Eng 2020121015245081
Eng 2020121015245081
https://www.scirp.org/journal/eng
ISSN Online: 1947-394X
ISSN Print: 1947-3931
Apolinar Albiter
Keywords
Sulfide Stress Cracking (SSC), Hydrogen Induced Cracking (HIC), Pitting,
Welding, X52 Steel
1. Introduction
The oil and gas industry can provoke a wide variety of corrosive environments.
Mexican crude oil and gas commonly contain entrained water, carbon dioxide
(CO2), hydrogen sulfide (H2S), high H2S and CO2 contents and heavy oil. There-
fore, the transportation of these corrosive fluids always results in the induce of
failures in the production systems; this shows the need to perform qualification
tests on candidate pipelines steels considered for the development of the Mex-
ican field, due to the high concentrations of H2S and CO2 expected in the exploi-
tation of mature fields.
Sulfide stress cracking (SSC) is a major concern for most oil and gas pipeline
operators for many years; however research work still is done to develop strate-
gies for a better management of this problem [1]-[7]. It is well known that
long-term operation of pipelines causes degradation of its mechanical properties,
such as embrittlement caused by SCC [2]. The SCC occurs due to the combina-
tion of three factors; a susceptible material, localized tensile stress above a thre-
shold and exposure to corrosive environment. However, sometimes due to en-
vironmental conditions, only corrosion occurs with no cracking [8]; nonetheless
in many times the cracks evolve from corrosion pitting [9].
Due to the presence of H2S, many metals are susceptible to: generalized, loca-
lized, pitting, and linear corrosion [10]. Therefore, most research focuses on the
rules and mechanisms of hydrogen damage, such as sulfide stress corrosion
cracking (SSC) and hydrogen-induced cracking (HIC), as well as the effect of
environmental factors (temperature, partial pressure of H2S, solution, and pH)
on the corrosion process [11].
Among the technological challenges being faced to put such corrosive hydro-
carbon’s fields into production, material selection for corrosive environments is
one of the most challenging. Materials selection requires knowledge of chemical
and physical characteristics of the corrosive environment, along with the opera-
tion conditions at which the material will be exposed, in order to ensure good
performance of the installations during his expected operational life. The high
pressure along with the CO2 content variable makes it impossible to use carbon
steel in well, risers and topsides piping’s; therefore it is required to use Corrosion
Resistant Alloys (CRAs) [12].
The understanding of corrosion mechanisms in the combined presence of H2S
and CO2 acidic gases has been discussed as a systematic approach for materials
design strategy for hydrocarbon production systems. But, such approach does not
deal with the important environmental cracking characteristics associated with
sour service; nonetheless it concentrates purely on metal loss degradation process
[13]. The combination of H2S and CO2 modifies the corrosion characteristics sig-
nificantly as compared to damage caused in the sole presence of CO2 or H2S.
Both CO2 and H2S are acid gases which when produced with the hydrocarbon
phase can render the associated water (condensed of formation) producing a
very corrosive environment leading to severe degradation. The selection of ma-
terials to resist such corrosive environment relies mainly on the type of corro-
sion anticipated (e.g. general or localized), the confidence in predicting the rate
and type of corrosion, risk of failure and life cycle cost. While the primary con-
2. Experimental Procedure
2.1. Steel Analyzed
The steel used for the assessment of SSC behavior, corrosion and hydrogen in-
duced cracking was an API X52 pipeline steel. The chemical composition of the
steel is shown in Table 1. For experimental tests, a section of X52 steel with lon-
gitudinal and circumferential welding was used. Steel samples were obtained
from a pipeline with an external diameter of 508 mm (20 in) and a wall thickness
of 19.05 mm (0.750 in). Therefore, microstructural characterization through
optical microscopy of the longitudinal and circumferential welding, along with
the base metal and weld was carried out.
