Integrity and Failure Analysis of Cement Sheath Subjected to Coalbed Methane Fracturing

Perforation and fracturing are typically associated with the development of coalbed methane wells.As the cement sheath is prone to failure during this process,in this work,the effects of the casing pressure,elastic modulus of the cement,elastic modulus of the formation,and casing eccentricity on the resulting stresses are analyzed in the frame of a finite element method.Subsequently,sensitivity response curves of the cement sheath stress are plotted by normalizing all factors.The results show that the maximum circumferential stress and Mises stress of the cement sheath increase with the casing internal pressure,elastic modulus of the cement and casing eccentricity.As the elastic modulus of the formation increases,the maximum circumferential stress of the cement sheath decreases,and its maximum Mises stress increases slightly.The cement sheath undergoes tensile failure during coalbed methane fracturing.The stress sensitivity of the cement sheath to the influential parameters is in the following order:casing internal pressure>elastic modulus of cement sheath>casing eccentricity>elastic modulus of formation.

Failure analysis of the needle valve body of R18CrNi8 steel

A needle valve is a key component of a diesel injector.The needle valve body of the diesel engine, made of R18CrNi8 steel, cracked and failed during the working process.The cracking failure reasons for the carburized injector valve body through chemical composition analysis, metallographic examination, scanning electron microscope(SEM) analysis, and energy spectrum analysis, were investigated.The results reveal that the original material of the needle valve is in conformity with the manufacturing requirement.Due to the high carburizing quenching temperature, the best carburized layer structure was not obtained, and the machining defect from which the crack emanated was not identified.The cracks expanded and eventually led to fracture under the action of altered stress and the high-temperature combustion environment during the operation of the engine.

Analysis on the Failure Causes of the Collapsed Tubing in an Oil Well

Due to the influence of multiple factors such as internal and external formation and mechanical pressure, medium corrosion and construction operation environment, a tubing collapse failure occurred in an oil well. In order to determine the failure cause of the tubing, physical and chemical tests and mechanical properties analysis were carried out on the failed tubing sample and the intact tubing. The results show that the chemical composition, ultrasonic and magnetic particle inspection, metallographic test, Charpy impact energy and external pressure mechanical property test of the failed tubing all meet the requirements of API Spec 5CT-2021 standard, but the yield strength of the failed tubing does not meet the requirements of API Spec 5CT-2021 standard. Through the analysis of the working conditions, it can be seen that the anti-extrusion strength of the tubing collapse does not meet the API 5C3 anti-extrusion strength standard. The failure type of the well tubing is tubing collapse caused by large internal and external pressure difference.

Reliability analysis of carbon fiber rod-reinforced umbilical cable under tension using an improved sampling method

The umbilical cable is a vital component of subsea production systems that provide power,chemical agents,control signals et al.,and its requirement for reliability is exceedingly high.However,as the umbilical cable is a composite structure comprising multiple functional units,the reliability analysis of such cables involves numerous parameters that can impact calculation efficiency.In this paper,the reliability analysis of a new kind of umbilical cable with carbon fiber rod under tension is analyzed.The global dynamic analytical model is first established to determine the maximum tension load,then the local analytical model of umbilical cable including each unit are constructed by finite element method(FEM).Based on the mechanical analytical model,the reliability of umbilical cable under tension load is studied using response surface method(RSM)and Monte Carlo method.During the calculation process,a new tangent plane sampling method to calculate the response surface function(RSF)is proposed in this paper,which could make sampling points faster come close to the RSF curve,and it is proved that the calculation efficiency increases about 33%comparing with traditional method.

