BRC-CORP 37-74-F 135 Section 27. HYDROGEN EMBRITTLEMENT Definition of the Problem Hydrogen embrittlement is a condition which can result in metal failure at a stress level below the yield strength. Fracture is accompanied by little er nu ductility, and occurs under che combined influence of a sustained, or slowly applied load, and a hydrogen charging environment. It differs from hydrogen blistering (Section 25) and hydrogen attack (Section 24) in that hydro gen ombrittlement de most covere in high otrength materiale and is reversible if detected before cracking occurs. near room temperature, Discussion of the Problem Hydrogen in the atomic state can diffuse through the structure of metals to highly stressed sites (e.g. notches, inclusions, or cracks) and can thereby produce enbrittlement of the metal. Because of the requirement of hydrogen diffusing to these sites, rapidly loaded specimens show little or no effect of dissolved hydrogen. The hydrogen may enter the metal from ecveral different sources 1) As a result of poor melting practice, such as charging wet scrap, 2) rom Some neat treating atmospheres, 3) From an electrochemical process, such as electroplating, 4) From poor welding techniques, such as the use of damp electrodes, or velding on metale covered by @ lydxeted evale, 5) From a high pressure, gaseous hydrogen environment, or 6) From corrosion in the presence of certain hydrogen "poisons", such as hydrogen sultide. ‘The critical concentrations of dissolved hydrogen depend on the stress (applied plus residual), the existing defect distributions, and the inherent tolerance of the metal toward hydrogen. In general, very low concentrations (in the ppm range) of diffusible hydrogen can be harmful. In the presence of very high hydrogen concentrations, residual stresses alone are sometimes oufficieut Wy cause crackling. One of the most connon forms of hydrogen enbrittlenent in the handling fof sour crude or gae, te that termed oulfide etrece correction crecking (occ Section 37 on Stress Corrosion Cracking). It has been experienced in sucker rods, high strength tubing and casing, wire ropes, high strength bolts, e.g. ASTM’A 193 Grade B7, relief valve springs, compressor valve springs and pla heat exchangers, and various pressure vessels. Figure 27-1 shows several high strength B7 type bolts failed by sulfide corrosion cracking. The effects of hydrogen enbrirclement are more severe near room temperature and in high strength materials. Because of the susceptibility of high strength materials, guidelines have been published for a maximum eafe hardness Level of 235 HB (22 HRC) for low alloy steele to be used in wet eulfide service. In some applications, more restrictive hardness limits are imposed. For instance, the maximum hardness of critical refinery materials used in vet sulfide environments 4s often held to 200 HB.136 BRC-CORP 37-74-F Hydrogen embrittlement may occur in many materials, including low alloy steels, stainless steels, nickel base alloys, and titanium, Other factors which may increase the susceptibility of a material to hydrogen embrittlement include cold working, a low pH environment, nickel contents greater than 1% in low alloy steels, and low temperatures. Figure 27-2 shows a section of normally resistant low strength tubing, which failed because of cold deformation, as a result of rotary straightening. Metastable austenitic stainless steels such as Types 304 and 316, which are normally resistant to hydrogen enbrittlement, also may become susceptible as a result of cold working. Methods of Checking for the Problem Hydrogen embrittlement cracks often propagate quite rapidly and can ead to catastrophic failures, Even frequent thorough inspections cannot fecessarily be exvected to detect sites af tmpending failures. Use of the hardness test in conjunction with previous experience with similar alloys may indicate whether a part 1s susceptible, should hydrogen charging occur. Confirming that a given failure has been the result of hydrogen eubrittlement is difficult and requires a complete laboratory failure analysis. Methods of Eliminating the Problem Failures caused by hydrogen embrittlement can be prevented by elimin- ating any one of its three necessary components: 1) reducing the operating stress Intoneity (a combination of applied streas, residual stress, and Dasimum defect size), 2) changing the severity of the hydrogen charging environment, or 3) substituting a more resistant material. For the first alternative, while no control is possible over the maximum defect size, it may be possible to derate the equipment, to reduce the operating stresses or thermally stress relieve the equipment to reduce residual stress. For the second alternative, use of certain corrosion inhibitors or changes in operating temperature may be suitable. Because upsets in operation can seriously alter the process environment, it is difficult to assure that unacceptable conditions will not occur. The third alternative is the one most frequently chosen. In the past, 4t was believed that the austenitic stainless steels and nickel base alloys were inmune to hydrogen embrittlement, but never data show this not to be the case. Several hydrogen related failures have vvcussed in equipment made from these materials. Figure 27-3 shovs an Inconel alloy X-750 tubing hanger which failed as a result of hydrogen embrittlement. Pitfalls ‘The most common pitfall associated with hydrogen embrittlement avoid- ance lies in the prevalent assumption that increasing the strength of a couponent will help prevent it from cracking. Actually, such a procedure can be expected to increase the cracking susceptibility, in an otherwise identical application The second most common pitfall involves the cadmium plating of high strength steel parts to protect them from hydrogen embrittlement. It is tree that caduium is nearly impervious to hydrogen. but unless a very cpectaliced Paating procedure is used, the plating process itself may inject sufficient hydrogen to cause delayed failure. se eS F7 eoooss Pocoooovooooooess BRC-CORP 37-74.F Figure 27-4 Failed B7 Stud Bolts from » Debutanizer Tops Condenser Magnifienion: 172% 37ES Pin End Box End Figure 972 C75 Tubing Failure Note that fracture tends to follow roll mark. 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