Search Results (16)

Sulfide stress cracking (SSC) failure is a main concern for the pressure vessel steel Q345 used in harsh sour oil and gas environments containing hydrogen sulfide (H₂S). Methods used to improve the strength of steel usually decrease their SSC resistance. In this work, a quenching and tempering (Q&T) processing method is proposed to provide higher strength combined with better SSC resistance for hot-rolled Q345 pressure vessel steel. Compared to the initial hot-rolled plates having a yield strength (YS) of ~372 MPa, the Q&T counterparts had a YS of ~463 MPa, achieving a remarkable improvement in the strength level. Meanwhile, there was a resulting SSC failure in the initial hot-rolled plates, which was not present in the Q&T counterparts. The SSC failure was not only determined by the strength. The carbon-rich zone, residual stress, and sensitive hardness in the banded structure largely determined the susceptibility to SSC failure. The mechanism of the property amelioration might be ascribed to microstructural modification by the Q&T processing. This work provides an approach to develop improved strength grades of SSC-resistant pressure vessel steels. Full article

In the oil and gas industry, the corrosion attributed to hydrogen sulfide (H₂S) is one of the most significant challenges. This review paper systematically investigates the diverse facets of H₂S corrosion, including its sources, corrosion locations, mechanisms, and resultant corrosion products. Understanding different forms of H₂S corrosion, such as stress-oriented hydrogen-induced cracking (SO-HIC), sulfide stress cracking (SSC), and hydrogen-induced cracking (HIC), provides a thorough comprehension of these phenomena. The paper discusses critical factors influencing H₂S corrosion, such as temperature, flow rate, pH, and H₂S concentration, highlighting their implications for sustainable practices in the oil and gas sector. The review emphasizes the significance of monitoring and mitigation strategies, covering continuous monitoring, applying corrosion inhibitors, selecting materials, and conducting thorough data analysis and reporting. Furthermore, the role of training in fostering a sustainable approach to H₂S corrosion management is highlighted. This exploration advances the overarching goal of sustainable development in the oil and gas industries by providing insights into understanding, monitoring, and mitigating H₂S corrosion. The findings presented here offer a foundation for developing environmentally conscious strategies and practices to guarantee the long-term viability and flexibility of refinery operations. Full article

The sulfide stress cracking (SSC) behavior of three micro-alloying 110 ksi grade Cr-Mo casing steels were evaluated according to the A-Method tensile test specified in the NACE TM0177 standard (NACE A-method). The fractures of SSC specimens and the micro-structures of the casing steels were characterized by scanning electron microscopy (SEM) with electron backscattering diffraction (EBSD) and transmission electron microscopy (TEM) in the BF and STEM mode. The results show that on the premise of 110 ksi, the yield strength of Co-Mo steel was satisfactory, finer spherical carbides increased the number of irreversible traps; widened polygonised martensitic laths, lowered dislocation density, and lowered the proportion of high-angle grain boundaries and the Σ3 boundaries decreased hydrogen permeability and diffusivity. The SSC resistance of Co-Mo steel with above micro structure characteristics was enhanced. Full article

Steel casing pipes used in the construction of deep oil wells usually require both high strength and corrosion-resistant behavior. Due to the exploration of deep H₂S-bearing oil reservoirs, sulfide stress cracking (SSC) is becoming an increasingly serious concern for casing steel. The nonmetallic inclusions in the steel are among the key reasons for its service failure. The rare earth element Ce can be used to modify the inclusions in casing steel and improve its SSC resistance. Here, taking C110 grade casing steel (the highest class currently in service) as the investigated object, the modification behavior of Ce inclusions in the steel and the effect of the addition of Ce in varying amounts (0.01, 0.024, and 0.042 wt.%) on the modified products were studied through high-temperature tube furnace experiments and thermodynamic calculations. The results showed that Ce had an obvious modification effect on the CaO·Al₂O₃ inclusions in casing steel, and the diffusion of dissolved Ce in the steel was the limiting step of the modification reaction. With the extension of reaction time, the sequence describing the modification of inclusions in the steel was determined as follows: CaO·Al₂O₃ → CeAlO₃ → Ce₂O₃/Ce₂O₂S. The final stable product after modification depended on the amount of Ce added. With 0.01 wt.% Ce, the stable phase in molten steel was Ce₂O₃; on the other hand, upon adding ≥0.024 wt.% Ce, the stable phase became Ce₂O₂S. In addition, the thermodynamic stability of Ce₂O₃ decreased, and it was transformed into CeAlO₃, Ce₂O₂S, Ce₂S₃, and CeS during solidification. On the basis of our results and the considerations for smooth casting, the addition of a proper amount of a rare earth element is suggested for industrial trials, following the achievement of a significant and surprising improvement in the qualified rate of SSC resistance for the final steel products. The relevant mechanism is also analyzed. Full article