C Si Mn P S Ni Cr Cu Mo V Nb Ti N B Al
0.06 0.190 0.92 0.012 0.002 0.120 0.120 0.210 0.020 0.045 0.045 0.015 0.004 0.0002 0.033
Faces to be examined
Circumferential weld
Faces to be examined
20
a)
Faces to be examined
Weld
c)
Dimensions in mm
20
b)
Figure 1. Specimen position and orientation for HIC testing: (a) parent metal, (b) longitudinal weld, and (c) circumferential weld.
The specimens were milled using coolant to avoid excessive overheating. After
milling, the specimens were wet grinded with 320-grade SiC grinding paper. A
minimum amount of material, up to 1 mm maximum, shall be removed from
the inner and outer pipe surfaces in order to remove oxidation and provide
prismatic specimens. After the specimens were ultrasonically cleaned (by im-
mersion) with a detergent solvent, it was flushed with methanol or acetone and
warm air-dried.
The formulations for the test solutions used to create the sour environments
are described in Table 2, with a modified brine solution with pH of 3.0. HIC
tests were performed using solution A. The temperature of the test solution was
25˚C a schematic sketch of the test assembly is shown in Figure 2.
The specimens were submerged in the brine solution and saturated with hy-
drogen sulfide at room temperature and it was maintained at a positive pressure
during the 96-hour test duration and following test procedure:
Sampling tube
Flow meter X X
X X X
Solution A Solution Ba
Reactive
Concentration (ppm) Concentration (ppm)
• The test brine solution was prepared and transferred to the glass-purging
vessel (Figure 2), ensuring that the volume of the test solution was sufficient
to cover all of the test specimens.
• The specimen was separated from the vessel floor and other test specimens
by suitable non-metallic rods with a minimum diameter of 6 mm.
• Purge test vessel with Nitrogen after purge the test solution, within the sealed
purging vessel, with Nitrogen for at least 1 hour at minimum rate or 100
ml/min/liter of test solution.
• Transfer the test solution from de purging vessel to the vessel via the airtight
filing tube, purge test solution, within the test vessel, with Nitrogen for at
least 1 hour at minimum rate or 100 ml/min/liter of test solution.
• Following the Nitrogen purge, the solution shall be saturate with 99.5% H2S
gas, at a minimum rate of 200 ml/min/liter of the test solution for a mini-
mum time of 60 minutes in the test vessel.
• Extract a sample from the solution, via the sampling tube and measure the
pH and the H2S concentration. If the H2S concentration is >2300 ppm and
the pH is within the specified range, the H2S gas will then be passed through
the test solution for a period of 96 hours at a minimum flow rate in order to
maintain a positive pressure. If not, continue saturation till H2S concentra-
tion is >2300 ppm.
• After the 96-hour exposure period, draw a sample of the solution and meas-
ure pH and H2S concentration. Stop the H2S flow and purge the solution with
Nitrogen at 200 ml/liter per hour flow rate for one-hour minimum to flush
out all the H2S from the test solution.
After exposure for 96 hours, the specimens were removed, cleaned and sec-
tioned for metallographic examination.
The cleaned specimens were visually inspected and sectioned as shown in
Figure 1. Each section was grounded, polished and etched in order to being ob-
served in the optical microscope.
Based on the crack measurement results, the crack sensitivity ratio (CSR), the
crack length ratio (CLR), and the crack thickness ratio (CTR) were calculated for
each section and the average for each test specimen according to the following
equations:
=
CSR
∑ ( a × b ) ×100 (1)
(W × T )
=
CLR
∑ ( a ) ×100 (2)
W
=
CTR
∑ ( b ) ×100 (3)
T
where a is crack length, b is the crack thickness, W is the section width and T is
the test specimen thickness.
All identifiable cracks, visible at magnification up to 100× (10× objective lens)
in the calculation, was included. Sometimes it was necessary to examine at high-
er magnifications to distinguish between small cracks, inclusions, pits or other
discontinuities.
