Root cause analysis (RCA) of fractured ASTM A53 carbon steel pipe at oil & gas company

Incident involving failures of ASTM A53 carbon steel (CS) pipe, connected to pressure safety valve (PSV) and carrying raw gas has caused serious supply disruption. This study was performed to identify the most probable cause of the pipe failure. It was conducted by reviewing the existing design, construction data and pipe material analysis using non-destructive techniques such as VT, PT, MT and UT along with metallographic, hardness and microscopic analysis. The investigation revealed that excessive material loss has occurred in both failure and its adjacent regions due to abrasive grinding, resulting in the formation of a through thickness flaw. These grindings were performed to accommodate the pre-installed piping spool to avoid alteration in the pipe position. RCA demonstrated that this rapid thinning of the steel pipe body later led to its failure. Metallurgical study using photomicrograph shows that the morphology of the steel material was consistent and did not show any evidence of internal corrosion or micro fractures. Further damage to the surface of already excessively reduced thickness occurred due to nominal pipe vibration and atmospheric effect during service. The research work described in the paper has a significant meaning to recognize the root cause of such failures in CS pipes and through given recommendations to eliminate future such happenings.