C O R R O S I O N R E S I S T A N T

A L L O Y S

F O R

O I L

A N D

G A S

P R O D U C T I O N

Part 1:

MANUFACTURING AND QUALITY CONTROL An overview of the facilities and systems that make up the worlds leading producer of corrosion- resistant alloys.

Page 3

Part 2:

MATERIALS SELECTION The capabilities of the industrys broadest selection of corrosion-resistant alloys.

Page 11

Part 3:

EFFECTS OF WELL ENVIRONMENTS Why nickel alloys are needed to resist corrosion in aggressive well fluids.

Page 29

Part 4:

CORROSION TESTING A compilation of corrosion data in environments relevant to oil and gas drilling and production.

Page 35

Publication No. SMC - 013 Copyright 2003 by Special Metals Corporation INCONEL , INCOLOY , MONEL , INCO -WELD , 625LCF , 725, 800HT and 925 are trademarks of the Special Metals Corporation group of companies.
The data contained in this publication is for informational purposes only and may be revised at any time without prior notice. The data is believed to be accurate and reliable, but Special Metals makes no representation or warranty of any kind (express or implied) and assumes no liability with respect to the accuracy or completeness of the information contained herein. Although the data is believed to be representative of the product, the actual characteristics or performance of the product may vary from what is shown in this publication. Nothing contained in this publication should be construed as guaranteeing the product for a particular use or application.

P A R T

INCONEL Ni-Cr Alloys INCONEL Ni-Cr-Fe Alloys INCONEL Ni-Cr-Mo Alloys INCOLOY Fe-Ni-Cr Alloys MONEL Ni-Cu Alloys INCO-WELD Welding Products

The Special Metals Group of companies was created in 1998, when Special Metals Corporation
of New Hartford, New York acquired Inco Alloys International Inc., including its Huntington Alloys and Wiggin Alloys divisions. With a history of alloy invention and production going back some 100 years, our new company continues to provide solutions to your difficult materials problems through such time-tested products as our worldrecognized INCONEL, INCOLOY and MONEL alloys. Todays Special Metals is a world leader in the invention, production and supply of the high-nickel, highperformance alloys used for the difficult jobs in engineering. These alloys are highly engineered to offer a superior combination of heat resistance, high temperature corrosion resistance, toughness and strength and are used in the worlds most technically demanding industries and applications. Special Metals offers the largest range of nickel-based alloys and product forms, as well as cobalt-based alloys, to more than 10 worldwide markets. We produce nickel alloys in all standard mill forms, from large ingots and billets to plate, sheet, strip, tubing, bar and wire, the latter of which includes core and filler wires for welding products. The company has manufacturing and research facilities in the USA and Europe, sales offices in North America, Europe and Asia, and a distribution network including most of the industrialized countries of the world. Contact any of our offices listed on the last page of this publication or visit the SMC website, www.specialmetals.com, for more information on our company and our products.

Melting furnaces

include this vacuum-induction furnace with its sophisticated control system. Melting under vacuum excludes contaminants and produces alloys of precise composition.

Electroslag remelting

enhances the structure and purity of the metal. The operation is carried out under strict, computerized control.

This two-high/four-high

reversing mill is used for primary breakdown of alloy ingots. The mill has computerized controls and can generate up to 10 million pounds (44MN) of separating force.
5

Computer-controlled extru-

sion presses produce seamless tubulars of up to 10 in (250mm) outside diameter.

M A N U F A C T U R I N G

A N D

Q U A L I T Y

C O N T R O L

Natural gas continues to be one of the worlds most abundant sources of energy. Increasingly, the recovery of new gas is from deep formations that pose hostile environments for downhole tubulars and other well components. In the past, the selection of metallic materials for oil and gas wells was a relatively straightforward proposition. Standard grades of low-alloy and carbon steels were specified for drilling and production tubulars with a few stainless steels and nickel alloys in common use for special applications such as valves and instrumentation. Today, materials selection for drilling and completion of wells can be a complex task involving high financial and safety risks. This situation is brought about by several factors, including 1. deeper wells involving higher temperatures and pressures, 2. enhanced recovery methods such as steam or CO2 injection, 3. increased weight considerations, especially offshore, and 4. the need for greater corrosion resistance in wells containing hydrogen sulfide (H2S), carbon dioxide (CO2), and chlorides (Cl-). Materials selection is especially critical for sour gas wells those containing H2S. Environments in sour wells are extremely corrosive to metals, and H2S is highly toxic. In some sour environments, corrosion can be controlled by using inhibitors along with carbon steel tubulars. However, inhibitors involve continuing high cost and may be unreliable, especially at higher temperatures. Adding corrosion allowance to the tubing wall increases string weight and reduces interior dimensions. In many cases, the preferred alternative in terms of life-cycle economy and safety is the use of a corrosion-resistant alloy (CRA) for tubulars and other well components.

M A N U F A C T U R I N G

A N D

Q U A L I T Y

C O N T R O L

A resistant alloy eliminates inhibitors, lowers weight, improves safety, eliminates or minimizes workovers, and reduces downtime. For many decades, Special Metals has been the worldwide leader in the development and application of corrosionresistant alloys, and the company is at the forefront in applying CRA technology to drilling and production of sour wells. Before that involvement, Special Metals had been a longtime supplier of nickel alloys for a range of corrosive or high temperature applications in hydrocarbon and petrochemical processing.

+ 7 Extruded tube shells

are cold worked to final size on drawbenches or rotatingdie tube reducers.

8+ 9

Oil-country tubular

goods are produced in wide ranges of diameters, wall thicknesses and lengths.

10 + 11

Special Metals quality

control system includes extensive laboratory facilities with state-of-the-art equipment such as scanning electron microscopes (10) and atomicabsorption spectrophotometers (11).

11

10

12+ 13

Ultrasonic (12) and

eddy-current (13) testing are part of the stringent quality control applied throughout production.
13

9
12

M A N U F A C T U R I N G

A N D

Q U A L I T Y

C O N T R O L

The MONEL, INCONEL and INCOLOY alloys invented by the company have long service histories in such diverse applications as drill collars, piping systems and valves, heat exchangers, process vessels and pyrolysis furnaces. Special Metals has manufacturing facilities and research laboratories in the USA and the UK. The facilities are unsurpassed in the production of high-performance alloys. They are fully integrated for complete product control and traceability from acquisition of raw materials through melting, hot working, cold working and shipment of finished goods. Strict quality control is built into all processing, a result of long experience in meeting the most stringent of materials requirements in the aerospace and nuclear industries. Impeccable material identification and carefully maintained computer records enable complete traceability of production history for many years. The initial alloying and melting greatly influence quality, and Special Metals has melting and remelting facilities that span the range of modern technology. Included are vacuum induction melting and air melting in conjunction
14

Long lengths mean less

with argon-oxygen decarburization (A.O.D.). Vacuum and electroslag remelting are used for even more precise control of composition and microstructure. Special Metals markets a range of alloys for sour-well components. The product line constitutes the broadest selection of CRA materials available from any supplier. It is a single source for alloys that deliver high performance in any known environment from bottom hole, to wellhead, to processing plant. Included are alloys strengthened by heat treatment as well as by cold work. Product forms range from small-diameter tubing and wire to 20,000 lb (9000 kg) ingots for large forged components such as block master valves. A full selection of matching and overmatching welding products are available.

threading and fewer joints in tubing strings.

10

P A R T

MATERIALS SELECTION

The broad line of corrosion-resistant alloys produced by Special Metals serves as a single source of materials for applications ranging from bottom hole to flare stack.

Above. The critical outer portion of the Gullfaks A flare boom is made of INCONEL alloy 625.

Right. Submarine oil hose for connection from supertankers to on-shore tank farms in Saudi Arabia. Connections are secured with MONEL alloy 400 nuts and bolts.