2.5. Sulfide Stress Cracking (SSC) at Low Pressure (LP) and High
Temperature and High Pressure (HT/HP)
SSC tests were performed according to NACE TM 0177 [18], method B and EFC
Publication: 16 “Guidelines on Material Requirements for Carbon and Low Al-
loy Steels for H2S—Containing Environments in Oil and Gas Production” [19].
Four Point Bent-Beam (FPBB) specimens, fabricated from API X52 pipeline
steel were machined and tested. The specimens were machined close to the ID
with the weld located on the center of the specimen as is shown in Figure 3.
Specimen’s dimensions were approximately 119.4 × 19.05 × 4.83 mm (4.7 × 0.75
× 0.19 in). Prior to testing, the specimens were measured, cleaned and degreased
in accordance with ASTM F21 [20].
The FPBB specimens were stressed up to 80% of the Actual Yield Strength
(AYS) for each test temperature. Tensile testing was performed on each material
to determine the AYS at different temperatures. The stresses were measured us-
ing two strain gauges attached adjacent to the weld as is shown in Figure 3. The
stress was applied on the root weld surface (ID in tension). The stresses were
recorded by the means of strain gauges on each side of the weld.
The stressed FPBB specimens were exposed in triplicate to each sour envi-
ronment to simulate the field conditions. The exposure time was 720 hours and
the environments consisted of two solutions (A and B) saturated. The summary
of the FPBB tests conditions for the SSC testing and corrosion tests are presented
in Table 3.
Eight liters of solution were prepared for testing and deaerated by purging
with nitrogen. The stressed specimens and the mass-loss coupons were placed
into the vessel and seal dry. After the solution was transferred into the vessel,
then it was purged with nitrogen for eight hours. Figure 4 shows the specimens
and set-up before the exposure.
Partial
Corrosion CO2/H2S Temperature pH
Test SSC pressure
Tests ratio (˚C) solution
No. (psi)
1 X - X 8 - - 25 - 3 -
2 X - X 16 - - 25 - 3 -
3 - X X 16 15 0.937 50 - 3.8 -
4 - X X 16 15 0.937 - 80 3.8 -
5 - X X 45 35 0.777 50 - 3.5 -
6 - X X 45 35 0.777 - 80 3.5 -
OD - Outside Diameter
Weld
ID - Inside Diameter
Strain gauges placed at 1mm
from weld
Figure 3. Location of strain gauges used to measure the apply stress in the FPBB tests.
Corrosion
coupon
50 mm
Corrosion
coupon
25mm
Framework
Four Point Bent-
Beam specimen
(FPBB)
For the exposure with total pressures below 16 psi, the solution was saturated
with the respective brine solution A. The brine solution was saturated at room
temperature and then the temperature was increased. Once the thermal equili-
brium was achieved, the conditions were maintained during all time testing.
Upon completion of the exposures, the pH of the solutions was measured at
room temperature. The FPBB specimens were removed, cleaned, and visually
examined at a magnification of 10× to determine the presence of cracking. The
cracking assessment was performed according to the NACE TM 0177 [18] and
EFC Publication 16 [19]. Metallographic analysis was performed on all FPBB
specimens after testing.
temperatures. All the test was performed under static conditions in autoclaves
with temperature and pressure control, in glass containers for low pressure tests.
After the 720 hours’ exposure time, the mass-loss coupons were removed and
photographed to document the surface appearance. Then, the coupons were
cleaned to remove corrosion products according to specifications of ASTM G1
[22], rinsed in toluene/acetone, dried and re-weighed. General corrosion rates of
each coupon were calculated according to the following equation.
534 ∗ W
CR ( mpy ) = (4)
ρ ∗ A ∗T
where W is the weight loss (mg), ρ is the density (g/cm3), A is the area (in2) and
T is the time (hours).
The coupons were visually examined at a magnification of 50× to find evi-
dences of localized corrosion. Any pitting was further characterized according to
the specification of ASTM G46 [23].
