The identification of hydrogen embrittlement and the role of intergranular brittle fracture of API 5DP G105 drill pipe failure on onshore drilling activity

Authors

DOI:

https://doi.org/10.15587/1729-4061.2026.361514

Keywords:

high-density completion fluid, hydrogen embrittlement, high-strength steel failure analysis, drilling completion

Abstract

The object of this study is high-strength steel of API 5DP Gr 105 that has been used during well completion in a corrosive environment. This work emphasizes key factors affecting material damage caused by slip marks, tensile load, and hydrogen content in contaminated brine and completion fluid, which were not addressed in previous studies. Several tests, including chemical, mechanical, and surface characterization, were conducted. The chemical composition test of the fluid shows that the brine has been contaminated by H2S gas and sulfur, with inevitable traces of chloride, bicarbonate, carbonate, bisulfide, and sulfide, providing active sites for hydrogen atom diffusion at the slip marks. The material composition test confirms that the failed material is API 5DP Gr 105. A noticeable amount of phosphorus increases grain boundary segregation and weakens the cohesive metallic bond. A hardness at 28 Rockwell C is inevitable and increases the material’s vulnerability to embrittlement, despite the Charpy energy test showing a manageable level, confirming local brittleness. The high tensile strength of 914 MPa is evidence of embrittlement, even though the material remains ductile, with a noticeable elongation of 20%. An intergranular crack was observed in the microstructure, and slip marks serve as stress concentrators for the crack. Thus, it can be concluded that the combination of tensile load, hydrogen gas content, local slip marks, and completion fluid in the well weakened the grain boundaries and served as an initial crack with a high hydrogen-atom concentration. This work models the root-cause analysis of high-strength steel during well-completion operations in an onshore facility

Author Biographies

Sidhi Aribowo, University of Indonesia

PhD Student

Department of Materials and Metallurgical Engineering

Johny Wahyuadi Soedarsono, Universitas Indonesia

Doctor of Engineering, Professor

Prof Johny Wahyuadi Laboratory

Department of Metallurgical and Materials Engineering

Suryadi Suryadi, Universitas Indonesia

Head of Engineering Services Division

Center for Materials Processing and Failure Analysis (CMPFA)

Department of Metallurgical and Materials Engineering

Slamet Nurhadi, Pertamina Drilling Services Indonesia

Maintenance Manager

Warneri Warneri, Pertamina Drilling Services Indonesia

Manager Rig Operation V

Sopar Mangarapot Simanullang, Pertamina Drilling Services Indonesia

Assistant Manager Quality Control

Agus Kaban, Universitas Indonesia

Master of Engineering, Graduate Student

Prof Johny Wahyuadi Laboratory

Department of Metallurgical and Materials Engineering

Raajwa Ayudhia Kamila, Universitas Indonesia

Research Assistant

Prof Johny Wahyuadi Laboratory

Department of Metallurgical and Materials Engineering

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The identification of hydrogen embrittlement and the role of intergranular brittle fracture of API 5DP G105 drill pipe failure on onshore drilling activity

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Published

2026-06-30

How to Cite

Aribowo, S., Soedarsono, J. W., Suryadi, S., Nurhadi, S., Warneri, W., Simanullang, S. M., Kaban, A., & Kamila, R. A. (2026). The identification of hydrogen embrittlement and the role of intergranular brittle fracture of API 5DP G105 drill pipe failure on onshore drilling activity. Eastern-European Journal of Enterprise Technologies, 3(1 (141), 53–63. https://doi.org/10.15587/1729-4061.2026.361514

Issue

Vol. 3 No. 1 (141) (2026): Engineering technological systems

Section

Engineering technological systems

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Copyright (c) 2026 Sidhi Aribowo, Johny Wahyuadi Soedarsono, Suryadi Suryadi, Slamet Nurhadi, Warneri Warneri, Sopar Mangarapot Simanullang, Agus Kaban, Raajwa Ayudhia Kamila

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