12

M A T E R I A L S

S E L E C T I O N

Selection of materials for downhole service in a sour well is governed by a complex set of factors. Operating temperatures can be as high as 800C (1470F). The hot gas is corrosive, and the marine atmosphere presents its own aggressive problems. High-temperature strength, corrosion-resistance, ease of fabrication and readily available welding products to match the base materials are all important considerations. As in materials selection for any application, the goal is to use a material that performs successfully while providing optimum economy. The material must provide the required physical and mechanical properties while resisting the particular environment of the well involved. And, expected changes in the well environment over time, such as increased chloride level, must also be considered. Other important environmental factors to consider are dissolved acid gases (CO2 and H2S) in the liquid phase, chloride ions from salt or brine, temperature, and pressure. In some formations, the presence of elemental sulfur is a further factor. The level of dissolved gases depends on the partial pressure of each gas above the liquid phase and on the temperature. Bottom-hole pressure normally increases with depth, and bottom-hole temperatures can be 500F (260C) or more in deep wells. Materials for downhole tubulars and other components for oil and gas production span a wide range of grades and compositions. As corrosion-resistance increases, so too does the complexity of the material, from plain carbon steel to martensitic stainless steel (e.g., 13% chromium steel), duplex (ferritic/austenitic) stainless steel (e.g., 22% chromium/5% nickel), fully austenitic stainless steel (e.g., 28% chromium/32% nickel), and nickel alloys of various compositions. In nickel alloys used for oil-country tubular goods, the levels of nickel, chromium and molybdenum act as primary determinants of corrosion-resistance. Relatively small amounts of other elements including copper, niobium, tungsten, aluminum and titanium may have significant effects on corrosion-resistance or strength.
Below. Welding MONEL alloy 400 sheet onto steel riser pipes for an offshore production platform. Used in the splash zone, the alloy is resistant to mussel build-up. Operators report no difficulty in clearing other types of marine fouling. Above. Special Metals supplies materials for the most severe sour well conditions.

13

Above. 60 tonnes of INCONEL alloy C-276 tubular product was specified for this sea-water cooled, interstage and after cooler fabricated by Hick Hargreaves & Co. Ltd., Bolton, England, for Marathon Oil U.K. Ltd. These 15 m diameter vessels are for use on the East Brae gas condensate production platform in the North Sea, to support gas recompressors capable of delivering 9.6 million m3 per day at 350 bar pressure.

Right. An offshore block master valve made of INCOLOY alloy 925. The valve body was forged from a 20,000 lb (9000 kg) ingot. INCOLOY alloy 925 was selected for its strength and corrosion- resistance during normal service and for its ability to meet fireresistance standards. The alloy has the high-temperature strength and stability to comply with API RP 6F, Fire Test for Valves. Among the requirements is the ability to withstand 2000F (1095C) internal temperatures with no leakage. (ABB Vetco Gray, Inc.)

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M A T E R I A L S

S E L E C T I O N

ALLOYS FOR DOWNHOLE TUBULARS

Special Metals manufactures oil-country tubular goods (OCTG) that withstand the most severe conditions in oil and gas fields around the world. These highly alloyed materials permit safe, economical production from reservoirs with extremes of temperature, pressure, and H2S content. INCONEL alloys C-276, G-3 and 050, and INCOLOY alloys 825 and 028 are most often chosen for the optimum combination of corrosion-resistance and economy. These alloys, along with a wide selection of other corrosion-resistant materials, are available in a variety of different forms for downhole accessories and surface equipment. Plain-end tubulars and coupling stock are produced in diameters, wall thicknesses and yield strengths for most tubing and casing requirements.
Above. INCOLOY alloy 800HT used for the top section of a flare tower for the Norne Field. Shown here under assembly at the Leirvik Sveis yard on the island of Stord, Norway. Below. A drain caisson (47 meters long, weighing 41 tonnes) for an offshore gas platform, made of 26 mm double-clad steel plate, with a 2 mm cladding of MONEL alloy 400 on either side of the steel.

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M A T E R I A L S

S E L E C T I O N

Above. A selection of valve components for offshore service, weld-overlaid with INCONEL alloy 625. This use of corrosion-resistant alloy overlays on steel components offers a cost-effective alternative to solid alloy construction. Right. INCOLOY alloy 925 fasteners, 4-16 mm diameter, are used in intelligent pigs for automated pipeline inspection procedures; particularly in areas of high H2S which could lead to sulfide stress cracking in conventional steels.

16

INCOLOY alloy 825, a nickel-iron-chromium alloy with additions of 2.2% copper and 3.0% molybdenum, resists oxidizing and reducing acids, chloride-ion stress-corrosion cracking, pitting and intergranular corrosion. The molybdenum addition is especially effective in increasing an alloys resistance to sour well environments. INCOLOY alloy 825 is a solid- solution alloy (not strengthened by heat treatment) that can be strengthened by cold work to minimum yield strengths (0.2% offset) up to 125,000 psi (862 MPa). INCOLOY alloy 825 could be considered for service in well environments where stainless steels would be susceptible to chloride stress cracking, pitting, or crevice corrosion. Depending on specific strength level and temperature, the alloy has been shown to be resistant to stress-corrosion cracking at H2S partial pressures up to about 1000 psi (7 MPa). The usual maximum service temperature is about 350F (175 C). INCONEL alloy G-3, a nickel-chromium-iron alloy with additions of 2.0% copper and 7.0% molybdenum, is similar to INCOLOY alloy 825 in nickel and chromium contents, but has approximately double the molybdenum. INCONEL alloy G-3 is a solid-solution alloy that can be cold worked to minimum yield strengths (0.2% offset) up to 130,000 psi (900 MPa). With its higher molybdenum, INCONEL alloy G-3 offers greater resistance to sour environments than INCOLOY alloy 825.
Above. MONEL alloys 400 and K-500 are used in wellhead hardware, pumps and valves. Below. INCOLOY alloy 925 completion tubing, 8.5 in (216 mm) diameter, 0.75 in (19 mm) wall, 110 ksi (758 MPa) yield strength. Available in lengths up to 30 ft (9.14 m).

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M A T E R I A L S

S E L E C T I O N

Right. An Otis Versa-Trieve production packer for use in intermediate pressure wells, and extensively used in sand control applications. Internal, flow-wetted components, such as the main mandrel, have been made of INCOLOY alloy 925.

Depending on such factors as strength level, temperature, and presence of free sulfur, INCONEL alloy G-3 is resistant to cracking at H2S partial pressures up to about 2500 psi (17 MPa). In the upper regions of H2S content, service temperature would be limited to about 350F (175C) although higher temperatures are possible at lower H2S levels. INCONEL alloy C-276, a nickel-molybdenum-chromium alloy with additions of iron (6%) and tungsten (4%), is used in the most severe sour well environments including those having free sulfur. Its molybdenum content of 16% is the highest commercially available in oil-country tubular goods, offering the maximum resistance to environments containing H2S. The solid-solution alloy can be cold worked to high strength levels and is available with minimum yield strength (0.2% offset) of 150,000 psi (1034 MPa). Depending on the combination of specific yield strength, temperature, and free-sulfur presence, lNCONEL alloy C-276 is resistant to cracking at H2S partial pressures up to about 10,000 psi (70 MPa). The alloy has shown resistance to sour environments at temperatures up to 500F (260C).
ALLOYS FOR DOWNHOLE ACCESSORIES AND SURFACE EQUIPMENT

The many different downhole components - hangers, valves, pumps, packers, wirelines, mandrels, screens, landing nipples, etc - needed to complete and produce a well face the same environment as the tubing string. Although some components may be under lower stress or have less critical functions, all downhole hardware in a sour well must have adequate resistance to the environment. The same alloys
Far Right. Otis SP-1 nonelastomer, flapper-type, tubing-retrievable sub-surface safety valves are used to shut off the flow of oil or gas from the producing tubing string. These surface controlled valves have been made with components of INCOLOY alloy 925.

used for tubulars are also used for other downhole components. In many cases, however, a different alloy is more appropriate for reasons of specialized properties, economy, or ease of fabrication.

18

Left. Fasteners of various nickel alloys provide strength and corrosionresistance in critical oilfield connections

Below. MONEL alloys 400, R-405 and K-500 are standard materials for valves, valve actuators and pumps in oil field and processing applications.

19

Left. A single point mooring buoy where the mating surBelow. INCOLOY alloy 25-6MO was used to fabricate this desalination unit for an offshore platform. The unit was fabricated by KGD Industrial Services Ltd. (Hereford, England) for Alfa Laval Desalt (Copenhagen, Denmark) faces of the universal joint are overlaid with INCONEL alloy 625 for resistance to stress-corrosion cracking and crevice corrosion.

