Predicting sulfide stress cracking in a sour environment: A phase-field finite element study

Abstract

Sulfide stress cracking (SSC) is a leading cause of failure in sour service environments, where the presence of wet hydrogen sulfide (H2S) causes hydrogen embrittlement and significantly influences the performance and lifespan of casing and tubing pipes. This work presents a numerical investigation on predicting the onset and growth of SSC in a sour environment using a coupled deformation–diffusion phase-field finite element framework, which incorporates the role of sub-surface hydrogen concentration due to H2S exposure and mechanical loading effects on the crack growth response. The numerical results agree with the experimental data from the notched slow strain rate testing performed on high-strength low alloy steel (HSLA) in a sour environment at room temperature. Recently, the oil and gas industry has been heading towards unconventional gas well applications that expose crucial parts of a well construction, such as production casings, to high internal pressures and a sour environment. To simulate such conditions, a numerical study is conducted that examines the onset and growth of SSC in pre-notched pressurized pipes subjected to H2S exposure. The geometry and boundary conditions used for the pre-notched pipes adhere to the API 579 standard for fitness for a service assessment of equipment containing identified flaws or damage. The findings of this comprehensive numerical investigation provide valuable insights into the effectiveness of a coupled phase-field approach for SSC and demonstrate its potential as an engineering tool for structural integrity assessments that consider environmental effects.