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Friday, 9 October 2015
Process Piping & Pipelines System
One
of the most important components of the infrastructure in the
industrialized world is the vast network of pipelines and process
piping—literally millions and millions of miles. The term “pipelines”
generally refers to the network of pipelines that transport water,
sewage, steam, and gaseous and liquid hydrocarbons from sources (e.g.,
reservoirs, steam plants, oil and gas wells, refineries) to local
distribution centers (“transmission pipelines”), and to the network of
pipelines that distribute such products to local markets and end users
(“distribution” pipelines). The term “process piping” generally refers
to the system of pipes that transport process fluids (e.g., air, steam,
water, industrial gases, fuels, chemicals) around an industrial facility
involved in the manufacture of products or in the generation of power.
Pipelines and process piping are generally made of steel, cast iron,
copper, or specialty metals in certain highly aggressive environments,
but the use of plastic materials is growing, especially in
hydrocarbon-based distribution lines and in sewer lines. Very
large-diameter water transmission lines are often made of reinforced
concrete.
The most common method of joining the individual segments of pipe is by welding (or soldering in the case of copper, and gluing in the case of plastics), although bolted flanges or threaded connections are often used in smaller-diameter process piping. In low-pressure piping systems that transport non-hazardous fluids like water and sewage, mechanical joints (e.g., “ball and spigot,” compression) that rely on friction are commonly used. Pipelines and piping are usually constructed and maintained in accordance with national and local regulations and applicable industry standards. For example, the most commonly used industrial code for the transport of liquids is ASME B31.4. B31.8 is most commonly used for the transmission and distribution of gas, and ASME B31.3 most often applies to process piping. Once assembled, pipelines are usually buried, but process piping is usually above ground.
Pipelines and process piping are the safest means to transport gases and fluids across countries or across manufacturing facilities. However, given the extensive network of pipelines and piping, failures do occur, which can be quite spectacular and lead to extensive property damage and loss of life. Given their potential impact, it is important to investigate the cause(s) of such failures, which often involve input from many different engineering and scientific disciplines. As such, Exponent, with its broad range of skill sets, is uniquely positioned to investigate such failures, and has done so on hundreds of occasions, ranging from quarter-inch process tubing to 20-ft-diameter concrete water distribution pipelines.
Equally
important, of course, is the prevention of pipeline and piping
failures. Our scientists and engineers provide in-depth technical
knowledge that has enabled us to make significant contributions to
clients during the design, layout, and construction of pipelines and
piping systems, and in the development and implementation of integrity
and risk management programs. Exponent staff has brought their expertise
to bear on preventive projects ranging in scope from reviewing the
design and construction of the process piping at petrochemical plants to
overall integrity reviews of long-distance oil and gas transmission
pipeline systems.
Clients that have utilized Exponent’s pipeline and process piping expertise have included Fortune 500 manufacturing and petrochemical companies, utilities, pipeline companies, insurers, and capital project lending organizations.
The most common method of joining the individual segments of pipe is by welding (or soldering in the case of copper, and gluing in the case of plastics), although bolted flanges or threaded connections are often used in smaller-diameter process piping. In low-pressure piping systems that transport non-hazardous fluids like water and sewage, mechanical joints (e.g., “ball and spigot,” compression) that rely on friction are commonly used. Pipelines and piping are usually constructed and maintained in accordance with national and local regulations and applicable industry standards. For example, the most commonly used industrial code for the transport of liquids is ASME B31.4. B31.8 is most commonly used for the transmission and distribution of gas, and ASME B31.3 most often applies to process piping. Once assembled, pipelines are usually buried, but process piping is usually above ground.
