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Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001820
EISBN: 978-1-62708-180-1
... Abstract This article describes the failure characteristics of high-pressure long-distance pipelines. It discusses the causes of pipeline failures and the procedures used to investigate them. The use of fracture mechanics in failure investigations and in developing remedial measures is also...
Abstract
This article describes the failure characteristics of high-pressure long-distance pipelines. It discusses the causes of pipeline failures and the procedures used to investigate them. The use of fracture mechanics in failure investigations and in developing remedial measures is also reviewed.
Book Chapter
Failures of Pipelines
Available to PurchaseSeries: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006822
EISBN: 978-1-62708-329-4
... Abstract This article discusses the failure analysis of several steel transmission pipeline failures, describes the causes and characteristics of specific pipeline failure modes, and introduces pipeline failure prevention and integrity management practices and methodologies. In addition...
Abstract
This article discusses the failure analysis of several steel transmission pipeline failures, describes the causes and characteristics of specific pipeline failure modes, and introduces pipeline failure prevention and integrity management practices and methodologies. In addition, it covers the use of transmission pipeline in North America, discusses the procedures in pipeline failure analysis investigation, and provides a brief background on the most commonly observed pipeline flaws and degradation mechanisms. A case study related to hydrogen cracking and a hard spot is also presented.
Book Chapter
Intercrystalline Corrosion of Welded Stainless Steel Pipelines in Marine Environment
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.bldgs.c9001171
EISBN: 978-1-62708-219-8
... Abstract The defects observed along weldings of stainless steel pipelines employed in marine environments were evidenced by metallographic and electrochemical examination. A compilation of cases on the effect of defective weldings, in addition to improper choice of stainless steel for water...
Abstract
The defects observed along weldings of stainless steel pipelines employed in marine environments were evidenced by metallographic and electrochemical examination. A compilation of cases on the effect of defective weldings, in addition to improper choice of stainless steel for water pipelines, lead to the conclusion that intercrystalline corrosion in steels involved precipitation of a surplus phase at grain boundaries. Intercrystalline corrosion in austenitic stainless steels due to precipitation of chromium carbides during conditions generated due to welding and ways to avoid the precipitation (including reduction of carbon content, appropriate heat treatment, cold work of steel, reduction of austenitic grain size and stabilizing elements) were described. The presence of microcracks due to highly localized heat concentrations with consequent thermal expansion and considerable shrinkages during cooling was investigated. The specimens were taken from various sources including transverse and longitudinal welding seam, sensitized areas and it was concluded appropriate material selection with respect to medium could control some corrosion processes.
Book Chapter
Failure of a Gasoline Pipeline
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.petrol.c9001586
EISBN: 978-1-62708-228-0
... Abstract On 9 March 2000, a gasoline pipeline failed near Greenville, TX releasing approximately 12,000 barrels of fuel. After the on-scene portion of the investigation was completed, an 8.5 ft. (2.6 m) section of the 28 in. (71 cm) diam pipe was sent to the materials laboratory for examination...
Abstract
On 9 March 2000, a gasoline pipeline failed near Greenville, TX releasing approximately 12,000 barrels of fuel. After the on-scene portion of the investigation was completed, an 8.5 ft. (2.6 m) section of the 28 in. (71 cm) diam pipe was sent to the materials laboratory for examination. Examination included optical and scanning electron microscopy of the fracture surfaces and metallographic examination of cross sections through the fracture surface. From the outer to inner edge of the fracture surface, three different areas were observed. Fracture features in area 1 were obliterated by corrosion. The fracture features in region 2 were relatively smooth, and striations were observed, typical of fatigue. In region 3, dimple features were observed, typical of ductile overstress. Also, corrosion pits were observed on the outer surface of the pipe section in locations where the protective black tar-like coating was cracked.
Book Chapter
Pipeline Failure by Transit Fatigue
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001822
EISBN: 978-1-62708-241-9
... Abstract A newly installed pipeline leaked during cleaning prior to hydrotest at a pressure of approximately 400 psig. The intended hydrotest pressure was 750 psig. The pipeline was constructed from spiral-welded API 5L-X65 HSLA steel and was intended for seawater injection. Analysis included...