Below. An onshore terminal where LPG is compressed and cooled from 133 to 26C in batteries of aircooled INCOLOY alloy 825 heat exchangers set 25 meters high in piperacks where wind speeds can exceed 120 mph.

20

M A T E R I A L S

S E L E C T I O N

For example, high strength is obtained in tubulars by cold working, but parts of heavy or non-uniform cross section cannot be strengthened by cold working. Such components need to be made of an alloy that can be strengthened by a precipitation hardening (age hardening) heat treatment. Special Metals markets the broadest range of corrosionresistant alloys in the industry. All are produced to the high standards of quality and performance applied to CRA tubing and casing, and are manufactured in a full range of standard mill forms including pipe, tubing, rounds, flats, hexagons, wire, plate, sheet, strip, and forging stock. From this extensive product line the best alloy can be selected in the required form for virtually any downhole or wellhead component. MONEL alloy 400, a solid-solution nickel-copper alloy with moderate strength and high corrosion- resistance, is especially resistant to sea water and brines. MONEL alloy R-405 is a free-machining version of MONEL alloy 400. MONEL alloy K-500 is a high-strength, age-hardenable version of MONEL alloy 400. INCONEL alloy 600 is a solid-solution nickel- chromium alloy with good strength and resistance to general corrosion in a variety of environments. INCONEL alloy 625, a solid-solution nickel- chromiummolybdenum-niobium alloy, has high strength and outstanding resistance to general corrosion, pitting, crevice corrosion, and stress-corrosion cracking. INCONEL alloy 718, an age-hardenable nickel-chromium-iron alloy containing significant amounts of niobium, molybdenum, titanium, and aluminum, combines good corrosion-resistance with extremely high strength. INCONEL alloy 725, an age-hardenable nickel-chromium-molybdenum-niobium alloy, combines the excellent corrosion-resistance of INCONEL alloy 625, including resistance to the effects of H2S, with high strength obtained by heat treatment instead of cold work.

INCONEL alloy 725HS, a high-strength version of INCONEL alloy 725. INCONEL alloy X-750 is a nickel-chromium alloy similar to INCONEL alloy 600 but made age-hardenable by additions of aluminum and titanium for higher strength in addition to corrosion resistance. INCONEL alloy 050, an alloy with excellent resistance to stress-corrosion cracking, particularly in sour gas environments, used for downhole tubing in oil and gas extraction. INCOLOY alloy 800 is a solid-solution nickel-ironchromium alloy with good strength and resistance to general corrosion in many environments. It is also available as INCOLOY alloys 800H and 800HT for higher strength at temperatures over 1100F (590C). INCOLOY alloy 925, an age-hardenable nickel-ironchromium-molybdenum-copper alloy, has the corrosionresistance of INCOLOY alloy 825 along with high strength achieved by heat treatment. The alloy was developed especially for sour-well components that cannot be strengthened by cold working. INCOLOY alloy 25-6MO, a solid-solution nickel-ironchromium alloy with a substantial (6%) addition of molybdenum, is especially useful to resist pitting and crevice corrosion in media containing chlorides, such as sea water. INCOLOY alloy 27-MO, a solid-solution nickel-ironchromium alloy with a substantial (7%) addition of molybdenum, is a higher alloyed version of INCOLOY alloy 25-6 MO. INCOLOY alloy 028, a corrosion-resistant austenitic stainless steel used for downhole tubing in oil and gas extraction operations.

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M A T E R I A L S

S E L E C T I O N

WHERE THE ENVIRONMENT IS AGGRESSIVELY CORROSIVE

For These Components Bellows expansion joints Specify These Proven Alloys INCOLOY alloy 825 MONEL alloy 400 INCONEL alloys 625, 625LCF & X-750

CHEMICAL COMPOSITIONS, %*, OF NICKEL ALLOYS FOR OIL-COUNTRY APPLICATIONS (cont. p.21)

Element Nickel Chromium Iron Copper Molybdenum Niobium Aluminum

Downhole tubing, casing INCOLOY alloys 825 & 028 and couplings INCONEL alloys C-276, G-3 & 050 Drill collars Drill pipe Fasteners MONEL alloy K-500 INCOLOY alloy 825 INCOLOY alloy 925 MONEL alloy K-500 INCONEL alloys 725,725HS, 686, & X-750 INCOLOY alloy 825 INCONEL alloy 625 MONEL alloy K-500 INCOLOY alloys 825 & 27-7 MO INCONEL alloy 625 INCOLOY alloys 800HT & DS INCOLOY alloy 925 INCONEL alloys 725, 725HS, & 718 INCOLOY alloys 825, 800HT, 27-7MO, & 25-6MO INCONEL alloy 625 MONEL alloy 400 INCOLOY alloy 825 MONEL alloy 400 INCONEL alloy 625 INCONEL alloy 725 & 725HS INCOLOY alloy 925 INCOLOY alloy 925 INCONEL alloys 718, 725, & 725HS

MONEL alloy 400 UNS N04400 63.0 min 2.5 28.0-34.0 0.024 0.3 2.0 0.5

MONEL alloy R-405 UNS N04405 63.0 min 2.5 28.0-34.0 0.025-0.060 0.3 2.0 0.5

MONEL alloy K-500 UNS N05500 63.0 min 2.0 27.0-33.0 2.30-3.15 0.35-0.85 0.01 0.25 1.5 0.5

INCONEL alloy 600 UNS N06600 72.0 min 14.9-17.0 6.0-10.0 0.5 0.015 0.15 1.0 0.5

INCONEL alloy 625 UNS N06625 58.0 min 20.0-23.0 5.0 8.0-10.0 3.15-4.15 0.40 0.40 0.015 1.0 0.10 0.50 0.50 0.015

Fittings Filters and separators Flare booms Flare stack tips Hangers Heat exchangers

Titanium Sulfur Tungsten Cobalt Carbon Manganese Silicon Phosphorus Boron Vanadium Nitrogen

Instrumentation tubing

* single values are maximum quantities except as indicated

Landing nipples Packers

Polished-bore receptacles INCONEL alloys 718 & 725 (PBRs) INCOLOY alloy 925 Pumps INCOLOY alloy 925 INCONEL alloy 718 MONEL alloys 400, R-405 & K-500 MONEL alloy 400 MONEL alloy 400 INCOLOY alloy 825 MONEL alloy 400 INCONEL alloy 625 INCOLOY alloys 825, 25-6MO, & 27-7 MO INCONEL alloy 725 INCOLOY alloy 925 INCONEL alloys X-750 & 725 INCONEL alloy 718 MONEL alloys 400 & K-500 INCOLOY alloy 925 MONEL alloy K-500 MONEL alloys 400 & K-500 INCOLOY alloys 825 & 925 INCONEL alloys 625, 718 & 725 MONEL alloys 400, R-405 & K-500 INCOLOY alloys 825, 25-6 MO, & 27-7 MO

Rig leg cladding Riser pipe cladding Sea-water piping

Side-pocket mandrels Springs Sucker rods Tool joints Tubing calipers Valves

Wire lines

Flattening tests can be used to evaluate the quality of downhole tubulars.

