Failure Analysis Report

TABLE OF CONTENT
SECTION TITLE PAGE

1. BACKGROUND 3

2. TEAM MEMBERS 3

METHOD OF ANALYSIS 3

2. VISUAL EXAMINATION TEST 4

3. LIQUID PENETRANT TEST 5

4. MAGNETIC PARTICLE TEST 6

5 HYDRO-STATIC PRESSURE TEST 7-8

STRUCTURAL INTEGRITY & POST TEST

6 9
EXAMINATION
7 REVIEW DECISION 10
REPORT ENCLOSUER
A) VISUAL INSPECTION REPORT
8 B) LIQUID PENETRANT TEST REPORT 10
C) MAGNETIC PARTICLE TEST REPORT
D) HYDRO-TEST GRAPH

1 Prepared Mr. Pankaj Kumar Approved By Mr. Pramod Kumar

 Left Blank

2 Prepared Mr. Pankaj Kumar Approved By Mr. Pramod Kumar

Background:-
American Completion Tools had supplied Flow Line Products to M/s. Top
Sun Technology Development Limited wide purchase order no.P12910-
PO-001 dtd.08.07.2019. On dated 11th August 2020, e-mail received that
the supplier 3” Fig.1502, M x F style-50, STD Service Swivel Joint found
crack during MPI testing at customer end.

Method of Analysis:-
Failure mode and effects analysis (FMEA) is the process of reviewing as many
components, assemblies, and subsystems as possible to identify potential failure
modes in a system and their causes and effects. It is used to systematically analyze
postulated component failures and identify the resultant effects on system
operations.

Team Members:-
1) Mr. Pramod Kumar (Manager QA/QC)
2) Mr. Pankaj Kumar (Engineer QA/QC)
3) Mr. Sumit Vashist (Production Engineer)
4) Mr. Rajesh Kr. Yadev (QC Inspector)
5) Mr. Sohan Lal (I/C Assly & Testing)

3 Prepared Mr. Pankaj Kumar Approved By Mr. Pramod Kumar

1. Visual Inspection Test:-
Visual inspection was done according to our internal procedure (QP-033, Rev02)
with SNT-TC-1A Level-II personnel and as per API 16C requirements. The visible
light intensity was 1080 Lux, during the visual inspection. The painting mark and
tool marks were found. During the inspection no significant visible crack/dent or
surface irregularities were found.
Visual inspection Report (ACT/VT/D1907262/01R dtd.21st Aug. 2020) is attached.

(Received in this condition from customer)

(After Removal of Paint)

4 Prepared Mr. Pankaj Kumar Approved By Mr. Pramod Kumar

2. Liquid Penetrant Test:-
Die Penetrating test was done according to our internal procedure (QP-035, Rev03)
with SNT-TC-1A Level-II personnel and as per API 16C requirements. The visible
solvent was used to locate the cracks, which are open to the surface. The available
Light intensity 1094 Lux, was observed during the test. The painting was removed
before DPT test. During the inspection no significant crack or surface irregularities
were found.
Liquid Penetrant Report (ACT/DPT/D1907262/01R dtd. 24th Aug. 2020) is attached.

(During Liquid Penetrant Test)

5 Prepared Mr. Pankaj Kumar Approved By Mr. Pramod Kumar

3. Magnetic Particle Inspection:-
Magnetic Particle test was done according to our internal procedure (QP-034,
Rev05) with SNT-TC-1A Level-II personnel and as per API 16C requirements. The
wet fluorescent examination method was used to locate the surface or sub-surface
Cracks. During the MPT test no significant or relevant indications were observed
and item was successfully passed test, and meets or exceeds the requirements of API-
16C.
MPT Report (ACT/MPI/D1907262/01R dtd. 24th Aug. 2020) is attached.

(During Magnetic Particle Test)

6 Prepared Mr. Pankaj Kumar Approved By Mr. Pramod Kumar

3a.Observations after NDT:-
Since the item was successfully passed all NDT tests, and meets or exceeds the
internal product specification requirements of ACT and API-16C, it was further
decided to carry out hydro-static pressure test at rated testing pressure i.e. 22,500
PSI.