Abstract
A newly installed pipeline leaked during cleaning prior to hydrotest at a pressure of approximately 400 psig. The intended hydrotest pressure was 750 psig. The pipeline was constructed from spiral-welded API 5L-X65 HSLA steel and was intended for seawater injection. Analysis included nondestructive testing, metallography, and scanning electron microscopy. Based on the results, the failure was attributed to transit fatigue, caused during highway transportation. Cracks along the toes of the weld from both the outside and inside surfaces, the transgranular nature of cracking, and the presence of fatigue striations all supported transit fatigue as the damage mechanism.
Book Chapter
Application of Fracture Mechanics to Pipeline Failure Analysis
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.petrol.c9001148
EISBN: 978-1-62708-228-0
... Abstract A natural gas pipeline explosion and subsequent fire significantly altered the pipeline steel microstructure, obscuring in part the primary cause of failure, namely, coating breakdown at a local hard spot in the steel. Chemical analysis was made on pieces cut from the portion...
Abstract
A natural gas pipeline explosion and subsequent fire significantly altered the pipeline steel microstructure, obscuring in part the primary cause of failure, namely, coating breakdown at a local hard spot in the steel. Chemical analysis was made on pieces cut from the portion of the pipe that did not fracture during the explosion and from piece 5-1 which contained the fracture origin site. Both pieces were found to have 0.30% carbon and 1.2% Mn with sulfur and phosphorus impurities acceptably low. Fracture mechanics analysis used in conjunction with fractographic results confirmed the existence of a very hard spot in the steel prior to the explosion, which was softened significantly in the ensuing fire. This finding allowed the micromechanism leading to fracture to be identified as hydrogen embrittlement resulting from cathodic charging.
Book Chapter
Failure of a Squeeze-Clamped Polyethylene Natural Gas Pipeline
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001275
EISBN: 978-1-62708-215-0
... to the 10-cm (4-in.) steel main to extend the main. Smaller service lines carried gas from the mains to the residences. Acommon maintenance practice on PE pipelines is the use of a bar clamp to squeeze the pipe flat whenever the flow of gas is to be stopped for down-stream maintenance. This greatly reduces...
Abstract
A high-density polyethylene (HDPE) natural gas distribution pipe (Grade PE 3306) failed by slow, stable crack growth while in residential service. The leak occurred at a location where a squeeze clamp had been used to close the pipe during maintenance. Failure analysis showed that the origin of the failure was a small surface crack in the inner pipe wall produced by the clamping. Fracture mechanics calculations confirmed that the suspected failure process would result in a failure time close to the actual time to failure. It was recommended that: materials be screened for susceptibility to the formation of the inner wall cracks since it was not found to occur in pipe typical of that currently being placed in service; pipes be re-rounded after clamp removal to minimize residual stresses which caused failure; and a metal reinforcing collar be placed around the squeeze location after clamp removal.
Book Chapter
Pipeline Failure Results from Lightning Strike: Act of Mother Nature?
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001823
EISBN: 978-1-62708-241-9
... Abstract A section of pipe in a hydrocarbon pipeline was found to be leaking. The pipeline was installed several decades earlier and was protected by an external coating of extruded polyethylene and a cathodic protection system. The failed pipe section was made from API 5L X46 line pipe steel...
Abstract
A section of pipe in a hydrocarbon pipeline was found to be leaking. The pipeline was installed several decades earlier and was protected by an external coating of extruded polyethylene and a cathodic protection system. The failed pipe section was made from API 5L X46 line pipe steel, approximately 22 cm (8.7 in.) OD x 0.5 cm (0.2 in.) wall thickness, which was electric resistance welded along the longitudinal seam. The pressure at the time and location of the failure was 2760 kPa, which corresponds to 20% of the specified minimum yield strength. The cause of failure (based on visual inspection, magnetic particle inspection, stereoscopic analysis, scanning electron microscopy, tensile and hardness testing, and chemical analysis) was attributed to damage resulting from a lightning strike.
