SHAKEEL PREC FIRST
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Transcript of SHAKEEL PREC FIRST
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
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