PSI - Issue 80

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ScienceDirect

Procedia Structural Integrity 80 (2026) 203–211 Structural Integrity Procedia 00 (2023) 000–000 Structural Integrity Procedia 00 (2023) 000–000

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© 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of Ferri Aliabadi © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of Professor Ferri Aliabadi. Keywords: Sulfide stress cracking; Phase-field; Pipe burst; OCTG; Finite element analysis Abstract The operational integrity of oil country tubular goods (OCTG)-grade alloys, specifically those used for production casing in sour service applications, is significantly influenced by sulfide stress cracking (SSC) due to hydrogen sulfide (H 2 S)-rich environments. Accurate prediction of burst pressure, therefore, becomes more challenging for ensuring safe operation and for advancing fitness for-service (FFS) assessment methodologies. A key factor often neglected in conventional evaluations is the presence of residual stresses introduced during manufacturing and fabrication. This study numerically investigates the influence of residual stresses on the burst performance of API 5CT C110, a high-strength, low-alloy carbon steel commonly used in deep sour condensate wells within the petroleum industry. We employ a coupled deformation-di ff usion-fracture phase-field framework, specifically calibrated to model pipe burst behavior under sour environment conditions, including internal pressure and exposure to H 2 S-containing aque ous test solutions. To represent manufacturing-induced stresses, residual stress fields, quantified in representative pipe segments, are incorporated into the finite element model using a thermo-mechanical equivalent loading approach. The resulting initial stress field is then mapped onto the pipe burst simulations to account for pre-existing stress distributions realistically. The findings reveal how residual stresses alter the crack driving force and, ultimately, influence crack initiation / growth, leading to pipe burst failure. © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of Professor Ferri Aliabadi. Keywords: Sulfide stress cracking; Phase-field; Pipe burst; OCTG; Finite element analysis Fracture, Damage and Structural Health Monitoring Quantifying the e ff ect of residual stresses on pipe burst in carbon steel tubulars in sour service through phase-field modeling AlokNegi a , Imad Barsoum a,b,c, ∗ a Department of Mechanical and Nuclear Engineering, Khalifa University, Abu Dhabi, 127788, United Arab Emirates b Advanced Digital & Additive Manufacturing (ADAM) Center, Khalifa University, Abu Dhabi, 127788, United Arab Emirates c Department of Engineering Mechanics, Royal Institute of Technology – KTH, Teknikringen 8, Stockholm, 100 44, Sweden Abstract The operational integrity of oil country tubular goods (OCTG)-grade alloys, specifically those used for production casing in sour service applications, is significantly influenced by sulfide stress cracking (SSC) due to hydrogen sulfide (H 2 S)-rich environments. Accurate prediction of burst pressure, therefore, becomes more challenging for ensuring safe operation and for advancing fitness for-service (FFS) assessment methodologies. A key factor often neglected in conventional evaluations is the presence of residual stresses introduced during manufacturing and fabrication. This study numerically investigates the influence of residual stresses on the burst performance of API 5CT C110, a high-strength, low-alloy carbon steel commonly used in deep sour condensate wells within the petroleum industry. We employ a coupled deformation-di ff usion-fracture phase-field framework, specifically calibrated to model pipe burst behavior under sour environment conditions, including internal pressure and exposure to H 2 S-containing aque ous test solutions. To represent manufacturing-induced stresses, residual stress fields, quantified in representative pipe segments, are incorporated into the finite element model using a thermo-mechanical equivalent loading approach. The resulting initial stress field is then mapped onto the pipe burst simulations to account for pre-existing stress distributions realistically. The findings reveal how residual stresses alter the crack driving force and, ultimately, influence crack initiation / growth, leading to pipe burst failure. Fracture, Damage and Structural Health Monitoring Quantifying the e ff ect of residual stresses on pipe burst in carbon steel tubulars in sour service through phase-field modeling AlokNegi a , Imad Barsoum a,b,c, ∗ a Department of Mechanical and Nuclear Engineering, Khalifa University, Abu Dhabi, 127788, United Arab Emirates b Advanced Digital & Additive Manufacturing (ADAM) Center, Khalifa University, Abu Dhabi, 127788, United Arab Emirates c Department of Engineering Mechanics, Royal Institute of Technology – KTH, Teknikringen 8, Stockholm, 100 44, Sweden

1. Introduction 1. Introduction

The growing global demand for energy has driven oil and gas exploration into increasingly challenging environ ments, including sour reservoirs characterized by high concentrations of hydrogen sulfide (H 2 S). These conditions impose severe demands on the structural integrity of OCTG, such as production casing and tubing. One of the most critical degradation mechanisms in these environments is sulfide stress cracking (SSC) — a hydrogen-assisted fracture The growing global demand for energy has driven oil and gas exploration into increasingly challenging environ ments, including sour reservoirs characterized by high concentrations of hydrogen sulfide (H 2 S). These conditions impose severe demands on the structural integrity of OCTG, such as production casing and tubing. One of the most critical degradation mechanisms in these environments is sulfide stress cracking (SSC) — a hydrogen-assisted fracture

∗ Imad Barsoum E-mail address: imad.barsoum@ku.ac.ae ∗ Imad Barsoum E-mail address: imad.barsoum@ku.ac.ae

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of Ferri Aliabadi 10.1016/j.prostr.2026.02.020 2210-7843 © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of Professor Ferri Aliabadi. 2210-7843 © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of Professor Ferri Aliabadi.