Blasting induced dynamic stress concentration and failure characteristics of deep-buried rock tunnel

In this study,the dynamic stress concentration factors(DSCF)around a straight-wall arch tunnel(SWAT)were solved analytically utilizing the complex variable function methods and Duhamel’s integral.The effects of wavelength,incident angle,and blasting rising time on the DSCF distribution were analyzed.Theoretical results pointed out dynamic disturbances resulting in compressive stress concentration in the vertical direction and tensile stress in the incident direction.As the wavelength and rising time increased,there was a tendency for the amplitude of stress concentration to initially rise and then converge.Moreover,a series of 3D FEM models were established to evaluate the effect of different initial stress states on the dynamic failure of the tunnel surrounding rock.The results indicated that the failure of the surrounding rock was significantly influenced by the direction of the static maximum principal stress and the direction of the dynamic disturbance.Under the coupling of static and blasting loading,damage around the tunnel was more prone to occur in the dynamic and static stress concentration coincidence zone.Finally,the damage modes of rock tunnel under static stress and blasting disturbance from different directions were summarized and a proposed support system was presented.The results reveal the mechanisms of deep-buried rock tunnel destruction and dynamically triggered rockburst.

Numerical analysis of hydraulic fracture propagation in deep shale reservoir with different injection strategies

Deep shale reservoirs are characterized by elevated breakdown pressures,diminished fracture complexity,and reduced modified volumes compared to medium and shallow reservoirs.Therefore,it is urgent to investigate particular injection strategies that can optimize breakdown pressure and fracturing efficiency to address the increasing demands for deep shale reservoir stimulation.In this study,the efficiency of various stimulation strategies,including multi-cluster simultaneous fracturing,modified alternating fracturing,alternating shut-in fracturing,and cyclic alternating fracturing,was evaluated.Subsequently,the sensitivity of factors such as the cycle index,shut-in time,cluster spacing,and horizontal permeability was investigated.Additionally,the flow distribution effect within the wellbore was discussed.The results indicate that relative to multi-cluster simultaneous fracturing,modified alternating fracturing exhibits reduced susceptibility to the stress shadow effect,which results in earlier breakdown,extended hydraulic fracture lengths,and more consistent propagation despite an increase in breakdown pressure.The alternating shut-in fracturing benefits the increase of fracture length,which is closely related to the shut-in time.Furthermore,cyclic alternating fracturing markedly lowers breakdown pressure and contributes to uniform fracture propagation,in which the cycle count plays an important role.Modified alternating fracturing demonstrates insensitivity to variations in cluster spacing,whereas horizontal permeability is a critical factor affecting fracture length.The wellbore effect restrains the accumulation of pressure and flow near the perforation,delaying the initiation of hydraulic fractures.The simulation results can provide valuable numerical insights for optimizing injection strategies for deep shale hydraulic fracturing.

Tensile Mechanical Behavior and Failure Mechanism of a Plain-Woven SiCf/SiC Composites at Room and Elevated Temperatures

Ceramic matrix composites (CMCs) are the preferred materials for solving advanced aerospace high-temperature structural components;it has the comprehensive advantages of higher temperature (~1500˚C) and low density. In service environments, CMCs exhibit complex damage mechanisms and failure modes, which are affected by constituent materials, meso-architecture and inhere defects. In this paper, the in-plane tensile mechanical behavior of a plain-woven SiCf/SiC composite at room and elevated temperatures was investigated, and the factors affecting the tensile strength of the material were discussed in depth. The results show that the tensile modulus and strength of SiCf/SiC composites at high temperature are lower, but the fracture strain increases and the toughness of the composites is enhanced;the stitching holes significantly weaken the tensile strength of the material, resulting in the material is easy to break at the cross-section with stitching holes.

PROGRESSIVE FAILURE ANALYSIS OF LAMINATED COMPOSITES WITH TRANSVERSE SHEAR EFFECTS

This paper deals with the progressive failure analysis of composite laminates. Triangular elements which include the transverse shear effects are us.d for the stress analysis. A new method for the calculation of the shear correction factors is presented. Several failure criteria are used to check the first ply failure and distinguish the laminate failure modes into fiber breakage or buckling, matrix cracking and delamination. After the failure is detected, the stiffness of the failed ply is modified according to the failure modes. The ultimate strength of the laminate is obtained by an iterative way. Several examples are given in the paper for stress analysis and progressive failure analysis of composite laminates.