CHEMICAL COMPOSITIONS, %, OF NICKEL ALLOYS FOR OIL-COUNTRY APPLICATIONS

(continued)

INCONEL alloy 718 UNS N07718

INCONEL alloy 725/725HS UNS N07725

INCONEL alloy G-3 UNS N06985

INCONEL alloy C-276 UNS N10276

INCONEL alloy X-750 UNS N07750

INCONEL alloy 050 UNS N06950

INCONEL alloy 25-6 MO UNS N08925

INCONEL alloy 27-7 MO UNS S31277

INCONEL alloy 028 UNS No8028

INCONEL alloy 800 UNS N08800

INCONEL alloy 825 UNS N08825

INCONEL alloy 925 UNS N09925

50.0-55.0 17.0-21.0 18.5 nom 0.30 2.80-3.30 4.75-5.50 0.20-0.80 0.65-1.15 0.015 1.0 0.08 0.35 0.35 0.015 0.006

55.0-59.0 19.0-22.5 9 nom 7.0-9.5 2.75-4.0 0.35 1.0-1.7 0.010 0.03 0.35 0.20 0.015

44 nom 21.0-23.5 18.0-21.0 1.5-2.5 6.0-8.0 0.50 0.03 1.5 5.0 0.015 1.0 1.0 0.04

57 nom 14.5-16.5 4.0-7.0 15.0-17.0 0.03 3.0-4.5 2.5 0.01 1.0 0.08 0.04 0.35

70.0 min 14.0-17.0 5.0-9.0 0.50 0.70-1.20 0.40-1.00 2.25-2.75 0.01 1.0 0.08 1.0 0.50

50.0 min 19.0-21.0 0.5 max 8.0-10.0 0.03 0.4 .02 max 1.0 max 1.0 max .03 max

24.0-26.0 19.0-21.0 46 nom 0.8-1.5 6.0-7.0 0.03 0.02 1.0 0.05 0.045 0.10-0.20

26.0-28.0 20.5-23.0 Balance 0.5-1.5 6.5-8.0 0.01 0.020 3.00 0.5 0.03 0.3-0.4

30.0-34.0 26.0-28.0 0.6-1.4 3.0-4.0 0.03 .03 max 2.5 max 1.0 max .03 max

30.0-35.0 19.0-23.0 39.5 min 0.75 0.15-0.60 0.15-0.60 0.0015 1.10 1.5 1.0

38.0-46.0 19.5-23.5 22.0 min 1.5-3.0 2.5-3.5 0.2 0.6-1.2 0.03 0.05 1.0 0.5

42.0-46.0 19.5-22.5 22.0 min 1.5-3.0 2.5-3.5 0.5 0.1-0.5 1.9-2.3 0.03 0.03 1.0 0.5 0.03

PHYSICAL PROPERTIESa OF NICKEL ALLOYS FOR OIL-COUNTRY APPLICATIONS

Youngs
Density Alloy MONEL alloy 400 MONEL alloy R-405 MONEL alloy K-500 INCONEL alloy 600 INCONEL alloy 625 INCONEL alloy 718 INCONEL alloy 725 INCONEL alloy 725HS INCONEL alloy X-750 INCONEL alloy G-3 INCONEL alloy C-276 INCONEL alloy 050 INCOLOY alloy 27-7 MO INCOLOY alloy 25-6MO INCOLOY alloy 028 INCOLOY alloy 800 INCOLOY alloy 825 lb/in3 0.318 0.318 0.305 0.306 0.305 0.296 0.300 0.300 0.299 0.294 0.321 0.303 0.289 0.290 0.290 0.287 0.294 g/cm3 8.80 8.80 8.44 8.47 8.44 8.19 8.30 8.30 8.28 8.14 8.89 8.39 8.02 8.03 8.03 7.94 8.14 Modulus 106psi 26.0 26.0 26.0 31.1 30.1 29.0 29.6 29.6 31.0 28.9 29.8 27.9 27.7 27.6 29.0 28.5 29.8 GPa 179 179 179 221 208 200 204 204 214 199 205 192 191 190 200 197 205 Magnetic Permeabilityb d d 1.002 1.010 1.0006 1.0011 <1.001 <1.001 1.0035 1.0002 1.004 1.005 1.014 1.005 Specific Heat Btu/ lb.F 0.102 0.102 0.100 0.106 0.098 0.104 0.103 0.108 0.102 0.109 0.12 0.11 0.11 0.105 J/ kg.C 427 427 419 444 410 435 431 452 427 454 500 460 460 440 of Expansionc 10-6/ 10-6/ F 8.8 8.7 8.3 7.9 7.4 8.0 7.5 7.5 7.5 8.1 7.2 7.5 8.8 9.9e 8.3 9.0 8.5 C 15.8 15.7 14.9 14.2 13.3 14.4 13.0 13.0 13.5 14.6 13.0 13.5 15.8 17.8e 14.9 16.2 15.3

Coefficient

Thermal
Conductivity Btu.in/ ft2.h.F 151 151 121 103 68 79 83 69 68 70 116 79 80 77 W/m. C 21.8 21.8 17.5 14.9 9.8 11.4 12.0 10.0 9.8 10 16.7 11.4 11.5 11.1

Electrical
Resistivity ohm. cmil/ft 329 307 370 620 776 751 688 688 731 739 604 480 560 595 678 701 ohmm 0.547 0.510 0.615 1.03 1.29 1.25 1.14 1.14 1.22 1.23 1.00 0.80 0.93 0.989 1.13 1.17

INCOLOY alloy 925 0.292 8.08 29.2 201 1.001 0.104 435 8.2 14.8 a Room-temperature values except for thermal expansion. b H=200 oersted (15.9kA/m). c Between room temperature and 600F (315C). d May be ferromagnetic at room temperature; Curie temperature varies from slightly below to somewhat over room temperature. e Between room temperature and 750F (400C).

23

Below. The QATARGAS project, in the Persian Gulf, is probably the largest investment in energy out of the Middle East. INCONEL alloy 625 was specified for Phase 1 piping systems at the wellheads, on the utility processing platform, and for inter-platform systems carried by bridges. INCOLOY alloy 825 tubing was specified for Phase 2 for its proven track record as a downhole tubular product in oil and gas fields worldwide.

Right. 7-inch (178 mm) diameter INCOLOY alloy 825 threaded tubing for the Phase 2 downhole requirements of the QATARGAS project. (Grant Prideco, Inc., Houston)

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M A T E R I A L S

S E L E C T I O N

TYPICAL MECHANICAL PROPERTIES FOR OIL COUNTRY TUBULAR GOODS

Yield Strength* Alloy ksi INCONEL alloy G-3 INCONEL alloy C-276 INCONEL alloy 050 INCOLOY alloy 028 INCOLOY alloy 825 INCOLOY alloy 925 125 125 125 110 110 110 MPa 862 862 862 758 758 758 ksi 130 130 130 130 130 140 MPa 896 896 896 896 896 965 % 13 13 13 15 16 18 Max. for sour well service C39 max. C45 max. C38 max. C33 max. C35 max. C38 max. Tensile Strength* Elongation Hardness, Rockwell* *

*Other strength levels available on request. **Condition and hardness limitations as stipulated by NACE MR0175.

TYPICAL MECHANICAL PROPERTIES FOR AGE-HARDENED CORROSION-RESISTANT ALLOY BAR

Yield Strength Alloy ksi MONEL alloy K-500 INCONEL alloy 718 INCONEL alloy 725 INCONEL alloy 725HS INCONEL alloy X-750 INCOLOY alloy 925 95 120 120 149 110 110 MPa 655 827 827 1029 758 758 ksi 130 150 150 199 165 140 MPa 896 1034 1034 1372 1138 965 % 20 20 20 22 20 15 Rockwell C35 C40 C40 C43 C35 C38 Tensile Strength Elongation Hardness*

*Condition and hardness limitations as stipulated by NACE MR0175.

TYPICAL MECHANICAL PROPERTIES FOR ANNEALED CORROSION-RESISTANT ALLOYS

Yield Strength Alloy ksi MONEL alloy 400 INCONEL alloy 600 INCONEL alloy 625 INCONEL alloy C-276 INCOLOY alloy 25-6MO INCOLOY alloy 27-7 MO INCOLOY alloy 800 INCOLOY alloy 825 35 45 80 60 48 60 35 45 MPa 214 310 552 414 331 415 214 310 ksi 80 95 135 115 100 120 85 100 MPa 552 655 931 793 690 830 586 690 % 40 40 45 50 42 50 45 45 Rockwell B65 B80 B95 B90 B88 B90 B70 B85 Tensile Strength Elongation Hardness

25

M A T E R I A L S

S E L E C T I O N

WEIGHTS AND PRESSURE RATINGS OF TUBING AND CASING (cont. on p.23)

