Failure Analysis of Leakage of Reducer Pipe in Natural Gas Treatment Plant

FENG Jinsong; ZHAO Xinkui; LI Guangshan; XIONG Xinmin; WU Donghui; CHEN Qingguo; CHANG Zeliang; ZHANG Shuxin; LAI Weiya

doi:10.7643/ issn.1672-9242.2025.12.013

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Equipment Environmental Engineering ›› 2025, Vol. 22 ›› Issue (12) : 103-110. DOI: 10.7643/ issn.1672-9242.2025.12.013

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Failure Analysis of Leakage of Reducer Pipe in Natural Gas Treatment Plant

FENG Jinsong^1,2,3,4, ZHAO Xinkui^1,2,3,4, LI Guangshan^5,6, XIONG Xinmin^1,2,3,4, WU Donghui^1,2,3,4, CHEN Qingguo^1,2,3,4, CHANG Zeliang^1,2,3,4, ZHANG Shuxin^5,6, LAI Weiya^5,6

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Abstract

The work aims to determine the cause of the cracking and leakage failure of a reducer pipe in a natural gas processing plant by physical and chemical tests and analyses of the pipe fitting. Macroscopic observation, chemical composition analysis, metallographic structure observation, mechanical property testing, scanning electron microscopy (SEM) analysis of fracture and crack morphology, and energy dispersive spectroscopy (EDS) detection were employed. The chemical composition and mechanical properties of the pipe fitting met the national standards. The reducer pipe was in service in an acidic wet gas environment containing H₂S, CO₂ and H₂O. There were residual stresses in the transition section, and the L360NB material was sensitive to stress corrosion cracking. These factors jointly led to the cracking. Comprehensive macroscopic, microscopic and EDS analyses indicated that the crack originated from the inner wall of the transition section. There were secondary cracks on both sides of the main crack, and the crack propagation was mainly intergranular with local transgranular propagation. The failure mechanism of the reducer pipe was wet hydrogen sulfide stress corrosion cracking. Similar pipe fittings should be inspected, and anti-sulfur materials should be selected and SSCevaluation should be conducted before use to determine their applicability under acidic conditions. Meanwhile, in-service inspection and risk assessment should be carried out for in-service pipe fittings.

Key words

reducer pipe / natural gas / hydrogen sulfide / residual stress / hydrogen sulfide stress corrosion cracking / failure analysis

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FENG Jinsong, ZHAO Xinkui, LI Guangshan, XIONG Xinmin, WU Donghui, CHEN Qingguo, CHANG Zeliang, ZHANG Shuxin, LAI Weiya. Failure Analysis of Leakage of Reducer Pipe in Natural Gas Treatment Plant[J]. Equipment Environmental Engineering. 2025, 22(12): 103-110 https://doi.org/10.7643/ issn.1672-9242.2025.12.013

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