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This paper discusses the detailed inspection, testing, metallurgical analysis and supporting factors from which the most likely cause of pitting corrosion was revealed in the DSS flowline welds.
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Pipelines and rigid risers made in conventional X65 grade require large wall thickness to withstand the high loads imposed during installation and under operating conditions in deep and ultra-deepwater field developments. The use of high-strength steels like X80 is an attractive alternative since it improves catenary weight by reducing wall thickness.
Electric Resistance Welded (ERW) pipes X60M / X65M API 5L PSL2, with resistance to ductile fracture propagation as per API 5L PSL2 Annex G [1] are achieved not only by setting the proper welding parameters and the steel cleanliness, but also by a combination of metallurgical processes affecting the final weld line and HAZ microstructure. The steel chemistry is the starting point to minimize the presence of inclusions, central segregation and the toughness impairment due to harmful elements, S, P, etc. on the pipe body, with a given casting and rolling technology. During the welding process, the right parameters combination is needed to avoid cold weld, penetrators, and other weld imperfections. At the last stage, the Seam Heat Treatment (SHT) has to be adjusted in a way that the steel response to the thermal cycles leads to the compliance of mechanical requirements at the weld line and Heat Affected Zone (HAZ). This heat treatment is performed through electromagnetic induction using several coils, which allows it to have a rapid and localized heating of the HAZ into the austenitic region, and that is followed by air cooling. The objective is to refine the structure and to eliminate brittle constituents around the weld line. As the SHT strongly affects the weld performance, the optimum processing conditions such as austenitization temperature and cooling rate may not be the same for all steel chemistry, and has to be carefully selected. The capability to model the thermal cycle after the ERW process and the understanding of the metallurgical behavior of different steel chemistries and dimensional configuration becomes the main target of any ERW pipe manufacturer aiming supply reliable Line Pipes as per API 5L PSL2 Annex G. In this work, a numerical thermal model of the SHT is presented along with validation and simulation results. A summary of metallurgical thermal cycle simulations by means of a Gleeble® 3500, applied on different steels is also included.
Stress corrosion cracking (SCC) has been observed for over six decades in light water reactors structural components, with wide variations in the rate of SCC initiation and crack growth. Newer materials have been adopted in the last three decades, primarily the ~30% Cr Alloy 690 (UNS N06690) and its weld metals, Alloy 52 (UNS W86052) and Alloy 152 (UNS W86152). These materials were initially viewed as immune to SCC, but are now recognized to be susceptibility to SCC, and can exhibit high growth rates in some conditions.