Nominal Weight, Threads and Coupling lb/ft 4.60 5.80 7.70 6.40 7.80 8.60 9.50 11.65 9.20 10.20 12.70 15.80 11.00 13.40 15.89 19.00 12.60 13.50 15.50 19.20 21.60 24.60 13.00 15.00 18.00 20.80 23.20 24.10 27.00 15.50 17.00 20.00 23.00 20.00 24.00 28.00 32.00 20.00 23.00 26.00 29.00 32.00 35.00 38.00 kg/m 6.85 8.63 11.46 9.52 11.61 12.80 14.14 17.34 13.69 15.18 18.90 23.51 16.37 19.94 23.65 28.28 18.75 20.09 23.07 28.57 32.14 36.61 19.35 22.32 26.79 30.95 34.53 35.86 40.18 23.07 25.30 29.76 34.23 29.76 35.72 41.67 47.62 29.76 34.23 38.69 43.16 47.62 52.09 56.55 Calculated Plain -End Weight INCOLOY alloy 825, INCONEL alloy C-276 INCONEL alloy G-3 lb/ft 4.60 5.97 7.59 6.38 7.95 8.76 9.54 11.87 9.13 10.27 12.98 15.95 10.85 13.42 16.49 19.40 12.70 13.52 13.54 19.40 22.17 24.45 13.31 15.43 18.61 21.41 23.96 24.94 27.55 15.92 17.50 20.56 23.39 20.23 24.47 28.70 32.39 20.28 23.49 26.63 29.81 32.87 35.89 38.66 kg/m 6.85 8.88 11.30 9.49 11.83 13.04 14.20 17.66 13.59 15.28 19.32 23.74 16.15 19.97 24.54 28.87 18.90 20.12 23.13 28.87 32.99 36.39 19.81 22.96 27.69 31.86 35.66 37.11 41.00 23.69 26.04 30.60 34.81 30.11 36.42 42.71 48.20 30.18 34.96 39.63 44.36 48.92 53.41 57.53 lb/ft 5.02 6.52 8.29 6.97 8.68 9.56 10.42 12.96 9.97 11.22 14.17 17.41 11.85 14.65 18.01 21.18 13.87 14.76 16.97 21.18 24.20 26.70 14.53 16.85 20.32 23.38 26.16 27.23 30.08 17.38 19.11 22.45 25.53 22.09 26.72 31.33 35.36 22.15 25.64 29.08 32.55 35.89 39.18 42.21 kg/m 7.47 9.70 12.34 10.37 12.92 14.23 15.51 19.29 14.84 16.70 21.09 25.91 17.63 21.80 26.80 31.52 20.64 21.97 25.25 31.52 36.01 39.73 21.62 25.08 30.24 34.79 38.93 40.52 44.76 25.86 28.44 33.41 37.99 32.87 39.76 46.62 52.62 32.96 38.16 43.28 48.44 53.41 58.31 62.82

Outside Diameter in 23/8 mm 60.3

Wall Thickness in 0.190 0.254 0.336 mm 4.83 6.45 8.53 5.51 7.01 7.82 8.64 11.18 6.45 7.34 9.52 12.09 6.65 8.38 10.54 12.70 6.88 7.37 8.56 10.92 12.70 14.22 6.43 7.52 9.19 10.72 12.14 12.70 14.22 6.98 7.72 9.17 10.54 7.32 8.94 10.59 12.06 6.91 8.05 9.19 10.36 11.51 12.65 13.72

27/8

73.0

0.217 0.276 0.308 0.340 0.440

31/2

88.9

0.254 0.289 0.375 0.476

Above. A 236 ft (72 m) flare tower with stack and flaretip components of INCOLOY alloys 800HT Below. An Indair flare at the and 825. works of the fabricator, F. Atkinson Ltd., Nottingham, England. The tulip is made of INCOLOY alloy 800HT, mounted above a cone of INCOLOY alloy DS.

101.6

0.262 0.330 0.415 0.500

41/2

114.3

0.271 0.290 0.337 0.430 0.500 0.560

127.0

0.253 0.296 0.362 0.422 0.478 0.500 0.560

51/2

139.7

0.275 0.304 0.361 0.415

65/8

168.3

0.288 0.352 0.417 0.475

177.8

0.272 0.317 0.362 0.408 0.453 0.498 0.540

26

*Based on 87.5% remaining body wall

WEIGHTS AND PRESSURE RATINGS OF TUBING AND CASING (continued)

Yield Strength:110,000 psi (758 MPa) Outside Diameter in 23/8 mm 60.3 Collapse Pressure* 1000 psi 16.13 21.01 26.72 27/8 73.0 14.55 19.09 21.04 22.94 28.52 31/2 88.9 13.53 16.67 21.05 25.85 4 101.6 11.06 16.65 20.46 24.06 41/2 114.3 9.21 10.68 14.34 19.01 19.80 23.97 5 127.0 5.84 8.85 13.47 17.00 19.02 19.80 21.88 51/2 139.7 5.63 7.48 11.10 14.54 65/8 168.3 4.03 6.73 10.16 13.20 7 177.8 2.98 4.44 6.23 8.53 10.78 13.03 15.11 MPa 111.2 144.9 184.2 100.3 131.6 145.1 158.2 196.6 93.3 114.9 145.1 178.2 76.3 114.8 141.1 165.9 63.5 73.6 98.9 131.1 136.5 165.3 40.3 61.0 92.9 117.2 131.1 136.5 150.9 38.8 51.6 76.5 100.3 27.8 46.4 70.1 91.0 20.5 30.6 43.0 58.8 74.3 89.8 104.2 Internal Yield Pressure* 1000 psi 15.40 20.59 27.23 14.53 18.48 20.62 22.77 29.46 13.97 15.89 20.62 26.18 12.61 15.88 19.97 24.06 11.59 12.41 14.42 18.39 19.25 23.96 9.74 11.40 13.94 16.25 18.40 19.25 21.56 9.63 10.64 12.63 14.52 8.37 10.23 12.12 13.80 7.48 8.72 9.95 11.22 12.46 13.69 14.85 MPa 106.2 142.0 187.7 100.2 127.4 142.2 157.0 203.1 96.3 109.6 142.2 180.5 86.9 109.5 137.7 165.9 79.9 85.6 99.4 126.8 132.7 165.2 67.2 78.6 96.1 112.0 126.9 132.7 148.7 66.4 73.4 87.1 100.1 57.7 70.5 83.6 95.2 51.6 60.1 68.6 77.4 85.9 94.4 102.4 Yield Strength:125,000 psi (862 MPa) Collapse Pressure* 1000 psi 17.90 23.88 30.36 16.07 21.70 23.91 26.07 32.41 14.89 18.94 23.92 29.38 12.03 18.92 23.24 27.34 9.89 11.60 15.84 21.61 22.50 27.24 6.05 9.48 14.82 19.32 21.68 22.50 24.86 5.89 7.89 12.08 16.06 4.17 7.02 10.99 14.55 2.98 4.65 6.45 9.11 11.71 14.31 16.76 MPa 123.4 164.7 209.3 110.8 149.6 164.9 179.8 223.4 102.7 130.6 164.9 202.6 82.9 130.5 160.2 188.5 68.2 80.0 109.2 149.0 155.1 187.8 41.7 65.4 102.2 133.2 149.5 155.1 171.4 40.6 54.4 83.3 110.7 28.8 48.4 75.8 100.3 20.5 32.1 44.5 62.8 80.7 98.7 115.6 Internal Yield Pressure* 1000 psi 17.50 23.39 30.95 16.51 21.00 23.43 25.87 33.84 15.87 18.06 23.44 29.75 13.33 18.05 22.69 27.34 13.17 14.10 16.38 20.90 21.88 27.22 11.07 12.95 15.84 18.46 20.91 21.88 24.50 10.94 12.09 14.36 16.51 9.51 11.62 13.77 15.68 8.50 9.91 11.31 12.75 14.16 15.56 16.87 MPa 120.7 161.3 213.4 113.8 144.8 161.5 178.4 233.3 109.4 124.5 161.6 205.1 91.9 124.5 156.4 188.5 90.8 97.2 112.9 144.1 150.9 187.7 76.3 89.3 109.2 127.3 144.2 150.9 168.9 75.4 83.4 99.0 113.8 65.6 80.1 94.9 108.1 58.6 68.3 78.0 87.9 97.6 107.3 116.3 Yield Strength:130,000 psi (896 MPa) Collapse Pressure* 1000 psi 18.47 24.83 31.58 16.56 22.56 24.87 27.11 33.70 15.33 19.56 24.87 30.55 12.33 19.53 24.17 28.44 10.09 11.88 16.31 22.47 23.40 28.31 6.16 9.66 15.25 20.09 22.48 23.40 25.86 5.99 8.00 12.39 16.55 4.20 7.09 11.25 14.95 2.98 4.69 6.49 9.27 12.00 14.72 17.26 MPa 127.4 171.2 217.7 114.2 155.6 171.5 186.9 232.4 105.7 134.9 171.5 210.6 85.0 134.7 166.7 196.1 69.6 81.9 112.5 154.9 161.3 195.2 42.5 66.6 105.1 138.5 155.0 161.3 178.3 41.3 55.2 85.4 114.1 29.0 48.9 77.6 103.1 20.5 32.3 44.7 63.9 82.7 101.4 119.0 Internal Yield Pressure* 1000 psi 18.20 24.33 32.19 17.17 21.84 24.37 26.90 34.82 16.51 18.78 24.37 30.94 14.40 18.77 23.60 28.44 13.70 14.66 17.04 21.74 22.75 26.83 11.51 13.47 16.47 19.20 21.75 22.75 25.48 11.38 12.58 14.93 17.17 9.89 12.09 14.32 16.31 8.84 10.30 11.76 13.26 14.72 16.18 17.55 MPa 125.5 167.8 222.0 118.4 150.6 168.0 185.5 240.1 113.8 129.5 168.0 213.3 99.3 129.4 162.7 196.1 94.5 101.1 117.5 149.9 156.9 185.0 79.4 92.9 113.6 132.4 150.0 156.9 175.7 78.5 86.7 102.9 118.4 68.2 83.4 98.7 112.5 61.0 71.0 81.1 91.4 101.5 111.6 121.0

