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In recent decade, the applications of DSS have significantly increased in oil & gas industry, due to their attractive properties compared to austenitic grades with similar corrosion resistance. The DSS products exhibit a better resistance to pitting, stress corrosion cracking and higher mechanical properties compared to other austenitic stainless steel grades. The microstructure of these materials consists of approximately 50% austenite (γ) and 50% ferrite (α) phases, obtained by means of a solution heat treatment.
Duplex stainless steel (DSS) materials are extensively used for various critical applications in the Oil & Gas industry. During the past 30 years, Petroleum Development Oman (PDO) an upstream operator is one of the major end-user of DSS materials. A variety of applications such as wellhead piping, flow lines, headers, pipelines, vessels, coolers, tubing, pump and piping components, etc. are installed with DSS materials. Fabrication, quality assurance and quality control measures of these DSS components are critical elements for achieving long-term plant design integrity with a minimal life cycle cost. The objectives of this paper are to share selected case studies of premature failures (less than two years) experienced with DSS components during operation and to discuss recent quality assurance (QA) & quality control (QC) challenges encountered during procurement, forming/ forging, welding, heat treatment, and inspection & testing of DSS components. Even with thirty years of user experience, the well-known DSS material issues continue to challenge the material, corrosion & quality engineers, as the quality failures recurrence is alarming.
The application of corrosion resistance alloys such as 25% Cr super duplex stainless steel (25Cr SDSS) has expanded in the oil & gas industry recently as new technologies made it feasible for Oil and Gas operators to invest in high sour and corrosive fields. 25Cr SDSS material is often used in critical applications such as piping, rotating equipment, coolers, and instrument components etc. SDSS materials are well known for the 50/50 austenite (γ) and ferrite (α) microstructure which provides the combination of corrosion resistance and high-performance mechanical properties.
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This paper will identify and document how these different factors affect the susceptibility of austenitic stainless steel to Chloride-Stress Corrosion cracking based on a review of currently available literature. A review of current industry best practices and a review of how the Oxygen content, the pH and application of stress relief affects Chloride-Stress Corrosion Cracking will be documented and presented.