The pitting depth was determined using optical measurements with an in-
verted metallurgical microscope and verified with a micrometer. The technique
consists on initially focusing on the undamaged surface of the coupon and then
re-focusing on the bottom of the pit. The difference in optical stage height is
then converted to units of length. This length is reported in mils (0.001 inch)
and corresponds to the pit depth. Once the maximum depth is established, the
penetration rate is calculated using the ratio of 365 days/time exposed. The pe-
netration rate is given in mils per year (mpy) units.
a) b)
Weld
Weld
1mm 1mm
c) d)
100μm 100μm
250
200
Hardness Vickers (HV)
150
100
50
Zone
a) b)
680 μm
100 μm 100 μm
c) d)
1.1 mm
100 μm 100 μm
Figure 7. Micrograph of specimen CS-05 (90˚ from weld): (a) section B at 100× po-
lished only (b) section B at 200× after being attacked with Nital 2%, (c) section C at
100× polished only, and (d) section C at 200× after being attacked with Nital 2%.
CS-379 64,072
25 64,616 51,693
CS-380 65,160
CS-381 58,624
50 60,183 48,146
CS-382 61,742
CS-383 63,033
65 61,075 47,293
CS-384 59,117
CS-385 57,696
80 57,892 46,313
CS-386 58,087
CS-387 55,926
150 55,716 44,572
CS-388 55,505
a)
Weld
a1
BM a2
Weld
a1 a2
200 μm 200 μm
The highest average value for general corrosion rate was 0.27 mm/year (10.6
mpy) corresponding to CS-53 and CS-54 coupons exposed to conditions of high
pressure and high temperature (HP/HT); and correspond to the testing condi-
tions No. 9 of Table 7 (96 psi of H2S and 53 psi of CO2 at 150˚C). This value can
be considered moderate, but should be used as a conservatively value because
the tests were performed under static conditions. Some images of this SSC-Four
Point Bent-Beam after testing are presented in Figure 9. The lowest average
value for general corrosion rate was 0.028 mm/year (1.1 mpy) belong to CS-61
and CS-62 coupons exposed to the testing conditions No. 1 of Table 7 (H2S at 8
psi; at 25˚C).
Test No. Specimen Max. Pit Depth (mils) Max. Pit Depth (mm) Corrosion rate (mpy) Observations
a)
CS-60
25mm
b)
CS-51
25mm
c)
CS-54
25mm
The localized corrosion rate was evaluated according to ASTM G46 [23]. For
this purpose, all the coupons were analyzed through optical microscopy; then
measurements of pitting depth using a micrometer were carried out. Table 8
a)
100 μm
b)
100 μm
c)
100 μm
As expected, a black scale was observed in all specimen’s surfaces after testing
due to the presence of sulfides. Localized corrosion (pitting) in all specimens of
X52 steel exposed to sour environments was observed. The specimen, CS-54 ex-
posed to environment No. 9 (96 psi H2S and 53 psi CO2 at 150˚C), presented the
deepest pit measured. The pit depth was 0.348 mm (13.7 mils) that corresponds
to a corrosion rate of 4.2 mm/year (167 mpy). It was also observed that HP/HT
environments not only generate the deepest pitting, but also these pits grow in
extension as shown in Figure 10(c).
Comparing the general corrosion rate against localized corrosion rate at high
temperature (150˚C) and high concentrations of H2S and CO2 (96 psi H2S and 53
psi CO2; test 9 from Table 3), the calculated average corrosion rate was 10.6 and
164 mpy, respectively. As expected, the localized corrosion (pitting) rate is high-
er than general corrosion rate.
From Equation (5), it can be observed that as the term H+ is removed through
the cathodic reaction of hydrogen reduction, more is formed, leading to the ap-
pearance of hydrogen gas on steels exposed to oxygen and free water containing
H2S as follows:
2H + + 2e → 2H ( atomic hydrogen ) → H 2 ( molecular hydrogen ) (6)
Then, the anion (HS−) dissociates further to S2− and H+. Therefore, the S2− ion
reacts with iron to form the black FeS corrosion product commonly found in
service. H2 may not be present in the bulk solution, but it can be formed locally
within the corrosion layer as a cathodic corrosion product, diffusing from its
electrochemical production at the metal surface to its final dispersion in the bulk
at the outer surface (contact surface).