Tribological Properties and Failure Analysis of PTFE Composites used for Seals in the Transmission Unit

The sealing rings are one of the most important components as the sealing devices in the wet clutch unit of a heavy vehicle. The sealing ring, made from PTFE composites, was subjected to serious wear on the sealing surface, but the mating metal surface only had slight abrasion. A specialized test rig was designed for wear research and failure analysis of the sealing ring. The composition analyses of the ring material, working conditions and wear surface characteristics by visual inspection and tribological properties as well as microscopic analysis with scanning electron microscope was performed to determine the wear mechanism and failure causes. Results revealed that the wear of PTFE composites was characterized by abrasion and adhesion after a certain duration testing, and the wear mechanism changed to thermal fatigue and abrasive wear in the stage of intense wear. The thermal deformation and fatigue were primarily responsible for the rapid wear of the PTFE composites for the sealing rings.

Failure analysis of AZ31 magnesium alloy sheets based on the extended GTN damage model

Based on the Gurson-Tvergaard-Needleman （GTN） model and Hill＇s quadratic anisotropic yield criterion, a combined experimental-numerical study on fracture initiation in the process of thermal stamping of Mg alloy AZ31 sheets was carried out. The aim is to predict the formability of thermal stamping of the Mg alloy sheets at different temperatures. The presented theoretical framework was implemented into a VUMAT subroutine for ABAQUS/EXPLICIT. Internal damage evolution due to void growth and coalescence developed at different temperatures in the Mg alloy sheets was observed by scanning electron microscopy （SEM）. Moreover, the thermal effects on the void growth, coalescence, and fracture behavior of the Mg alloy sheets were analyzed by the extended GTN model and forming limit diagrams （FLD）. Parameters employed in the GTN model were determined from tensile tests and numerical iterative computation. The distribution of major and minor principal strains in the specimens was determined from the numerical results. Therefore, the corresponding forming limit diagrams at different stress levels and temperatures were drawn. The comparison between the predicted forming limits and the experimental data shows a good agreement.

Failure analysis of polycrystalline diamond compact cutters for breaking rock by bending waves theory

The breakage mechanism of the polycrystalline diamond compact(PDC) cutters was analyzed by the energy theory of bending waves. The cutting tests of granite block were conducted on a multifunctional testing device by using the cutter at three kinds of negative fore angles of 30°, 45° and 60°. The results show that, when the edge of the PDC layer is broken, the layer of tungsten cobalt is broken a little under the angle of 30°, while the layer of tungsten cobalt is broken continuously under the angle of 60°, their maximum depths are about 2 and 7 mm respectively in the two cases. The eccentric distance mainly depends on the negative fore angle of the cutter. When the cutter thrusts into the rock under an attack angle of 60°, the energy of bending waves reaches the maximum since the eccentric distance is the maximum. So the damage of cutter is the most serious. This test result is consistent with the conclusion of theoretical analysis well. The eccentric distance from the axial line of cutter to the point of action between the rock and cutter has great effect on the breakage of the cutter. Thus during the process of cutting, the eccentric distance should be reduced to improve the service life of PDC cutters.

Time between failures model and failure analysis of CNC system

To provide basis for the reliability improvement design of CNC system, the failure data of a type of CNC system in one year are collected under field conditions in workshops. The distribution model parameters of time between failures are estimated by least square method and hypothesis testing is done by d-test method. It is proved that the time between failures of the CNC system follows Weibull distribution and the system has entered into the wear-out failure period. The failure positions and failure causes are analyzed further to indicate the weak subsystems of the CNC system. It can be found that servo unit, electrical system, detecting unit and power supply are principal failure positions and the main failure cause is breakage of components. The corresponding improvement measures are put forward. The paper provides a reference to reliability design and analysis of CNC system for the manufacturer and has great guidance to using and maintaining CNC system for the user.

MMM testing and failure analysis of fastening bolts on reciprocating compressor cylinder cover

To avoid the serious accidents caused by the failure fastening bolts on reciprocating compressor cylinder cover,a new nondestructive testing(NDT) technology,metal magnetic memory(MMM) testing,was applied to safety evaluating and failure analyzing for the fastening bolts.Based on the dynamic stress calculation of the failure bolts,MMM testing was carried out at workshop.Given are the MMM stress distribution characteristics of the failure bolts and fracture faces.It has been found that the MMM signal variation amplitude of the crack transition zone in the fracture surface is minimal,that of the crack initiation zone is in the middle,and that of the tear fracture zone is maximal.The failure reasons were analyzed with MMM effect.The results of the metallographic examination showed that the validity and feasibility of MMM testing and failure analysis.This means MMM technology is a new,fast and validity method of failure analysis.

