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Various austenitic stainless steels such as UNS S30409, S31609, S32109 and 34709 are widely used in complex refinery or chemical plants at temperature ranges between 550°C and 950°C. However, Stress Relaxation Cracking (SRC) in welded joints or cold deformed parts has been a serious problem during fabrication or operation. Several researches were conducted to construct SRC test methods. This included the evaluation of SRC susceptibilities among various austenitic stainless steels and to determine SRC mechanism within TNO Science and Industry or JIP1-4. It was concluded that SRC was caused by the accommodation of strain due to both carbide/nitride precipitation hardening inhibiting dislocation movement and the formation of precipitation free zone along the M23C6 carbide at grain boundary during stress relaxation process of welding residual stresses at temperatures between 550°C and 750°C.
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Underground natural gas storage (UGS) is an important component of the overall natural gas transportation and distribution system. It enables the utilities to supply natural gas during high seasonal demand periods and store gas during periods of lower demand. There are approximately 627 underground gas storage sites worldwide with a working gas capacity of 319.3 Billion m3 ( about 11.8 Trillion Cubic feet). The U.S. has a total of 414 natural gas storage fields, out of which 25 are inactive.
Metallic corrosion is a natural inevitable phenomenon defined commonly as the deterioration of metals due to reactions with their environments. The global cost of corrosion estimated by NACE in 2013 was found to be $2.5 trillion (USD), which is approximately 3.4% of the global gross domestic product (GDP). The two-year global study released at the CORROSION 2016 conference in Vancouver, B.C., Canada, assessed the economics of corrosion and the role of corrosion management in establishing best practices for the different industrial sectors. It found that implementing corrosion prevention best practices could result in global annual savings of 15-35 % of the cost of damage, which is equivalent to $375-875 billion (USD). These estimations excluded the cost of individual safety and environmental consequences from corrosion. Corrosion mitigation has been extensively researched. The methods of corrosion prevention include, but are not limited to, selection of the right material of construction, coatings, corrosion inhibitors, and cathodic protection.1,2
Stress corrosion cracking (SCC) is a failure mechanism that occurs in susceptible materials exposed to a corrosive environment and submitted to tensile stress above a certain threshold. In the presence of these combined factors, SCC can occur and potentially lead to the failure of an asset. This failure mechanism has been widely reported in several susceptible alloys of carbon steel, making SCC a considerable threat for pipelines in contact with corrosive soil.
Industrial usage of Plasma Electrolytic Oxidation (PEO) has grown consistently in recent years, thanks to the improved characteristics imparted to the oxide film in terms of surface adhesion, hardness, crystallinity, uniformity, and corrosion resistance. The metallic substrate is not subjected to elevated temperature and the overall equipment complexity is relatively simple, making the technique a good candidate for surface functionalization. In PEO treatments, high voltages are employed (~ 150-750 V 1) allowing for the formation of an insulating, or at least semiconductive, oxide layer that’s limits ion transport responsible for the initial coating growth. Beyond the spark voltage (prerequisite the enter the PEO regime) oxidation does not occur only as the result of a continuous flow of ions but rather it takes place after the cooling of a plasma discharge.
Martensitic stainless steel (MSS) well tubulars are favorable due to their high strength and relatively low cost and are therefore widely applied in the Oil & Gas industry. This is especially the case for 13Cr and Super13Cr grades, which are often selected for mildly sour gas fields, where a relatively low content of H2S is present. When selecting martensitic stainless steels for sour service, the susceptibility to Stress Corrosion Cracking (SCC) and Sulfide Stress Cracking (SSC), determined by standard laboratory tests, are the most important selection criteria.
Traditional solutions for the chemical passivation of stainless steel are nitric acid based, with the addition of sodium dichromate as an inhibitor for precipitation hardened and free machining stainless steels. These passivation chemistries are difficult to handle from an environmental health and safety point of view, particularly the dichromate inhibited versions. Citric acid passivation has been pursued as a replacement for both nitric acid and inhibited nitric acid based chemistries for many years, and has been incorporated into consensus specifications such as ASTM A967 and SAE AMS2700.
Deep well casing is an important part of oilfield production. In the long service life of well casing, corrosion can result in wall thinning and even perforation of the casing due to contacting with soil, water and other naturally occurring substances within the formation. The most economic and effective method to decrease corrosion of well casing is cathodic protection (CP). However, the vertical depth of casing is several kilometers, and CP current requirements of casing in different layers are quite different. At the same time, the conductivity of different formations will affect the distribution of CP current.
Top of line corrosion (TLC) is a degradation mechanism predominantly encountered in the oil and gas industry. Initiation of TLC requires a stratified flow regime with wet gas transportation and the existence of a significant temperature gradient between the hot fluid inside the pipeline and the colder external environment.1,2,3 This temperature difference results in the condensation of water vapor, present in the gas phase, onto the cooler, upper internal section of the pipeline. The condensed water can be particularly aggressive as it lacks dissolved salts (e.g. bicarbonates), some of which are able to buffer the bulk electrolyte, increasing the pH and suppressing corrosivity.4,5,6 The absence of such salts typically results in a very low pH condensate (<pH 4), often containing dissolved acidic gases, such as carbon dioxide (CO2) and hydrogen sulfide (H2S), and also acetic acid (HAc), which can cause severe degradation, particularly in the form of localized corrosion.5
The use of Duplex Stainless Steels (DSS) in refinery sour environments is governed by ANSI/NACE MR0103/ISO 17945NACE “Metallic materials resistant to sulfide stress cracking in corrosive petroleum refining environments” which limits DSS base materials to be used in Hydrogen Sulfide (H2S) services to a maximum hardness of 28 HRC for materials with a PREN ≤ 40 and to a maximum hardness of 32 HRC for those materials with PREN > 40.1 These hardness values are in line with the hardness requirements of solution annealed as produced straight tubes, but when the heat exchanger design requires the use of integral finning or u-bend tubes, these are subject to significant work hardening that results in as bent and as finned heat exchanger tubes with hardness measurement as high as 418 HV0.5 or 35.6 HRC which clearly exceeds the allowable limits stated above.
Oilfield waters have a complex composition depending on reservoir rock at different geographical locations that can be carried into the production water1. The alteration in environmental conditions such as pressure, temperature, salt content or pH can cause the liquid to oversaturate and the contained ions to form complexes. These will precipitate out of the solution, deposit and grow on contacting surfaces such as reservoirs, upstream production tubing, sub-surface safety valves, water injection lines to top side refining equipment namely heat exchangers and transport lines 2–4. Scaling can also be induced by incompatible mixing of fluids. For example CaCO3 and /or BaSO4 form through typical mixing of SO4 2- containing sea water with the formation water that carries high concentrations of divalent cations such as Ca2+and Ba2+2. Similarly, sulfide scales form upon mixing with H2S-containing formation water enriched with Fe, Zn or Pb ions 5. ZnS and PbS have been observed to form in presence of only 25 ppm H2S at gulf of Mexico containing 50 ppm Zn and 5 ppm Pb , due to their low solubility constant Ksp 6,7.
13Cr-5Ni-2Mo type Super Martensitic stainless steels referred to as SMSS-13Cr type grades can provide good general corrosion resistance such as in high CO2 environments combined with higher strengths and excellent toughness2 making them a prospective material choice for long term downhole completion equipment depending on actual well conditions. One of the main limiting factors for the use of SMSS-13Cr type grades is the Sulfide Stress Cracking (SSC) resistance in presence of H2S in downhole well conditions. Therefore, a good understanding of this behavior is essential to facilitate the material selection process.