Publication SAW SOUR SERVICE 2023 PDF
Publication SAW SOUR SERVICE 2023 PDF
Publication SAW SOUR SERVICE 2023 PDF
of Pipeline Welds
This article was developed by Task Group T-1F-23 on Sulfide Stress Cracking
Resistance of Pipeline Welds, chaired by T.V. Bruno (Metallurgical Consultants,
Inc., Houston, Texas).
Nearly
all
electric -resistance
welded (ERW) pipe is post-weld heat treated
and cold-reduced for diameter control after
welding. Consequently, residual stresses
from welding and forming not only are
relieved, but residual compressive stresses
are often induced on the inside surface. In
one study of 6- and 8-inch (15.24-cm and
20.32-cm) API Grade X46 ERW line pipe,
compressive residual hoop stress of about 10
to 50 percent of the pipes yield strength
(YS) was found on the inside surface.4 As a
result, residual stresses normally are not a
serious consideration in cracking of ERW
pipe.
Most pipeline girth welds are not
subject to post-weld heat treatment, cold
expansion,
or
other
stress-relieving
influences, and the residual stresses are
often assumed to approach the US, although
this may not always be the case. Both
experimental and theoretical residual stress
measurements reported on 24-in. (61-cm)
OD by 0.610-in (16mm) wall X65 pipe
show the maximum residual tensile hoop
stresses on the inside surface adjacent to the
weld to be about 60 percent of the pipes
YS.5 These stresses decrease rapidly and
become compressive within a short distance
(e.g., 1/2 in. [12mm]) from the weld
centerline. Axial stresses on the inside
surface are actually compressive for up to
6.25 in. (15 cm) from the weld, but studies
have indicated that, for thinner wall pipe,
axial stresses are tensile. In any event, the
residual stresses at girth welds can be fare
below the YS.
Some companies post-weld heat
treat girth welds to be used in critical service
using electric-resistance or exothermic
methods.
The heat treatment reduces
residual stresses and softens hard
microstructures.
Submerged Arc Welded Pipe
Potential conditions in SAWs that
can lead to cracking are:
1) Hard welds resulting from the wire
and flux combinations.
2) Local hard spots in otherwise soft
welds.
3) Hard HAZs resulting from the
chemical composition of the base metal.
4) Susceptible soft microstructures
that develop in the subcritical or intercritical
areas of the HAZ.
The first three conditions are hardness
dependent: susceptibility increases with
increasing hardness. However, chemical
composition and microstructure are also
important variables, and there effect is
unclear.
Figure 4
Hard spots in inside weld of SAW pipe that failed
in service.
Figure 1
Schematic illustration of the morphology
of hydrogen-induced stepwise cracks,
SSC-1 and SSC- II
Figure 2
Service failure of SAW pipe.
Figure 5
(top) Hard spots from Figure 4 at higher
magnification.
Figure 6
(bottom) Small hard spot with crack that did
not propagate.
Figure 3
Cracks in Figure 2 at higher magnification.
Figure 7
Fracture and cracks (arrow) in ERW that
failed in sour service.
Figure 8
Area indicated by arrow in Figure 7 at
higher magnification.
Figure 9
Distribution of manganese in ferrite-pearlite
bands in carbon steel. 17
Figure 10
Cracking of ERW casing that failed in
sour service.
Figure 11
Microstructure near cracks showing darketching pearlite and bainite bands.
Figure 12
SEM micrographs showing incipient
crac king in inclusions in bainite bands.
Figure 13
Influence of ERW defects on KISCC
Figure 14
Typical GMA pipeline girth weld showing HV
10 hardness.
Figure 16
Specimen from pipeline girth weld tested in sour
water without failure.
Figure 15
Cracks in HAZ of GMA girth weld in sour
service.
Figure 17
Effect of second pass on maximum girth weld hardness.20
Figure 18
Hardness survey (HRB and HV -10) of pipeline
girth weld.
Figure 19
Girth weld with one-pass backweld.
Figure 20
Girth weld with thru-pass backweld.
Figure 21
Relationship between typical carbon contents and yield strength of line pipe steels.
Figure 22
Evolution of low -carbon contents for high-strength line pipe steels.