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Failure Analysis Report of Wellhead Choke Assembly

Mari Petroleum Company Limited, Sujawal Field

January 2014

Failure Analysis Report of Wellhead Choke Assembly at Sujawal Field, MPCL

Table of Contents
1. INTRODUCTION: ............................................................................................................................................ 3 2. WELLHEAD DATA:......................................................................................................................................... 3 2.1 DESIGN PARAMETERS ........................................................................................................................... 3 2.2 OPERATING PARAMETERS .................................................................................................................... 3 3. FAILURE HISTORY: ....................................................................................................................................... 4 4. ROOT CAUSE FAILURE ANALYSIS METHODOLOGY: ................................................................................. 5 5. INSPECTION FINDINGS:.................................................................................................................................. 6 5.1 EXTERNAL VISUAL INSPECTION:.......................................................................................................... 6 5.2 INTERNAL VISUAL INSPECTION: ........................................................................................................... 6 5.3 POSITIVE MATERIAL IDENTIFICATION (PMI):....................................................................................... 6 5.4 REMOTE VISUAL INSPECTION (RVI) / VIDEOSCOPY:.......................................................................... 6 5.5 ULTRASONIC THICKNESS GAUGING (UTG): ........................................................................................ 6 5.6 METALLOGRAPHY .................................................................................................................................. 6 6. FINDINGS AND OBSERVATIONS: .................................................................................................................. 7 7. FAILURE ANALYSIS: ....................................................................................................................................... 8 7.1 CODE CRITERIA FOR CO2 CORROSION AGAINST ACTUAL EVIDENCE: .......................................... 9 7.2 CODE CRITERIA FOR CAVITATION CORROSION AGAINST ACTUAL EVIDENCE: ......................... 10 8. DESCRIPTION OF DAMAGE MECHANISM: ................................................................................................. 11 8.1 CO2 CORROSION: ................................................................................................................................. 11 8.2 CAVITATION CORROSION: ................................................................................................................... 11 9. CONCLUSION: ............................................................................................................................................... 12 10. ANNEXURES ................................................................................................................................................ 12

Date: 30-Jan-2014

SGS JKHI-140027

MPCL Ref no. 7100015783

Page: 2 of 12

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Companys findings at the time of its intervention only and within the limits of Clients instructions, if any. The Companys sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law. SGS Pakistan Private Limited -H 3/3, Sector 5, Korangi Industrial Area, Karachi-74900, Pakistan. UAN: 92 (21) 111 222 747 Tel : 92-21-35121388-97 Fax: 92 (21) 3 5121386-87 Web : ww.sgs.com

Failure Analysis Report of Wellhead Choke Assembly at Sujawal Field, MPCL

1. INT RO D UCT IO N: Determine the root cause and contributing causes for Local metal loss at wellheads fixed choke and choke assembly of Sujawal Field. This root cause study will help to take decision for mitigation and prevention for the future occurrence of this kind of failure.

2.

W E LLH E AD D AT A:

2. 1 D E SIG N P AR AM E T ER S

Material Of construction choke size Year of Installation (choke) Manufactured by

: : : :

EE-NL (As per API 6A - PSL-3, PR-2, TC-PU) 28/64 March, 2013 Cortec (Model PH2 Alloy Steel)

2. 2 O P E R AT I NG P AR AM ET E R S

Wellhead Fluid Pressure (psi) Operating Temperature( F) CO2 (mol%) H2S (ppm) Flow of Gas ( MMSCFD) Flow of Condensate (bbl/day) Flow of Water (bbl/day) Upstream Pressure (psi) Downstream Pressure (psi)

: : : : : : : : :

2302 120 4.544 (on dry basis) 2 4 (on dry basis) 09 60 - 70 20 2121 933

Date: 30-Jan-2014

SGS JKHI-140027

MPCL Ref no. 7100015783

Page: 3 of 12

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Companys findings at the time of its intervention only and within the limits of Clients instructions, if any. The Companys sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law. SGS Pakistan Private Limited -H 3/3, Sector 5, Korangi Industrial Area, Karachi-74900, Pakistan. UAN: 92 (21) 111 222 747 Tel : 92-21-35121388-97 Fax: 92 (21) 3 5121386-87 Web : ww.sgs.com

Failure Analysis Report of Wellhead Choke Assembly at Sujawal Field, MPCL 3. F AIL U RE H I ST O RY :

