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Document Title: Leak investigation of circumferencial weld seam failure of V-3369

Client: United Energie akistan Limited!


"#V $o% &o: Contract &o: C'&-(-)*3-+)
"e,ort date: -a. 3/ 0)+0 age + of 1
Leak Investigation of Circumferencial Weld Seam failure of V-3369
"#V team visited t2e Tangri facilit. for t2e ins,ection of su%3ected leak dated )3-)4-0)+0
and following are t2e o%servations:
1) Location: Tangri 5acilit.
) !ate of Ins"ection: )3-)4-0)+0
3) #$ui"ment %&i"e !escri"tion: E6ui,ment V-3369
') Vicinit( )eference: 7nside fence
*) +luid inside %Service: Lean 8mine
6) Coating ,("e: aint
-) ."erating ,em"/ % &ressure: +9)
)
5 9 3:; si <,ositive ,ressure=
0) Location of Leak: #2ell to 2ead circumferencial weld seam
9) 1or"2olog( of "oint of failure: Transverse crack
13) Leaked e$ui"ment connected to s(stem % Isolated: Connected
11) ,("e of Welding: #u%merged 8rc >elding
1) ), level: +
13) Stress Relieving: No

&2otogra"2s of #$ui"ment and &oint of +ailure
Leaked Weld Seam
Document Title: Leak investigation of circumferencial weld seam failure of V-3369
Client: United Energie akistan Limited!
"#V $o% &o: Contract &o: C'&-(-)*3-+)
"e,ort date: -a. 3/ 0)+0 age 0 of 1



Point of failure
Point of failure after scrubbing Paint
Drop wise leakage
Morphology of point of
failure after 12 hours
Morphology of point of
failure after 3 hours
Morphology of point of
failure after 3 hours
Document Title: Leak investigation of circumferencial weld seam failure of V-3369
Client: United Energie akistan Limited!
"#V $o% &o: Contract &o: C'&-(-)*3-+)
"e,ort date: -a. 3/ 0)+0 age 3 of 1