Book Chapter
Failure of a Type 304 Stainless Steel White Liquor Transfer Pipeline
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.pulp.c9001565
EISBN: 978-1-62708-230-3
... C (375 deg F) and the solution contained approximately 700 ppm chlorides. Liquid penetrant inspection of the pipeline showed the leaks were numerous and confined adjacent to the welds. A metallographic specimen from the circumferential weld showed the cracks initiated at the inside surface...
Abstract
A stainless steel pipe transferring hot white liquor solution of sodium hydroxide and sodium sulfite, developed leaks adjacent to the welds within four years of service. The stainless steel pipe was AISI type 304 and welded with E308 weld electrodes. The service temperature was 190 deg C (375 deg F) and the solution contained approximately 700 ppm chlorides. Liquid penetrant inspection of the pipeline showed the leaks were numerous and confined adjacent to the welds. A metallographic specimen from the circumferential weld showed the cracks initiated at the inside surface. In addition to the base metal, SCC also had initiated at a notch at the weld root due to improper welding procedures. Failure was attributed to chloride-induced SCC with secondary contributory factors, including improper welding procedures. It was recommended that the pipeline be replaced with a material more resistant to SCC. The candidate materials are commercial grade unalloyed titanium or Inconel 600, which have superior resistance to SCC compared to austenitic stainless steels.
Book Chapter
Stress Corrosion Cracking of Ring Type Joint of Reactor Pipeline of a Hydrocracker Unit
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001774
EISBN: 978-1-62708-241-9
... Abstract A ring-type joint in a reactor pipeline for a hydrocracker unit had failed. Cracks were observed on the flange and the associated ring gasket during an inspection following a periodic shutdown of the unit. The components were manufactured from stabilized grades of austenitic stainless...
Abstract
A ring-type joint in a reactor pipeline for a hydrocracker unit had failed. Cracks were observed on the flange and the associated ring gasket during an inspection following a periodic shutdown of the unit. The components were manufactured from stabilized grades of austenitic stainless steel; the flange from type 321, and the ring gasket from 347. Examination revealed that the failure occurred by transgranular stress-corrosion cracking, initiated by the presence of polythionic acid. Detailed metallurgical investigation was subsequently conducted to identify what may have caused the formation of polythionic acid in the process gas.
Book Chapter
Stress-Corrosion Cracking of a Monel 400 Tube
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001775
EISBN: 978-1-62708-241-9
... Abstract A bent Ni-Cu Monel 400 alloy tube, which operated as part of a pipeline in a petrochemical distillery, failed by through-thickness cracking. The pipeline was used to carry a stream of gaseous hydrocarbons containing hydrochloric acid (HCl) into a reaction tower. The tower provided...
Abstract
A bent Ni-Cu Monel 400 alloy tube, which operated as part of a pipeline in a petrochemical distillery, failed by through-thickness cracking. The pipeline was used to carry a stream of gaseous hydrocarbons containing hydrochloric acid (HCl) into a reaction tower. The tower provided a caustic solution (NaOH) to remove HCl from the stream, before the latter was directed to a burner. Metallographic examination showed that the cracks were intergranular and were frequently branched. Although nominal chemical composition of the component was found within the specified range, energy dispersive x-ray analysis (EDXA) indicated significant segregation of sulfur and chlorine along the grain boundaries. Failure was attributed to hypochlorous-acid (HClO)-induced stress-corrosion cracking (SCC). The HClO was formed by the reaction of HCl with atmospheric O 2 that entered the tube during shutdowns and startups. Residual stresses, originating from in situ bend forming of the tube during assembly of the line, provided a driving force for crack growth, and the segregation of sulfur on grain boundaries made the material more susceptible to cracking.