100
CS CS
0.05
0
7 or 10 100
Figure 11. Cracking limits for carbon steel pipelines as function par-
tial pressure of H2S and CO2.
• CO2/H2S ratio.
• Temperature.
• Fluid Chemistry (water chemistry, pH, organic acids, water cut, oil wettabili-
ty, phase ratios, etc.).
• The hydrocarbon phase.
• Flow characteristics and fluid velocity.
• Steel surface.
• Corrosion products, such as: scales, wax and asphaltenes.
• Steel chemistry.
4. Conclusions
According to the results obtained from the qualification tests of X52 steel to be
used in fields at high pressure and high temperature we can draw the following
conclusions:
• The oil and gas industry could use carbon steels pipelines in partial pressure
higher than 10 psia of CO2. X52 steel is not susceptible to HIC or SSC phe-
nomenon at the studied conditions; however, the values of the corrosion rate
are considered moderate, but under conditions of hydrodynamic flow regime
they can be greatly increased.
• In the combined environment of CO2 and H2S, there is a competitive interac-
tion between FeCO3 and FeS corrosion products leading to cracking and/or
rupture of protecion layers, resulting in progressive localized corrosion.
• Vickers hardness measurements were made on the welded joints of X52 steel
obtaining the maximum hardness in the weld beads (216 HV) which meets
the requirements established in NACE MR 0175/ISO 15156 (maximum 248
HV).
• Tensile tests were performed according to ASTM E21 for each test tempera-
ture in order to characterize the steel before performing the SSC. The average
yielding stress (AYS) used in SSC tests by Four Point Bend Beam technique
decreases as temperature of the test increases.
• The results of HIC tests, performed according to NACE TM 284, showed that
welding joints did not exhibit cracks, except for specimen CS-5 obtained
from the base metal at 90 degrees from the longitudinal weld. However, the
obtained values did not exceed the criteria established in NACE TM 0284.
• Results of SSC did not show indications of cracking after the exposure to
sour solutions, except specimen CS-13, which was exposed to solution B sa-
turated with 96 psi of H2S and 53 psi of CO2 at 150˚C. This sample showed
subsurface cracks after metallographic examination, located between the up-
per and lower weld bead, and some of them seem to have their origin from a
welding defect.
• The highest average value for general corrosion rate was 0.27 mm/year (10.6
mpy) corresponding to CS-53 and CS-54 coupons exposed to the testing
conditions of 96 psi H2S and 53 psi CO2 at 150˚C. These values can be consi-
dered conservatively because the tests were performed under static condi-
tions.
• Localized corrosion (pitting) in all specimens of X52 steel exposed to the sour
environments was observed. Specimen CS-54 exposed to environment No. 9
(96 psi H2S and 53 psi CO2 at 150˚C) presented the deepest pit measured
0.348 mm (13.7 mils) that correspond to a corrosion rate of 4.2 mm/year
(167 mpy).
• Comparing the general corrosion rate with localized corrosion rate at high
temperature (150˚C) and high concentrations of H2S and CO2 (96 psi H2S
and 53 psi CO2), the calculated average corrosion rate was 10.6 and 164 mpy,
respectively. As expected, the localized corrosion (pitting) rate is higher than
general corrosion rate.
Acknowledgements
The author would like to thanks Dr. Pedro Hernandez and Dr. Antonio Contre-
ras for the technical support during experimental tests. The financial support
received from Instituto Mexicano del Petróleo through the project manager Li-
borio Garcia and Eduardo Antonio Castillejos is gratefully acknowledged.
Conflicts of Interest
The author declares no conflicts of interest regarding the publication of this pa-
per.
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