SSCC : SULPHIDE STRESS CORROSION

CRACKING
IGC : INTERGRANULAR CORROSION
TWO IMPORTANT CORROSIONS TYPES
ENCOUNTERED BY US ARE COVERED:
BROADLY CLASSIFIED AS :

LOW TEMPERATURE CORROSION
---- CORROSION AT ROOM
TEMPERATURE AND BELOW

HIGH TEMPERATURE CORROSION
---- ELEVATED TEMPERATURE
CORROSION INCLUDING
THAT BY MOLTEN METALS
MEDIA
ONE OF THE MOST IMPORTANT
FACTORS.

PROCESS FLUIDS
CONTAMINANTS
SOLVENTS
CATALYSTS ETC.
HIC --
HYDROGEN INDUCED CRACKING
SSCC ---
A CRACKING PROCESS THAT
REQUIRES SIMULTANEOUS ACTION
OF A CORRODENT AND SUSTAINED
TENSILE STRESS.
WATER :
FUNCTIONS AS ELECTROLYTE
HYDROLYSES INORGANIC SALTS
COMBINATION OF AIR & WATER
IS DANGEROUS ---
AIR SUPPLIES O
2
WATER ACTS AS ELECTROLYTE
SOURCES :
ALMOST EVERY PART OF PROCESS
MEDIA :
EXCLUDED :
FAILURES DUE TO REDUCED SECTION AS A
RESULT OF CORROSION
FAILURES DUE TO INTER - CRYSTALLINE OR
TRANS - CRYSTALLINE CORROSION
H
2
S SOUR WATER
COMMON SOURCES :
CRUDE OIL
DECOMPOSITION OF ORGANIC
COMPOUNDS OF SULPHUR
PROCESS WATER CARRYING H
2
S
WITH NH
3
HCN ETC.
H
2
S REACTS WITH STEEL TO GIVE
A BLACK SULPHIDE FILM

C.S. HAS GOOD RESISTANCE TO
AQUEOUS SULPHIDE CORROSION
SOUR WATER
COMMON SOURCES

PROCESS WATER CARRYING H
2
S
WITH NH
3
HCN ETC
AQUEOUS H
2
S
C.S. AND LAS ARE USED
AQUEOUS H
2
S + NH
3
ETC

CONDITION MORE SEVERE

C.S. & LAS NOT USED

DEPENDING ON SEVERITY
S.S OR TITANIUM USED
HIC NACE STANDARD TM - 02 84

SSCC NACE STANDARD TM - 01 77
HIC TESTING :
SPECIMEN SIZE :
20 X 20 X 100 mm

SOLUTION :
A -- SODIUM CHLORIDE +
ACETIC ACID ( pH 2.7 )
SATURATED WITH H
2
S

B -- SYNTHETIC SEA WATER
( AS PER ASTM D 1141 )
pH 8.1 - 83
SATURATED WITH H
2
S

TEST DURATION :
96 HOURS ( 4 DAYS )

FINAL pH
SOLUTION A -- 4.0
SOLUTION B -- 4.8 - 5.4
TEST RESULT :

THREE SECTIONS OBSERVED

BLISTERS SHALL BE NIL

CSR , CLR AND CTR SHALL
BE WITHIN SPECIFIED
LIMITS

CSR =100 [ (a x b) / ( W x T) ]

CLR =100 [ a / ( W x T) ]

CTR =100 [ b / ( W x T) ]

a = CRACK LENGTH
b = CRACK AREA THICKNESS
W = SECTION WIDTH
T = TEST SPECIMEN THICKNESS
SSCC TESTING :
SPECIMEN SIZE :

ROUND BAR TENSILE SPECIMEN
GAUGE DIA. 6.35 mm
GAUGE LENGTH 25.4 mm
( OVERALL LENGTH 200 mm)

SOLUTION :
A -- SODIUM CHLORIDE +
ACETIC ACID ( pH 2.6 - 2.8 )
SATURATED WITH H
2
S

B -- SODIUM CHLORIDE +
SODIUM ACETATE +
ACETIC ACID ( pH 3.4 - 3.6 )
SATURATED WITH H
2
S

TEST DURATION :
720 HOURS ( 30 DAYS )

FINAL pH
SOLUTION A -- 4.0
SOLUTION B -- 4.0
TEST LOAD :

GENERALLY LOADED TO
72% OF STANDARD METAL
YIELD STRENGTH.