4. Hydro-Static Pressure test:-

To carry out hydro-testing, the component was duly assembled with inventory piece
of the same size. The hydro-test was done in two cycles.

(During Hydro-Testing)

7 Prepared Mr. Pankaj Kumar Approved By Mr. Pramod Kumar

4a. Primary Hydro-test Cycle:-
The primary cycle consists of pressure test at rated testing pressure i.e. 22,500 PSI at
room temperature with holding time of 05 minutes. No visible leakage or pressure
drop was observed during the holding time.

(Hydro-Testing at 22,500 PSIG)

(Hydro-Testing graph at 22,500 PSIG)

8 Prepared Mr. Pankaj Kumar Approved By Mr. Pramod Kumar

4b. Secondary Hydro-test Cycle:-
The secondary cycle consists of pressure test at rated testing pressure i.e. 22,500 PSI
at room temperature with holding time of 15 minutes. No visible leakage or pressure
drop was observed during the holding time. Video recording of hydro-testing is
available with ACT and will be provided as when required.

The item was successfully passed the hydro-test and compliance with the product
specification requirements of ACT flow line components and API-16C, second
edition, March 2015.

5. Structural Integrity & Post Test Examination:-

After all testing is completed. The product is disassembled and component is visually
examined/inspected. It is observed that no permanent deformation is observed or
found.
The item was successfully compliance with the product specification requirements of
ACT flow line components and API-16C, second edition, March 2015.

(No Deformation found after hydro-testing)

9 Prepared Mr. Pankaj Kumar Approved By Mr. Pramod Kumar

5. Review Decision:-
Since all the relevant testing of the component found satisfactory. The team decided
that the component is fit for use in hydro-fracturing operations.
The item was successfully compliance with the product specification requirements of
ACT flow line components and API-16C, second edition, March 2015.
Hence, customer will be notified accordingly.

6. Report Enclosures:-
The following inspection reports are attached as enclosures.
1) Visual Examination Report.
2) Liquid Penetrant Report.
3) Magnetic Particle Examination Report.
4) Hydro- Test Graph.

10 Prepared Mr. Pankaj Kumar Approved By Mr. Pramod Kumar

FORM NO. : QC-27C, REV. NO.: 01
FIRST RELEASED ON.: 04.10.2017

Visual Inspection Report

Report No.: ACT/VT/D1907262/01R Date: 21/08/2020

Work Order & Date : P12910-PO-001 DTD.-08/07/2019

MALE WITH NIPPLE 3" FIG-1502 (LONG SWEEP) STD.

Item Description: (H.Code-D-121) QTY-01 nos

Technique Used Direct Visual Examination

Reference Procedure: QP-033 Rev-02 Reference Standard: API 16C

Method of Examination: Direct Visible Material Thickness: N/A

Light Intensity: 1080 LUX Welding Thickness: N/A

Natural & Artificial source

Light Source: Type Of Joints: N/A

Job Card No. / SO No.: D1907262 Surface Condition: M/C Finish

Acceptance Criteria: QP-033 Rev-02 clause-17.2 Stage Of Exam: Final

No any relevent indication observed & material found satisfactory

Observation/Result

Checked By: Approved By:

Name: A.K Name: P.K

Cert. no- EEGPL/PIPL/VT/1603/014 Cert. no- EEGPL/PIPL/VT/0405/17

Level: II Level: II
 FORM NO.QC-27
REV.-08, ISSUE: 0

L I QU I D P E N E T R A N T R E P O R T
Work Order No.: D1907262 Purchase Order No.: P12910-PO-001 Dtd. 08/07/2019

Part Number: 50110503M- STD Rev. Procedure No.: QP – 035 Rev: 03 Quantity: 01 NOS

Part Description: MALE WITH NIPPLE 3” FIG-1502 SWIVEL JOINT, STYLE-50 STD. SERVICE (H. Code- D-121)
Serial Number (s)
N/A REPORT No. ACT/DPT/D1907262/01R Date: 23/08/2020
Examined:
Standard Technique : ASTM E165 Method of Test : Visible / Colour Contrast --- Visible