Pipelines and process piping are the safest means to transport gases and fluids across countries or across manufacturing facilities. However, given the extensive network of pipelines and piping, failures do occur, which can be quite spectacular and lead to extensive property damage and loss of life. Given their potential impact, it is important to investigate the cause(s) of such failures, which often involve input from many different engineering and scientific disciplines. As such, Exponent, with its broad range of skill sets, is uniquely positioned to investigate such failures, and has done so on hundreds of occasions, ranging from quarter-inch process tubing to 20-ft-diameter concrete water distribution pipelines.
Equally
important, of course, is the prevention of pipeline and piping
failures. Our scientists and engineers provide in-depth technical
knowledge that has enabled us to make significant contributions to
clients during the design, layout, and construction of pipelines and
piping systems, and in the development and implementation of integrity
and risk management programs. Exponent staff has brought their expertise
to bear on preventive projects ranging in scope from reviewing the
design and construction of the process piping at petrochemical plants to
overall integrity reviews of long-distance oil and gas transmission
pipeline systems. Clients that have utilized Exponent’s pipeline and process piping expertise have included Fortune 500 manufacturing and petrochemical companies, utilities, pipeline companies, insurers, and capital project lending organizations.
Analysis Pipeline Failure
Applied Technical Services performs
metallurgical pipe failure analysis and corrosion testing. Our
capabilities include root cause determination of component and material
failures incorporating analysis of engineering problems and
specifications.
Our assessment services include evaluating various process and water
pipe failures manufactured from steel pipe, PVC pipe, copper pipe,
ABS pipe, CPVC pipe, HDPE pipe, polyethylene pipe, cast iron pipe and
Kitec pipe. We perform scanning electron microscopy (SEM);
microstructural analysis; optical metallography; mechanical property
analysis; and scale and corrosion deposit analysis.
Our procedures assess, investigate and test engineered materials to
identify the causes of failure events. In addition to problem solving,
ATS assists in removing the root cause by systematically reviewing the
components and processes that led to failure. Our pipe failure analysis
material engineers reconstruct incidents, collect and analyze critical
data for detailed analysis and reporting.
Our goal is to provide thorough pipe failure analysis results in
compliance with industry standards by delivering economical and
technologically advanced solutions.
Failure theories provide techniques to calculate stresses, and damage
mechanisms describe material failures due to those stresses. Code
techniques provide safe, conservative rules for initial pipe design, but
the analysis of pipe failures requires added understanding of failure
theories, plastic deformation, fatigue cracks, and crack growth after
initial fracture.
Types of Pipe Failure Analysis:
- Pipeline Failure Analysis
- PVC Pipe Failure
- Copper Pipe Failure
- Water Pipe Failure
- ABS Pipe Failure
- CPVC Pipe Failure
- HDPE Pipe Failure
- Polyethylene Pipe Failure
- Cast Iron Pipe Failure
- KITEC Pipe Failure
Friday, 2 October 2015
Mechanical Failure Analysis
ATS’ mechanical failure analysis team is
dedicated to helping individuals, corporations and manufacturers
identify the root causes of component and system failures. Our
technically advanced labs enable our experts to perform accurate and
efficient tests, incorporated in precise and detailed reports. With
years of experience, our professionals perform daily inspections on a
wide variety of mechanical failures which may include common fatigue and
overstress failures to and unique failures.
Our services are prevalent among the automotive, aerospace, nuclear,
manufacturing and military industries. Testing is performed per industry
standards, including ASTM E2332, ASTM E3, ASTM E18, ASTM E384, ASTM
E112, ASTM E10, ASTM A247, ASTM B487, ASTM B748, equivalent ISO
standards, and applicable specialized procedures.
Tests Include:
- Optical Factography
- Scanning Electron Microscopy
- Energy Dispersive Spectoroscopy (EDS)
- Impact Testing
- Tensile Testing
- Shear Testing
- Torsion Testing
- Pressure Testing
- Hardness Testing
Results May Reveal Mechanical Failures Due To:
- Ductility Issues
- Brittle Products and Components
- Fatigue
- Overload
- Environmental Effects
- Manufacturing Defects
- Contamination
- Corrosion
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