FAILURE ANALYSIS AND REDESIGN OF SOFT IRON (AISI 1008) RING GASKET FOR APPLICATION IN OIL AND GAS FIELD.

BY: SHAKEEL AHMAD SUPERVISED BY: Dr. ASHFAQ KHAN

CONTENTSAimObjectivesCauses of Gasket FailureLiterature reviewMethodologyGantt chartUtilization of research result

AIMThe aim of this project is to conduct the failure analysis of Soft Iron ( AISI 1008) Ring gasket and make modification to enable it to better withstand failure.

OBJECTIVES Perform comparative Test’s by microscopy of failed and

new gasket.To identify the causes of Gasket Failure. Identify the modifications possible in gasket to avoid

failure.Modify the gasket to better with stand failure.Test the modified and original gasket and evaluate the

comparative performance.

CHRISTMAS TREE, RTJ FLANGE AND GASKET

Christmas TreeRing

Gasket

Flanges

CORROSIONOne of the most probable cause of failure is erosion-corrosion in the present case as clearly shown by the visual examination of the gasket.The chemical reaction of an engineering materials with its

environment result a consequent deterioration in properties of the material.

It is a natural phenomena that occurs over time.It happens at different rates with different metals

depending on its environment.

EROSION-CORROSION Erosion is a wearing away process by the mechanical

abrasion caused by suspended particles in moving environment.

Erosion corrosion is the accelerated deterioration in materials property due to movement of erosive environment.

Erosion produce a distinctive surface pattern, appears in the form of groove, waves or valleys oriented with respect to the fluid flow direction.

OTHER FORMS OF CORROSIONUniform corrosion Galvanic or two metal corrosion Crevice corrosion Pitting corrosion Intergrainular corrosion Selective corrosion Stress corrosion cracking

LITERATURE REVIEW Ring gasket: A device for sealing two flanges, and are

manufactured from different materials and in different shapes[1, 2].Erosion: A wearing away process due to mechanical abrasion of

suspended particles in moving fluid[12]. Corrosion: One of the big problem in oil and gas field in terms of

failure, production loss and safety[5, 12].Analysis: Analyzing the corrosion mechanism is carried out by

material characterization[8].Control of corrosion: In order to prolong the lifetime of material

required a special attention[9, 10]. Various techniques are used for corrosion control in oil and gas

field[7, 11].

CONTI….Technique: Chemical inhibition, cathodic protection,

design modification and material coating techniques are used[15].

Coating Materials: Different coating material such as CERMET (CrC-NiCr, WC-Co-Cr), Cr-C, Chromium, Aluminum, Copper and Zinc[13].

Coating Equipment: Detonation Gun(D-Gun) and High-Velocity Oxy Fuel (HVOF) equipment are used for coating[3]. HVOF D-Gun

Testing: Various test are performed to identify the corrosion rate for the new developed materials[12].

Test Equipment: Pin on Disc Tribometer are used to measure the wear rate in order to find out erosion rate[13, 14].

Pin on Disc Tribometer

METHODOLOGYPreparation of metallographic specimen of both corrode

and uncorrode gasket for material characterization.Performing various microscopic test of both specimen.Taking comparative analysis to identify corrosion

mechanism and change’s in material properties ( mechanical, physical and chemical)Modifying the gasket without altering its primary purpose.Modification can be brought by coating the material on

selective area of the gasket.

CONTI…Selective area can be find out experimentally by measuring the

thickness of flanges with gasket before tighten and then after tighten.

Various coating cermets ( CrC-NiC, WC-Co-Cr) are used for protection.

Also various coating metals such as Aluminum, Chromium, Copper and Zinc are used.

We will use such coating material having long life, best erosive-corrosive resistance, withstand high temperature, minimal cost and best wear resistance.

Coating process is taking out by one of coating equipment [ (High Velocity Oxy Fuel “HVOF”), (Detonation Gun “D-Gun”)]

CONTI… Test can be performed to find out the erosion rate in terms

of wear rate.Pin On Disc Tribometer Equipment is used to find out

wear rate.Comparing the result of both modified and original

gasket.

Analysis

Control

Testing

Literature Review Metallographic Specimen Preparation(Sectioning, Mounting, Coarse Grinding, Fine Grinding, Fine Polishing, Etching)

Microstructural Characterization (EDS Testing, SEM Testing, XRD Testing, Rockwell Hardness Test)

Data Collection and Corrosion Analysis(Comparative Analysis of Both corrode and

uncorrode gasket)

Thermal Spray Coating (cermets material, Metals)

Modifying gasket erosive resistance

High Velocity Oxy Fuel, Detonation Gun

Experimentally Selection Coating Area

Erosive test in Terms of Wear

Physical Testing, Pin on Disc Tribometer

TestingComparing the

Result

GANTT CHART Activity 2015-16

August September October November December January February March

Literature ReviewMetallographicSpecimen preparation

Material Charactrizati-on

MetalCoating

Thesis and paper writing

Submission

Utilization of Research Result

To know the cause of failure.

It is low cast and more reliable corrosion control process than others.

Providing the result to oil industries to avoid failure.

Reference 1. James Walker., moorflex technology guide of ring gasket, UK2. L.P. Deer Park., flexitallic-rtj product data, usa3. Int. J. Elecrochem Sci., Erosion-corrosion of cermet coating, 8(2013)

1117-11374. Xinming Hu., Khalid Alzawai,Adinesh Gnanawelu, Anni Newile, wear 271 ( 2011)1432-14375. G.T. Burstien., Corrosion Metals and Environment Reaction., Vol; 1, 3rd

Edition, 3-293(1).6. R. Malka Srdjan Nesic, Danial A. Gulino., Wear 262(2007) 791-7997. L.S. Moiseeva, Protection of metals, Vol 41, No.1 (2005) 76-838. B. Kuznika., Engineering Failure Analysis,Vol 16, (2009) 2382-23879. V.S Sastri., Introduction and Forms of Corrosion., 1st Edition, 9(1).

10. L.L. Faulkner., Practical Engineering Failure Analysis., 291(8), 344(9).

11. G.T. Burstien., Corrosion and Corrosion Control.Vol; 2, 3rd Edition, 366(12), 475(13).

12. Pierre R. Robrge., Hand Book of Corrosion Engineering, 781(9), 831(10)

13. M. Farooq., journal of faculty of engineering and technology, Vol 22, No.1 (2015), 1-6.

14. Tushiu Nakamura., Surface and coating technology, 204(2009) 42-53.

15. Sukhpa sigh chatha., Journa of mienrals and material charactrization and engineering, Vol 11, No.6 (2012) 569-586

16, Hongjun Zhu., Numerical Analysis of Flow Erosion on Drill Pipe in Gas Drilling, Vol 22 (2012) 83-91

Thanks