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Low-alloy steel of API(1) 5L grade X65 is commonly used as line pipe material for sour service applications, where, due to stringent operation limits, resistivity to Hydrogen Induced Cracking (HIC), Sulfide Stress Cracking (SSC) and Stress-Oriented Hydrogen Induced Cracking (SOHIC) is required and tested before and after plate into pipe forming. Within recent years more challenging requirements have been introduced, including more severe corrosion test conditions, increased mechanical properties and extended limitations regarding hardness, to enable application to increasingly severe sour service conditions. For steel plants and plate manufacturers this entails the necessity to further improve the quality of their products together with separate improvements and modifications on the production plants and processes that have been implemented anyway.
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Applicability of High Strength Line Pipe solution has been evaluated by conducting 30-day Hydrogen Induced Cracking (HIC) tests. Reproducibility of corrosion loss and HIC damage was investigated in comparison with those of the conventional solution, specified by NACE TM0284-2016, Solution C.
New axially loaded full ring test method which was developed and demonstrated to combine the benefits of retaining a full as-welded pipe pup-piece, permitting single-sided exposure, with the advantage of tensile loading of the complete tubular specimen.
With increasing oil & gas demand and depletion of sweet reserves, oil & gas companies in the regionaleconomies are focusing towards the exploitation of sour resources. This necessitates the use of pipelinesand down-hole tubing made from special steels with significant resistance to hydrogen-induced cracking(HIC). These steels are produced through specific technologies for enhanced chemical composition controland microstructural engineering to incorporate the required strength, weld ability and improved HICresistance. It is well established that the HIC initiates at sites with microstructural heterogeneities whetherdue to presence of gross nonmetallic inclusions or the micro-structural constituents. The presence of centralsegregation further aggravates the conditions particularly when the final pipe sizes require the longitudinalslitting of the coils. Presence of non-metallic inclusions in the steel makes it vulnerable to hydrogen-inducedcracking under wet H2S environment. The mechanism of HIC begins with the generation of hydrogen atomsby corrosion reaction of H2S and Fe in the presence of free water. The hydrogen atoms then diffuse intosteel and accumulate around the inclusions. The higher number of inclusions equates to the more sitesavailable for hydrogen adsorption. Recombination of hydrogen atoms to H2 molecules builds up a heavygas pressure in the interface between matrix and inclusions. Cracking initiates because of the tensile stressfield caused by hydrogen gas pressure and crack propagates in the surrounding steel matrix. Thelongitudinal slitting exposes the internal microstructural abnormalities to the skelp edges which are thenincorporated in the thermally stressed weld zone. While the post-weld heat treatment (PWHT) mostlyhomogenizes the weld zone microstructure, the presence of excessive central line features cannot becompletely removed thereby making this zone more prone to HIC attack
As environmental sulfur limits become more stringent, there has been a recent surge in preferential and localized corrosion in amine units. This has occurred even with HIC (Hydrogen Induced Cracking) resistant steels and in equipment where velocity limits are not exceeded.Amine absorbers and associated rich amine piping particularly around the welds, downcomers and other turbulent locations are particularly vulnerable.
South Ghawar Producing Department has exerted substantial efforts towards executing a seldom project of replacing numbers of extraordinary vessels. Those horizontal vessels were recommended for replacement due to major and excessive Step Wise Cracking, irregular blister and inclusions identified in several traps. These vessels are subject to Hydrogen Induced Cracking, known as HIC and this is mainly SGPD facilities were constructed on old time where SAES was not mandating to utilize HIC resistance material. In 2014, a company wide survey started and as a result 27 out of 121 were identified with HIC damage. To overcome these challenges, SGPD developed a robust action plan, which consists of two parts:● Long Term Plan which is replacing the impacted vessels with upgraded material “HIC resistance material”● Short Term Plan to continue the safe and reliable operation of impacted vessels until the vessels are replaced by managing and monitoring HIC growth.With the short and long term action plan, SGPD controlled HIC concern in affected vessels. But we didn’t want to stop here and we wanted to go the extra mile and add a proactive measure rather than only reactive. Therefore, we partnered with R&DC to implement a proactive initiative at SGPD as the first department in Saudi Aramco called Step-Wise Hydrogen Induced Cracking Toolkit which falls under IR.4.0.