Composite wrap repair of a failed pressure vessel — Experimental and numerical analysis

Abstract

This experimental and numerical study deals with the failure of two steel pressure vessels that failed during hydrostatic test at a pressure lower than test pressure. Failure was noticed because of pressure drop and fluid leakage during the test and, later, by observing through-wall cracks that formed on the vessels. Experimentally, visual and ultrasonic non-destructive testing was performed to check the vessel for possible cracks and to measure wall thickness. Microscopy was employed to inspect the existing cracks and determine their dimensions. Results revealed pitting corrosion at the bottom part of the vessel to be the cause of the cracks. Numerical analysis was performed to assess the possibility of retaining the functionality of the vessel by using composite patch repair procedure. Results proved that repaired vessel can retain the pressure bearing capacity and numerically obtained results were confirmed by experimental investigation on the similar vessels. As a conclusion, some recommendations are given to avoid future failures of such pressure vessels.