This document provides an overview of a project to analyze the failure of soft iron ring gaskets used in oil and gas applications and redesign the gasket to prevent failure. The objectives are to identify the causes of failure through testing and microscopy, understand possible modifications to avoid failure, modify the design, and test the modified design. A literature review is performed on ring gasket materials and corrosion. Methodology describes preparing specimens for analysis, coating experiments, and wear testing. Project timeline is provided in a Gantt chart. The research aims to understand failure mechanisms and provide industry with reliable corrosion control.

1. FAILURE ANALYSIS AND REDESIGN OF
SOFT IRON (AISI 1008) RING GASKET
FOR APPLICATION IN OIL AND GAS
FIELD.
BY: SHAKEEL AHMAD
SUPERVISED BY: Dr. ASHFAQ KHAN

2. CONTENTS
Aim
Objectives
Causes of Gasket Failure
Literature review
Methodology
Gantt chart
Utilization of research result

3. AIM
The aim of this project is to conduct the failure analysis
of Soft Iron ( AISI 1008) Ring gasket and make
modification to enable it to better withstand failure.

4. OBJECTIVES
Perform comparative Test’s by microscopy of failed and
new gasket.
To identify the causes of Gasket Failure.
 Identify the modifications possible in gasket to avoid
failure.
Modify the gasket to better with stand failure.
Test the modified and original gasket and evaluate the
comparative performance.

5. CHRISTMAS TREE, RTJ FLANGE
AND GASKET
Christmas Tree Ring Gasket
Flanges

6. CORROSION
One of the most probable cause of failure is
erosion-corrosion in the present case as
clearly shown by the visual examination
of the gasket.
The chemical reaction of an engineering materials with its
environment result a consequent deterioration in
properties of the material.
It is a natural phenomena that occurs over time.
It happens at different rates with different metals
depending on its environment.

7. EROSION-CORROSION
 Erosion is a wearing away process by the mechanical
abrasion caused by suspended particles in moving
environment.
 Erosion corrosion is the accelerated deterioration in
materials property due to movement of erosive
environment.
 Erosion produce a distinctive surface pattern, appears in
the form of groove, waves or valleys oriented with
respect to the fluid flow direction.

8. OTHER FORMS OF CORROSION
Uniform corrosion
 Galvanic or two metal corrosion
 Crevice corrosion
 Pitting corrosion
 Intergrainular corrosion
 Selective corrosion
 Stress corrosion cracking

9. LITERATURE REVIEW
Ring gasket: A device for sealing two flanges, and are
manufactured from different materials and in different
shapes[1, 2].
Erosion: A wearing away process due to mechanical abrasion
of suspended particles in moving fluid[12].
Corrosion: One of the big problem in oil and gas field in terms
of failure, production loss and safety[5, 12].
Analysis: Analyzing the corrosion mechanism is carried out by
material characterization[8].
Control of corrosion: In order to prolong the lifetime of
material required a special attention[9, 10].
Various techniques are used for corrosion control in oil and gas
field[7, 11].

10. CONTI….
Technique: Chemical inhibition, cathodic protection,
design modification and material coating techniques are
used[15].
Coating Materials: Different coating material such as
CERMET (CrC-NiCr, WC-Co-Cr), Cr-C, Chromium,
Aluminum, Copper and Zinc[13].
Coating Equipment: Detonation Gun(D-Gun)
and High-Velocity Oxy
Fuel (HVOF) equipment
are used for coating[3].
HVOF D-Gun

11. Testing: Various test are performed to identify the
corrosion rate for the new developed materials[12].
Test Equipment: Pin on Disc
Tribometer are used to measure
the wear rate in order to
find out erosion rate[13, 14].
Pin on Disc Tribometer

12. METHODOLOGY
Preparation of metallographic specimen of both corrode
and uncorrode gasket for material characterization.
Performing various microscopic test of both specimen.
Taking comparative analysis to identify corrosion
mechanism and change’s in material properties
( mechanical, physical and chemical)
Modifying the gasket without altering its primary purpose.
Modification can be brought by coating the material on
selective area of the gasket.

13. CONTI…
Selective area can be find out experimentally by measuring the
thickness of flanges with gasket before tighten and then after
tighten.
Various coating cermets ( CrC-NiC, WC-Co-Cr) are used for
protection.
Also various coating metals such as Aluminum, Chromium,
Copper and Zinc are used.
We will use such coating material having long life, best
erosive-corrosive resistance, withstand high temperature,
minimal cost and best wear resistance.
Coating process is taking out by one of coating equipment [
(High Velocity Oxy Fuel “HVOF”), (Detonation Gun “D-
Gun”)]

14. CONTI…
Test can be performed to find out the erosion rate in terms
of wear rate.
Pin On Disc Tribometer Equipment is used to find out
wear rate.
Comparing the result of both modified and original gasket.

15. Analysis
Control
Testing
Literature Review
Metallographic Specimen Preparation
(Sectioning, Mounting, Coarse Grinding, Fine Grinding, Fine Polishing, Etching)
Microstructural Characterization
(EDS Testing, SEM Testing, XRD Testing, Rockwell Hardness Test)
Data Collection and Corrosion Analysis
(Comparative Analysis of Both corrode and uncorrode gasket)
Thermal Spray Coating
(cermets material, Metals)
Modifying gasket erosive resistance
High Velocity Oxy Fuel, Detonation Gun
Experimentally Selection Coating Area
Erosive test in
Terms of Wear
Physical Testing, Pin on
Disc Tribometer Testing
Comparing the Result

16. GANTT CHART
Activity 2015-16
August September October November December January February March
Literature
Review
Metallograp
hic
Specimen
preparation
Material
Charactrizati
-on
Metal
Coating
Thesis and
paper writing
Submission

17. Utilization of Research Result
To know the cause of failure.
It is low cast and more reliable corrosion control
process than others.
Providing the result to oil industries to avoid failure.

18. Reference
1. James Walker., moorflex technology guide of ring gasket, UK
2. L.P. Deer Park., flexitallic-rtj product data, usa
3. Int. J. Elecrochem Sci., Erosion-corrosion of cermet coating, 8(2013) 1117-1137
4. Xinming Hu., Khalid Alzawai,Adinesh Gnanawelu, Anni Newile, wear 271
( 2011)1432-1437
5. G.T. Burstien., Corrosion Metals and Environment Reaction., Vol; 1, 3rd Edition,
3-293(1).
6. R. Malka Srdjan Nesic, Danial A. Gulino., Wear 262(2007) 791-799
7. L.S. Moiseeva, Protection of metals, Vol 41, No.1 (2005) 76-83
8. B. Kuznika., Engineering Failure Analysis,Vol 16, (2009) 2382-2387
9. V.S Sastri., Introduction and Forms of Corrosion., 1st Edition, 9(1).

19. 10. L.L. Faulkner., Practical Engineering Failure Analysis., 291(8), 344(9).
11. G.T. Burstien., Corrosion and Corrosion Control.Vol; 2, 3rd Edition, 366(12), 475(13).
12. Pierre R. Robrge., Hand Book of Corrosion Engineering, 781(9), 831(10)
13. M. Farooq., journal of faculty of engineering and technology, Vol 22, No.1 (2015), 1-6.
14. Tushiu Nakamura., Surface and coating technology, 204(2009) 42-53.
15. Sukhpa sigh chatha., Journa of mienrals and material charactrization and engineering,
Vol 11, No.6 (2012) 569-586
16, Hongjun Zhu., Numerical Analysis of Flow Erosion on Drill Pipe in Gas Drilling, Vol
22 (2012) 83-91

20. Thanks