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By
Friedrich Karl Naumann, Ferdinand Spies
By
S.M.R. Ziaei, A.H. Kokabi, J. Mostowfi
By
Friedrich Karl Naumann, Ferdinand Spies
By
Friedrich Karl Naumann, Ferdinand Spies
By
Friedrich Karl Naumann, Ferdinand Spies
By
Peter F. Ellis, II
By
Friedrich Karl Naumann, Ferdinand Spies
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Hydrogen sulfide
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Book Chapter
Failure of Coiled Tubing due to Hydrogen Sulfide (H 2 S) Exposure
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.petrol.c0051870
EISBN: 978-1-62708-228-0
... stress and corrosion in the presence of water and hydrogen sulfide was concluded to have initiated the failure which was propagated by fatigue. It was recommended that in the presence of known corrosive environments the tubing should not be used above 50% of its theoretical fatigue life. Coiled...
Abstract
Coiled tubing with 80 ksi yield strength manufactured to a maximum hardness of 22 HRC to meet NACE Standard MR0175 requirement for sour gas service failed after being on 38 jobs (70% of its estimated fatigue life). A transverse crack where a leak occurred was identified as the primary failure point. Numerous OD surface fissures were revealed by a low-power microscope. A brittle zone near the OD, identified as a sulfide stress crack with additional fatigue cracking was revealed by SEM. Sulfide stress cracking defined as brittle failure by cracking under the combined action of tensile stress and corrosion in the presence of water and hydrogen sulfide was concluded to have initiated the failure which was propagated by fatigue. It was recommended that in the presence of known corrosive environments the tubing should not be used above 50% of its theoretical fatigue life.
Book Chapter
Damage to Tool Joints in Hydrogen Sulfide-Carrying Natural Gas Drilling Operation
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.petrol.c9001179
EISBN: 978-1-62708-228-0
... at 530 deg C. The connectors were made of SAE 4140 Cr-Mo steel. The material for the rod pipes was Fe-0.4C-1Mn steel. Structural stresses played a role in the cracking. Iron sulfide formed on the fracture planes and flake-like stress cracks occurred in the steel. The hydrogen sulfide content of the gas...
Abstract
During natural gas drilling in the EMS region in 1956, considerable numbers of longitudinal cracks and transverse fractures occurred in the connecting pieces of the bore rods. The connectors were screwed onto the rods by means of a fine thread and tightly joined with it by shrinkage at 530 deg C. The connectors were made of SAE 4140 Cr-Mo steel. The material for the rod pipes was Fe-0.4C-1Mn steel. Structural stresses played a role in the cracking. Iron sulfide formed on the fracture planes and flake-like stress cracks occurred in the steel. The hydrogen sulfide content of the gas was the cause of damage. Hydrogen liberated by reaction with the iron caused the formation of iron sulfide after penetration of the steel, which had an explosive effect during molecular separation under high pressure. This in turn caused the crack formation in conjunction with the external and residual stresses.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c0048702
EISBN: 978-1-62708-220-4
... the major constituents. Fig. 1 Failed aluminum brass condenser tube from a saltwater heat exchanger. The tube failed from pitting caused by hydrogen sulfide and chlorides in the feedwater. (a) Cross section of tube showing deep pits and excessive metal wastage. 2 3 4 ×. (b) Higher...
Abstract
An aluminum brass seawater surface condenser failed due to pitting after less than one year of service. Large pits filled with a green deposit were evidenced under the nonuniform black scale present over the entire inside surface of the tube. The black deposit was identified as primarily copper sulfide, with zinc and aluminum sulfides while the green deposit was revealed to be copper chloride. The combination of sulfide and chloride attack on the tubes was concluded to have resulted in the failure. Injection of ferrous sulfate upstream of the condenser which could aid the formation of protective oxide films was recommended.
Book Chapter
Failure Analysis: Sulfide Stress Corrosion Cracking and Hydrogen-Induced Cracking of A216-WCC Wellhead Flow Control Valve Body
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001820
EISBN: 978-1-62708-241-9
... of failure and provide preventive measures. The valve body was made of A216-WCC cast carbon steel. Its inner surface was covered with cracks stemming from surface pits. Investigators concluded that the failure was caused by a combination of hydrogen-induced corrosion cracking and sulfide stress-corrosion...