In March 2013, the Choke of size 28/64 was installed in Choke assembly. In August 2013, the fixed choke assembly was dismantled and inspected visually, no damage threats were found in Choke and Choke Assembly. Due to operational constraint entire inspection was not carried out at that time, and only previous installed choke beam was replaced by the choke of same size i.e. 28/64. In December 2013, Increase in flow of well head fluid with the gradually decrease in flowing pressure was observed. In December 14, 2013 the complete Christmas tree was dismantled and all the components were inspected by the Mari Petroleum Engineers. During inspection of wellhead components Corrosion due to local metal loss was observed at Fixed choke assembly and choke cap, wing valve at upstream of fixed choke, upstream of instrument flange and slight pitting corrosion observed at bottom of swab valve and at tree cap. Below is the pictorial Presentation of findings;

Localize Corrosion at Choke Cap

Severe Corrosion inside choke body

Internal thread of choke body damaged

Date: 30-Jan-2014 SGS JKHI-140027

Slight pitting / corrosion observed at bottom end of Swab Valve

MPCL Ref no. 7100015783 Page: 4 of 12

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Companys findings at the time of its intervention only and within the limits of Clients instructions, if any. The Companys sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law. SGS Pakistan Private Limited -H 3/3, Sector 5, Korangi Industrial Area, Karachi-74900, Pakistan. UAN: 92 (21) 111 222 747 Tel : 92-21-35121388-97 Fax: 92 (21) 3 5121386-87 Web : ww.sgs.com

Failure Analysis Report of Wellhead Choke Assembly at Sujawal Field, MPCL

Severe corrosion observed at Wing Valve, Upstream of Fixed Choke

Pitting/ Corrosion found in internal thread of Tree cap

After the finding of severe inside erosion in choke and metal loss at choke assembly, the wellhead took into operation through the Variable choke and it is also decided to carryout Root Cause Failure analysis (RCFA) of Choke assembly to determine the causes of failure. 4. RO O T C AU S E F AI L UR E AN AL Y S IS M ET HO DO LO G Y : For detailed RCFA Methodology, inspection of choke assembly was carried out and laboratory reports provided by MPCL were reviewed in detail. During field visit, the wellhead was in operation through variable choke; therefore, internal condition of all the components of wellheads could not be inspected. The fixed choke has been isolated and available for internal visual inspection, after that the fixed choke assembly was moved to SGS Head office for further analysis. This report is limited to analysis of fixed choke assembly and it has been assumed that the same mechanism is active in other parts of the wellhead. The root cause failure analysis methodology of choke assembly was structured on the following components; Equipment design, operation and fluid composition data review Visual inspection include internal and external inspection Non destructive testing include Metallography, PMI, UTG and RVI

After obtaining these data, analysis conducted with the help of the following references for the determination of probable damage mechanism. References: 1. 2. 3. 4. API RP 571: Damage Mechanisms Affecting Fixed Equipment in the Refining Industry. API RP 581: Risk Based Inspection Technology. ASM Metals Handbook Volume 11: Failure Analysis and Prevention. th API-6A, 19 Edition : Specification for wellhead and Christmas tree equipment

Date: 30-Jan-2014

SGS JKHI-140027

MPCL Ref no. 7100015783

Page: 5 of 12

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Companys findings at the time of its intervention only and within the limits of Clients instructions, if any. The Companys sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law. SGS Pakistan Private Limited -H 3/3, Sector 5, Korangi Industrial Area, Karachi-74900, Pakistan. UAN: 92 (21) 111 222 747 Tel : 92-21-35121388-97 Fax: 92 (21) 3 5121386-87 Web : ww.sgs.com

Failure Analysis Report of Wellhead Choke Assembly at Sujawal Field, MPCL 5. I N S PE CT IO N F IN DI NG S:

5. 1 E XT ER N AL VI S U AL I N S P ECT IO N :