*Based on 87.5% remaining body wall

27

M A T E R I A L S

S E L E C T I O N

SPECIFICATIONS AND DESIGNATIONS FOR NICKEL ALLOYS USED IN OIL-COUNTRY APPLICATIONS

Alloy MONEL alloy 400 UNS N04400 NACE MR-01-75 ASTM B 127 B 163-165 B 366 B 564 B 725 B 730 B 751 B 775 B 829 B 164 B 865 B 163 B 166-168 B 366 B 516-517 B 564 B 751 B 775 B 829 B 366 B 443-444 B 446 B 564 B 704-705 B 751 B 775 B 829 B 637 B 670 ASME SB-127 SB-163-165 SB-366 SB-564 SB-751 SB-775 SB-829 SB-164 SB-163 SB-166-168 SB-366 SB-516-517 SB-564 SB-751 SB-775 SB-829 SB-366 SB-443, 444 SB-446 SB-564 SB-704-705 SB-751 SB-775 SB-829 SB-425 SB-637 SAE AMS 4544 4574,4575 4675 4730, 4731 7233 BS 3072-3076 DIN 17743 17750-54 Werkstoff Nr. 2.4360 VdTV 263

MONEL alloy R-405 MONEL alloy K-500 INCONEL alloy 600

N04405 N05500 N06600

MR-01-75 MR-01-75 MR-01-75

4674 7234 4676 5540 5580 5665 5687 7232

3072-3076 3072-3076

17743 17752-54 17742 17750-54

2.4375 2.4816

305

INCONEL alloy 625

N06625

MR-01-75

5581 5599 5666 5837 5869

3072 3074 3076

17744 17750-52

2.4856

499

INCONEL alloy 718

N07718

MR-01-75

INCONEL alloy 725 INCONEL alloy X-750

N07725 N07750

MR-01-75 MR-01-75

B 805 B 637

SB-443, 444 SB-446 SB-637

5589, 5590 5596, 5597 5662-5664 5832 5962 5542 5582, 5583 5598 5667-5671 5698, 5699 5747

2.4668

HR505

2.4669

INCONEL alloy G-3

N06985

MR-01-75

INCONEL alloy C-276

N10276

MR-01-75

INCONEL alloy 050 INCOLOY alloy 800

N06950 N08800

MR-01-75 MR-01-75

INCOLOY alloy 825

N08825

MR-01-75

INCOLOY alloy 925 INCOLOY alloy 25-6MO

N09925 8926

MR-01-75 MR-01-75

B 366 B 581, 582 B 619 B 622 B 626 B 751 B 775 B 829 B 366 B 564 B 574, 575 B 619 B 622 B 626 B 751 B 775 B 829 B 163 B 366 B 407-409 B 514, 515 B 564 B 751 B 775 B 829 B 163 B 366 B 423-425 B 564 B 704, 705 B 751 B 775 B 829 B 366 B 472 B 625 B 649 B 673, 674 B 677 B 751 B 775 B 804 B 829 B 668 B 709

SB-366 SB-582 SB-619 SB-622 SB-626 SB-751 SB-775 SB-829 SB-366 SB-582 SB-619 SB-622 SB-626 SB-751 SB-775 SB-829 SB-163 SB-366 SB-407-409 SB-514, 515 SB-564 SB-751 SB-775 SB-829 SB-163 SB-366 SB-423-425 SB-564 SB-704, 705 SB-751 SB-775 SB-829 SB-423-425 SB-564 SB-366 SB-625 SB-649 SB-673, 674 SB-677 SB-751 SB-775 SB-804 SB-829 SB-668 SB-709

17744 17750-52

2.4619

17744 17750-52

2.4819

400-12.98

5766 5871

3072-3076

470

1.4876

412

1.4529

INCOLOY alloy 028

N08028

MR-01-75

1.4563

P A R T

EFFECTS OF WELL ENVIRONMENTS

E F F E C T S

O F

W E L L

E N V I R O N M E N T S

Corrosive well environments degrade materials in three general ways: 1. Weight-loss corrosion, in which the metal surface is more or less uniformly attacked. 2. Pitting or crevice corrosion, in which metal

corrosion operate by different mechanisms. Pitting occurs when a point location becomes anodic to the surrounding metal, resulting in continuing corrosion penetration at the anodic point. Crevice corrosion takes place when the concentration of metallic ions or oxygen is different in a crevice (or under a deposit) than in the surrounding environment. Such localized corrosion can be particularly likely on materials such as stainless steels that form protective, passive surface films. Chloride ions in the environment can accumulate and penetrate the passive film to allow corrosion at the area of film removal. Nickel alloys also form passive films. However, chromium and molybdenum, especially the latter, are highly effective in preventing localized corrosion. Nickel alloys used for downhole applications generally contain sufficient molybdenum and chromium to avoid pitting and crevice corrosion. ENVIRONMENT-INDUCED CRACKING The combined effects of stress and certain corrosive environments can cause failure of metals not by mass loss but by brittle fracture at stress levels substantially under a metals yield strength. Tubing strings are unavoidably under high stress, and sour wells present a corrosive environment that can induce cracking. In deep, sour gas wells, the avoidance of environmental cracking is often the primary consideration in materials selection. The problem is compounded by several interacting factors. As well depth increases, more strength is required in the tubing string, and, in general, metals are more susceptible to cracking as their strength and hardness increase. To that situation is added that both stress and aggressiveness of environment increase with depth. Materials selection is critical. It must be determined with certainty that the selected material will not undergo cracking in the particular well environment. Failure of tubing by environmental cracking can be sudden, with no foretelling evidence such as wall thinning by corrosion.

loss is highly localized. 3. Environment-induced cracking, in which brittle fracture occurs with no significant metal loss. WEIGHT-LOSS CORROSION (GENERAL CORROSION) The complexity of a material affects its resistance to weight-loss corrosion. Carbon dioxide dissolved in the liquid phase creates an acidic solution that can cause rapid weight-loss corrosion of carbon steels, even at relatively low temperatures. Chlorides and H2S increase the corrosivity of the solution. Martensitic stainless steels are also susceptible to weight-loss corrosion, especially at high temperatures with chlorides or H2S present. Duplex and austenitic stainless steels have higher resistance to weight-loss corrosion. Nickel alloys generally show complete resistance to weight-loss corrosion even under conditions of high temperatures and high concentrations of chlorides and H2S. When dissimilar metals are in contact while exposed to an aqueous environment, galvanic effects can cause or alter corrosion reactions. The less noble metal in the galvanic couple is corroded at a higher rate than would occur if the metal were exposed alone. The effect is more pronounced if the surface area of the less noble metal is small in relation to the more noble metal. In general, nickel alloys and austenitic stainless steels are similar enough in corrosion potential that galvanic corrosion is not a serious problem when couples are formed within or between the two materials groups. However, galvanic corrosion is a possibility when highly alloyed materials are connected to carbon steels, alloy steels, or martensitic stainless steels. LOCALIZED CORROSION Pitting and crevice corrosion have similar consequences: localized destruction of metal. However, the two forms of

30

Weight-corrosion, also

called general corrosion, results in nearly uniform deterioration of a metals surface.