Abstract
A group of control valves that regulate production in a field of sour gas wellheads performed satisfactorily for three years before pits and cracks were detected during an inspection. One of the valves was examined using chemical and microstructural analysis to determine the cause of failure and provide preventive measures. The valve body was made of A216-WCC cast carbon steel. Its inner surface was covered with cracks stemming from surface pits. Investigators concluded that the failure was caused by a combination of hydrogen-induced corrosion cracking and sulfide stress-corrosion cracking. Based on test data and cost, A217-WC9 cast Cr–Mo steel would be a better alloy for the application.
Book Chapter
Corrosion Failure of a Tee Fitting
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.petrol.c0048698
EISBN: 978-1-62708-228-0
.... The tee joint in the piping between the heat exchanger and the sieve bed failed after 12 months. A hole in the tee fitting and a corrosion product on the inner surface of the pitting was revealed by visual examination. Iron sulfide was revealed by chemical analysis of the scale which indicated hydrogen...
Abstract
Wet natural gas was dried by being passed through a carbon steel vessel that contained a molecular-sieve drying agent. The drying agent became saturated after several hours in service and was regenerated by a gas that was heated to 290 to 345 deg C in a salt-bath heat exchanger. The tee joint in the piping between the heat exchanger and the sieve bed failed after 12 months. A hole in the tee fitting and a corrosion product on the inner surface of the pitting was revealed by visual examination. Iron sulfide was revealed by chemical analysis of the scale which indicated hydrogen sulfide attack on the carbon steel. The presence of oxygen was indicated by the carbon and sulfur found in the scale on the piping and in the sieves indicated that oxygen combined with moisture produced conditions for attack of hydrogen sulfide on carbon steel. Turbulence with some effect from the coarse grain size was interpreted to have contributed. The piping material was changed from carbon steel to AISI type 316 stainless steel as it is readily weldable and resistant to corrosion by hydrogen sulfide.
Book Chapter
Corroded Pipes from Gas Generating Plant
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.petrol.c9001166
EISBN: 978-1-62708-228-0
... product from each pipe section were analyzed for carbon, sulfur, and iron and were found to consist mainly of iron sulfide mixed with soot and rust. The damage resulted from a high content of hydrogen sulfide in the gas (6% CO2, 20% CO, 8 to 12% H2, 0.5 to 1.5% CH4, remainder N2). To process the coal...
Abstract
After four months at a temperature of 400 to 5000 C, pipes at a gas generating plant were so heavily eroded they had to be replaced. Three sections of pipe, from different locations, were analyzed to determine whether mechanical wear or corrosion caused the damage. Samples of corrosion product from each pipe section were analyzed for carbon, sulfur, and iron and were found to consist mainly of iron sulfide mixed with soot and rust. The damage resulted from a high content of hydrogen sulfide in the gas (6% CO2, 20% CO, 8 to 12% H2, 0.5 to 1.5% CH4, remainder N2). To process the coal in question, the pipes material should be a heat-resistant steel that contains more chromium and has greater resistance to hydrogen sulfide.
Book Chapter
Localized Corrosion of Inclusions in a Type 303 Stainless Steel Vending-Machine Valve
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c0091358
EISBN: 978-1-62708-233-4
... used in the valve. Manganese sulfide stringers in the valve were exposed at end-grain surfaces in contact with the beverage. The stringers, which were anodic to the surrounding metal, were subject to corrosion, producing a hydrogen sulfide concentration in the immediately adjacent liquid...
Abstract
After about two years in service, a 303 stainless steel valve in contact with a carbonated soft drink in a vending machine occasionally dispensed a discolored drink with a sulfide odor. According to the laboratory at the bottling plant, the soft drink in question was strongly acidic, containing citric and phosphoric acids and having a pH of 2.4 to 2.5. Investigation (visual inspection, chemical analysis, immersion testing in the soft drink, and 100x unetched micrographs) supported the conclusion that the failure was caused by the size and distribution of sulfide stringers in the alloy used in the valve. Manganese sulfide stringers in the valve were exposed at end-grain surfaces in contact with the beverage. The stringers, which were anodic to the surrounding metal, were subject to corrosion, producing a hydrogen sulfide concentration in the immediately adjacent liquid. Recommendations included changing the valve material to type 304 stainless steel.
Book Chapter
Corroded Pump Impeller
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001165
EISBN: 978-1-62708-234-1
... in the scrubbing water was actually sulfide (including hydrogen sulfide) and was the main cause of corrosion. Graphitic corrosion Pump impellers Sulfides Gray iron Dealloying/selective leaching A Cast iron pump impeller showed strong corrosion after an operating period of only one-half year. As can...
