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The Case Studies of Stress Corrosion Cracking in Oil Industry(石油工业中应力腐蚀研究)

The Case Studies of Stress Corrosion Cracking in Oil Industry(石油工业中应力腐蚀研究)

  • 作者
  • 李晓刚 等 著

本书透过大量石油工业中的典型失效案例,通过实验室条件下的模拟和加速试验,对典型石油工业腐蚀体系下的应力腐蚀案例的开裂过程与机理进行深入剖析,最终找到能够很好重现实际应力腐蚀过程的实验室加速试验条件与载荷谱,以期对石油工业腐蚀体系下应力腐蚀寿命的准确评估和安全评定提供有力的佐证,进而为国内外石油生产的安全运行、节约能源等提供重要的理论与技术支撑。


  • ¥298.00

ISBN: 978-7-122-35797-7

版次: 1

出版时间: 2020-09-01

图书介绍

ISBN:978-7-122-35797-7

语种:英文

开本:16

出版时间:2020-09-01

装帧:精

页数:335

编辑推荐

本书内容均为作者团队原创,全部来源于作者的研发成果:全书结合石油工业中典型应力腐蚀失效案例,深度剖析其开裂过程与机理,并实现科学模拟与重现,为石油工业腐蚀体系下应力腐蚀寿命的准确评估和安全评定提供有力佐证。

