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!