PREPARED FOR:

PT CHEVRON INDONESIA COMPANY (CICO)

TECHNICAL REPORT AND LAB ANALYSIS

FAILURE ANALYSIS OFDISCHARGE GATE VALVE
P 1224E
REPORT NO. REPORT NO.FA-0XX/FA/CMPFA/2017

CENTER FOR MATERIALS PROCESSING AND FAILURE ANALYSIS

MRC BUILDING 2ND FLOOR, FACULTY OF ENGINEERING, UNIVERSITAS INDONESIA
DEPOK 16424
PHONE: 021 788 49045
FAX: 021 788 88111
E-MAIL: FA@METAL.UI.AC.ID
CMPFA UI – Technical Report Failure Analysis

Document Number:
REPORT
FA-0XX/FA/CMPFA/2017

Customer: Validation date:

PT CHEVRON INDONESIA 28th December 2017
COMPANY (CICO)

Report Title:
Failure Analysis of Discharge Gate Valve P 1224E

Description of Problem:
PT Chevron Indonesia Company (CICO) asked Centre of Material Procesing and Failure Analysis (CMPFA UI) to conduct
material and failure analysis forDischarge Gate Valve P 1224E.This valve is heavily corroded and failed at the top of disc
area. The failed material consist of stem and disc were sent to the CMPFA laboratory for furher analysis

Executive Summary:
PT Chevron Indonesia Company (CICO) asked Centre of Material Procesing and Failure Analysis (CMPFA UI) to conduct
material and failure analysis forDischarge Gate Valve P 1224E. This valve is heavily corroded and failed at the top of disc
area.
The results of visual observations show that corrosion occurs entire of the disc and stem. Based on report during the gate
valve dismantling, the casing wass also attacked by corrosion. The disc was detached from the stem due to the corrosion at
that area. The disc and stem should be made by 13Cr materialbased on the specification. The stem chemical composition
confirmed the result, while the disc showed less chromium content for 13 Cr material standard (Stem : ASTM A276 Gr 410).
The disc was made by overlay methods and the remaining overlay materials is only found at little area of disc where the flow
did not touch directly with the materials. The internal area of disc did not showed any trace of overlay area. The disc covered
by thick corrosion product. It containt significant amount of iron, carbon, sulphur, silicon and magnesium.Silicon is an
indication of sand while magnesium and antoher element is an indication of high total dissolve solid in materials.
This failure was caused by mixed event. Sulphate Reducing Bacterial attack the materials in the center of the gate valve ring.
It made the colony at the valve materials. High Total dissolve solid help the bacterial to growth better in this waste water line
pipe. The other contribution factor is the chromium content. It did not have a sufficient Chromium content as a 13 Cr
material. It makes the corrosion properties is not sufficient to withstand the environment corrosivity. Absence of chromium
overlay at the failed area make it vulnerable with the galvanic corrosion due to more noble metals composed the stem (13Cr)

APPROVAL SHEET

Laboratory Costumer

Written by: Yus Prasetyo ST. MT Approved by: Yudha Pratesa ST. M.T Received by:

Title: Manager Title: Expert Title:

Signature: Signature: Signature:

DISCLAIMER

CMPFA-UI provides this report only for the client and makes no representations nor warranties, either expressed
or implied, to other parties and specifically provides the results of this report “as is” based on the
information provided by client.

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1. Introduction

PT Chevron Indonesia Company (CICO) asked Centre of Material Procesing and Failure Analysis (CMPFA UI) to
conduct material and failure analysis forDischarge Gate Valve P 1224E.This valve is heavily corroded and failed at the
top of disc area. The failed material consist of stem and disc were sent to the CMPFA laboratory for furher analysis

Figure 1. Received sample to be analyzed by CMPFA UI

2. Visual Inspection

Connection between stem and disc

It showed heavy corrosion attack
No overlay material showed in the internal
area of disc

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Rest of Rest of overlay in disc materials

No Overlay
Center of the disc did not have any
overlay
residual overlay material

Another side of disc also showed heavy

corrosion and thick corrosion product

Another area of disc showed a thick scale

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3. Chemical Composition Test

 Ring

Item %C %Si %Mn %P %S %Cr %Ni %Mo %Fe

13 Cr Detached Area 0.175 0.46 0.71 0.034 0.0062 <0.0030 0.0057 0.0026 Bal.

Rest of overlay area 0.155 0.493 0.52 0.048 <0.0035 7.55 0.11 0.338 Bal.

SS 410 Martensitic 0.08- 1.00 1.00 0.040 0.030 11.5-

- -
*Ref Materials 0.15 max max max max 13.5

The chemical composition test was performed using Optical Emission Spectrometer. This method was conducted based
on ASTM A 751 for practice and terminology for chemical analysis of steel product. The result showed the ringwas
made by low carbon steel material that were coated by overlay material. The overlay material was made by Fe-Cr
alloy and did not meet the specification for 13Cr chemical composition standard materials.

