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51318-11625-Cracking of Duplex Stainless Steel in Refining Operations

Sudhakar Mahajanam / Fred Addington / Adarsh Ranganathan / Yuting Mao / Joanna Folse / Chloe Lins / Cesar Espinoza
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In this paper, case studies related to DSS cracking are presented specific to the refining industry. Two cases of chloride stress corrosion cracking (Cl-SCC) of 2205 DSS tubing are presented.

Product Number: 51318-11625-SG
Author: Sudhakar Mahajanam / Fred Addington / Adarsh Ranganathan / Yuting Mao / Joanna Folse / Chloe Lins / Cesar Espinoza
Publication Date: 2018
Industry: Petroleum Refining
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Duplex stainless steels (DSSs) are complex steels. These materials were originally manufactured to exploit the benefits of high strength and corrosion resistance arising from the duplex microstructure, i.e., ferrite and austenite. However, this very duplex nature can make these steels susceptible to failures commonly observed in both austenitic and ferritic stainless steels. In addition, improper fabrication and welding techniques can lead to the formation of deleterious sigma and chi phases, which can cause brittle failure.

In this paper, case studies related to DSS cracking are presented specific to the refining industry. Two cases of chloride stress corrosion cracking (Cl-SCC) of 2205 DSS tubing are presented. One of them occurred in an overhead exchanger tube of the crude tower, while the other failure occurred in a top pump-around exchanger tube. The mode of failure was intergranular and transgranular cracking respectively. A third case discusses sulfide stress cracking (SSC) on a 2205 DSS outlet piping of a high pressure separator in a hydrocracker unit. Improper fabrication procedures were found to be responsible for the failure of this material. Recommendations and mitigation measures to avoid such failures have been provided.

Keywords: Duplex stainless steel, chloride stress corrosion cracking, sulphide stress cracking, SCC, SSC, intergranular attack, transgranular cracking

Duplex stainless steels (DSSs) are complex steels. These materials were originally manufactured to exploit the benefits of high strength and corrosion resistance arising from the duplex microstructure, i.e., ferrite and austenite. However, this very duplex nature can make these steels susceptible to failures commonly observed in both austenitic and ferritic stainless steels. In addition, improper fabrication and welding techniques can lead to the formation of deleterious sigma and chi phases, which can cause brittle failure.

In this paper, case studies related to DSS cracking are presented specific to the refining industry. Two cases of chloride stress corrosion cracking (Cl-SCC) of 2205 DSS tubing are presented. One of them occurred in an overhead exchanger tube of the crude tower, while the other failure occurred in a top pump-around exchanger tube. The mode of failure was intergranular and transgranular cracking respectively. A third case discusses sulfide stress cracking (SSC) on a 2205 DSS outlet piping of a high pressure separator in a hydrocracker unit. Improper fabrication procedures were found to be responsible for the failure of this material. Recommendations and mitigation measures to avoid such failures have been provided.

Keywords: Duplex stainless steel, chloride stress corrosion cracking, sulphide stress cracking, SCC, SSC, intergranular attack, transgranular cracking

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Picture for Duplex Stainless Steel Chloride Stress Corrosion Cracking Risk in Refining
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51313-02520-Duplex Stainless Steel Chloride Stress Corrosion Cracking Risk in Refining

Product Number: 51313-02520-SG
ISBN: 02520 2013 CP
Author: Karly Moore
Publication Date: 2013
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Picture for Chloride Stress Cracking of an Austenitic Stainless Steel Pipe Fitting in a Hydroprocessing Unit
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51317--9518-Chloride Stress Cracking of an Austenitic Stainless Steel Pipe Fitting in a Hydroprocessing Unit

Product Number: 51317--9518-SG
ISBN: 9518 2017 CP
Author: Hayrik Allahverdian
Publication Date: 2017
$20.00

Case study: Cracking occurred in a (UNS S32100) type austenitic stainless steel nozzle fitting at a low point in the reactor effluent piping in a Gasoil Hydrotreater unit following start up. Normal preventive measures had been taken.  The failed sample was removed for metallurgical analysis and determination of mechanism(s).
Picture for Weld preferential high temperature sulfidation
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51318-11142-Weld preferential high temperature sulfidation

Product Number: 51318-11142-SG
Author: Matthieu Devallée / Xavier Roumeau / Francois Dupoiron
Publication Date: 2018
$20.00

Very different corrosion behavior was observed between adjacent welds. This paper describes the investigation to identify the corrosion mechanism, trying to understand the influence of filler metal composition and welding parameters.
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