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As the service conditions for non-metallics becomes ever more challenging, their reliability and fitness for service evaluation requires more refined levels of testing. For elastomers used in HPHT sour conditions, the need to evaluate their ability to continue to seal requires testing that closer represents them as an elastomer seal and not as an elastomer material. This paper discusses new methods to test new techniques for the use of sour gas to conduct rapid decompression testing and new functional testing techniques to measure their ability to seal. The increased use of composite materials in more aggressive service has required new evaluation approaches to be developed and new standards written to match. This paper also discusses these new test methods for testing at a material and a pipe level within these standards.
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The total project study focused on six suction and discharge drums. Each of them was built with twohemispherical heads and a number of shells. The H2S service and Stress Corrosion Cracking (SCC) from this specific oil and gas field required the equipment to be cladded with Alloy 825 to protect them from corrosion.
Test results for four alloys in six different sour environments are presented. Alloys 625, 825, 316L and carbon steel were testing in sour gas with varying exposure to moisture at 280°C. Corrosion rates for each alloy over a 30 day period are measured from mass and thickness changes.
Hydrogen sulfide (H2S) is one of the most common gases in the oil and gas industry. Once dissolved in aqueous environments, H2S can induce corrosion damage to carbon steel. It has been proposed that the severity of the damage is related to parameters such as temperature, partial pressure, microstructure of steel, etc.
Frequency scan fatigue crack growth rate tests were performed at a fixed stress intensity factor range to determine the effect of frequency in two different sour environments. Both sour environments had the same partial pressure of H2S (0.21psia) but different pH values.
Resistance testing of low alloyed steel pipes to Hydrogen Induced Cracking (HIC) is performed according to NACE standard TM0284. Fitness-for-purpose testing, where the appropriate environment and pressures are selected, has been included.
Available fracture toughness (FT) test methodologies are reviewed in this publication to compare their details.
Carbon and low alloy steels (CS and LAS, respectively) used for exploration and production in the oil and gas (O&G) industry are normally exposed to environments that may contain H2S in a wide range of concentrations. In aqueous solutions, H2S acts as a cathodic poison.1,2 A cathodic poison inhibits the recombination of atomic hydrogen to H2, and as a result, favors its absorption by the metal.1,2 In the presence of a susceptible microstructure and the simultaneous effect of applied or residual tensile stress, a crack can nucleate and propagate, when a critical concentration of hydrogen is reached in the metal.3 This environmentally assisted cracking (EAC) phenomenon is known as Sulfide Stress Cracking (SSC).2 SSC is commonly addressed as a case of hydrogen embrittlement (HE) damage.2
The manufacturing and field experience of high strength low alloy (HSLA) steel plates produced by Thermo-Mechanical Controlled Process (TMCP) are well defined in industry standards and literature. The TMCP method consists of a well-prescribed rolling pass schedule followed by accelerated cooling that leads to a fine-grain microstructure with the desired mechanical properties of the produced plates.Quite recently, this TMCP process resulted in detrimental local variations with hidden hardness variations on pipe ID, so-called Local hard Zones (LHZ).
New axially loaded full ring test method which was developed and demonstrated to combine the benefits of retaining a full as-welded pipe pup-piece, permitting single-sided exposure, with the advantage of tensile loading of the complete tubular specimen.
Alloy UNS N07718 (hereafter abbreviated as 718) is one of the most versatile precipitation-hardened nickel-based corrosion-resistant alloys (CRAs) used for both surface and sub-sea components in oil and gas production service. API 6ACRA1 provides heat treatment windows and acceptance criteria for 718 in these oil and gas production environments, in which the heat treatment is intended to obtain high strength and to minimize the formation of δ-phase at grain boundaries. As pointed out in NACE MR0175 Part 32 (Table 1), field failures of 718 components in sour service are primarily related to stress corrosion cracking (SCC) at elevated temperatures and hydrogen embrittlement in the lower temperature range. The latter is specifically called galvanically induced hydrogen stress cracking (GHSC or GIHSC), which is typically caused by atomic hydrogen uptake from galvanic corrosion or cathodic protection (CP) when 718 is used with steel components in a seawater environment. CP is normally used to protect steel component from corrosion in subsea environments.