Abstract
After operating for six months, a pump impeller (of nickel-containing cast iron) showed considerable corrosion. Cross sections showed substantial penetration of the wall thickness without loss of material. The observed supercooled structure implied low strength but would not affect corrosion resistance. Etching of the core structure showed a selective form of cast iron corrosion (spongiosis or graphitic corrosion) which lowered the strength of the cast iron enough that a knife could scrape off a black powder (10.85% C, 1.8% S, 1.45% P). Analysis showed that some of the “sulfate” found in the scrubbing water was actually sulfide (including hydrogen sulfide) and was the main cause of corrosion.
Book Chapter
Leaking Coil Made of Stainless Steel
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.chem.c9001169
EISBN: 978-1-62708-220-4
... corrosion agents, especially chlorides. If chlorides were absent, hydrogen sulfide which causes similar pitting and is capable of causing cracks could be suspected. Favorable state of stresses, which could be residual or due to heat treating, bending or straightening operations, would be recommended...
Abstract
Austenitic stainless steel (X 10 Cr-Ni-Mo-Ti 18 10, Material No. 1.4571) cooling coils were found leaking in 15 spots after eight weeks of service in an apparatus in which ammonium sulfide solution was converted into ammonium sulfate. The external temperature of the coil was approximately 175 deg C and it was cooled by water at 3 atm. Examination of two sections of the coil showed pinhead size pitting cavities at the exterior surface and partially parallel and partially angled array of fine cracks on external as well as the internal surfaces of the bend. Metallographic examination conducted on longitudinal and transverse sections showed predominantly transcrystalline cracks, originated from the pits at the external surfaces of the pipe. Their appearance suggested they were stress corrosion cracks that occur in austenitic steels under the combined effect of stresses and certain corrosion agents, especially chlorides. If chlorides were absent, hydrogen sulfide which causes similar pitting and is capable of causing cracks could be suspected. Favorable state of stresses, which could be residual or due to heat treating, bending or straightening operations, would be recommended for better behavior of the container.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c0048819
EISBN: 978-1-62708-233-4
... Abstract A large pressure vessel that had been in service as a hydrogen sulfide (H2S) absorber developed cracks and began leaking at a nozzle. The vessel contained a 20% aqueous solution of potassium hydroxide (KOH), potassium carbonate (K2CO3), and arsenic. The vessel wall was manufactured...
Abstract
A large pressure vessel that had been in service as a hydrogen sulfide (H2S) absorber developed cracks and began leaking at a nozzle. The vessel contained a 20% aqueous solution of potassium hydroxide (KOH), potassium carbonate (K2CO3), and arsenic. The vessel wall was manufactured of ASTM A516, grade 70, low-carbon steel plate. A steel angle had been formed into a ring was continuously welded to the inside wall of the vessel. The groove formed by the junction of the lower tray-support weld and the top part of the weld around the nozzle was found to have a crack. Pits and scale near the crack origin were revealed by microscopic examination and cracking was found to be transgranular. Periods of corrosion alternated with sudden instances of cleavage, under a tensile load, along preferred slip planes were interpreted during examination with a microscope. It was concluded that the combination of the residual plus operating stresses and the amount of KOH present would have caused stress corrosion as a result of caustic embrittlement. It was recommended that the tray support should be installed higher on the vessel wall to prevent coincidence of the lower tray-support weld with the nozzle weld.
Book Chapter
Corrosion Failure of a Chemical Process Piping Cross-Tee Assembly
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001325
EISBN: 978-1-62708-215-0
... Abstract A carbon steel piping cross-tee assembly which conveyed hydrogen sulfide (H7S) process gas at 150 to 275 deg C (300 to 585 deg F) with a maximum allowable operating pressure of 3 MPa (450 psig) ruptured at the toe of one of the welds at the cross after several years of service...
Abstract
A carbon steel piping cross-tee assembly which conveyed hydrogen sulfide (H7S) process gas at 150 to 275 deg C (300 to 585 deg F) with a maximum allowable operating pressure of 3 MPa (450 psig) ruptured at the toe of one of the welds at the cross after several years of service. The failure was initially thought to be the result of thermal fatigue, and the internal surfaces exhibited the “elephant hide” pattern characteristic of thermal fatigue. However metallographic failure analysis found that this pattern was the result of corrosion rather than thermal fatigue. Corrosion caused failure at this location because the weld was abnormally thin as fabricated. Thus, failure resulted from inadequate deposition of weld metal and subsequent wall thinning from internal corrosion. It was recommended that the cross-tee be replaced with a like component, with more careful attention to weld quality.
