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Performance Test Results of New Artificial Non-Metallic Abrasive

Abrasive material forms a major component for surface preparation in coating applications. Since blastin
g method developed in 1890s, abrasive materials and its application methods also significantly improve
d to enhance blasting efficiency. In general, steel grit and shot ball are being used predominantly as me
tallic abrasives. Garnet and coal slag are used as non-metallic abrasives. Each abrasive is selected and
applied in accordance with the work location and substrate material of structures to be coated. In this st
udy, we have evaluated a new artificial non-metallic abrasive (ferrochrome slag) which is a by-product fr
om ferrochrome production process for stainless steel. This evaluation also included the checking of sur
face cleanliness performance and coating quality based on international test methods and field trials. Fo
r verifying the cleanliness quality, various tests were conducted as per international standards (ISO 850
1-8503). Sea water immersion test (ISO 2812-2) and cyclic test (ISO 12944-9) were carried out to check
coating performance after blasting. The field test results indicates that all inspection and quality criteria o
f surface preparation were met as per international standards. Furthermore, coating performance test re
sults also showed this abrasive does not have any adverse effect on coating properties.

Product Number: MPWT19-14265
Author: Sangki Chi, Ebad ul Haque, Shaj K. Manjalivalapil
Publication Date: 2019
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Role of Metallographic Characterization in Failure Analysis – Case Studies

Product Number: MPWT19-14379
Author: Syed Ahsan Ali
Publication Date: 2019

Conducting a materials failure analysis requires a carefully planned series of steps intended to
arrive at the cause of the problem. Consistent with the current trend towards better accountability
and responsibility, failure analysis purpose has been extended in deciding which party may be
liable for losses, be they loss of production, property damage, injury, or fatality [1]. Hence it
increases the importance of proper implementation of characterization tools in failure analysis to
rightly identify the failure mode.
Present work discusses a few case studies to shed light upon the importance of the metallurgical
characterization tools and techniques in identification of correct failure mode. Some typical case
studies where metallography plays a very important role have been discussed, such as improper
welding joints which led to premature failure, sensitization and stress corrosion cracking in S.S.,
improper heat treatment and forging indicated the microstructures which led to the premature
failure. These cases are examples of only a few laboratory based investigations which justify that
without metallography it is not possible to diagnose the causes of premature failures.
Generally, examination of failed components commence with the low-power stereomicroscope
whereas hand-held magnifying lenses are still in wide use by experts to study fractures mostly
limited now for field purpose [2]. Metallographic examination typically is performed after nondestructive
and macroscopic examination procedures while using the light optical microscopy
which helps to assess the failure mode with respect to material defects, shortcomings in
processing, metallurgical changes etc. Since light optical microscopy has limited value for direct
observation of fracture surfaces (more limited for metals than non-metals), with still more factual
information can be gathered by scanning electron microscopy at higher magnification.

Picture for Non-metallic Applications in Oil & Gas Industry
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Non-metallic Applications in Oil & Gas Industry

Product Number: MPWT19-14383
Author: Mohamed Al Ghosain, Ali Azman Faheem, Ullah Mohamed, Zohair Zaki
Publication Date: 2019

Corrosion, either internal or external, along with other types of defects on pipelines eventually lead to leaks without proper treatment. This gives rise to several issues, including environmental and safety hazards, and in case of pipe leaks in a plant, a loss of the efficiency of the process or, ultimately, failure of the process. Replacing the corroded pipelines (piping) can be difficult, costly and time consuming especially for plant. A required shutdown causes major economic loss. Thus, instead of a replacement of the defected pipelines, the installation of online repair is a better option.
Repairs of pipelines include metallic and non-metallic repairs. Metallic repairs generally require welding or hot works which is not suitable for online repair of pipes containing hydrocarbons. In such cases the use of non-metallic composite repairs is the optimum solution. A non-metallic composite repair system is a system used to reinforce structures using a fiber equipped with a thermoset epoxy system. The epoxy system consists of a hardener and a resin which, after mixing, become solid through a polymerization reaction after a short duration of time, a process that is called curing. Depending on the temperature, the duration of time changes in an inverse relation. The higher the temperature, the smaller the duration of time needed for curing. This system can be used to reinforce pipelines with both external and internal corrosion and it can be used on Straight Pipes, Tees, Elbows, Flanges and weld joints. The repair system can also be installed online without the need for a shutdown in a short amount of time and a small requirement of labor intensity, making it cost effective. It is also environmentally friendly. In this paper we are going to present cases that were resolved by our company that demonstrate how successful these non-metallic composite repairs are and how diverse their applications can be