Surface breaking transverse Crack
Document Title: Leak investigation of circumferencial weld seam failure of V-3369
Client: United Energie akistan Limited!
"#V $o% &o: Contract &o: C'&-(-)*3-+)
"e,ort date: -a. 3/ 0)+0 age ; of 1
&ro"osed 4!# ,ec2ni$ues:
#urface %reaking cracks can %e investigated and si?ed using com%ination of following non
destructive e@aminationA
+! DT
0! -7
3! U5D
;! "T
Limitations of !&, and 1&I:
Tem,erature limitation restricted t2e use of -7 and DT tec2ni6ues on e@amination
surface! T2e recommended tem,erature of manufacturer of all consuma%les ,resent on
site was 44C w2ile of e@amination surface was 16C!
Limitation of ),:
8s e6ui,ment was connected to s.stem limiting t2e ,ossi%ilit. of ,anoramic tec2ni6ue/ t2e
onl. ,ossi%le wa. to carr. out "T was D>#7 tec2ni6ue! T2e e@,osure time calculated wit2
ma@!+) Ci for single e@,osure using even D* film was a%out * 2ours!
-oreover ,otential 2ealt2 and safet. 2a?ards of gamma ra.s do not ,ermit radiogra,2. as
a %etter c2oice for crack investigation!
#5ecution and Limitations of 6,:
T2e onl. non destructive e@amination tec2ni6ue w2ic2 could ,rove 2el,ful in failure
investigation was Ultrasonic flaw detection wit2 following draw %acks affecting t2e
relia%ilit. and accurac. of t2e test as far as availa%le resources are concerned!
+! U5D is alwa.s recommended a%ove wall t2ickness of +3mm of e@amination
surfaces for relia%le and ,recise results! #,ecial ,ur,ose miniature ,ro%es wit2
2ig2er fre6uenc. and mock u, %locks for cali%ration can %e 2el,ful for %etter
detection of discontinuities as far as t2ickness ranges %elow +3mm are
concerned!
0! E@amination surface tem,erature a%ove 64C im,acts t2e test accurac. as
mentioned in 87 4+) and 8#-E V! #,ecial ,rocedures are to %e 6ualified for
carr.ing out suc2 sort of researc2 work including cali%rating t2e e6ui,ment on
2ot mock u, %locks and esta%lis2ing t2e tem,erature correction factor!
3! #ki, distance re6uirements w2ile using t2e narrowest availa%le *) degree
s2ear wave ,ro%e were not met as far as low t2ickness of test o%3ect is
concerned! 5lus2ing t2e weld ca,,ing e6ual to %ase metal could serve t2e
,ur,ose %ut e6ui,ment was in-service and no 2ot work was ,ermitted!
Document Title: Leak investigation of circumferencial weld seam failure of V-3369
Client: United Energie akistan Limited!
"#V $o% &o: Contract &o: C'&-(-)*3-+)
"e,ort date: -a. 3/ 0)+0 age 4 of 1
Bowever ultrasonic flaw detection wit2 longitudinal and s2ear wave e@amination was
carried out %. cali%rating t2e e6ui,ment on t2e 2ot test o%3ect and following are t2e main
findings:
T2e defect was c2aracteri?ed as transverse crack and onl. ,revailed t2e ca,,ing
of weld! Crack has not still propagated into HAZ.
&ormal %eam scanning over weld ca,,ing did not reveal an. ot2er o%3ectiona%le
discontinuit. in t2e vicinit. of ,oint of failure as marked in sna, %elow! #2ar,
ec2oes in con3unction wit2 %ack wall were received at t2e t2ickness of 1mm and
4mm near t2e ,oint of failure!
#2ear wave e@amination over weld ca,,ing also counter ,roved t2e results of
normal %eam scanning! T2ere are c2ances of metal deterioration dee, %elow 1mm
of weld!
&o o%3ectiona%le indication was noticed in B8C
&o o%3ectiona%le indication was noticed in scanning area of +ft a%ove and +ft
%elow t2e ,oint of failure!
Length of !rack "2# mm as measured by $%D&
Document Title: Leak investigation of circumferencial weld seam failure of V-3369
Client: United Energie akistan Limited!
"#V $o% &o: Contract &o: C'&-(-)*3-+)
"e,ort date: -a. 3/ 0)+0 age 6 of 1
)oot Cause of +ailure:
Amine stress corrosion cracking is most likely to occur in lean !A" #!A services
and associated $ith residual stresses %rom $elding" cold $orking or %a&rication" that
not have &een removed through an e%%ective stress relieving treatment. #ame is t2e
case wit2 su%3ect e6ui,ment! #u%merged 8rc >elding ,rocess wit2 2ig2er 2eat
in,ut 2as %een a,,lied for 3oining of %ase metal and 2ead and no 2eat treatment is
given to remove residual stresses! Conse6uence is t2e origination of transverse
crack after e6ui,ment is in service!
Dased on t2e age of e6ui,ment <almost +) .ears= and findings u, to now/ one can
guess t2at transverse cark is t2e result of ,ro,agation of residual weld defect
omitted at t2e time of fa%rication! T2e defect ,ro,agated wit2 time under stress
conditions due to service and resulted into surface %reaking crack! 8lt2oug2 t2e
defect remains in an acce,ta%le limit at t2e time of fa%rication/ as e6ui,ment is "T-
