP579 Section 3 - Lessons learnt from Historical Equipment
Failures
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Corrosion failure
F
a
i
l
u
r
e

p
r
e
s
s
u
r
e

(
p
s
i
)
100
200
300
400
500
600
700
Assessment
Thickness (mm)
3.2 3.7
BS 7910
B31.G
Minimum measured thickness
Averaged measured thickness
Flaw could have failed Flaw could have failed
within operating band within operating band
High probability pipe High probability pipe
failed due to pressure failed due to pressure
rise within operating rise within operating
range range
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Factors affecting structural integrity
MATERIAL
PROPERTIES
FLAWS,
GEOMETRY
STRESSES
Session 2/22
Fitness-for-Service (FFS) Assessment based on API RP579 Section 3 - Lessons learnt from Historical Equipment
Failures
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Lessons to be learnt from industrial
failures
Welds, including repairs and attachments
Flaws
Sub-critical crack growth
Fracture toughness
Temperature
Residual stresses
Environment
Inspection