 Stem
The chemical composition test was performed using Optical Emission Spectrometer to evaluate materials. This method
was conducted based on ASTM A 751 for practice and terminology for chemical analysis of steel product. The result
showed the stem was made by 13 Cr Stainless steel materials (SS 410 Martenistic SS)

Item %C %Si %Mn %P %S %Cr %Ni %Mo %Fe

Stem 0.134 0.56 0.378 0.024 <0.0035 11.83 0.102 0.049 Bal.

SS 410
0.08-0.15 1.00 1.00 11.5-
Martensitic*Ref 0.040 max 0.030 max - -
min max max 13.5
Materials

4. Hardness Vickers

This test was performed using hardness vicker methods. It was conducted at the disc material. Hardness vickers test
result showed the overlay material had a sufficient hardness number to be considered as martensitic stainless steel
material. Hardness vickers of overlay materials is about ± 448 Hv. On another hand, area without overlay material (base
material) showed the lower hardness. The hardness test was taken at three area: overlay, heat affected zone and base
metals. Heat affected zone is an area in boundary between base metals and overlay. It was a base metal area thathad
different microstructure caused by overlay provess

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Table 1 Hardness vickers test result

DIA Avg
Sample Avg HV
I II (Hv)
Overlay 34,4 35,5 34,95 455 448
34,2 35,2 34,7 462
35,5 36,6 36,05 428
Reference
344
410

Table 2 Haz and base metals

DIA
Sample AVG HV Avg
I II
Heat affected
193
zone 53,7 53,6 53,65 193
52,7 55,5 54,1 190
53,2 53,6 53,4 195
Base Metals 62,5 64 63,25 139 133
66,5 65,5 66 128
62,9 66,5 64,7 133

5. SEM –EDS test

Scanning Electron Microscope (SEM) and Energy Disepersive Spectroscopy (EDS) was conducted in several location.
Some comparison was made between the uncovered chrome overlay area and trace of overlay materials

5.1 Scale

The uncovered area at the ring showed high percentage of iron,oxygen, sulphur, carbon, silicon and calcium. The result
showed no chromium detected at the scale. It indicated the scale was a product of ring base material and did not come
from the 13%chromium overlay materials.

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Figure 2 EDS and SEM from the scale

5.2 Ring Materials

The existing materials of the ring material showed significant amount of chromium and oxygen in the rest of crhomium
overlay. However, the Cr percentage did not sufficient to state as 13 Cr materials. This result is also confirmed the OES
result.

Figure 3 SEM and EDS result from rest of overlay materials

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6. X-ray diffractionTest

X-ray Diffraction test result showed the scale/corrosion product was composed by siderite (FeCO3), pyrite (FeS) and
Iron Oxide (Fe2O3). Iron oxide is a typical product of iron oxidation in water. However, the percentage of this phase
could be contributed by oxidation during storage (after dismantling). On the other hand, siderite is product of CO2
corrosion and Pyrite (FeS) is a product between iron and sulphur. This sulphur could be formed by sulphate reducing
bacterial(SRB) activity or H2S gas. However, this cases showed the highest possibility is caused by SRB activity. This
activity was confirmed by SRB possitive check. Moreover, based on field sampling, H2S content is about 0.103 ppm
which is very low. The solution also had neutral pH (±7.2) which indicated the sour service did not happend in this
failure incident.

Figure 4 XRD analysis result

7. Microstructure

Microstructure test was conducted at the ring materials. It was taken cross section to find out the thickness of overlay
materials and the bonding between overlay and base metals. The result showed the base metal consist of ferrite and
pearlite structure which is typical microstructure of carbon steel. The pearlite percentage is sufficient to be classfied as
low carbon steel. The bonding behaviour of Overlay and base metals is shown by Heat Affected Zone (HAZ) . Heat
affected zone is an area that also exposed by heat during overlay and the microstructure tranformed into the other
phase/morpholog. The bonding is good that showed by absence of crack. The overlay area showed martensitic phase
which showed a high hardness number

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Overlay

HAZ

Figure 3 Heat affected zone condition showed microstructure changed and no crack was found.

Figure 4 13%Cr overlay microstructure

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Figure 5 Ferrite (white) and pearlite (grey) phase is found at the base metal

8. Field Data

Parameters Value Documents

Life time 3 years ARIBA LINE PROCUREMENT

Pressure 260 psig As Built Doc Drwing no ST-PP-

5944

Temperature 200 As Built Doc

Drwing no ST-PP-5944

Total Dissolve Solid 7341 Client Lab test

Ph 7.3 Client Lab test

SRB Positive Client Lab test

H2S 0.103 Client Lab test

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9. Discussion

9.1 Laboratorium Findings

Based on the laboratorium testing result, there are several significant findings :
 Materials of ring is not a full 13Cr steel (Martensitic stainless steel), it was made by overlay process
 Most of the overlay on the ring material had lost
 Based on visual examination, there is no indication that overlay process applied at entire of the ring.
 Connection between the ring and stem did not show any trace of overlay
 The failure area (jont of ring and stem) showed corrosion attack
 Thick scale / corrosion product found in the entire ring
 The remaining overlay material found at area that was covered by ring seat during application
 Chemical composition of overlay materials is under specification
 There is an evidence of Iron sulphide form XRD and EDS analysis that indication Microbial corrosion
product or sour service product
 Hardness of overlay material is high that sufficient to confirm as martensitic stainless steel