2

Pitting is localized pene-

tration, normally at many different sites. The metal between pits is relatively unaffected although pits may become connected as attack progresses.

Crevice corrosion under

removed bolts.

31

Crevices and surface

deposits can result in different concentrations of dissolved matter, such as metal ions, leading to accelerated local corrosion.

6 6

+ 7 Stress-corrosion crack-

ing in stainless-steel vessel and tube.

32

E F F E C T S

O F

W E L L

E N V I R O N M E N T S

Magnified (100X) appearance of stresscorrosion cracking.

In sour wells, environmental cracking can occur by two different mechanisms: hydrogen embrittlement and stress corrosion. Hydrogen embrittlement involves a cathodic reaction in which hydrogen ions are reduced to elemental hydrogen. Hydrogen ions may result from galvanic corrosion of connected dissimilar metals or from acidizing operations performed on the reservoir. In sour wells, however, the major source is usually dissolved H2S in well fluids. Elemental hydrogen absorbed by a metal can lower ductility to the point where the metal becomes embrittled. If the metal is under sufficient stress, cracking results. Such cracking in H2S environments is termed sulfide stress cracking (SSC). Hydrogen embrittlement and SSC are essentially low-temperature phenomena with maximum severity occurring in the room-temperature range. Stress corrosion involves an anodic reaction in which a crack is initiated and propagated in stressed metal by dissolution of metal ions. Metal loss continues at the leading edge of the crack until brittle fracture occurs. Such stress-corrosion cracking (SCC) can be caused by various media. In sour wells, SCC can result from two corrosive species: chloride ions and H2S. Chloride SCC normally is not a problem with ferritic materials and nickel alloys. Austenitic stainless steels, especially those of relatively low nickel content, can suffer chloride SCC at

33

E F F E C T S

O F

W E L L

E N V I R O N M E N T S

temperatures as low as 140F (60C) and become more susceptible at higher temperatures. Stress-corrosion cracking induced by H2S is similar to chloride SCC but affects a broader range of materials, including nickel alloys. This form of environmental cracking is often the major factor in overcoming the effects of sour well environments on materials. The potential for SCC becomes greater with higher temperatures and concentrations of H2S and with the presence of chloride ions and elemental sulfur. Extremely hot and sour wells require corrosion-resistant alloys with high contents of nickel, chromium and molybdenum. Virtually all metallic materials are susceptible to SSC or SCC in sour environments, although the conditions for susceptibility vary widely. A major factor is the concentration of dissolved H2S, which increases with partial pressure of the gas. Low-alloy and carbon steels are vulnerable to SSC at partial pressure of H2S as low as about 0.05 psi (345 Pa). By definition (NACE MR-01-75) a well with a
The classic indicator of susceptibility to chloride-ion stresscorrosion cracking is the boiling 42% magnesium chloride test. The test has shown that alloys containing more than about 45% nickel are immune to chloride stress cracking.

partial pressure of H2S greater than 0.05 psi (345 Pa) is designated as sour. If a well is sour, downhole components must be made of a corrosion-resistant alloy that will resist the particular sour conditions.

34

P A R T

CORROSION TESTING

C O R R O S I O N

T E S T I N G

Nickel alloys used for downhole service do not undergo localized corrosion or chloride-ion stress corrosion cracking in sour well environments and experience only slight weightloss corrosion. Levels of C02 and chlorides important factors in evaluating stainless and carbon steels are generally negligible when nickel alloys are considered. Environmental cracking induced by H2S, either sulfide stress cracking (SSC) or stress-corrosion cracking (SCC), is the operative mode of potential failure for nickel alloys. Most nickel alloys are resistant to SSC and SCC with the degree of resistance depending on alloy composition, strength level, stress level, temperature, and amount of H2S in the environment. Laboratory tests using different combinations of those variables can determine conditions under which alloys do or do not suffer cracking. Two widely used tests are the C-ring test and the slow-strain-rate test. Both tests involve exposure of specimens to simulated sour well environments, but at stress levels substantially higher than normal service conditions. The C-ring test uses a specimen made from a portion of tubing cross section with circumferential stress applied by a tightened bolt. A formula is used to relate deflection of the Cring to axial tensile yield strength of the material. A stress equal to 100% of yield strength (0.2% offset) is frequently
2

applied. The stressed C-ring is exposed to a sour environment and periodically inspected for cracking. A standard environment for SSC is the NACE Solution, which is stipulated by test standards of the National Association of Corrosion Engineers. It consists of 5% sodium chloride and 0.5% acetic acid in distilled water saturated with hydrogen sulfide. The NACE test (TM-01-77) is conducted at room temperature and atmospheric

36

+ 2 + 3 Alloys are evaluat-

ed in a fully equipped corrosion laboratory that includes autoclaves for testing at high pressures and temperatures.

Alloys are exposed to vari-

ous corrosive environ-ments in the laboratory to predict their performance under service conditions.

+6+7+

Special Metals maintains extensive computerized corrosion data in both proprietary and commercial systems. Test results such as slow-strain-rate data can be presented by computer.
7

37

C O R R O S I O N

T E S T I N G

pressure. The alloy C-rings are often galvanically coupled to carbon steel to expose the specimen to hydrogen that evolves as the steel corrodes. Stressed C-rings, normally not coupled to steel, are also used in autoclave tests to determine resistance to SCC at high temperatures and pressures. The slow-strain-rate test determines resistance to SCC. A tensile specimen is exposed to the sour environment while being subjected to stress that produces a constant, slow rate of strain. The results are normally compared with a slowstrain rate test performed in air at the same strain rate. Differences between the two tests in time to fracture, percent elongation, and percent reduction of area indicate the effect of the sour environment on the material. Ratios of test-solution values to air values are often used as gauges of a materials performance. Because the slow-strain-rate test causes continual rupturing of any passive films on the specimen, it may be more severe than the C-ring test. Another test sometimes used to evaluate materials in sour environments is the constant-load test. The specimen is exposed to the environment while under an unvarying tensile load. The accompanying tables and charts indicate the resistance of Special Metals products to various environments in different test types. In the slow-strain-rate tests, the strain rate was 4x10-6 s-1 unless otherwise noted. Test solutions were made up with distilled water along with amounts of corrosive species as described with the test results. As shown by the results of tests in environments containing elemental sulfur, wells in sour formations that also contain free sulfur are especially harsh environments. The presence of free sulfur can deduct 50F (30C) or more from the temperature capability of an otherwise resistant alloy.
9

C-ring specimen used to determing resistance to sulfide stress cracking and stress-corrosion cracking,

38

10

12

10

Slow-strain-rate specimen

used to detemine resistance to sulfide stress cracking and stress-corrosion cracking.

11

Apparatus for sulfide

stress-cracking testing (NACE test).

11 12

Apparatus for slow-strain-

rate testing.