Review on failure analysis of interconnections in power devices

Interconnections in microelectronic packaging are not only the physical carrier to realize the function of electronic circuits,but also the weak spots in reliability tests.Most of failures in power devices are caused by the malfunction of interconnections,including failure of bonding wire as well as cracks of solder layer.In fact,the interconnection failure of power devices is the result of a combination of factors such as electricity,temperature,and force.It is significant to investigate the failure mechanisms of various factors for the failure analysis of interconnections in power devices.This paper reviews the main failure modes of bonding wire and solder layer in the interconnection structure of power devices,and its failure mechanism.Then the reliability test method and failure analysis techniques of interconnection in power device are introduced.These methods are of great significance to the reliability analysis and life prediction of power devices.

Impact of failure mode and effects analysis-based emergency management on the effectiveness of craniocerebral injury treatment

BACKGROUND Craniocerebral injuries encompass brain injuries,skull fractures,cranial soft tissue injuries,and similar injuries.Recently,the incidence of craniocerebral injuries has increased dramatically due to the increased numbers of traffic accidents and aerial work injuries,threatening the physical and mental health of patients.AIM To investigate the impact of failure modes and effects analysis(FMEA)-based emergency management on craniocerebral injury treatment effectiveness.METHODS Eighty-four patients with craniocerebral injuries,treated at our hospital from November 2019 to March 2021,were selected and assigned,using the random number table method,to study(n=42)and control(n=42)groups.Patients in the control group received conventional management while those in the study group received FMEA theory-based emergency management,based on the control group.Pre-and post-interventions,details regarding the emergency situation;levels of inflammatory stress indicators[Interleukin-6(IL-6),C-reactive protein(CRP),and procalcitonin(PCT)];incidence of complications;prognoses;and satisfaction regarding patient care were evaluated for both groups.RESULTS For the study group,the assessed parameters[pre-hospital emergency response time(9.13±2.37 min),time to receive a consultation(2.39±0.44 min),time needed to report imaging findings(1.15±4.44 min),and test reporting time(32.19±6.23 min)]were shorter than those for the control group(12.78±4.06 min,3.58±0.71 min,33.49±5.51 min,50.41±11.45 min,respectively;P<0.05).Pre-intervention serum levels of IL-6(78.71±27.59 pg/mL),CRP(19.80±6.77 mg/L),and PCT(3.66±1.82 ng/mL)in the study group patients were not significantly different from those in the control group patients(81.31±32.11 pg/mL,21.29±8.02 mg/L,and 3.95±2.11 ng/mL respectively;P>0.05);post-intervention serum indicator levels were lower in both groups than pre-intervention levels.Further,serum levels of IL-6(17.35±5.33 pg/mL),CRP(2.27±0.56 mg/L),and PCT(0.22±0.07 ng/mL)were lower in the study group than in the control group(30.15±12.38 pg/mL,3.13±0.77 mg/L,0.38±0.12 ng/mL,respectively;P<0.05).The complication rate observed in the study group(9.52%)was lower than that in the control group(26.19%,P<0.05).The prognoses for the study group patients were better than those for the control patients(P<0.05).Patient care satisfaction was higher in the study group(95.24%)than in the control group(78.57%,P<0.05).CONCLUSION FMEA-based craniocerebral injury management effectively shortens the time spent on emergency care,reduces inflammatory stress and complication risk levels,and helps improve patient prognoses,while achieving high patient care satisfaction levels.

FAILURE ANALYSIS AND INSPECTION OF CRACKING OF IN-SERVICE CATALYTIC REGENERATOR

The special subject 'research on life prediction technology of important in-service pressure' mainly analyzes the failure mechanism of large-sized important and criticalin-service pressure vessels under the action of working medium and investigates safety assessmentand life prediction technology with a view to enhance the operation reliability of in-servicepressure vessels in China. Based on a series of accident investigation and test & measuringresearch, the cause of cracking of catalytic regenerator is analyzed and the in-line non-destructiveexamination method and failure prevention measures for the cracking of catalytic regenerator areproposed.

