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After 30 Years Of Duplex Stainless Steel Experience In Oil & Gas - Do We Still Face Challenges?

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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.

Product Number: 51322-17690-SG
Author: Janardhan Rao Saithala, Amjad Kharusi, Mohammed Ghafri, Talal Nabhani Manish Kulkarni, Nasser Behlani,
Publication Date: 2022
Industries: Corrosion Monitoring and Control , Coatings and Linings , Coatings
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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.

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.

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Failure Cases Of Super Duplex Stainless Steel Pump Components

Product Number: 51322-17689-SG
Author: Janardhan Rao Saithala, Amjad Kharusi, Mohammed Ghafri, Ossama Mohammed, Abdul Majeed, Manish Kulkarni, Talal Nabhani
Publication Date: 2022
$20.00

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. 
Picture for 03398 SELECTIVE CORROSION IN DUPLEX STAINLESS
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03398 SELECTIVE CORROSION IN DUPLEX STAINLESS STEEL

Product Number: 51300-03398-SG
ISBN: 03398 2003 CP
Author: Wen-Ta Tsai, Kuen-Ming Tsai, Changjan Lin
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Picture for A Review Of Chloride Stress Corrosion Cracking Factors For Austenitic Stainless Steel
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A Review Of Chloride Stress Corrosion Cracking Factors For Austenitic Stainless Steel

Product Number: 51322-17524-SG
Author: Sangeetha Rao
Publication Date: 2022
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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.
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