External condition of choke and choke assembly has no sign of corrosion or any other deterioration.
5. 2 INT ER N AL VI S U AL I N S P ECT IO N : Metal loss due to localize corrosion found inside the body of choke assembly. (See the below attached reference fig:1 and 2) Metal loss due to localize corrosion found on the choke cap. (See the below attached reference fig: 3) Local metal loss observed inside the choke via Videoscopy. (See the below attached reference fig: 4) Metal loss due to localize corrosion found at the up-stream Nozzle (N1) of the choke assembly. (See the below attached reference fig: 5) Abrasive surface found at the downstream Nozzle (N2) of choke assembly. (See the below attached reference fig: 6) 5. 3 PO S IT IV E M AT E R I AL I D ENT IF IC AT I O N ( PM I) : Positive material identification (PMI) was performed to confirm the material of construction of fixed choke beam and choke assembly. Readings were collected from three locations of choke assembly by using PMI and the material is identified as Medium Alloy Steel. While for the choke, the material of construction is identified as Stainless Steel (SS-446). PMI Report attached as Annexure-A. 5. 4 R EM O T E V I SU AL IN S P ECT IO N ( R VI) / V ID EO S CO PY : Remote visual inspection was performed to analyse the internal condition of choke. After videoscopy severe localize metal loss found inside the choke. CD of Video is attached. Pictures of videoscopy attached as Annexure-B. 5. 5 ULT R AS O NI C T H I CK NE S S G AU G ING ( U T G ) : Ultrasonic thickness measurement was performed to determine the metal loss in choke beam. After performing UTG, metal loss of 2.6 mm is found at localize corroded section of the choke beam. The depth of metal loss found at the choke cap is 1.5 mm. 5. 6 M ET ALLO G R AP H Y Metallographic testing was performed at the Choke assembly cap. Test was performed to investigate the material degradation. No Metallurgical anomalies were observed. Metallographic report is attached as Annexure -C Defect Sketches of choke assembly attached as Annexure-D.

Date: 30-Jan-2014

SGS JKHI-140027

MPCL Ref no. 7100015783

Page: 6 of 12

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Companys findings at the time of its intervention only and within the limits of Clients instructions, if any. The Companys sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law. SGS Pakistan Private Limited -H 3/3, Sector 5, Korangi Industrial Area, Karachi-74900, Pakistan. UAN: 92 (21) 111 222 747 Tel : 92-21-35121388-97 Fax: 92 (21) 3 5121386-87 Web : ww.sgs.com

Failure Analysis Report of Wellhead Choke Assembly at Sujawal Field, MPCL 6. FI ND IN G S AN D O B S ER V AT IO N S:

Fig: 1 - Metal loss found inside the body of choke assembly

Fig: 2 - Metal loss and severe corrosion found inside the body of choke assembly

Fig: 3 - Metal loss and corrosion found on the choke cap

Fig: 4 - Metal loss found via Videoscopy inside the choke beam

Fig: 5 - Pitting corrosion found at the upstream Nozzle (N1) of choke assembly

Fig: 6 Rough surface found at the downstream Nozzle (N2) of choke assembly

Date: 30-Jan-2014

SGS JKHI-140027

MPCL Ref no. 7100015783

Page: 7 of 12

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Companys findings at the time of its intervention only and within the limits of Clients instructions, if any. The Companys sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law. SGS Pakistan Private Limited -H 3/3, Sector 5, Korangi Industrial Area, Karachi-74900, Pakistan. UAN: 92 (21) 111 222 747 Tel : 92-21-35121388-97 Fax: 92 (21) 3 5121386-87 Web : ww.sgs.com

Failure Analysis Report of Wellhead Choke Assembly at Sujawal Field, MPCL 7. F AI L UR E AN AL Y S I S: Since the wellhead is in service of well fluids containing Gas, Condensate and water. The chemical analysis revealed the presence CO2 (4.5 mol %) and H2S (2-4 ppm) in the stream. Therefore, primarily the susceptibility of CO2 Corrosion is analysed. Due to the presence of turbulence flow and fluid impingement conditions in the choke assembly, secondly the susceptibility of Cavitations is analysed.

Date: 30-Jan-2014

SGS JKHI-140027

MPCL Ref no. 7100015783

Page: 8 of 12

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Companys findings at the time of its intervention only and within the limits of Clients instructions, if any. The Companys sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law. SGS Pakistan Private Limited -H 3/3, Sector 5, Korangi Industrial Area, Karachi-74900, Pakistan. UAN: 92 (21) 111 222 747 Tel : 92-21-35121388-97 Fax: 92 (21) 3 5121386-87 Web : ww.sgs.com

Failure Analysis Report of Wellhead Choke Assembly at Sujawal Field, MPCL

7. 1 CO DE C RIT ER I A FO R CO 2 CO R RO S IO N AG AI N ST ACT U AL E VI D EN C E:

