Stress Corrosion Cracking of Pipelines

274 Pages·2013·4.935 MB·English

by  Y. Frank Cheng(auth.)

Stress Corrosion
Cracking of Pipelines
WILEYSERIESINCORROSION
R.WinstonRevie,SeriesEditor
CorrosionInspectionandMonitoring·PierreR.Roberge
CorrosionResistanceofAluminumandMagnesiumAlloys:Understanding,Performance,
andTesting·EdwardGhali
MicrobiologicallyInfluencedCorrosion·BrendaJ.LittleandJasonS.Lee
CorrosionResistanceofAluminumandMagnesiumAlloys·EdwardGhali
MetallurgyandCorrosionControlinOilandGasProduction·RobertHeidersbach
GreenCorrosionInhibitors:TheoryandPractice·V.S.Sastri
HeterogenousElectodeProcessesandLocalizedCorrosion·YongjunTan
StressCorrosionCrackingofPipelines·Y.FrankCheng
Stress Corrosion
Cracking of Pipelines
Y. Frank Cheng
ProfessorandCanadaResearchChair
inPipelineEngineering
UniversityofCalgary
A JohnWiley&Sons,Inc.,Publication
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LibraryofCongressCataloging-in-PublicationData
Cheng,Y.Frank,1969–
Stresscorrosioncrackingofpipelines/Y.FrankCheng.
pagescm
Includesbibliographicalreferencesandindex.
ISBN978-1-118-02267-2(cloth)
1.Pipelines–Corrosion. 2.Pipelines–Cracking. 3.Steel–Corrosion. I.Title.
TJ930.C5452013
621.8(cid:3)672–dc23
2012035723
PrintedintheUnitedStatesofAmerica
10 9 8 7 6 5 4 3 2 1
Tomywife,Jianshu(Jenny),andmyson,Winston
Contents
Foreword xiii
Preface xv
ListofAbbreviationsandSymbols xix
1 Introduction 1
1.1 Pipelinesas“EnergyHighways” / 2
1.2 PipelineSafetyandIntegrityManagement / 3
1.3 PipelineStressCorrosionCracking / 3
References / 5
2 FundamentalsofStressCorrosionCracking 7
2.1 DefinitionofStressCorrosionCracking / 7
2.2 SpecificMetal–EnvironmentCombinations / 9
2.3 MetallurgicalAspectsofSCC / 11
2.3.1 EffectofStrengthofMaterialsonSCC / 11
2.3.2 EffectofAlloyingCompositiononSCC / 11
2.3.3 EffectofHeatTreatmentonSCC / 11
2.3.4 GrainBoundaryPrecipitation / 12
2.3.5 GrainBoundarySegregation / 12
vii
viii CONTENTS
2.4 ElectrochemistryofSCC / 13
2.4.1 SCCThermodynamics / 13
2.4.2 SCCKinetics / 14
2.5 SCCMechanisms / 15
2.5.1 SCCInitiationMechanisms / 15
2.5.2 Dissolution-BasedSCCPropagation / 16
2.5.3 MechanicalFracture–BasedSCCPropagation / 18
2.6 EffectsofHydrogenonSCCandHydrogenDamage / 20
2.6.1 SourcesofHydrogen / 20
2.6.2 CharacteristicsofHydrogeninMetals / 21
2.6.3 TheHydrogenEffect / 21
2.6.4 MechanismsofHydrogenDamage / 25
2.7 RoleofMicroorganismsinSCC / 27
2.7.1 MicrobiallyInfluencedCorrosion / 27
2.7.2 MicroorganismsInvolvedinMIC / 29
2.7.3 RoleofMICinSCCProcesses / 31
2.8 CorrosionFatigue / 32
2.8.1 FeaturesofFatigueFailure / 33
2.8.2 FeaturesofCorrosionFatigue / 34
2.8.3 FactorsAffectingCFandCFManagement / 35
2.9 ComparisonofSCC,HIC,andCF / 35
References / 37
3 UnderstandingPipelineStressCorrosionCracking 43
3.1 Introduction / 43
3.2 PracticalCaseHistoryofSCCinPipelines / 44
3.2.1 Case1:SCCofEnbridgeGlenavonPipelines
(SCCinanOilPipeline) / 45
3.2.2 Case2:SCCofWilliamsLakePipelines(SCCinaGas
Pipeline) / 46
3.3 GeneralFeaturesofPipelineSCC / 46
3.3.1 High-pHSCCofPipelines / 47
3.3.2 NearlyNeutral–pHSCCofPipelines / 48
3.3.3 CrackingCharacteristics / 48
3.4 ConditionsforPipelineSCC / 50
3.4.1 CorrosiveEnvironments / 50
3.4.2 SusceptibleLinePipeSteels / 53
3.4.3 Stress / 58
CONTENTS ix
3.5 RoleofPressureFluctuationinPipelines:SCCorCorrosion
Fatigue? / 62
References / 68
4 NearlyNeutral–pHStressCorrosionCracking
ofPipelines 73
4.1 Introduction / 73
4.2 PrimaryCharacteristics / 73
4.3 ContributingFactors / 75
4.3.1 Coatings / 75
4.3.2 CathodicProtection / 79
4.3.3 SoilCharacteristics / 81
4.3.4 Microorganisms / 83
4.3.5 Temperature / 85
4.3.6 Stress / 85
4.3.7 SteelMetallurgy / 88