The effects of Al deoxidation and Zr deoxidation on the microstructure and properties of sulfide stress corrosion resistant high-strength steel have been investigated. The feasibility of the Zr deoxidation instead of Al deoxidation was confirmed by the thermodynamic analysis of the deoxidation of various elements. The experimental results indicate that the average diameters of the inclusions in Al-Steel and Zr-Steel were 2.45 μm and 1.65 μm, respectively. The Al-Steel and Zr-Steel contained 22.38% and 68.77% inclusions per unit area, respectively, and the fraction of inclusions in the Al-Steel and Zr-Steel with diameters less than 2 μm was about 73.46% and 89.63%, respectively, indicating that the Zr deoxidation process could effectively refine inclusions and promote dispersion. The average diameters of austenite grain for the Al-Steel and Zr-Steel were about 9.1 μm and 8 μm, respectively. The fine particles in Zr-Steel could pin the austenite grain boundaries and clearly refine the grains. The average grain size of tempered martensite was 8.2 μm and 3.8 μm, respectively. The yield strength of the Al-Steel and Zr-Steel was 922 MPa and 939 MPa, respectively; the impact energy was 60 ± 6 J and 132 ± 6 J, respectively. Moreover, the fracture time of the NACE-A was from 28 h (Al-Steel) to 720 h (Zr-Steel) without fracture. The experimental steel deoxidized by Zr achieved a simultaneous improvement in strength, toughness and sulfide stress corrosion resistance, and the effect of inclusions on the fracture of the sulfide stress corrosion resistant high-strength steel can be explained by the Griffith theory. Full article

The impeller under consideration is a rotor wheel of a centrifugal compressor, made of 17-4PH martensitic precipitated hardening stainless steel. Its total operating lifetime was estimated to 80,000 h, but it fractured beforehand, 4 days after the scheduled overhaul without any observed pre-symptoms. The important causes of the failure were its working conditions: a moist H₂S environment, the applied shaft fitting stress, and the martensitic structure of its material. In the article the post-failure analysis of an impeller is described, explaining the root cause of the impeller failure by means of both experimental and Finite Element Methods (FEM). Sulfide Stress Cracking (SSC) was found to be the primary failure mechanism for the impeller under investigation. Details of the investigations and possible corrective measures to improve performance impellers used under harsh environment conditions are discussed. Full article

The influence of tempering temperature on the microstructure of 0.5Cr0.4W steels was investigated by scanning electron microscope, and the roles of grain boundary character, dislocation, and Taylor factor in sulfide stress cracking (SSC) resistance were interpreted using the election backscattered diffraction technique. The 0.5Cr0.4W steels tempered at 690 °C, 700 °C, and 715 °C all showed tempered martensites. The specimen tempered at 715 °C exhibited a higher critical stress intensity factor (K_ISSC) of 34.58 MPa·m^0.5, but the yield strength of 800 MPa did not meet the criterion of 125 ksi (862 MPa) grade. When the specimen was tempered at 690 °C, the yield strength reached 960 MPa and the K_ISSC was only 21.36 MPa·m^0.5, displaying poorer SSC resistance. The 0.5Cr0.4W steel tempered at 700 °C showed a good combination of yield strength (887 MPa) and SSC resistance (K_ISSC: 31.16 MPa·m^0.5). When increasing the tempering temperature, the local average misorientation and Taylor factor of the 0.5Cr0.4W steels were decreased. The reduced dislocation density, and greater number of grains amenable to slippage, produced less hydrogen transport and a lower crack sensitivity. The SSC resistance was, thus, increased, owing to the minor damage to hydrogen aggregation. Therefore, 700 °C is a suitable tempering temperature for 0.5Cr0.4W casing steel. Full article