S. No.

Susceptibility of as per Code / Industries Guidelines

Actual Scenario of choke

Meet Criteria Yes

01

API-571, Clause 4.3.6.2; Affected Material- Material of construction Carbon steel & Low alloy Steel assembly-Alloy steel

02

API-581, Table 2.B.13.1; Partial pressure of Partial pressure of CO2 = 104.51psi CO2 above 30 psi cause severe corrosion API-571 and 581, pH in the range of 4.5 6 pH of wellhead fluid =5.44 enhance corrosion rate API-581, temperature below 140 C (284 F) Temperature of wellhead fluid = 120 F increase corrosion rate API-581, Total pressure above 250 psi increase Operating pressure of wellhead fluid = corrosion 2302 psi API-571, Clause-4.3.6.3; corrosion occur in Wellhead fluid contains gas, condensate liquid phase increase the rate of corrosion and water as well API-571, Clause 4.3.6.5; Corrosion generally Turbulent flow inside the choke due to occurs in areas of turbulence and impingement flow through the orifice and sometimes at the root of Piping welds API-571, Clause 4.3.6.7; Corrosion may occur along the bottom surface of the pipe if there is a separate water phase, at the top surface of the pipe if condensation in wet gas systems is anticipated, and in the turbulent flow areas at elbow and tees

Yes

03

Yes

04

Yes

05

Yes

06

Yes

07

Yes

08

Pitting /Corrosion found at the bottom surface of the Upstream nozzle (N1) of fixed choke assembly also localize corrosion found at the cap of assembly

Yes

11

API-581, Presence of water

Well fluid contain Water

Yes

12

API-571, Clause 4.3.6.5; Localized thinning, Localize metal loss Pitting and grove like pitting corrosion and grooving in areas of structure found inside the choke and turbulence choke assembly

Yes

Date: 30-Jan-2014

SGS JKHI-140027

MPCL Ref no. 7100015783

Page: 9 of 12

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Companys findings at the time of its intervention only and within the limits of Clients instructions, if any. The Companys sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law. SGS Pakistan Private Limited -H 3/3, Sector 5, Korangi Industrial Area, Karachi-74900, Pakistan. UAN: 92 (21) 111 222 747 Tel : 92-21-35121388-97 Fax: 92 (21) 3 5121386-87 Web : ww.sgs.com

Failure Analysis Report of Wellhead Choke Assembly at Sujawal Field, MPCL 7. 2 CO D E C RIT ER I A FOR C AV IT AT IO N CO RRO S IO N AG AI N ST ACT U AL

E VI D EN C E:

S. No. 01

Susceptibility of cavitations as per Code / Industries Guidelines API-571, Clause 4.2.15.1 (a) formation and instantaneous collapse of innumerable tiny vapour bubbles

Actual Scenario at Choke assembly

Meet Criteria

According to process conditions and parameters, formation and collapsing of vapour bubbles is expected According to process conditions and parameters, formation and collapsing of vapour bubbles is expected On the basis of data provided by MPCL, wellhead fluid contains gas, condensate and water; hence the bubbles may contain the gas.

Yes

02

API-571, Clause 4.2.15.1 (b) collapsing bubbles exert severe localized impact forces that can result in metal loss

Yes

03

API-571, Clause 4.2.15.1 (c) bubbles may contain the vapour phase of the liquid, air or other gas entrained in the liquid medium.

Yes

04

API-571, Clause 4.2.15.2 Affected material copper and brass, cast iron, carbon steel, low alloy steels, 300 Series SS, 400 Series SS and nickel base alloys

Material of construction of choke assembly-Alloy steel, fixed choke Stainless steel SS-446

Yes

05

API-571, Clause 4.2.15.4 Damage can also be found in restricted-flow passages or other areas where turbulent flow is subjected to rapid pressure changes within a localized region

Turbulent flow inside the choke due to flow through the orifice and damage also observed in the restricted flow passage (choke beam) During internal visual inspection of choke and choke assembly Pitting and grove like structure found.