4.4 InitiationofStressCorrosionCracksfromCorrosionPits / 89
4.5 StressCorrosionCrackPropagationMechanism / 96
4.5.1 RoleofHydrogeninEnhancedCorrosion
ofSteels / 96
4.5.2 Potential-DependentNearlyNeutral–pHSCCof
Pipelines / 99
4.5.3 PipelineSteelsinNearlyNeutral–pHSolutions:Always
ActiveDissolution? / 101
4.6 ModelsforPredictionofNearlyNeutral–pHSCCPropagation / 104
References / 111
5 High-pHStressCorrosionCrackingofPipelines 117
5.1 Introduction / 117
5.2 PrimaryCharacteristics / 117
5.3 ContributingFactors / 118
5.3.1 Coatings / 118
5.3.2 CathodicProtection / 119
5.3.3 SoilCharacteristics / 123
5.3.4 Microorganisms / 125
5.3.5 Temperature / 125
5.3.6 Stress / 125
5.3.7 Metallurgies / 128
x CONTENTS
5.4 MechanismsforStressCorrosionCrackInitiation / 128
5.4.1 ElectrochemicalCorrosionMechanismofPipelineSteels
inaThinLayerofCarbonate–BicarbonateElectrolyte
TrappedUnderaDisbondedCoating / 128
5.4.2 ConceptualModelforInitiationofStressCorrosionCracks
inaHigh-pHCarbonate–BicarbonateElectrolyteUndera
DisbondedCoating / 133
5.5 MechanismsforStressCorrosionCrackPropagation / 137
5.5.1 EnhancedAnodicDissolutionataCrackTip / 137
5.5.2 EnhancedPittingCorrosionataCrackTip / 143
5.5.3 RelevancetoGrainBoundaryStructure / 144
5.6 ModelsforthePredictionofaHigh-pHStressCorrosionCrack
GrowthRate / 144
References / 145
6 StressCorrosionCrackingofPipelinesinAcidicSoilEnvironments 149
6.1 Introduction / 149
6.2 PrimaryCharacteristics / 150
6.3 ElectrochemicalCorrosionMechanismofPipelineSteelsinAcidic
SoilSolutions / 151
6.4 MechanismsforInitiationandPropagationofStressCorrosion
Cracks / 151
6.5 EffectofStrainRateontheSCCofPipelinesinAcidicSoils / 154
References / 157
7 StressCorrosionCrackingatPipelineWelds 159
7.1 Introduction / 159
7.2 FundamentalsofWeldingMetallurgy / 160
7.2.1 WeldingProcesses / 160
7.2.2 WeldingSolidificationandMicrostructure / 160
7.2.3 ParametersAffectingtheWeldingProcess / 162
7.2.4 DefectsattheWeld / 162
7.3 PipelineWelding:MetallurgicalAspects / 163
7.3.1 X70SteelWeld / 163
7.3.2 X80SteelWeld / 163
7.3.3 X100SteelWeld / 164
7.4 PipelineWelding:MechanicalAspects / 164
7.4.1 ResidualStress / 164
7.4.2 HardnessoftheWeld / 166
CONTENTS xi
7.5 PipelineWelding:EnvironmentalAspects / 170
7.5.1 IntroductionofHydrogenintoWelds / 170
7.5.2 CorrosionatWelds / 172
7.5.3 ElectrochemistryofLocalizedCorrosionatPipeline
Welds / 173
7.6 SCCatPipelineWelds / 178
7.6.1 EffectsofMaterialPropertiesandMicrostructure / 178
7.6.2 EffectsoftheWeldingProcess / 179
7.6.3 HydrogenSulfideSCCofPipelineWelds / 179
References / 180
8 StressCorrosionCrackingofHigh-StrengthPipelineSteels 185
8.1 Introduction / 185
8.2 DevelopmentofHigh-StrengthSteelPipelineTechnology / 186
8.2.1 EvolutionofPipelineSteels / 186
8.2.2 High-StrengthSteelsinaGlobalPipeline
Application / 187
8.3 MetallurgyofHigh-StrengthPipelineSteels / 189
8.3.1 ThermomechanicalControlledProcessing / 189
8.3.2 AlloyingTreatment / 189
8.3.3 MicrostructureofHigh-StrengthSteels / 190
8.3.4 MetallurgicalDefects / 192
8.4 SusceptibilityofHigh-StrengthSteelstoHydrogenDamage / 193
8.4.1 HydrogenBlisteringandHICofHigh-StrengthPipeline
Steels / 193
8.4.2 HydrogenPermeationBehaviorofHigh-Strength
PipelineSteels / 196
8.5 MetallurgicalMicroelectrochemistry
ofHigh-StrengthPipelineSteels / 199
8.5.1 MicroelectrochemicalActivityatMetallurgical
Defects / 199
8.5.2 PreferentialDissolutionandPittingCorrosion
AroundInclusions / 203
8.6 StrainAgingofHigh-StrengthSteelsandItsImplicationon
PipelineSCC / 207
8.6.1 BasicsofStrainAging / 208
8.6.2 StrainAgingofHigh-StrengthPipelineSteels / 212
8.6.3 EffectofStrainAgingonSCCofHigh-StrengthPipeline
Steels / 214