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The paper reviews the history of Hydrogen Induced Stress Cracking (HISC) failures of duplex and super duplex stainless steels when deployed subsea and subject to CP at potentials around minus 1V.
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Based on alloy development and manufacturer independent supply experience of super duplex steel over a 30 year period the paper considers some of the less well known but recurring problems and the methods used to ameliorate them.
A comprehensive test program is described quantifying the HISC performance of retrieved superduplex stainless steel subsea components and, comparing the actual performance against the limits derived following DNV RP F112: 2008.
Materials properties that are used in specific oil and gas environments are de-rated due to the risks associated with hydrogen embrittlement cracking. In oil production environments the concern is for the onset of stress corrosion cracking (SCC), while in seawater environments the concern is for Hydrogen Induced Stress Cracking (HISC). Both are hydrogen embrittlement phenomena with the distinction being the source of hydrogen for each. In SSC the source of hydrogen is from the presence of H2S in the oil production fluids, and in HISC the source of hydrogen is from the dissociation of water from the cathodic protection system. This paper is focused on the latter phenomena and aims to characterize the susceptibility of carbon alloy steels as applied in fastener applications, in a seawater environment under cathodic protection.
As a companion document to MR21525, this Technical Report provides results, review and commentary on many investigations of HSC and includes important literature data, references, background information, service experience and related standards that were utilized in the development of the AMPP MR21525. Most of the information in this Technical Report covers findings from HSC field experience and HSC data from brine/CP exposure tests or from other cathodic charging experiments. It is important to note, in the use of MR21525 and in the review of data contained herein, that HSC can also be induced from hydrogenating environments and conditions other than from just from CP exposure alone. A non-exhaustive list of such conditions is presented later in this Technical Report.
Precipitation hardened (PH) nickel-base alloys are frequently used as engineering materials in the Oil & Gas industry. They excel because of their outstanding combination of strength, toughness, and corrosion resistance. In that regard, alloy N07725 is of high interest as it offers better corrosion resistance than the widely used N07718, while also offering better high temperature strength than solid-solution nickel-base alloys.
This paper addresses the relationship between hardness and environmental cracking resistance in nickel base alloys. The work here builds on the presentation made to AMPP’s SC08 Fall 2021 meeting on October 19th.
To evaluate through fracture toughness tests the susceptibility of SDSS to HISC and to determine the effect of the cathodic protection potential and the stress intensity factor rate (K-rate).
Several offshore field failures in recent years have been attributed to Hydrogen Induced Stress Cracking (HISC) of high strength, highly corrosion resistant Precipitation Hardened Nickel Alloys (PHNA’s) such as UNS N07716, UNS N07718 and UNS N07725.
Hence, HISC is a constant concern regarding subsea components subjected to high tensile stress, and the industry is searching for solutions to their technical needs: High strength corrosion resistant alloys (CRA’s) resistant to seawater (high Pitting Resistance Equivalent number (PREN)) but also resistant to HISC.
For PHNA’s, improved processing (chemical composition limits and processing temperatures) and improved quality control methods as well as refined acceptance criteria are all under consideration.
As long ago as 1973, design codes1 considered the possibility of hydrogen embrittlement due to CP. Between 1986 and 19952-4 the failure of DSS fasteners subjected to CP were reported. These were associated with high ferrite levels in the steel (approximately 70%) combined with precipitation hardening at 475°C to give the high levels of strength desired for fastener applications. At the same time, the susceptibility of DSS welds to hydrogen embrittlement had been reported5. Just like the fastener failures, the hydrogen cracking of welds was associated with high ferrite levels (70%), highly restrained joints and in the case of welds, high levels of diffusible hydrogen.