39

C-RING TESTS IN NACE SOLUTIONa

Yield Strength (0.2% Offset) Alloy INCONEL alloy 625 Material Condition Cold Worked Cold Worked Cold Worked Age Age Age Age Age Hardened Hardened Hardened Hardened Hardened Simulated Well Age None None None None None None None None 1000 psi 125.0 160.0 176.0 120.0 130.0 134.0 139.0 156.0 90.0 117.6 128.6 130.8 132.9 133.0 137.8 119.4 132.3 135.3 136.9 137.7 181.7 126.6 155.1 166.8 188.7 138.0 147.0 114.0 139.0 176.0 186.0 113.5 139.5 176.0 180.0 185.5 MPa 862 1103 1214 827 896 924 958 1076 621 811 887 902 916 917 950 823 912 933 944 949 1253 873 1069 1150 1301 952 1014 786 958 1214 1282 783 962 1214 1214 1279 Hardness, Duration, RC Days 30.5 37.5 41 30 37 38.5 38 41 25 37 40 41.5 36 39 39 26 30 31 32 38 35 43 30 33 38 35.5 43.5 46 38 35.5 43.5 44 46 42 10 6 42 42 42 42 60 30 30 30 30 42 30 42 43 43 43 30 30 30 43 43 43 43 42 42 42 42 42 42 42 42 42 42 42

Sulfide Stress Cracking No Yes Yes No No No No No No No No No No No No No No No No, Nob No, Nob No, Yesb No No No No No No No No No No No No No No No

INCONEL alloy 718

INCONEL alloy 725

Cold Worked None Age Hardened None Age Hardened None Age Hardened 600F (315C)/1000h Age Hardened None Age Hardened None Cold Worked & Aged None Cold Cold Cold Cold Cold Cold Cold Cold Cold Cold Worked Worked Worked Worked Worked Worked Worked Worked Worked Worked 600F 600F 600F 600F 600F 600F 600F 600F 600F 600F (315C)/1000h (315C)/1000h (315C)/1000h (315C)/1000h (315C)/1000h (315C)/1000h (315C)/1000h (315C)/1000h (315C)/1000h (315C)/1000h None None None None None None (260C)/500h (260C)/500h (260C)/500h (260C)/500h (260C)/500h

INCONEL alloy G-3

INCONEL alloy C-276

INCOLOY alloy 825 INCOLOY alloy 925

Cold Worked Cold Worked Age Hardened Cold Worked Cold Worked & Cold Worked & Age Hardened Cold Worked Cold Worked & Cold Worked & Cold Worked &

Aged Aged Aged Aged Aged 500F 500F 500F 500F 500F

a Room-temperature tests at 100% of yield strength in 5% NaCl plus 0.5% acetic acid saturated with H S. All specimens were coupled to 2 carbon steel. b

Duplicate test specimens.

40

C O R R O S I O N

T E S T I N G

WEIGHT-LOSS TESTSa IN H2S ENVIRONMENTS

Corrosion Rate 300F(149C) 400F(204C) mpy mm/y 0.0 0.3 0.1 0.1 0.4 0.1 0.1 0.4 0.1 3.0 0.7 0.1 27 78 221 206 299 0.000 0.008 0.003 0.003 0.010 0.003 0.003 0.010 0.003 0.076 0.018 0.003 0.69 1.98 5.61 5.23 7.59 mpy 0.1 0.4 0.2 0.1 0.5 0.5 0.1 0.5 0.4 0.3 2.3 1.2 1.1 113 169 278 172 mm/y 0.003 0.010 0.005 0.003 0.013 0.013 0.003 0.013 0.010 0.008 0.058 0.030 0.28 2.87 4.29 7.06 4.37 Alloy

WEIGHT-LOSS TESTSa IN FREE-SULFUR ENVIRONMENTS

Corrosion Rate Test Mediab A B A B A B A B A B mpy 0.2 0.1 0.7 0.2 1.1 1.2 1.1 1.6 3.9 4.5 mm/y 0.005 0.003 0.018 0.005 0.028 0.030 0.028 0.041 0.099 0.114

Alloy

H2S Pressure psi kPa 69 345 690 69 345 690 69 345 690 69 345 690 69 345 690 345 690

INCONEL alloy C-276 INCONEL alloy 625

INCONEL alloy 625

10 50 100 10 50 100 10 50 100 10 50 100 10 50 100 50 100

INCOLOY alloy 825

INCOLOY alloy 925 INCOLOY alloy 825 AISI Type 316

INCOLOY alloy 925

INCONEL alloy 718

a b

MONEL alloy K-500

Autoclave tests of 15-day duration on unstressed coupons. Solution A: 15% NaCl plus 200 psi (1380 kPa) H2S Plus 100psi (690 kPa) C02 plus 1 g/L of sulfur at 450F (232C). Solution B: 25% NaCl plus 200psi (1380 kPa) H2S Plus 100psi (690 kPa) C02 Plus 1 g/L of sulfur at 400F (204C).

9Cr/1Mo Steel
a

Autoclave tests of 14-day duration in 15% NaCl/distilled water with total gas pressure of 1000 psi (6.9 MPa) consisting of 500 psi (3.4 MPa) C02 plus N2 and H2S.

STRESS-CORROSION-CRACKING TESTSa IN FREE-SULFUR ENVIRONMENT

Yield Strength (0.2% Offset) 1000 psi Mpa 898 993 1103 876 1069 1151 1158 Stress-Corrosion Cracking 350F (177C) Yesc No No No No No No Yes Yes No No No No 375F (191C) 400F (204C) No No No No No No No No No No No No No No No No No Yes No Yes 425F (218C) 450F (232C) 475F (246C) 5OOF (26OC)

Alloy INCONEL alloy 718 INCONEL alloy 625 INCONEL alloy C-276

Material Condition

Age Hardened 130.3 Cold Worked Cold Worked Cold Cold Cold Cold Worked Worked Worked Worked 144.0 160.0 127.0 155.0 167.0 168.0

a C-ring autoclave tests of 14-day duration at 100% of yield strength in 25% NaCl plus 0.5% acetic acid plus 1 g/L sulfur plus 120 psi (827 kPa) H2S. b One of two specimens cracked. c At 275F (135C),

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T E S T I N G

42

STRESS-CORROSION-CRACKING TESTSa IN HIGH-TEMPERATURE SOUR ENVIRONMENTS

Yield Strength (0.2% Offset) Alloy INCONEL alloy 625 Material Condition Cold Cold Cold Cold Cold Cold Cold Worked Worked Worked Worked Worked Worked Worked 1000 psi 128.0 177.1 128.0 177.1 125.0 160.0 176.0 120.0 134.0 197.0 133.5 133.5 137.5 137.5 183.3 133.5 133.5 137.5 183.3 194.7 194.7 131.0 138.0 147.0 Aged Aged Aged Aged 166.0 133.5 185.5 114.0 139.0 176.0 185.5 MPa 883 1221 883 1221 862 1103 1214 827 924 1358 920 920 948 948 1264 920 920 948 1264 1342 1342 903 952 1014 1145 783 1279 786 958 1214 1279 Hardness, RC 37 41 37 41 30.5 37.5 41 30 38.5 37.5 33 33 30 30 38 33 33 30 38 43.5 43.5 30 30 33 40.5 38 46 38 35.5 43.5 46 Test Mediab A A B B C C C C C C D D D D D E E E E A B A C C A B B C C C C

Stress Duration, Corrosion Days Cracking 15 15 15 15 42 42 42 42 42 20 60 120 90 120 120 60 120 120 120 15 5 15 42 42 15 15 15 42 42 42 42 No No No No No No No No No Yes No No Yes No No No No No No No No Yes No No Yes Yes Yes No No No No

INCONEL alloy 718

Age Hardened Age Hardened Cold Worked Cold Cold Cold Cold Cold Cold Cold Cold Cold Worked Worked Worked Worked Worked Worked Worked Worked Worked

INCONEL alloy G-3

INCONEL alloy C-276 INCOLOY alloy 825

Cold Worked Cold Worked Cold Worked Cold Worked Cold Worked Cold Worked & Age Hardened Cold Worked & Age Hardened Cold Worked Cold Worked & Cold Worked &

INCOLOY alloy 925

a Autoclave tests on C-ring specimens stressed at 100% of yield strength. b Test Media: A = 15% NaCl plus 200 psi (1380 kPa) H2S PIUS 100 PSi (690 kPa) C02 plus 1 g/L of suifur at 450F (232C). B = 25% NaCl plus 200 psi (1380 kPa) H2S PIUS 100 PSi (690 kPa) C02 plus 1 g/L of sulfur at 400F (204C). C = 15% NaCl saturated with H2S plus 1000 psi (6.9 MPa) gas phase of 1% H2S, 50% C02, 49% N2 at SOOF (260C). D = 25% NaCl plus 100 psi (690 kPa) H2S plus 200 psi (1380 kPa) C02 at 400F (204C). E = Same as D but at 425F (218C).

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