High-strength oil country tubular goods (OCTG) like C110, according to standard API 5CT (yield strength at least 758 MPa), are subject to requirements in terms of mechanical and corrosion properties. In this work, we studied the microstructure of seamless casing tubes made of class C110 high-strength steel with a 194.5 mm diameter and 19.7 mm wall thickness, and its influence on sulfide stress corrosion cracking (SSC). Casing tubes were obtained from continuous billets by screw piercing with preliminary quenching and tempering. It was shown that cracking during the tests always begins from the inner surface of the tube. Rough segregation bands were found on the inner tube surface, which occupies about a third of the thickness of the wall. To increase the resistance of 0.3C-Cr-Mn-Mo + 0.15(V + Nb + Ti) steel to SSC, primary recommendations for adjusting the chemical composition, production technology and heat treatment were developed. Full article

The scope of this study includes modeling and experimental investigation of sulfide stress cracking (SSC) of high-strength carbon steel. A model has been developed to predict hydrogen permeation in steel for a given pressure and temperature condition. The model is validated with existing and new laboratory measurements. The experiments were performed using C-110 grade steel specimens. The specimens were aged in 2% (wt.) brine saturated with mixed gas containing CH₄, CO₂, and H₂S. The concentration H₂S was maintained constant (280 ppm) while varying the partial pressure ratio of CO₂ (i.e., the ratio of partial pressure of CO₂ to the total pressure) from 0 to 15%. The changes occurring in the mechanical properties of the specimens were evaluated after exposure to assess material embrittlement and SSC corrosion. Besides this, the cracks developed on the surface of the specimens were examined using an optical microscope. Results show that the hydrogen permeation, and subsequently SSC resistance, of C-110 grade steel were strongly influenced by the Partial Pressure Ratio (PPR) of CO₂ when the PPR was between 0 and 5%. The PPR of CO₂ had a limited impact on the SSC process when it was between 10 and 15 percent. Full article

High-strength oil country tubular goods (OCTG) like C110, according to standard API 5CT (yield strength at least 758 MPa), are subject to requirements in terms of mechanical and corrosion properties. In this work, we studied the influence of seamless tubes microstructure with a 177.8 mm diameter and 10.36 mm wall thickness of class С110 high-strength steel to sulfide stress corrosion cracking (SSC) and sulfide stress corrosion cracking with low strain rates (SSRT). Tubes were obtained from continuous billets by screw piercing with preliminary quenching and tempering. It was established that cracking during the tests always begins from the inner surface of the tube. Rough segregation bands were found on the inner tube surface, which occupies about a third of the thickness. It is shown that the SSRT assessment technique allows to estimate the threshold value of the resistance. Full article

The review presented herein is regarding the stress corrosion cracking (SCC) phenomena of carbon steel pipelines affected by the corrosive electrolytes that comes from external (E) and internal (I) environments, as well as the susceptibility and tensile stress on the SCC. Some useful tools are presented including essential aspects for determining and describing the E-SCC and I-SCC in oil and gas pipelines. Therefore, this study aims to present a comprehensive and critical review of a brief experimental summary, and a comparison of physicochemical, mechanical, and electrochemical data affecting external and internal SCC in carbon steel pipelines exposed to corrosive media have been conducted. The SCC, hydrogen-induced cracking (HIC), hydrogen embrittlement, and sulfide stress cracking (SSC) are attributed to the pH, and to hydrogen becoming more corrosive by combining external and internal sources promoting cracking, such as sulfide compounds, acidic soils, acidic atmospheric compounds, hydrochloric acid, sulfuric acid, sodium hydroxide, organic acids (acetic acid, mainly), bacteria induced corrosion, cathodic polarization, among others. SCC growth is a reaction between the microstructural, chemical, and mechanical effects and it depends on the external and internal environmental sources promoting unpredictable cracks and fractures. In some cases, E-SCC could be initiated by hydrogen that comes from the over-voltage during the cathodic protection processes. I-SCC could be activated by over-operating pressure and temperature at flowing media during the production, gathering, storage and transportation of wet hydrocarbons through pipelines. The mechanical properties related to I-SCC were higher in comparison with those reviewed by E-SCC, suggesting that pipelines suffer more susceptibility to I-SCC. When a pipeline is designed, the internal fluid being transported (changes of environments) and the external environment concerning SCC should be considered. This review offers a good starting point for newcomers into the field, it is written as a tutorial, and covers a large number of basic standards in the area. Full article

