Integrating Materials Laboratory Testing, Inspection Records, Process Records, and Statistical Analyses to Evaluate a Pipe Recall

This presentation will focus on the materials investigation of a major pipe recall of approximately 5.5 km/3.5 miles of installed superalloy pipe used in the transport of untreated sour gas. The pipe material was recalled and replaced, and the decision to recall and replace was later challenged on the basis that a “test and replace” approach could have been employed. A wholistic approach was undertaken to evaluate whether a recall and replacement was warranted, which required a thoughtful and complex integration of materials laboratory testing of a large number of samples, previously collected materials test data, inspection records, process records, and statistical analyses. This presentation highlights the importance of multifaceted data collection and interpretation, particularly in demanding and involved investigations.