A non-return valve ( in an oil exploration at Natuna Sea) classified as 16K-150 experiences failure as shown in Figure 1.

The valve is used to flow seawater as a gate valve with normally open system. The valve disk is operated by screw manually. The failure took place when the pressure is still below working pressure (16 kg/cm2), i.e. about 5 kg/cm2. Prepare a report on the failure analysis using the data provided. You may add information related to the case. Give recommendation to prevent such case reoccurring.

Figure 1. The non-return valve shows a block of fractured valve wall. Seawater flows through the valve from bottom side to right side. The valve type is normally open

Figure 2. The outer valve body is paint coated, but several locations show paint peeling and severe corrosion attacks develop on these open area (see arrows)

Figure 3. Crack branching occurs on the valve body. Severe corrosion attack happens on the outer valve body whereas the paint coating is peeled (see arrows)

Figure 4. Open burst fracture on the valve body indicates brittle fracture without any sign of necking.

Figure 5. The fractured valve body

Figure 6. Macroetching on the cross section of the valve body exhibits carbide networks distribution.

Figure 7. Fracture tip shows crack propagation perpendicular to valve body circumference

Figure 8. Microstructure

Figure 9. Corrosion attack on the fracture tip

Figure 10. The microstructure of valve body

Fig 11. Microstructure

Composition: C 2.9 Si 1.98 Mn Ni Cr 0.414 0.013 0.08 Mo 0.27 V 0.011 W 0.011 Ti 0.003 Cu 0.003 S 0.008 P 0.02

Hardness: randomly over the sampless surface

Location

HB

97

116

119

95

97

121

116

114