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This paper summarizes the results of a research project on environmental effects on the environmentally assisted fatigue lifetime of laboratory specimens made of austenitic stainless steel type 316L and corresponding welds. In particular, investigations on the effect of hold-times, applied during testing in high-temperature water and tests on the fatigue welds were performed.
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Accelerated testing of corrosion-resistant coatings is a critical tool used in the development of protective coatings. Tests such as ASTM B117, ISO 12944, ISO 9227, etc. are commonly used to predict the long-term viability of these coatings in exposure times of months rather than years or even decades. While this type of testing gives meaningful results and is essential to the research and development of new technology, results can often be hard to accurately analyze due to the levels of variability inherent to accelerated testing.
Saudi Aramco coating standards have been holding a great status of prestige, not only in the Arabian Gulf area, but all around the world. Due to the size and significance of Saudi Aramco as one of the largest oil-and-gas producers in the world, the coating applications for its facilities had to follow suit. Yet, the coating standards were also interconnected with the coating industry, its limitations and old practices.
Steel pipelines are sometimes subjected to demanding sour environments resulting from the presence of high H2S contents. Pipeline materials, therefore, must be resilient against sulfide stress cracking (SSC) which is caused by H2S. Beginning in the 1980s, thermo-mechanically controlled processed (TMCP) steels have been widely used for the manufacturing of large-diameter sour service pipelines. The failure of the Kashagan pipelines in 2013 raised concern regarding the use of TMCP steels in sour environments. These concerns arise from the potential for local hard zones (LHZs) to be produced on the surface of the line pipe during TMCP processes, ultimately leading to through-wall SSC failures. In the present study, several X60 - X65 TMCP steels (both with and without LHZs) have been tested under different Region 3 (R3) conditions in the NACE MR0175/ISO15156-2 pH-H2S partial pressure diagram. It can be concluded that the presence of LHZs increases TMCP steels’ sour cracking susceptibility; however, TMCP steels without LHZs pass the SSC tests at even the most severe R3 environments. Traditional HRC or HV10 testing are not able to detect LHZs, and so lower load HV 0.5 or HV 0.1 tests are necessary. For TMCP steels, the current R3 may be further divided into R3-a and R3-b sub-regions. The sour cracking severity of R3-a is less than that of R3-b. Additional actions, like enhanced mill qualification of the TMCP plate, should be considered to ensure that no LHZs exist in steels to be utilized in R3-b environments.
Stainless steel UNS S17400 (17-4PH) has been successfully used in oilfield services outside the traditional NACE MR0175/ISO 15156 limits for permanent equipment. The exact operational envelops of 17-4PH (HH1150), including the tensile threshold stress, sour gas partial pressure, temperature, and exposure time that enable the crack-free usage of 17-4PH (HH1150) are not well established. For service equipment, NACE MR0175/ISO15156 currently provides exemptions from the tight environmental restrictions of permanent equipment, but instead limits the maximum applied stress to a debatable 60% of the specified minimum yield strength (SMYS). In this investigation, the sulfide stress-corrosion cracking of 17-4PH is revisited through 51 new NACE TM0177 Methods A tests conducted over 240 hours minimum (480hrs in certain cases). Under unrestricted sour gas partial pressures, the threshold tensile stress below which cracking does not occur is between 45% and 60% of the SMYS at ambient temperature. Alloy 17-4PH is also less susceptible to sulfide stress cracking as temperature increases from 70°F (21°C) to 350°F (177°C). Risk of sulfide stress cracking is also greatly mitigated when delta ferrite is controlled. With reduced delta ferrite, as provided by two out of three tested heats, and reverted austenite promoted by both chemical composition and longer aging treatments, no cracking is seen at 60% stress level up to 45psi H2S (0.31MPa); at 45% stress level, this value is increased to 120psi (0.83MPa) based on newly-collected test data.
Pre-salt carbonate reservoirs in the Santos Basin are a challenge for offshore well design andconstruction. Located under a salt layer of around 2000 m, they generate large amounts of carbon dioxide associated with oil and gas production. To avoid releasing millions of cubic meters of CO2 into the atmosphere, the gas is reinjected or used for artificial lift purposes, where its fraction can reach up to 80% of the total composition.
Composite repair systems’ performance relies heavily on the levels of adhesion between the initial layer of the composite system and the substrate. Enhanced adhesion translates to improved performance of the composite system since better bonding (whether mechanical or chemical) enhances the load transfer from the substrate to the composite layers as well as limit the porosity that would allow liquid or gas molecules to flow through. The aim of this study was to prove quantitatively how the APS atmospheric plasma surface preparation can improve the performance of composite repair systems whether on leaking or nonleaking defects.
Organic coatings protect the underlying metallic substrate against corrosion by acting as a barrier to corrosive species such as water, ions, and oxygen. Unfortunately, coatings might contain defects and could degrade or disbond under some environmental conditions, resulting in favorable pathways for such corrosive species.
Barrier protection is one of the modes by which intact coatings provide protection to metal substrates through a reduction of the transport of materials, ions, or charge.