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After 30 Years Of Duplex Stainless Steel Experience In Oil & Gas - Do We Still Face Challenges?

In recent decade, the applications of DSS have significantly increased in oil & gas industry, due to their attractive properties compared to austenitic grades with similar corrosion resistance. The DSS products exhibit a better resistance to pitting, stress corrosion cracking and higher mechanical properties compared to other austenitic stainless steel grades. The microstructure of these materials consists of approximately 50% austenite (γ) and 50% ferrite (α) phases, obtained by means of a solution heat treatment.

Product Number: 51322-17690-SG
Author: Janardhan Rao Saithala, Amjad Kharusi, Mohammed Ghafri, Talal Nabhani Manish Kulkarni, Nasser Behlani,
Publication Date: 2022
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$20.00
$20.00

Duplex stainless steel (DSS) materials are extensively used for various critical applications in the Oil & Gas industry. During the past 30 years, Petroleum Development Oman (PDO) an upstream operator is one of the major end-user of DSS materials. A variety of applications such as wellhead piping, flow lines, headers, pipelines, vessels, coolers, tubing, pump and piping components, etc. are installed with DSS materials. Fabrication, quality assurance and quality control measures of these DSS components are critical elements for achieving long-term plant design integrity with a minimal life cycle cost. The objectives of this paper are to share selected case studies of premature failures (less than two years) experienced with DSS components during operation and to discuss recent quality assurance (QA) & quality control (QC) challenges encountered during procurement, forming/ forging, welding, heat treatment, and inspection & testing of DSS components. Even with thirty years of user experience, the well-known DSS material issues continue to challenge the material, corrosion & quality engineers, as the quality failures recurrence is alarming.

Duplex stainless steel (DSS) materials are extensively used for various critical applications in the Oil & Gas industry. During the past 30 years, Petroleum Development Oman (PDO) an upstream operator is one of the major end-user of DSS materials. A variety of applications such as wellhead piping, flow lines, headers, pipelines, vessels, coolers, tubing, pump and piping components, etc. are installed with DSS materials. Fabrication, quality assurance and quality control measures of these DSS components are critical elements for achieving long-term plant design integrity with a minimal life cycle cost. The objectives of this paper are to share selected case studies of premature failures (less than two years) experienced with DSS components during operation and to discuss recent quality assurance (QA) & quality control (QC) challenges encountered during procurement, forming/ forging, welding, heat treatment, and inspection & testing of DSS components. Even with thirty years of user experience, the well-known DSS material issues continue to challenge the material, corrosion & quality engineers, as the quality failures recurrence is alarming.

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