图书前言

Stress Corrosion Cracking (SCC) is the brittle cracking of metal under the combined influence of stress and a corrosive medium in specific environments.Throughout the history of modern industrial development, there have been a plethora of cases involving sudden and catastrophic accidents caused by stress corrosion. In the 1800s, the alkali brittle cracking of British boilers first incited research into the mechanics and forms of stress corrosion. In 1925, Moore performed the first systematic analysis of stress corrosion in the laboratory, discovering that the seasonal cracking of brass was caused primarily by intergranular stress corrosion in the presence of ammonia. Brown later introduced fracture mechanics theory to the field of material corrosion, laying the foundation for mechanical studies of stress corrosion in the 1960s. In 1967, Parkins, the main founder of stress corrosion research and theory, then combined these mechanics with electrochemical measurement methods to establish the core methods for study of the mechanisms of stress corrosion. This allowed for numerous studies to be conducted on the forms and systems of environment-sensitive cracking under the influence of various states of stress and in various media, contributing greatly to modern stress corrosion theory.
During this period, the incidence of stress corrosion faults had been expanding both in volume and scope; affected industries included petroleum mining, chemical and marine engineering, and nuclear energy. As such, stress corrosion research developed radically, gradually adopting one of the most distinguished research areas within the field of material corrosion and protection. More recently, scientific understanding of mechanical-chemical behavior and the mechanisms of SCC at the micro and nano-scales has seen some development. It has also been recognized that stress corrosion also occurs in non-metallic materials; environmental cracking in polymer materials has the same characteristics and rules as stress corrosion in metals.
SCC is best characterized as the cracking of metal placed under tensile stress for a period of time, within a specific corrosive medium. From the perspective of fracture mechanics, it takes a certain amount of time for the crack to initiate, expand, and finally reach critical stress, resulting in an unstable fracture. The minimum stress causing SCC is far less than the strength, σb, of the material, and there may be no apparent macro-plastic deformation before fracture. 
Stress corrosion mechanisms can be divided into two types: hydrogen-induced cracking and anodic dissolution. In hydrogen-induced cracking, the cathodic process is a hydrogen evolution reaction, in which hydrogen entering the metal causes cracking. An example is the SCC of ultra-high strength steel in water. In anodic dissolution, the cathodic process is an oxygen uptake reaction and not related to hydrogen. Stress corrosion is from anodic dissolution. Examples include brass in ammonia solution or titanium in methanol solution. It should be noted that in the process of anodic dissolution a hydrogen evolution reaction still takes place at the cathode, but it remains less than the critical value required for hydrogen-induced cracking. This form of SCC should still be considered as anodic dissolution. An example of this is seen when austenitic stainless steel is stress corroded in hot salt solution. The amount of hydrogen entering the metal is too low to cause hydrogen-induced cracking, so it instead promotes SCC via anodic dissolution.
It has been proposed that the mechanisms of anodic-dissolution-based SCC can be further subdivided into the following theories and models: (1) the slip dissolution mechanism or membrane rupture theory (2) the preferred dissolution mechanism, including the intergranular preferential dissolution model and tunnel corrosion model (3) the medium-induced cleavage mechanism, and (4) the theory of corrosion-induced plastic deformation leading to SCC cracking. 
There is not yet any consensus on the mechanisms of hydrogen-induced cracking. The common point of various theories is that hydrogen atoms are accumulated in high stress regions by stress-induced diffusion, and the material is broken when the hydrogen concentration reaches a critical value. Theories and models on hydrogen enrichment include: (1) hydrogen pressure theory (2) adsorption hydrogen reducing surface energy theory (3) weak bond theory, and (4) hydrogen promoting local plastic deformation theory.
For more than two decades, little progress has been made in the study of stress corrosion mechanisms. This is attributable to the lack of observation and research on mechanical-chemical behavior at crack tips on the micro and nano scales. However, with the more recent development of micro-area electrochemical testing technology, understanding of stress corrosion is projected to advance again. Micro-area electrochemical testing can be used to compare the electrochemical reactivity of the sample surface under the presence or absence of stress, and the local electrochemical reaction characteristics at different positions of the crack tip can also be obtained. These micro-area measurement techniques include scanning vibration reference electrode technology (SVET), local electrochemical impedance spectroscopy (LEIS), scanning Kelvin probe technology (SKP), and capillary microelectrode technology. Such techniques allow for unprecedented insight into the processes of stress corrosion initiation and development at the atomic level.This correlates to an improved understanding of local corrosion processes in the aqueous solution at the crack tip, including the behaviors of ions, passivation film, sediments and corrosion products. Combined with finite element analysis and other numerical simulation methods, we are better equipped than ever to analyze the effects of mechanical and electromechanical factors on the mechanisms of the SCC process.
Increasingly advanced morphological observation methods have also been used in crack tip behavior analysis, such as focused ion-beam tomography (FIB) and X-ray tomography. Through advanced, three-dimensional in situ structural analysis, information regarding the initiation of and changes to the crack tip structure can be further obtained, providing further insight to the evolution process and mechanisms of SCC. With recent technological advancements, even spatial radiotracer methods combined with electrochemical methods are possible.
Research on SCC in China remains in sync with international progress. The primary body of research in China focuses on the influence of environmental factors, loading conditions, and heat treatment methods on the SCC process. Focus can remain on problems with practical application, such as those seen with pipeline steel, nickel-based alloys in nuclear plants, and the SCC of steel for pressure vessels. Various advanced research and analysis methods are being gradually applied in said research. However, there remains a lack of distinctive research direction and few distinguished fields of study, which, to some extent, limits the originality and innovation of results in the study of SCC and crack tip behavior in China.
Due to the complexity of the stress corrosion process, it is difficult to establish a unified stress corrosion model and associated mechanisms explaining the SCC phenomenon. Theoretical research is limited in application. Therefore, greater attention should be devoted to solving issues as they materialize in practice. Through the study of specific stress corrosion failure cases under actual service conditions, simulations, and acceleration tests conducted in laboratory settings, the SCC process of a certain system can be studied in depth, and a suitable stress corrosion model established to effectively analyze and explain it. By finding the laboratory accelerated test conditions that can reproduce the actual stress corrosion process, an accurate assessment of stress corrosion life and targeted protection measures can be achieved. This has been the foremost strategy for stress corrosion research in recent years.
The petroleum industry has so far used industrial systems with the largest variety of metal materials, the most complex corrosive media, and a large variety of complex loads, resulting in a large number of stress corrosion accidents. Petroleum is a flammable, liquid, organic mineral that is found in the porous media of underground rock and consists of various hydrocarbons and their derivatives. Natural gas is a flammable gas that also exists in porous underground rock and is similarly composed of hydrocarbons and their derivatives. The oil industry centers on exploration, drilling, development, oil recovery, gathering, refining and storage. Industrial processes are divided into two major sections: oil exploration and mining (upstream) and petrochemical refinement (downstream). Every aspect of the oil industry is closely linked to metallic materials, especially various steels, exposed to extremely harsh environments and various loads of stress.
Petroleum exploration and production mainly includes the engineering of drilling, oil production, extraction and transportation. Corrosive media during drilling primarily include the atmosphere, drilling fluids, and subterranean products found in the process of drilling. Corrosive media during oil production include: water in oil and gas, H2S, CO2, various inorganic salts, organic acids, etc. and; soil moisture, O2, CO2, various inorganic salts, various organic acids, and microorganisms (sulfate-reducing bacteria). The corrosive environments of oil and gas transport pipelines can be divided into the inner environment and the outer environment of the pipeline, separated by the pipe wall. The main corrosive media are the same as those experienced during oil production.
Petroleum refining equipment can be divided by function into the following categories: distillation, catalysis, hydrogenation, coking and auxiliary equipment.Since the materials comprising such equipment are subjected to corrosive, hightemperature, high-pressure environments, there are a large number of factors potentially driving stress corrosion. Typical stress corrosion environments include: (1) high concentrations of HCI, H2S and H2O found in light oil regions; (2) sulfur-rich environments created by the various sulfides contained in crude oil, which can decompose to highly corrosive active sulfur at various fraction points, and; (3) hydrogen embrittlement or high temperature, high pressure hydrogen environments. In addition, the high temperature H2S+H2 environment, RN2?CO2? H2S+H2 environment, NxO+H2O environment, H2S+NH3+H2+H2O environment and the composite environment composed of the above systems are common stress corrosion systems.
An extension of petroleum refinement is the deep processing of petroleum, which involves the conversion of oil into various chemical products. The types of metal materials used, corrosive media and various loads are exceptionally complicated in this process, with the highest variation of corrosion environments found across all operations in the petroleum industry. Almost all stress corrosion systems are involved. Examples of these systems include: the presence of sulfide, CO2, H2S and organic acid in the dilution steam generation system of the ethylene cracking unit; the high temperature hydrochloric acid corrosion environment in styrene, phenol/acetone and m-cresol equipment; high temperature sulfuric acid, hydrogen fluoride and hydrofluoric acid in isobutylene units, nitrile and styrene-butadiene rubber units, and viscose production units; and the corrosive hydroxide environment created by organic acids in petroleum chemical fiber equipment, such as acetic acid, maleic acid, adipic acid, terephthalic acid and hydroxide organic acids.
This book seeks to elaborate upon simulations and accelerated tests under laboratory conditions on the basis of typical petroleum industry stress corrosion case analysis, and to study in depth the cracking process and mechanisms of stress corrosion cases under typical petroleum industry corrosion systems. It will attempt to determine the laboratory accelerated test conditions and load spectrum that can best reproduce the actual stress corrosion process, and thereby establish a strong correlation between indoor and outdoor stress corrosion acceleration testing in order to achieve accurate assessment of safety and stress corrosion in typical petroleum industry environments. As such, it will strive to incite innovative understandings of the mechanisms driving SCC.

