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New Material Application Limits of Duplex Stainless Steel in Sour Service

Duplex Stainless steel (22Cr) also known as corrosion resistant alloy (CRA) has been extensively used in oil and gas industry for critical applications such as wet gas production flow lines and pipelines. A number of new sour Oil & Gas projects with high salinity (exceeding 200000ppm NaCl) will be developed in the coming years in Petroleum Development Oman (PDO). So far DSS material is qualified upto 10mbar partial pressure of H2S (ppH2S) in 160000ppm chloride levels. The operating conditions of these new projects are outside these current material operating limits of 22Cr DSS. The objective of the study was to enable wider use of 22 Cr DSS grades (lower cost CRA) in highly sour projects in high chloride environments instead of selecting more expensive CRA materials like 25 Cr super duplex alloy 825 or alloy 625. Pitting crevice and stress corrosion cracking tests were conducted on both parent metal and representative welds in high ppH2S and in high chloride environments. The results established the new threshold sour service limits of DSS material which resulted in significant cost savings for various projects. The paper will present the test results and discuss the opportunities for DSS application.

Product Number: 51319-12814-SG
Author: Janardhan Saithala
Publication Date: 2019
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