Step-Wise Cracking

(Cause, Detection and Monitoring)

Mohammad Abu four ASNT NDT Level III

Outline
Objective Background Cause & results of Step-Wise cracking Wet H2S Damage in Carbon steel Case Study and NDT equipments used Detection & Monitoring utilizing Advanced Ultrasonic systems Conclusion

What is Nondestructive testing?

Nondestructive testing is an examination performed on any type of test object without changing or altering that object in any way

What is destructive testing?

Destructive testing has been defined as a form of mechanical testing of materials. The specimens being test are subject to destroyed or mechanically changed.

What is Advanced Non-Destructive Testing?

Advanced Non-Destructive Testing is an examination performed on any type of test and all the data are analyzed and recorded by computers.

Objective
To determine the presence of the step-Wise Cracking in order to avoid plant equipments failures

Background
Step-Wise Cracking is advanced stage of HIC where multiple cracks parallel to pipe/equipments surface link together to form a stair pattern and results a throughthickness crack driven by high levels of stress

SWC

SWC

Cause of HIC/Step-Wise cracking

H2S containing electrolytes Extremely corrosive to low-alloy steels. Anodic metal dissolution is accelerated. Hydrogen atoms originating from the corrosion reactio can diffuse into the steel

Cause of HIC/Step-Wise cracking

Hydrogen atom diffuse through metal. several damage processes occur in susceptible steel Pressure builds up until it exceeds the strength of the steel and cracks begin to develop

Wet H2S Damage

Hydrogen blisters Hydrogen Induced Cracking (HIC) & Step-Wise Cracking (SWC)

Consequences of Step-Wise cracking

Leak and Release toxic substances (H2S) Fatal incident Disaster Fire Production Loss

Case Study
High Pressure Production Trap Material is C/S (No HIC resistance) Internal surface is not coated Service is Sour Gas Concentration of H2S is too high

Ultrasonic Testing (UT)

High-frequency sound pulses from a transducer propagate through the test material, reflecting at interfaces.

Manual Ultrasonic inspection System

D-Meter Ultrasonic Flaw Detector

Advanced NDT Equipments Used

Advanced Automated Ultrasonic System Phased Array Ultrasonic system

Results of The Advanced UT (Detection)

HIC/Hydrogen Blisters

Results of The Advanced UT (Detection)

HIC/Hydrogen Blisters Multi-depth of HIC/Inclusions

Results of The Advanced UT (Detection)

Multi-depth of HIC/Inclusions

Results of The Advanced UT (Detection & Monitoring)

Reflection From the inner surface BWR

Reflection from HIC/inclusions

Results of The Advanced UT (Detection & Monitoring)

Reflection From the inner surface BWR

Reflection from HIC/inclusions

Results of The Advanced UT (Detection & Monitoring)

Step-Wise Cracking

HIC Slices.ppt

Sector Scan showing Multiple layered blistering and Stepwise cracking.

Depth Converted C-Scan

Blistering

Stepwise Cracking

Results of Phased Array (Detection & Monitoring)

Step-Wise Cracking connected from the Inner surface to the HIC/blisters

Height of the SWC

Height of the SWC

Monitoring utilizing Phased Array

Step-Wise Cracking connected from the Inner surface to the HIC/blisters

Height of the SWC Height of the SWC

Destructive Test

Metallurgy analysis

Advantages of Automated Ultrasonic & Phased Array Systems

Provide precise & accurate information of Step-Wise cracking Permanent record & scanning details Live A-Scan can be saved and viewed for future analysis

Conclusions
The inspection requires characterization of the defect areas to differentiate between different stages of Hydrogen-Induced cracking. To ensure the plant safety and reliability, advanced ultrasonic equipments and qualified Technicians are required to detect & Monitor step-wise cracking to avoid any rapture which can result in damaging plant equipments and possible lost of life cracking (HIC) and step-wise

Thank you !!!