精彩书摘

本书透过大量石油工业中的典型失效案例,通过实验室条件下的模拟和加速试验,对典型石油工业腐蚀体系下的应力腐蚀案例的开裂过程与机理进行深入剖析,最终找到能够很好重现实际应力腐蚀过程的实验室加速试验条件与载荷谱,以期对石油工业腐蚀体系下应力腐蚀寿命的准确评估和安全评定提供有力的佐证,进而为国内外石油生产的安全运行、节约能源等提供重要的理论与技术支撑。

目录

Preface                             vii

Fore word                           ix

Chapter 1 Stress Corrosion Cracking Case Study of 40CrNiMo Drill Pipe Bit in Gas Field       1
1.1 Experimental results and analysis               2
1.2 Observation and Analysis of Microscopic Morphology     4
1.3 Conclusion                      12

Chapter 2 Stress corrosion cracking mechanism of 40CrNiMo steel in simulated drilling fluid environment 13
2.1 Test Method                       14
2.2 Test results and discussion                15
2.3 Conclusion                      26

Chapter 3 Stress corrosion failure cases of P110 pipeline for CO2-driven Oil Recovery     27
3.1 Test results and analysis                  28
3.2 Stress Analysis of Pipeline                37
3.3 Cause Analysis of Oil Pipe Cracking            38
3.4 Conclusion                      40

Chapter 4 Stress Corrosion Cracking Mechanism of P110 Tubing in Simulated Fluid of Oil Well Annulus  41
4.1 Test Method                       42
4.2 Test results and analysis                  44
4.3 Analysis of the failure mechanism for tubing stress corrosion  51
4.4 Conclusion                      54

Chapter 5 Stress Corrosion Cracking Case Studies of N80 Oil Casing under High CO2 Pressure    55
5.1 Test results and analysis                  56
5.2 Stress Analysis of Pipeline                60
5.3 Cause Analysis of Oil Pipe Cracking            61
5.4 Conclusion                      62

Chapter 6 Stress Corrosion Cracking mechanism of N80 Pipe Steel under high CO2 pressure     65
6.1 Experimental methods                   65
6.2 Test results and analysis                  66
6.3 Conclusion                      77

