Reports and Publications
Forensic Failure Analysis of Polymer Based Composite Materials
Composite components typically fail due to design flaws, material and manufacturing defects, or issues arising during use. Investigating these failures involves analyzing extensive data quickly and efficiently. Understanding these factors is crucial for improving composite material reliability.
Ensure you stay informed about the key factors influencing composite material failures to enhance your failure investigation processes and improve component reliability. Read more
Pipe Stress Analysis
A petrochemical plant faced issues with a self-regulating valve and replaced it with a manual valve lacking upstream pressure control. This control is vital for maintaining back pressure and protecting upstream equipment. An engineering design package for installing a new pressure control valve was prepared, requiring a revalidation of the piping stress analysis.
Revalidate the piping stress analysis to ensure safe and effective operation with the new pressure control valve. Read more
Integrity Assessment for Underground Pipeline Based on Phonon Diagnostic Technique
A Phonon Diagnostic Technique (PDT) study was conducted to assess the condition of a 12” underground pipeline after 6 years of operation. PDT identifies “Active Defects,” which are areas that are actively deteriorating. The study aims to detect various types of defects, such as metal loss, crack-like issues, and anomalies, and to evaluate their severity for projecting the pipeline’s remaining life. Phonon-Active Areas (PhAA) are highlighted as potential safety threats to facility operations in the future.
Perform a thorough PDT inspection to identify and assess active defects in underground pipelines, ensuring timely maintenance and safeguarding operational safety. Read more
Remaining Life Assessment of Waste Heat Boiler
Petromaster Ltd. was tasked with inspecting and assessing the remaining life of a waste heat boiler at Industrial Waste Recycling Company. This horizontal smoke tube shell type boiler uses flue gases from an incinerator to produce steam for power generation.
Ensure the boiler’s integrity and performance by completing the inspection and remaining life assessment to prevent potential issues and optimize operation. Read more
Peculiar Case of Under-Deposit Corrosion in HRSG Tube
Petromaster was tasked with assessing the condition and performing a root cause failure analysis of an HRSG tube sample from a horizontal gas-flow design unit. The 900 mm tube sample showed three holes along one side, with significant damage to the tube fins due to water jetting. Visual examination revealed brown or reddish-brown deposits on the internal surfaces, with noticeable grey metallic coloration around the holes, suggesting that deposits were displaced by pressure drops caused by the leaking tube.
Conduct a detailed analysis to identify the cause of under-deposit corrosion and implement corrective measures to prevent future failures. Read more
Hidden Attack in Boiler Tubes (Hydrogen Attack)
Petromaster was tasked to perform a Root Cause Failure Analysis on a ruptured water-wall tube from a power boiler. The objective was to investigate and identify the factors contributing to the tube’s failure. The analysis focused on detailed visual examinations of the tube’s condition, both external and internal, to assess the nature of the damage and any contributing factors.
Conduct a detailed analysis to determine the cause of the rupture and address any underlying issues to prevent future failures. Read more
Failure Analysis Study of Super Duplex Stainless Steel (SDSS) Valve in Reverse Osmosis Plant
Conduct a thorough root cause failure analysis to address the corrosion issue and prevent future occurrences in the RO plant. Read more
Correlation of Internal Carburization and Creep Damage in Furnace Tubes
At a petrochemical plant, producing ethylene through thermal cracking of hydrocarbons, predicting the lifespan of cracking furnace tubes is challenging due to high-temperature creep and carburization affecting the inner walls. The HP40Nb (25Cr35Ni1Nb) heat-resistant alloy is commonly used for these tubes due to its favorable balance of cost and high-temperature performance.
Regularly monitor and evaluate the condition of cracking furnace tubes to manage high-temperature creep and carburization effectively, ensuring reliable performance and extending tube life. Read more
Accelerated Erosion of Catalyst Lift line in CCR Unit of a Refinery
The control of process parameters play pivotal role in maintaining asset integrity in industry. Even short term operation outside the integrity operating windows can result in accelerated damage and affect the mechanical integrity of assets. The current article discusses a case study where higher velocity of catalyst in the catalyst line resulted in significant erosion and thickness loss in the catalytic reforming unit.
Implement rigorous monitoring and control of process parameters to prevent accelerated erosion and ensure the long-term integrity of catalytic reforming units. Read more
Fitness for Service Assessment of LP Rotor for Steam Turbine
The goal of this engineering task was to conduct a Fitness-for-Service assessment of LP rotors with observed pitting corrosion damage at turbine stages L-2 (LFR3, LBR3), L-1 (LFR4, LBR4), and L-0 (LFR5, LBR5).
Perform the Fitness-for-Service assessment promptly to evaluate and address the corrosion damage in the LP rotors to ensure operational safety and efficiency. Read more
Natural Gas Pipeline & Boiler Skid Auxiliary Piping Condition Assessment
Petromaster Ltd recently conducted an integrity assessment of the Paper Manufacturing Company’s natural gas pipeline, which has been in service since 2013. This pipeline, with a nominal thickness of 9.53 mm and diameters of 12″ and 10″, primarily runs elevated on pipe racks. The assessment also covered auxiliary and boiler skid piping with different specs.
For a detailed look at our findings and the pipeline layout, click to Read more
Is In-Situ Metallography Really a Potent Tool to Identify the Deterioration Modes in Components?
Recently, metallurgists have debated the effectiveness of In-Situ Metallography for accurately identifying damage mechanisms, as some standards like API 571 suggest. In this article, I’ll share insights from my decade of experience analyzing micrographs of materials in extreme conditions.
So, what damage can Replica Metallography reveal? In-Situ Metallography is crucial for pinpointing high-temperature damage mechanisms in metals. Here are a few examples:
Read more for detailed observations.