Surface Condition : Finish (M/C) Surface Temp. 10 to 520C : 35 °C Non- Contact Thermometer (Sr.no- 141000968)
Scope of Examination:
1094 Lux Surface
Light Intensity 1076 lux min. : Free From Dust Particles Rust, Grease etc.
(Digital lux meter-Sr. no-AB- 26874) Preparation
Area of Testing : All Accessible Surface
Liquid Penetrant Type : Red Solvent Make : CHECKMATE Exp. Date : MAY-2021 Batch No. CI-Pu-294
Penetrant Dwell Time Start : Time Format 24 hrs. 11:10 am
Total Penetrant Dwell Time (10 Minutes. Min.) : 20 minutes (Stop Watch-JS-307)
Penetrant Dwell Time End : (HH :MM) 11:30 am
Excess Penetrant Remove from surface : Solvent Wipe Clean with Lint free cloth
Cleaner : Non Aqueous Cleaner Make : CHECKMATE Exp. Date : OCT-2021 Batch No. CI-Cu-294

Developer Type : Non Aqueous Developer Make : CHECKMATE Exp. Date : OCT-2021 Batch No. CI-Du-292
Developing Time (10 Minutes Min.) : 20 minutes Post Cleaning : Solvent Clean / Soap water clean - Solvent Clean
Acceptance Standard : API-16C & (Procedure No- QP-035 Rev-03)
Indication observed (type location & extent) : No indication observed
Location of relevant indication (if, any) / Remarks: No relevant indication observed
Result : Result found Satisfactory (Qty-01 no) Surface DP test accepted
PERFORMED BY: A.K WITNESSED / REVIEWED BY: P.K

(Cert. No. & Level) - JTS/145-R2/PT LEVEL-II (Cert. No. & Level)- EEGPL/PIPL/PT/1805/17
FORM NO.: QC-27A
REV.-08 ISSUE-00

MAGNETIC PARTICLE REPORT

S.O. No: D1907262 Report No.: ACT/MPI/ D1907262/001 Dtd.24/08/2020
Purchaser : TOP SUN TECH DEVELOPMENT LTD, UK Purchase Order No.: P12910-PO-001 Dtd. 08/07/2019
Part Number : 50110503M Rev: - Procedure No.: QP-34 Rev: 05
Item Description : 3”MALE WITH NIPPLE (LONG SWEEP) (FIG.-1502) (STD )( H.Code.D-121) Quantity: 01NOS
Inspection Authority : ASNT LEVEL II
Serial Number(s) Examined : N/A
Accessible outer Method of Examination : FLUORESCENT WET Applying Method : Pouring
Examination Coverage :
finish surfaces PARTICLE
Material of Construction : AISI-8620
Equipment Make & Model: MAGNAFLUX Y7 AC-DC
Serial Number : 2019104435 Calibration Due : 09-02-2021
Magnetizing Technique : Yoke Technique (Longitudinal) Equipment Used Scanning Direction : Scanning in Two
perpendicular direction
Lifting Power/Calibration: 13.5 Kgs. On DC (2” to 4”) Leg Length Concentration Check Centrifuge tube 0.22 ml
(0.1 - 0.4 ml) per 100 ml :
Particle Used : Magnaflux (MG410) Surface preparation: Clean (Free from Dirt, Grease etc.)
DC : YES AC : -
Magnetization Test : Field Indicator Lighting Equipment & intensity Portable Bulb 100 W (Ultra Violet Light),
(PIE GAUGE) (Minimum – 1000 µ w/cm2) (1150 µ w/cm2 ) & white light 018 lux)
Material Temperature : 42 C
Demagnetization : Yes (checked with gauss meter- observed value upto 2 gauss)
Technique Standard : ASTM E-709 Acceptance Criteria: QP-034, Rev.05 Clause: 4.17.1 (API-16C)
No relevant indication observed
Location of relevant indication (if, any): NIL
Remarks / Result: Result were found Satisfactory.
PERFORMED BY: S. K. WITNESSED / REVIEWED BY: P. K.

(Cert. No. & Level) : JTS/493 R2/MT (Level-II) (Cert. No. & Level) : EEGPL/ PIPL/MT/1605/17 (Level-II)