Book Chapter
Examination of a Blistered and Cracked Natural Gas Line
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.petrol.c9001235
EISBN: 978-1-62708-228-0
... may drop. This measure was ultimately recommended, deemed more effective and cheaper. Blistering Cracking (fracturing) Hydrogen sulfide Natural gas Pipelines Fe-0.22C Hydrogen damage and embrittlement A welded natural gas line of 400 mm O.D. and 9 mm wall thickness made of unalloyed...
Abstract
A welded natural gas line of 400 mm OD and 9 mm wall thickness made of unalloyed steel with 0.22C had to be removed from service after four months because of a pipe burst. Metallographic examination showed the pipe section located next to the gas entrance was permeated by cracks or blisters almost over its entire perimeter in agreement with the ultrasonic test results. Only the weld seam and a strip on each side of it were crack-free. Based on this investigation, the pipeline was taken out of service and reconstructed. To avoid such failures in the future, two preventative measures may be considered. One is to desulfurize the gas. Based on tests, however, the desulfurization would have to be carried very far to be successful. The second possibility is to dry the gas to such an extent as to prevent condensate, and this corrosion, from forming no matter how low winter temperatures may drop. This measure was ultimately recommended, deemed more effective and cheaper.
Image
Stepwise cracking of a low-strength pipeline steel exposed to hydrogen sulf...
Available to PurchasePublished: 01 January 2002
Fig. 8 Stepwise cracking of a low-strength pipeline steel exposed to hydrogen sulfide (H 2 S). 6×
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Image
Stepwise cracking of a low-strength pipeline steel exposed to hydrogen sulf...
Available to PurchasePublished: 15 January 2021
Fig. 8 Stepwise cracking of a low-strength pipeline steel exposed to hydrogen sulfide (H 2 S). Original magnification: 6×
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Image
Low-carbon steel tee fitting in a line leading to a natural-gas dryer that ...
Available to Purchase
in Failure Analysis of Heat Exchangers
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Fig. 3 Low-carbon steel tee fitting in a line leading to a natural-gas dryer that failed from hydrogen sulfide corrosion. (a) Arrangement of piping showing point of leakage in the tee fitting. (b) Inner surface of the tee fitting showing corrosion deposit and area of complete penetration
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Image
Low-carbon steel tee fitting in a line leading to a natural-gas dryer that ...
Available to PurchasePublished: 01 January 2002
Fig. 3 Low-carbon steel tee fitting in a line leading to a natural-gas dryer that failed from hydrogen sulfide corrosion. (a) Arrangement of piping showing point of leakage in the tee fitting. (b) Inner surface of the tee fitting showing corrosion deposit and area of complete penetration
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Low-carbon steel tee fitting in a line leading to a natural-gas dryer that ...
Available to Purchase
in Corrosion Failure of a Tee Fitting
> ASM Failure Analysis Case Histories: Oil and Gas Production Equipment
Published: 01 June 2019
Fig. 1 Low-carbon steel tee fitting in a line leading to a natural-gas dryer that failed from hydrogen sulfide corrosion. (a) Arrangement of piping showing point of leakage in the tee fitting. (b) Inner surface of the tee fitting showing corrosion deposit and area of complete penetration
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Image
Failed aluminum brass condenser tube from a saltwater heat exchanger. The t...
Available to PurchasePublished: 01 January 2002
Fig. 4 Failed aluminum brass condenser tube from a saltwater heat exchanger. The tube failed from pitting caused by hydrogen sulfide and chlorides in the feedwater. (a) Cross section of tube showing deep pits and excessive metal wastage. 2 3 4 ×. (b) Higher magnification view of a pit
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Image
Failed aluminum brass condenser tube from a saltwater heat exchanger. The t...
Available to Purchase
in Pitting of a Condenser Tube in a Saltwater Heat Exchanger Due to Hydrogen Sulfide Contamination
> ASM Failure Analysis Case Histories: Chemical Processing Equipment
Published: 01 June 2019
Fig. 1 Failed aluminum brass condenser tube from a saltwater heat exchanger. The tube failed from pitting caused by hydrogen sulfide and chlorides in the feedwater. (a) Cross section of tube showing deep pits and excessive metal wastage. 2 3 4 ×. (b) Higher magnification view of a pit
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Image
Failed aluminum brass condenser tube from a saltwater heat exchanger. The t...
Available to Purchase
in Failure Analysis of Heat Exchangers
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Fig. 4 Failed aluminum brass condenser tube from a saltwater heat exchanger. The tube failed from pitting caused by hydrogen sulfide and chlorides in the feedwater. (a) Cross section of tube showing deep pits and excessive metal wastage. Original magnification: 2.75×. (b) Higher-magnification
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