Yes

06

API-571, Clause 4.2.15.5 damage generally looks like sharp-edged pitting but may also have a gouged appearance in rotational components

Yes

Date: 30-Jan-2014

SGS JKHI-140027

MPCL Ref no. 7100015783

Page: 10 of 12

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Companys findings at the time of its intervention only and within the limits of Clients instructions, if any. The Companys sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law. SGS Pakistan Private Limited -H 3/3, Sector 5, Korangi Industrial Area, Karachi-74900, Pakistan. UAN: 92 (21) 111 222 747 Tel : 92-21-35121388-97 Fax: 92 (21) 3 5121386-87 Web : ww.sgs.com

Failure Analysis Report of Wellhead Choke Assembly at Sujawal Field, MPCL 8. D E S CR IPT IO N O F D AM AG E M EC H AN I S M :

8. 1 CO 2 CO R RO SI O N : Aqueous CO2 corrosion of carbon and low alloy steels is an electrochemical process involving the anodic dissolution of iron and the cathodic evolution of hydrogen. Carbon dioxide (CO2) corrosion results when CO2 dissolves in water to form carbonic acid (H2CO3). The acid may lower the pH and sufficient quantities may promote general corrosion and/or pitting corrosion. Corrosion usually occurs in Boiler feed water, condensate systems and effluent gas streams of the shift converters. This corrosion results localized thinning and/or pitting corrosion of carbon steel. It also corrodes the metal by making grooves in areas of turbulence. CO2 Corrosion generally occurs in areas of turbulence and impingement and sometimes at the root of piping welds. In the scenario of wellhead assembly and choke corrosion, the susceptible factors of CO2 corrosion are turbulent flow, low pH, higher partial pressure of CO2, and presence of water in wellhead fluid. As mentioned above, alloy steel is more susceptible, metal loss and pits are identified in the choke assembly due to CO2 corrosion.

8. 2 C AV IT AT IO N CO R RO SIO N: Cavitation is a form of erosion caused by the formation and instantaneous collapse of innumerable tiny vapor bubbles. The collapsing bubbles exert severe localized impact forces that can result in metal loss referred to as cavitation damage. Cavitation damage generally looks like sharp-edged pitting and may also have a grooving appearance. This damage occurs only in localized low-pressure zones. Cavitation is most often observed in pump casings, pump impellers (low pressure side) and in piping downstream of orifices or control valves. It is also found in restricted-flow passages or other areas where turbulent flow is subjected to rapid pressure changes within a localized region. In actual scenario, turbulent flow found in fixed choke with the rapid pressure change which causes cavitation damage in the form of grooves and sharp pits inside the choke. The affected material for this damage includes copper and brass, cast iron, carbon steel, low alloy steels, 300 Series SS, 400 Series SS and nickel base alloys thats why Fixed choke of SS-446 is more susceptible to cavitation damage.

Date: 30-Jan-2014

SGS JKHI-140027

MPCL Ref no. 7100015783

Page: 11 of 12

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Companys findings at the time of its intervention only and within the limits of Clients instructions, if any. The Companys sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law. SGS Pakistan Private Limited -H 3/3, Sector 5, Korangi Industrial Area, Karachi-74900, Pakistan. UAN: 92 (21) 111 222 747 Tel : 92-21-35121388-97 Fax: 92 (21) 3 5121386-87 Web : ww.sgs.com

Failure Analysis Report of Wellhead Choke Assembly at Sujawal Field, MPCL 9. CO NC LU S IO N: Based on the thorough study of data gathered, internal and external visual inspection, NDT and Metallographic results, nature and location of corrosion, it is concluded that the probable causes of wellhead choke assembly failure is the combine effect of CO2 Corrosion and Cavitation . The evidence revealed that this corrosion initiated due to the combined action of corrosion in an aqueous environment containing Co2, and the presence of turbulence in flow of wellhead fluid.

10 . AN N E X U R E S Annexure A: Report of Positive Material Identification Annexure B: Report of Videoscopy Annexure C: Report of Metallography Annexure D: Defect Sketches

Date: 30-Jan-2014

SGS JKHI-140027

MPCL Ref no. 7100015783

Page: 12 of 12

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Companys findings at the time of its intervention only and within the limits of Clients instructions, if any. The Companys sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law. SGS Pakistan Private Limited -H 3/3, Sector 5, Korangi Industrial Area, Karachi-74900, Pakistan. UAN: 92 (21) 111 222 747 Tel : 92-21-35121388-97 Fax: 92 (21) 3 5121386-87 Web : ww.sgs.com

