Fastener Failure Led to Dumped Oil in Gulf of Mexico
Hydrogen embrittlement caused a 2020 flowline jumper failure that resulted in the release of approximately 479 barrels of oil in the U.S. Gulf of Mexico, the Bureau of Safety and Environmental Enforcement (BSEE) reported.
The incident occurred on July 24, 2020, in the Fieldwood Energy-operated deepwater Katmai field. The affected well is located in about 2,082 feet of water approximately 140 miles south of New Orleans.
A panel consisting of BSEE subject matter experts, engineers, inspectors and specialized investigators conducted its investigation to determine the probable causes and contributing factors that led to the leak resulting from a flowline jumper failure and fracture of four of the eight flange fasteners at a flanged connection.
Lower flange connection
According to BSEE’s panel investigation report, the fractured studs were composed of a corrosion-resistant nickel-based alloy susceptible to hydrogen embrittlement in subsea environments. Hydrogen embrittlement occurs when metals absorb hydrogen, leading to reduced ductility and loadbearing capacity.
BSEE also found, among other contributing factors, that a gap in the quality assurance/quality control process allowed for a non-compliance subsea flange fastener installation.
In response, BSEE issued a safety alert urging operators and contractors to utilize an industry-knowledgeable metallurgist to verify subsea fasteners are fit for service and not prone to hydrogen embrittlement or any other environmental cracking failures, share subsea leak detection system learnings with industry, and emphasize that company, contract and sub-contract personnel enact management of change when there are modifications associated with equipment, operating procedures, personnel changes, materials and operating conditions.
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