Hydrogen Induced Cracking

Hydrogen Damage
Refers to mechanical damage of metal
Caused by the presence/Interaction with
Hydrogen
Can be classified in to following types
1) Hydrogen Blistering
2) Hydrogen Embrittlement
3) Hydrogen Attack
4) Decarburization

Hydrogen Blistering
Occurs due to penetration of H2 in to metal
Results in to local deformation and in extreme
cases, complete destruction of the vessel wall
Acid Electrolyte
H+
H
e
H

H+
H2

H
H

H2

H
H

H2

Air

Void

Hydrogen Embrittlement
Caused by the penetration of H2 in to a metal
loss of ductility - Embrittlement
Tendency increases with Hydrogen Concentration
Catastrophic failure occurs if hydrogen
concentration > 6 ppm
Steels with >= 75 ksi are prone to Hydrogen
Embrittlement
Steels with >=110 ksi are very much susceptible to
Hydrogen Embrittlement

Hydrogen Embrittlement
Absorption of hydrogen due to presence of H 2 gas
Hydrogen Stress Cracking
Absorption of hydrogen due to corrosion reaction
Stress Corrosion Cracking
Corrosion due to the presence of H2S -Sulfide Stress Corrosion Cracking

Hydrogen Attack & Decarburization

Elevated temperature phenomenon
Dissolved Hydrogen diffuses in to steel and reacts
with carbon or carbides to from Methane Bubble
(CH4)
C [Fe] + 4 H [Fe] = CH4
Formation at surface is known as Surface
decarburization
Formation within the metal is known as Internal
decarburization
Initially CH4 forms in micro voids grows to cracks

Hydrogen Attack & Decarburization

Rate of reaction depends on
(1) Amount of H2
(2) % C in the alloys
(3) Amount of CH4

Hydrogen Induced Cracking (HIC)

Step Wise Cracking (Blistering)
Hydrogen Stress Cracking
Hydrogen Embrittlement
Hydrogen Induced Step Wise Cracking
All are known as Hydrogen Induced Cracking (HIC)

Hydrogen Induced Cracking (HIC)

Mechanism of Cracking
In the Presence of H2S, the process of cracking
(HIC) can be divided in to 5 stages
1) Corrosion : Hydrogen Production
2) Hydrogen Diffusion
3) Hydrogen trapping in defaults
4) Increasing of pressure
5) Cracking

Hydrogen Induced Cracking (HIC)

Factors leading to Cracking
Main external Factors:
-Acidity of the environment
-H2S content
Metallurgical Factors :
-Susceptible Microstructure
-Inclusions in steel ( S, P, As etc)

Hydrogen Induced Cracking (HIC)

Factors leading to Cracking
Susceptible Microstructure
-- Hardened micro structure
-- No PWHT
Inclusions in the steel (Cracking often begins near
inclusions)
-- Sulphide inclusions ( S= 0.001% Max)
-- Oxide Inclusions ( O= 0.002% Max)

Hydrogen Induced Cracking (HIC)

Summary
Most serious type of stress corrosion cracking - due
to hydrogen (occurs in sour service)
Hydrogen usually picked up from sulfide solutions
Occurs in cathodically protected structures if the
level of protection is too high
H2S poisons the oxide surface - allows Hydrogen to
diffuse in to steel
Hardness exceeding 22HRC (appx. 248HV)
prone to cracking

Hydrogen Induced Cracking (HIC)

Summary
Link-up of cracks at different planes to form steps
across the thickness
Cracks reduce the effective wall thickness
The term HIC has been widely used and adopted
by NACE international
Several service failures

HIC TESTING

Standard Test ---- HIC

General
NACE TM 0284 96
Std Test method for evaluating HIC resistance of
pipeline and pressure vessel steels
Provides results at simulated environment
No acceptance or rejection criteria

Standard Test ---- HIC

Test Specimens Pipeline Steels

Standard Test ---- HIC

Test Specimens Pipeline Steels

Standard Test ---- HIC

Test Specimens Pressure Vessel Plate

Standard Test ---- HIC

Reagents
Solution A -- Nitrogen gas for purging,
H2S gas,
5.0% Sodium Chloride (NaCl)
0.50% Acetic Acid (CH3COOH)
Solution B -- Nitrogen gas for purging,
H2S gas,
Synthetic Sea Water

Standard Test ---- HIC

Test Procedure
Test Specimen Exposure
Wide faces vertical
Separated from
vessel

Standard Test ---- HIC

Testing Apparatus
Flow meter

Trap

Trap
H2S Cylinder
Test Specimens

Solution

10 % NaOH
Solution

Standard Test ---- HIC

Evaluation of Test Specimens
Sectioning of test specimen
Surface examination
Section to be polished metallographically and
etched
Include all identifiable cracks visible at 100X in
the calculations
Measurement of cracks (Crack length and
thickness)
Cracks separated by 0.5 mm - considered as
single crack

Standard Test ---- HIC

Evaluation of Test Specimens
w
b
a
T
b
a

Crack Sensitivity Ratio (CSR) = [(a x b)/ (W x T)] x 100%

Crack Length Ratio (CLR) = (a / W) x 100%
Crack Thickness Ratio = (b / T)x 100%

Standard Test ---- HIC

Reporting Test Results
Method of testing
Test solution used
pH of the test solution before introduction of H2S
pH of the test solution after completion of the test
Individual CSR, CLR and CTR

Hydrogen Induced Cracking (HIC)

Preventive Measures
Using Clean Steel -- Killed Steel
Using Coating (Metallic, Inorganic and Organic)
Using Inhibitors
Removing poisons
Substituting alloys (Ni, Cr etc.)
Reduce corrosion rate
Baking
Practicing proper welding

Hydrogen Induced Cracking (HIC)

Preventive Measures
Using Clean Steel -- Killed Steel
Using Coating (Metallic, Inorganic and Organic)
Using Inhibitors
Removing poisons
Substituting alloys (Ni, Cr etc.)
Reduce corrosion rate
Baking
Practicing proper welding