Comprehensive Reliability Allocation Method for CNC Lathes Based on Cubic Transformed Functions of Failure Mode and Effects Analysis

Reliability allocation of computerized numerical controlled（CNC）lathes is very important in industry.Traditional allocation methods only focus on high-failure rate components rather than moderate failure rate components,which is not applicable in some conditions.Aiming at solving the problem of CNC lathes reliability allocating,a comprehensive reliability allocation method based on cubic transformed functions of failure modes and effects analysis（FMEA）is presented.Firstly,conventional reliability allocation methods are introduced.Then the limitations of direct combination of comprehensive allocation method with the exponential transformed FMEA method are investigated.Subsequently,a cubic transformed function is established in order to overcome these limitations.Properties of the new transformed functions are discussed by considering the failure severity and the failure occurrence.Designers can choose appropriate transform amplitudes according to their requirements.Finally,a CNC lathe and a spindle system are used as an example to verify the new allocation method.Seven criteria are considered to compare the results of the new method with traditional methods.The allocation results indicate that the new method is more flexible than traditional methods.By employing the new cubic transformed function,the method covers a wider range of problems in CNC reliability allocation without losing the advantages of traditional methods.

Comparison of Cox proportional hazards model,Cox proportional hazards with time-varying coefficients model,and lognormal accelerated failure time model:Application in time to event analysis of melioidosis patients

Objective:To compare the prognostic factors of mortality among melioidosis patients between lognormal accelerated failure time(AFT),Cox proportional hazards(PH),and Cox PH with time-varying coefficient(TVC)models.Methods:A retrospective study was conducted from 2014 to 2019 among 453 patients who were admitted to Hospital Sultanah Bahiyah,Kedah and Hospital Tuanku Fauziah,Perlis in Northern Malaysia due to confirmed-cultured melioidosis.The prognostic factors of mortality from melioidosis were obtained from AFT survival analysis,and Cox’s models and the findings were compared by using the goodness of fit methods.The analyses were done by using Stata SE version 14.0.Results:A total of 242 patients(53.4%)survived.In this study,the median survival time of melioidosis patients was 30.0 days(95%CI 0.0-60.9).Six significant prognostic factors were identified in the Cox PH model and Cox PH-TVC model.In AFT survival analysis,a total of seven significant prognostic factors were identified.The results were found to be only a slight difference between the identified prognostic factors among the models.AFT survival showed better results compared to Cox's models,with the lowest Akaike information criteria and best fitted Cox-snell residuals.Conclusions:AFT survival analysis provides more reliable results and can be used as an alternative statistical analysis for determining the prognostic factors of mortality in melioidosis patients in certain situations.

Failure analysis of air fan blades

The failure of all 12 blades of an air fan was investigated by metallurgical and mechanical experiments and an examina-tion of the fracture surface. The experimental results show that the cast aluminium-silicon alloy without any modification had a number of material defects, such as coarse grains, a loose structure, a large number of shrinkage holes, a long and thin bold-pin shaped silicon-phase, poor material strength and serious brittleness. In addition, installed on the spindle without elastic conjunction, blade No.10 vibrated and inevitably.spun off due to the large centrifugal force. Therefore, blade No.10 first cracked at the locking handle, then broke at the root, which caused all the other 11 blades to be broken by the crack of blade No.10.

System failure analysis based on DEMATEL–ISM and FMECA

A new method of system failure analysis was proposed. First, considering the relationships between the failure subsystems,the decision making trial and evaluation laboratory(DEMATEL) method was used to calculate the degree of correlation between the failure subsystems, analyze the combined effect of related failures, and obtain the degree of correlation by using the directed graph and matrix operations. Then, the interpretative structural modeling(ISM) method was combined to intuitively show the logical relationship of many failure subsystems and their influences on each other by using multilevel hierarchical structure model and obtaining the critical subsystems. Finally, failure mode effects and criticality analysis(FMECA) was used to perform a qualitative hazard analysis of critical subsystems, determine the critical failure mode, and clarify the direction of reliability improvement.Through an example, the result demonstrates that the proposed method can be efficiently applied to system failure analysis problems.