Chapter 7 Stress Corrosion Failure Analysis of Stainless Steel and 35CrMo Steel for Oil Tree     79
7.1 Experimental results and analysis             80
7.2 Analysis of Cracking Reasons of Oil Production Tree Material   86
7.3 Conclusion                      86

Chapter 8 Stress Corrosion Cracking Mechanism of 00Cr13Ni5Mo Oil Bundle Unit       89
8.1 Experimental Method                  90
8.2 Test results and analysis                  92
8.3 Discussion                       106
8.4 Conclusion                        108

Chapter 9 Stress Corrosion Cracking Process of 2205 Duplex Stainless Steel in the Simulated Environment of Oil and Gas Field                 109
9.1 Experimental Method                    110
9.2 Test results and analysis                   111
9.3 Discussion                       120
9.4 Conclusion                        122

Chapter 10 Stress Corrosion Cracking Case Study of Pipeline Steel in Typical Soil Environment  125
10.1 Experimental methods                 126
10.2 Test results and analysis                   130
10.3 Discussion                       141
10.4 Conclusion                        143

Chapter 11 Stress Corrosion Cracking Mechanism of X70 in Acid Soil Environment     145
11.1 Test method                     146
11.2 Test results and analysis                   149
11.3 Discussion                       166
11.4 Conclusion                        168

Chapter 12 Stress Corrosion Cracking Case Study of Pipeline Steel in Typical Soil Environment    171
12.1 Experimental methods                 171
12.2 Test results and analysis                   172
12.3 Discussion                       185
12.4 Conclusion                        187

Chapter 13 Stress Corrosion Cracking Case Study of Distillation Intake Pipe Welding Seam in Atmospheric-Vacuum Distillation Unit                 189
13.1 Test results and analysis                   190
13.2 Analysis of corrosion mechanism               199
13.3 Conclusion                        200

Chapter 14 Stress Corrosion Cracking Process of Distillation Intake Pipe Welding Seam in Atmospheric-Vacuum Distillation Unit                 201
14.1 Experimental method                    202
14.2 Experimental results and analysis               202
14.3 Analysis and discussion                   211
14.4 Conclusion                        212

Chapter 15 Stress Corrosion Cracking Case Study of Catalytic Cracking Units       213
15.1 Experimental analysis of corrosion cracking failure of catalytic cracking unit        214
15.2 Analysis of the Causes of Stress Corrosion Cracking     219
15.3 Conclusion                        224

Chapter 16 Stress Corrosion Cracking Mechanism of Fluid Catalytic Cracking Unit       225
16.1 Experimental method                    225
16.2 Experimental results and analysis               226
16.3 Analysis and discussion                   237
16.4 Conclusion                        241

Chapter 17 Stress Corrosion Cracking Case Study of Cold High-Pressure Separator in Hydrocracking Unit  243
17.1 D405 cold and high-pressure separator equipment      244
17.2 Operating Environment of D405 Equipment           246
17.3 Conclusion                        251

Chapter 18 Stress Corrosion Cracking Mechanism of 16Mn Steel in Wet H2S Environment   253
18.1 Experimental methods                 254
18.2 Experimental results and analysis               254
18.3 Analysis of stress corrosion cracking mechanism         270
18.4 Conclusion                        272

Chapter 19 Hydrogen Diffusion and Influencing Factors in Stress Corrosion Cracking of 16Mn Steel in Wet H2S Environment      275
19.1 Experimental methods                 275
19.2 Experimental results                  276
19.3 Analysis and discussion                   281
19.4 Conclusion                        283

Chapter 20 Crack Growth Model for Stress Corrosion Cracking of 16Mn steel in Wet H2S Environment    285
20.1 Basic Process of Wet H2S Cracking            286
20.2 Crack Propagation Model for Wet H2S Cracking         287
20.3 Application of crack growth model for wet H2S cracking      290
20.4 Conclusion                        297

Chapter 21 Stress Corrosion Cracking Case Study of Glycine Production Plant       299
21.1 Experimental results and analysis               300
21.2 Analysis of Corrosion Failure Mechanism         306
21.3 Conclusion                        308

Chapter 22 Stress Corrosion Cracking Mechanism of Glycine Production Plant   309
22.1 Experimental methods                 310
22.2 Test results and analysis                   311
22.3 Stress Corrosion Mechanisms of 304L Stainless Steel in Glycine Synthesis Medium      319
22.4 Conclusion                        321

Afterword                         323

Index                           325

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