Book Chapter
Cracking of a Field Girth Weld
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.petrol.c0047537
EISBN: 978-1-62708-228-0
... Abstract During the construction of a large-diam pipeline, several girth welds had to be cut out as a result of radiographic interpretation. The pipeline was constructed of 910 mm (36 in.) diam x 13 mm (0.5 in.) wall thickness grade X448 (x65) line pipe. The girth welds were fabricated using...
Abstract
During the construction of a large-diam pipeline, several girth welds had to be cut out as a result of radiographic interpretation. The pipeline was constructed of 910 mm (36 in.) diam x 13 mm (0.5 in.) wall thickness grade X448 (x65) line pipe. The girth welds were fabricated using standard vertical down stove pipe-welding procedures with E7010 cellulosic electrodes. The crack started partially as a result of incomplete fusion on the pipe side wall, which in turn was a result of misalignment of the two pipes. The crack was typical of hydrogen cracking. Girth welds can be made using cellulosic electrodes. For high-risk girth welds, an increase in preheat and/or a reduction in the local stress by controlling lift height or depositing the hot pass locally before lifting may be required.
Book Chapter
Failure of a Buried Type 304L Stainless Steel Drain Line by Galvanic Attack
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0046535
EISBN: 978-1-62708-234-1
... of pipe were joined by shielded metal arc welding. Soundness of the welded joints was determined by water back-pressure testing after several lengths of pipe had been installed and joined. Before completion of the pipeline, a pressure drop was observed during back-pressure testing. An extreme depression...
Abstract
One of five underground drain lines intended to carry a highly acidic effluent from a chemical-processing plant to distant holding tanks failed in just a few months. Each line was made of 304L stainless steel pipe 73 mm (2 in.) in diam with a 5 mm (0.203 in.) wall thickness. Lengths of pipe were joined by shielded metal arc welding. Soundness of the welded joints was determined by water back-pressure testing after several lengths of pipe had been installed and joined. Before completion of the pipeline, a pressure drop was observed during back-pressure testing. An extreme depression in the backfill revealed the site of failure. Analysis (visual inspection, electrical conductivity, and soil analysis) supported the conclusions that the failure had resulted from galvanic corrosion at a point where the corrosivity of the soil was substantially greater than the average, resulting in a voltage decrease near the point of failure of about 1.3 to 1.7 V. Recommendations included that the pipelines be asphalt coated and enclosed in a concrete trough with a concrete cover. Also, magnesium anodes, connected electrically to each line, should be installed at periodic intervals along their entire length to provide cathodic protection.
Image
Cathodic protection of a buried pipeline using a buried magnesium anode. So...
Available to PurchasePublished: 01 January 2002
Fig. 8 Cathodic protection of a buried pipeline using a buried magnesium anode. Source: Ref 6
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Image
Impressed-current cathodic protection of a buried pipeline using graphite a...
Available to PurchasePublished: 01 January 2002
Fig. 9 Impressed-current cathodic protection of a buried pipeline using graphite anodes. Source: Ref 6
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Image
Stepwise cracking of a low-strength pipeline steel exposed to hydrogen sulf...
Available to PurchasePublished: 01 January 2002
Fig. 8 Stepwise cracking of a low-strength pipeline steel exposed to hydrogen sulfide (H 2 S). 6×
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Image
Transmission pipeline rupture that resulted from significant wall loss due ...
Available to PurchasePublished: 30 August 2021
Fig. 23 Transmission pipeline rupture that resulted from significant wall loss due to general corrosion
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Image
Cathodic protection of a buried pipeline using a buried magnesium anode. So...
Available to Purchase
in Analysis and Prevention of Environmental- and Corrosion-Related Failures
> Failure Analysis and Prevention
Published: 15 January 2021
Fig. 25 Cathodic protection of a buried pipeline using a buried magnesium anode. Source: Ref 13
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Image
Impressed-current cathodic protection of a buried pipeline using graphite a...
Available to Purchase
in Analysis and Prevention of Environmental- and Corrosion-Related Failures
> Failure Analysis and Prevention
Published: 15 January 2021
Fig. 26 Impressed-current cathodic protection of a buried pipeline using graphite anodes. Source: Ref 13
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