2.1.

5 Bypass Gas Nozzle Natural Gas Line

 Blockage was suspected in the gas injector or the upstream check
valves.
 The piping spool downstream control valve FV-10302 were suffering
from major metal loss due to erosion/corrosion which lead to pin hole
and leakage which was identified in February 2021.

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 Corrosion mapping was applied on February 2021 and found general
metal loss in the inner surface downstream the steam injection point.
The minimum identified thickness was 4.4 mm which is lower than the
minimum required thickness according to ASME 31.3 under design
condition. However, it’s exceeding the minimum required thickness
under normal operating conditions (3.6 mm).

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Bypass Gas Nozzle Natural Gas Line
History
 Due to high corrosion rates, fitness for service (FFS) was applied to
identify the remaining lifetime to confirm safe operating. The results
showed that the remaining thickness is not accepted according ASME
FFS for the design condition. While during the normal operation it could

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fit up to 146 days since 19 of February 2021.
 Another corrosion mapping was performed to verify the actual thickness
and corrosion rates after 54 days from the 1st applied corrosion
mapping. The pipe has severe metal loss exceeding the calculated for
short and long terms. Accordingly, FFS was repeated and the results
shows the remaining lifetime almost 26 days for safe shut down.
Immediate action was taken to shut down the plant and replace the
defected spool with new similar one.The new spool was pre-fabricated
at an external workshop and installed on site. Just one 3” joint was
2 welded on site during the shut down.
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 Bypass Gas Nozzle Natural Gas Line
Inspection findings and Examination
 The spool with the pinhole was replaced by the newly fabricated spool
and the 3” elbow joint was welded on site.
 The welded joint was inspected (Check fit-up and pre-heat before
welding, visual and PT after welding) and found accepted.

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 Radiography test done for the welded joint and the results were
accepted.

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 Bypass Gas Nozzle Natural Gas Line

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