THIS MAY BE CHANGED BY
CUSTOMER
TEST IS DEEMED PASSED IF

SPECIMEN DOES NOT BREAK

EXAMINATION AT 10 X DOES
NOT REVEAL CRACKS
SUSCEPTIBLE MATERIALS :
STAINLESS STEELS
PROCESS :
CORROSION RESISTANCE OF
STAINLESS STEELS IS DERIVED
FROM

Cr + O
2
--------> Cr
2
O
3

FROM
METAL
FROM
ATMOSPHERE
Cr
2
O
3
FORMS A TENACIOUS FILM

ON THE SURFACE.

MINIMUM 12 % Cr IS NEEDED
TO MAKE STEEL STAINLESS
WHEN S.S. PASSES THROUGH THE
TEMPERATURE RANGE OF 425
O
C
TO 850
O
C WE HAVE :

C + Cr -----> Cr
23
C
6

THE REACTION OCCURS AT
GRAIN BOUNDARIES
THUS THERE IS A BAND AT THE
GRAIN BOUNDARIES WHERE

Cr IS LESS THAN 12%
THIS AREA IS NO MORE
STAINLESS
THE PROCESS FLUIDS AND
CONTAMINANTS CAN ATTACK
IN THIS AREA.
THERE ARE A LOT OF PROCESSES
OF MANUFACTURING THAT TAKE
SS IN THIS RANGE

EG. WELDING ; CUTTING ; HOT/WARM
FORMING
SERVICE TEMPERATURE CAN ALSO
BE IN THIS RANGE
THUS THERE IS A NEED TO TEST
THE SUSCEPTABILITY TO IGC

THIS NEED IS GOVERNED BY
SERVICE CONDITIONS
APPLICABLE STD. ASTM A262
THERE ARE 5 PRACTICES
PRACTICE SOLUTION APPLICATION
A OXALIC ACID RAPID
ETCH TEST IDENTIFICATION
OF MATERIALS
WHICH WILL FAIL

B FERRIC SULPHATE DETECTS IGC BUT
+ SULPHURIC ACID NOT SIGMA PHASE
SUSCEPTABILITY

C 65 % NITRIC ACID DETECTS IGC BUT
AND SIGMA PHASE
SUSCEPTABILITY

E Cu +CuSO
4
+ DETECTS IGC BUT
16 % H
2
SO
4
NOT SIGMA PHASE
SUSCEPTABILITY

F Cu +CuSO
4
+ DETECTS IGC BUT
50 % H
2
SO
4
NOT SIGMA PHASE
SUSCEPTABILITY


PRACTICE TEST CONDITIONS

A ETCHING AND EXAMIN AT
250 x AND 500 x

B BOILING SOLUTION
120 HOURS

C BOILING SOLUTION
240 HOURS


E BOILING SOLUTION
24 HOURS

F BOILING SOLUTION
120 HOUR
NORMALLY PRACTICE B ; C AND E

ARE USED
IN PRACTICE B AND C WEIGHT
LOSS IS MEASURED.
THE CORROSION RATE IS GIVEN
BY THE WEIGHT LOSS
THIS IS NOT THE CORROSION
RATE IN ACTUAL SERVICE.

THE RESULT IS A RELATIVE
MEASURE
IN PRACTICE E SPECIMEN IS
BENT THROUGH 180
O
OVER A
FORMER OF 1T RADIUS.

THE BENT SURFACE IS EXAMINED
AT 100 x AND 250 x

TEST IS PASSED IF THERE ARE NO
CRACKS. CRACKS FROM EDGE ,
WRINKLES AND ORANGE PEEL
EFFECT ARE DISREGARDED.
PRACTICE B EVALUATION
Millimeter Per Month =
7290 x W
A x d x t
W = Weight Loss in gms.
A = Total Area of the Sample in cm
2
t = Time of Exposure in hours
d = Density of sample in gms / cc
Millimeter Per Month x 0.04 = Inches Per Month
Millimeter Per Month x 0.47 = Inches Per Year
Millimeter Per Month x 12 = Millimeter Per Year
Millimeter Per Month x 472 = mpy
Millimeter Per Month x Density / 3 =
Milligram Per Square Decimeter Per Day
PRACTICE C EVALUATION
3440880 (W)
( A ) ( d ) ( t )
MPY =
A= Total Specimen area (cm
2
)
W= Weight loss ( gms)
d= Density of sample ( gms / cm
3
)
t = Time of exposure ( hrs)
PRACTICE E
EVALUATION
FAILED MARGINAL
( DOUBTFUL )
PASSED
STEP DUAL
DITCH
As Received
After exposure
After bending
PARENT METAL
100 x
100 x
100 x
HAZ
Before exposure
After exposure
WELD
Before exposure
After exposure
PASSED
FAILED