Annexure -A

Positive Material Identification Report

Reference: SP-TM-12

INDUSTRIAL SERVICES

Page: 1 of 2 Rev. no: 0 Approval Date: 30th July2010

POSITIVE MATERIAL IDENTIFICATION

Annex A: PMI Report
ELEMENTAL CHEMICAL COMPOSITION REPORT
Client Name: Mari Petroleum Company Limited (Sujawal Field) Project: Root cause Failure Analysis of Choke Failure Material: -Sample No Element Date: 15-01-2014 Object: Choke Assembly Job Ref. No: JKHI-140027 % age Composition Alloy Grade Sheet: 1 of 2 Equipment Model: Niton XLt Minimum Exposure Time: 30 Sec Elapsed Time(sec)

Location 1 (Choke Assembly)

Fe Si Cr Al Mn Mo S Pb Ti V Fe Si Cr Mn Mo S V Ti Fe Si Cr Mn Mo S V Ti

95.000 1.780 1.040 0.890 0.493 0.186 0.102 0.073 0.023 0.014 95.580 1.220 1.020 0.499 0.218 0.119 0.018 0.015 96.29 0.423 1.12 0.689 0.228 0.053 0.03 0.007

Alloy Steel

30

Location 2 (Choke Assembly)

Alloy Steel

30

Location 3 (Assembly Cap)

Alloy Steel

30

Note:
Inspected By Name/Sign: Syed Ali Saquib Date: 15-01-2014 Reviewed by Name/Sign: Tauqeer Ahmed Date: 15-01-2014

Reference: SP-TM-12 Page: 1 of 1

INDUSTRIAL SERVICES

Rev. no: 0 Approval Date: 30th July2010

POSITIVE MATERIAL IDENTIFICATION

Annex A:
Client Name: Mari Petroleum Company Limited (Sujawal Field) Project: Root cause Failure Analysis of Choke Failure Material: -Sample No Element Nb P V S Si Cr Fe

PMI Report
ELEMENTAL CHEMICAL COMPOSITION REPORT Date: 15-01-2014 Object: Choke Beam Job Ref. No: JKHI-140027 % age Composition 0.070 0.141 0.146 0.744 1.260 22.080 73.380 Alloy Grade Sheet: 2 of 2 Equipment Model: Niton XLt Minimum Exposure Time: 30 Sec Elapsed Time(sec)

Location 1

SS-446

30

Note:
Inspected By Name/Sign: Syed Ali Saquib Date: 15-01-2014 Reviewed by Name/Sign: Tauqeer Ahmed Date: 15-01-2014

Annexure -B

Videoscopy of Choke Beam

Videoscopy Report of Choke Beam

ANNEXURE -B

Pictures of Corrosion inside the fixed choke beam:

Sizing of Pits by Remote Visual Inspection:

Annexure -C

Metallograpghy Report

JKHI- 140027 Date: 30-01-2014 Page: 1 of 1

IN-SITU METALLOGRAPHY REPORT EQUIPMENT: CHOKE ASSEMBLY

Location: Sujawal Field, MPCL Material.: Alloy Steel Surface Condition: Polished Etching: 5% Nital Date: 30-01-2014 Object: Choke Assembly Cap Sample Preparation: ASTM E-3 Technique: Reflected Light Microscopy No. of Pages: 01 Test Method:ASTM E-1351,E-407 Ref Drawing No. ---

Sample no. 01: Choke Assembly Cap

Original Magnification 400 X Observations / Notes

Micrograph consists of ferrite phase (White Regions) Alloy carbides (Dark Regions) forming homogenous matrix. No metallurgical anomalies like grain coarsening, micro fissures, voids were observed in the microstructure examined. Microstructure found normal.

Analysed By Arslan Hafeez khan

Reviewed By Mohsin Riaz

Date:

Date:

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Companys findings at the time of its intervention only and within the limits of Clients instructions, if any. The Companys sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents. Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law. SGS Pakistan Private limited, Korangi Industrial Area, Karachi.

Annexure -D

Sketches

UPSTREAM NOZZEL OF CHOKE (N-1)

0 3 6 9 0
45 25

155

15

30

45 55 20

- DEFECT
All dimensions are given in mm.

DOWNSTREAM NOZZEL OF CHOKE (N-2)

0 3 6 9 0

170
40

- DEFECT
All dimensions are given in mm.

CHOKE ASSEMBLY
0 3 6 9 0

80

15

170

45 30 30

- DEFECT
All dimensions are given in mm.

CHOKE ASSEMBLY CAP

0

30

40

- DEFECT
All dimensions are given in mm.