+/ %ut a%sence of >BT assist t2e a%ove 2.,ot2esis! According to A'( )*+
pu&lication" ',H- o% all amine circuits is essential to avoid any catastrophic %ailures
in $elding and heat a%%ected .ones.
8%ove ,asted sna,s s2ow t2at first a single ,oint of failure a,,eared on weld
seam! 8fter some 2ours cou,le of more ,in 2oles t.,e indications was vivid on
weld seam! 8fter 3) 2ours of service after leakage/ ,oints got connected
t2emselves and transformed into surface %reaking transverse crack!
&ro"osed ,em"orar( )e"air 7( 6#&:
8s vessel is not 2eat treated and ,ro,agation of crack is towards %ase metal/ ,atc2
wit2 larger dimension in t2e direction of ma3or a@is of crack ,ro,agation is
recommended! #c2ematic la.out for cold ,atc2 work is given %elow!
'ne of t2e greatest disadvantages of ,atc2 working is t2at t2e ,ro,agation of crack
cannot %e monitored on ,eriodic %asis as t2ere will %e no ,rovision for scanning
area for UT!
Document Title: Leak investigation of circumferencial weld seam failure of V-3369
Client: United Energie akistan Limited!
"#V $o% &o: Contract &o: C'&-(-)*3-+)
"e,ort date: -a. 3/ 0)+0 age * of 1
&ro"osed Cold &atc2-Work on Weld Seam Leakage of V-3369
1ft
1ft
1 ft
V-3369
Please note that' about 2(ft area of all circumferential weld seam at li)uid to *apor
interface location was $%D scanned +with straight beam,' indication were obser*ed in shell
to dish welding seam as marked in abo*e sketch&
Notes:
Surface should be properly cleaned of both patched plate and *essel plate area which
suppose to be patched&
Proper mi-ing and application of bel.ona 1311 chemical&
Proper intact of patched plate with *essel plate
Proposed repair by bel.ona cold
patch work +see below detail,
Detail dimension and magnified *iew
of patch work by bel.ona
%ailure/leak area
A A View given below
0iew 12(12
Weld seem
MS plate
3ndication found on both
weld seam of front and
back side of 0(3345
3ndication found on
back side weld seam of
0(3345
CW-1 CW-2 CW-3
CW-4
Document Title: Leak investigation of circumferencial weld seam failure of V-3369
Client: United Energie akistan Limited!
"#V $o% &o: Contract &o: C'&-(-)*3-+)
"e,ort date: -a. 3/ 0)+0 age 1 of 1
&ro"osed &ermanent )e"air:
ermanent re,air involves grinding t2e defect <crack= until it is com,letel. removed from
t2e %ase and weld metal and t2en weld %uild u,/ ,refera%l. using ET8>!># %. strictl.
controlling t2e welding ,arameters! 5ollowing ste,s s2ould %e followed w2ile ,ermanent
re,air is madeA
'ffline t2e e6ui,ment!
>eld metal and ad3acent %ase metal s2ould %e ground 9 gouged until crack is
com,letel. removed! Drilling t2e 2oles on %ot2 ends of crack and t2en grinding it
ma. eliminate t2e as,ect of furt2er ,ro,agation of crack during grinding!
UT/ "T/ -T/ T or com%ination of t2ese tec2ni6ues s2ould %e utili?ed to assure
t2at no more defects are ,resent in t2e vicinit. of ground area! Radiography o% all
$elding seams o% e/uipment must &e carried out to assure the sound health o% other
remaining $elds as %ailure has occurred on the $elding seam rather than &ase metal
or HAZ.
'nce t2e ade6uate certaint. level is ac2ieved t2at affected area is free of crack
and an. ot2er discontinuit./ ne@t ste, is weld %uild u,!
ET8>!># wit2 low 2eat in,ut is ,refera%le in t2e situations like t2at! Fualified
e@,erienced welder s2ould %e c2osen to accom,lis2 t2e welding ,rocess %. strictl.
following all t2e welding ,arameters!
8ccording to 87 9;4 ,u%lication/ >BT of all 8mine ,i,ing circuits and
e6ui,ments is essential at t2e time of fa%rication as well as after an. re,air/
alteration or rerating of e6ui,ment! >BT of t2e e6ui,ment s2ould %e t2e ne@t
ste, to %e followed after weld %uild u,!
8s t2e e6ui,ment is offline/ "adiogra,2. of all welding seams %efore and after
>BT must %e carried out to ensure t2e integrit. of t2e e6ui,ment for continued
safe o,eration! 8s leak 2as occurred on welding seam! 7t is im,ortant to know
a%out t2e 2ealt2 of ot2er welding seams to avoid an. ,otential of failure!
Hydro testing is graded as prime tool to ensure the integrity o% any %a&rication or
repair $ork &ut can this step can &e alternated $ith R-01- on the sole discretion o%
end user 2o$ner0user) in consultation $ith A'( +13 (nspector" !ngineer and
corrosion specialist.
ainting t2e e6ui,ment after mandator. surface ,re,aration will %e t2e final ste, to
%e followed according to standard UE a,,roved ,rocedures!

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