The Basic Problems of Breakdown of Oil Refining Equipment

The paper describes typical cases of failure of elements of oil refining equipment, including the destruction of welded joints made by austenitic electrodes, furnace coil pipes cracking, hydrogen cracking, metallurgical cases and corrosion. The causes of destruction and depressurization are classified with the identification of the main problems and the relations between them.

Time Dependence of Hydrogen Induced Cracking of X70 Pipeline Steel Under Severe and Mild Sour Service Conditions Using Ultrasonic Analysis

A standard NACE hydrogen induced crack test was used to evaluate the resistance of two compositions of X70 steel (X70-X (Ca/S ratio of 2.5) and X70-B (Ca/S ratio of < 0.5)) under severe (pH = 2.7 and 100% H2S) and mild (pH = 5.5 and 100% H2S) sour service conditions. An ultrasonic technique was developed to quantify the severity of hydrogen cracking in both steels as a function of test conditions, steel type and time. In this procedure, a series of local ultrasonic measurements was taken for each test sample to determine a local crack to backwall signal ratio (LCBR). The LCBR values were integrated over the entire sample to give a global crack to backwall ratio (GCBR). A larger GCBR value corresponds to greater hydrogen cracking severity in the sample. Energy dispersive X-ray (EDX) spectroscopy and glancing angle X-ray diffraction (XRD) were used to characterize the surface corrosion products that formed during testing. For severe sour service conditions, the GCBR value reached an asymptotic value of approximately 33% and 47% for X70-X (after 4 days) and X70-B (after 2 days) steels, respectively. For mild sour service conditions, no cracking was observed for testing of less than 16 days. After 32 days, X70-B showed a GCBR of approximately 18%. The onset of cracking of X70-X steel occurred between 32 and 64 days. Samples tested for 64 days showed a GCBR of 30% and 16% for X70-X and X70-B, respectively. Glancing XRD measurements showed the presence of surface FeS on both steels tested under mild sour service. Quantitative XRD (QXRD) analysis was used to obtain the surface coverage of FeS as a function of test time. EDX mapping confirmed the presence of a high sulfur content over a significant fraction of the surface. XRD measurements of X70-B steel under severe sour service after 8 days did not show a significant amount of FeS. The surface FeS is believed to alter hydrogen ingress into the steel, making it difficult to directly compare measured GCBR values obtained under mild and severe sour service.

Weld Hydrogen Cracking Susceptibility

Weld hydrogen cracking has been recognized as an issue of concern and a wide range of hardenability criteria and single pass weld testing techniques have been developed to demonstrate material weldability, however, hydrogen cracks continue to be identified in welds. The potential for hydrogen cracking is related to the presence of hydrogen, the local tensile strain state and the susceptibility of the material microstructure. The weldment slow bend test and hydrogen effusion and cracking model has been used in Pipeline Research Council International (PRCI) research reported in this paper to support the development of an understanding of the interaction of these factors in promoting hydrogen cracking. The slow bend testing procedure is described with examples of the effects of increasing hydrogen and/or strain conditions are used to illustrate hydrogen cracking susceptibility. The slow bend testing procedure was applied to a range of steel weld metals to develop an understanding of the factors which make one more or less susceptible to hydrogen cracking. Combining the results of slow bend testing, the susceptibility of deposited shielded metal arc weld material to hydrogen cracking is defined using a hydrogen susceptibility curve that establishes the critical strain to form a crack as a function of hydrogen concentration. Cracking susceptibility is described through the definition of material ductility and embrittlement indices, which are derived from the hydrogen susceptibility curves. Cracking susceptibility is then correlated with mechanical, chemical and microstructure properties of the deposited welds. This model to predict weld metal hydrogen cracking susceptibility was developed to support electrode selection and welding procedure development to preclude hydrogen cracking. The results in this paper can be used to reduce the risk of hydrogen cracking and support the development of industry guidance.

Effect of vacuum smelting method on the quality of pipe steel of northern application

Pipe metal of Northern application must meet increased requirements of strength properties, low-temperature ductility, cold resistance and weldability. Cracks, skins, flaws, roll-ins and other defect are not allowed on the surface of pipes. The fulfillment of the requirements substantially can be provided by the process of steel smelting by a vacuum remelting method. Study of the effect of 03ХГ grade pipe steel smelting in vacuum and without vacuum on its contamination by nonmetallic inclusions and resistance against hydrogen cracking was accomplished. The smelting of ingots of adjusted chemical composition was carried out in a vacuum induction furnace ZG-0.06L. To imitate the process of hot roughing rolling, hydraulic press П6334 of 250 t force was used. Finishing rolling was carried out at reversible hot rolling mill 500 duo, combined with a controlled cooling facility. It was determined, that the samples, smelted in vacuum, had insignificant number of nonmetallic inclusions and withstand the test of resistance against hydrogen cracking; cracks were not detected on them. After testing on resistance against hydrogen cracking of the samples smelted without vacuum, cracks were discovered, located on both the surface and central layers amounting to 600 mm and 1700 mm length correspondently. It was shown, that steel smelting in vacuum allows to reach a high degree of the steel purity, results in increased crack growth resistance and in decreased number of nonmetallic inclusions in the pipe steel of Northern application.