The effect of Ti and B microalloying on the hardenability, prior austenite grain size (PAGS), mechanical properties, and sulfide stress cracking (SSC) of C110 grade steel was studied by Jominy testing, static tensile testing, an optical microscope (OM), scanning electron microscopy (SEM) and double cantilever beam (DCB) testing. The results show that the addition of 0.015% Ti and 0.002% B into a medium-carbon Fe-Cr-Mo-Nb-V steel increased the hardenability and refined the PAGS and quenched martensite packets, and the size of carbides was reduced. It is believed that these behaviors are responsible for the improvement in the threshold stress intensity factor K_ISSC. Full article

This study examined the effects of alloying elements (C, Mo) on hydrogen-induced cracking (HIC) and sulfide stress cracking (SSC) behaviors of A516-65 grade pressure vessel steel in sour environments. A range of experimental and analytical methods of HIC, SSC, electrochemical permeation, and immersion experiments were used. The steel with a higher C content had a larger fraction of banded pearlite, which acted as a reversible trap for hydrogen, and slower diffusion kinetics of hydrogen was obtained. In addition, a higher hardness in the mid-thickness regions of the steel, due to center segregation, resulted in easier HIC propagation. On the other hand, the steel with a higher Mo content showed more dispersed banded pearlite and a larger amount of irreversibly trapped hydrogen. Nevertheless, the addition of Mo to the steel can deteriorate the surface properties through localized pitting and the local detachment of corrosion products with uneven interfaces, increasing the vulnerability to SSC. The mechanistic reasons for the results are discussed, and a desirable alloy design for ensuring an enhanced resistance to hydrogen assisted cracking (HAC) is proposed. Full article

C110 oil well casing tubes should have high strength and corrosion resistance which is commonly used for deep wells operation containing corrosive media. In this paper, the microstructure evolution of a kind of semi-macro segregation originated banded structure in casing tubes is studied under different heat treatments. It is shown that the characteristics of the banded structure will change significantly in subsequent hot working and heat treatment processes. For the hot-rolled ones, the banded structure is composed of pearlite plus bainite. After quenching, it evolves into martensite band with high concentration solute elements. Finally, the banded structure will change into a carbide banding under the following tempering process. The temperature and cooling rate of the tempering practice show an obvious effect on the final band structure. To improve anti-SSC (sulfide stress corrosion cracking) performance, the favorable QT (quenching and tempering) practice for C110 steel should be a higher tempering temperature and a quicker cooling rate, from which the banded structure defects can be decreased together with an obvious improvement of the tube wall hardness uniformity. Full article

Nonmetallic inclusions have a strong influence on the hydrogen-induced cracking (HIC) and sulfide stress cracking (SSC) in pipeline steels, which should be well controlled to improve the steel resistance to HIC and SSC. The effects of cooling rate on the formation of nonmetallic inclusions have been studied both experimentally and thermodynamically. It was found that the increasing cooling rate increased the number density and decreased the size of the inclusions, while the inverse results were obtained by decreasing the cooling rate. Furthermore, as the cooling rate decreased from 10 to 0.035 K/s, the inclusions were changed from Al₂O₃-CaO to Al₂O₃-CaO-MgO-CaS. At a high cooling rate, the reaction time is short and the inclusions cannot be completely transformed which should be mainly formed at high temperatures. While, at low cooling rate, the inclusions can be gradually transformed and tend to follow the equilibrium compositions. Full article