9.2 Failure Mechanism

From laboratorium result, it can be elobarated to find out possibility of failure in Discharge Gate ValveP
1224E. The result is showed in table xxx

Corrosion mode Characteristics/Requirement Evidence Probability

condition

Stress corrosion Brittle fracutre, common happend No brittle fracture less

cracking in amine solution for high stregth
not amine services
steel materials

H2S cracking Low Ph, High partial pressure No cracking, Ph less

H2S, cracking will happen for neutral
martensitic stainless steel material

CO2 corrosion High partial pressure, siderite, low Siderite found, Less (it attack as
Ph However it is not the consequence of
major cause of the failure
overlay failure.
13 Cr material is not
suspectible for CO2
corrosion

Erosion corrosion Erosion particle, high velocity Sandy environment Less

Materials was coated
by 13 Cr which had
good properties of
erosion corrosion
Elbow was installed
before the gate
valve, there is no
issue of erosion in
that area

Microbial induced Suitable environmnet for SRB Iron sulphide (Fes) high
corrosion colony, trap fluid, high TDS
High TDS
Colony of SRB
confirmed

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Galvanic Different material was connected Stem : ASTM A276 Gr high

corrosion in electrolyte 410 and carbon steel
(Ring)

9.2 Microbial Induced Corrosion

Microbiological Induced Corrosion (MIC) is the term used for the phenomenon that corrosion is initiated and/or
accelerated by the activities of micro-organisms. MIC is an electrochemical process. Micro-organisms are
capable of affecting the extent, severity, and course of corrosion with the presence of an energy source, a
carbon source, an electron donator, an electron acceptor, and water must be also present to initiate MIC.
Corrosion mechanism MIC from SRB are started from consumption of the cathodic hydrogen by enzyme
2- 2-
called hydrogenase. Hydrogen is used for Suphate (SO 4 ) reduction into Sulfide (S ). Sulfide will react with
into FeS which known as the corrosion product from MIC (fig xxx).[1-2]
2+
Fe

Gate Valve P1224E operated in intermitten services. This line also contains high total dissolve solid (TDS)
and low temperature services. It ideal condition for the bacterial to make a colony on the valve disc. This
bacterial caused the overaly breakdown and attacked the base metal later. The remaining overlay area was
not attacked due to it position that covered by seat and made the colony hard to growth there. The MIC attack
severe on the connection area due to presence of trapped water at that area. The water was trapped when to
valve closed.

The disc overaly consist lower chromium content for a Stainless steel 410 (SS 410). It make the overlay ability
to prevent the corrosion is not as optimum as the SS 410 material. Chromium is an essential element for
corrosion prevention. It could make a passive layer called chromium oxide (Cr2O3) which very dense and
could be repassivated if broken. However, this layer will form better in chromium level above 11% Cr. Below
this number, the chromium layer is not uniform and dense enough. Presence of bacterial colony made the
overlay material failed easier.

9.3 Galvanic Corrosion

Based on the visual examination, corrosion attacked at entire area of disc even the connection between the
stem and disc. In this case the connection seems exposed with the environment. This condition made the
galvanic corrosion happend in the connection. Based on visual examination, we cannot see any indication the

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overlay was made in the entire area especially in the connection. The connection materials was made by
carbon steel material while the stem was made by 13%Cr ( ASTM A276 Gr 410 ). Both of the component had
different material that formed a galvanic corrosion. The galvanic corrosion made the active material (disc) corroded
while the stem is safe.

9.4 Effect of Overlay Composition

Based on Optical Emission Spectroscopy (OES) and Energy Dispersive Spectroscopy (EDS) test, the overlay
material did not have sufficient chromium percentage to be considered as 13 Cr ( SS 430) material. The composition
is about 7-8 %. It will reduce the endurance for corrosion attack. Stainless steel will made a compact layer minimum
at 11% Cr alloy. Below this composition, the chromium oxide layer is not uniform and the layer is not dense.

Figure 6 Effect of chromium in corrosion

10. CONCLUSION

This failure was caused by mixed event. Sulphate Reducing Bacterial attack the materials in the center of the gate valve
ring. It made the colony at the valve materials. High Total dissolve solid help the bacterial to growth better in this waste
water line pipe. The other contribution factor is the chromium content. It did not have a sufficient Chromium content as a
13 Cr material. It makes the corrosion properties is not sufficient to withstand the environment corrosivity. Absence of
chromium overlay at the failed area make it vulnerable with the galvanic corrosion due to more noble metals composed
the stem (13Cr)

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