Corrosion-Resistant Alloys in Oil and Gas Production, Volumes I-II

1137 Pages·1996·99.26 MB·English

by  Kolts

Corrosion-Resistant Alloys
in Oil and Gas Production
Volume I and Volume II
Juri Kolts and Stephen Yb! Ciaraldi,
editors
NACE International Houston 19%
NACE International
0 1996 by NACE International
All rights reserved.
Printed in the United States of America
Library of Congress Catalog Card Number: 96-069736
ISBN: 1-877914-92-4
Reproduction of contents in whole or part or transfer into electronic
or photographic storage without permission of copyright owner is
expressly forbidden.
Neither NACE International, its officers, directors, nor members
thereof accept any responsibility for the use of the methods and ma-
terials discussed herein. No authorization is implied concerning the
use of patented or copyrighted material. The information is advisory
only, and the use of the materials and methods is solely at the risk of
the user.
NACE International, 1440 South Creek Dr., Houston, TX 77084
[phone]
Preface
Following decades of low product margins, the “oil crisis” of the 1970s resulted in substantial increases in
energy prices. This economic trend produced a surge in oil and gas exploration, development, and production,
including the pursuit of deep, highly pressured, and environmentally hostile hydrocarbon reserves. The associ-
ated technical hurdles spawned a significant increase in research and other technology activities aimed at
addressing the challenges.T hese technology activities continued through the 1980s and are still ongoing today.
Despite lower product prices, technology is now recognized as a critical enabling element for economic feasi-
bility of many oil and gas developments and a substantial contributor to minimizing exploration and produc-
tion costs.
Materials technology was among those advanced by the recent petroleum industry events just described.
Advancements were particularly evident in the use and further development of corrosion-resistanta lloys for
oil and gas production. Historically, corrosion-resistant alloys had been used in instruments, valve compo-
nents, and downhole equipment. In the 1980s, use of corrosion-resistanta lloys was extended to tubing and
liners. ’Ihis increasingly common application was fueled by the recognition that alloy use could provide
considerable cost savings through a project’s life cycle, despite higher initial capital expense. More recently,
process facilities in offshore production, especially in the North Sea, have utilized increased volumes of corro-
sion-resistant alloys. This usage also has been driven by life cycle cost savings.
Corrosion-resistanta lloys offer technical advantages by virtue of their high corrosion resistance and often
higher strength. These properties improve safety and reliability by reducing the need for corrosion-induced
workovers and the maintenance of downhole inhibition programs. The higher strengths permit extension to
deeper and higher pressure wells. Although each project has its own particular attributes, cost savings associ-
ated with corrosion resistant-alloys often are related to:
0 the high cost of offshore personnel;
increased cost of deferred production in high productivity fields;
0 increased emphasis on non-staffed or minimally staffed facilities;
increased cost of remedial work in subsea, deep water, or deep well production;
cost savings associated with improved safety and reliability.
Selections of specific alloys from among the large number available are made on the basis of mechanical
properties, corrosion resistance, and resistance to environmental cracking. Because of the large range of
environmental conditions encountered in oil and gas production, the materials options available to resist these
environments also is quite broad. This range of materials includes the martensitic stainless steels to the highly
alloyed nickel- and cobalt-base alloys. The economic impact of utilizing the “proper” alloy is significant.
Despite the increased use of corrosion-resistant alloys for oil and gas production, the experience base is
quite limited. This compilation of selected papers was thus prepared to provide a ready one-source overview.
The compilation emphasizes not only the interactions between corrosion-resistanta lloys and environments
observed in laboratory tests, but also pertinent field experience. It includes contributions of alloy suppliers,
component manufacturers, and end users, providing multiple perspectives on the subject.
xi
NOTE: As in all compilations, many excellent publications are left out because of space, scope, or
because the editors have missed these in the literature search. We apologize to those authors whose papers
have been overlooked. To the authors contributing to this compilation, we extend our compliments because
they have provided an excellent data base for the introduction, and continued use, of a new technology in the
petroleum industry. Their efforts and ddcation have resulted in safe and cost-effective improvements to
industry practice.
Juri Kolts Stephen W. Ciaraldi
xii
Contents
Preface ............................................................................................................................................... xi
VOLUME I
Section 1 Martensitic Stainless Steels
“Failures of Martensitic Stainless Steels in Sweet and Sour Gas Service”
J.D. Alkire, S.W. Ciaraldi ................................................................................................... 3
“Development of Sour Resistant Modified 13CR OCTG”
H. Ash, T. Hara, A. Kawakami, A. Takahashi .............................................................. 12
“Experiences with 13CR for Mitigating CO, Corrosion in the Oilfield,
Case Histories: The Gulf of Mexico and Inland Gas Wells”
D.A. Baudoin, D.K. Barbin, J. Skogsberg ....................................................................... 26
“Experience of 13% Cr Tubing 11: 10 years and 1 million feet later”
M. Bonis, J.L. Crolet ....................................................................................................... 39
“Corrosion Behavior of 1 to 22 Percent Chromium Steels and Monel K-500
in COPrine Environments”
J.R. Bryant, G.B. Chitwo. .............................................................................................. 49
“Laboratory Test for Evaluating Alloys for H,S Service”
D.S. Bums ....................................................................................................................... 65
“Corrosion Performance of 13 Cr Stainless Tubulars in Sour Environments”
W.C. Chen ........................................................................................................................ 73
“Some Limitations on the Use of 13Cr Alloys for Corrosive Gas
and Oil Production”
S.W. Ciaraldi .................................................................................................................... 82
“13Cr Tubulars Solve Corrosion Problems in the Tuscaloosa Trend
J.D. Combes, J.G. Kerr, L.J. Klein .................................................................................. 91
“Effect of Stress and Environment on Failures of 17-4 pH Stainless Steel
Valve Stems”
F.S. Gareau, N.A. Chambers, A.M. Martinson ................................................................ 99
“Corrosion Assisted Cracking of CA-6NM
D.A. Hansen, T. Doody .................................................................................................. 110
“Corrosion Behavior of 9 to 25% Cr Steels in Wet CO, Environments”
A. Ikeda, S. Mukai, M. Ueda .......................................................................................... 112
iii
“Effect of Microstructure on the Sulfide Stress Corrosion Cracking Resistance
of AISI 410 and 420 Steels”
Y. Ishizawa, T. Shimada, M. Tanimura .......................................................................... 120
“Operational Experience of Using 13%Cr Tubular Steels”
M.B. Kermani, G. Weighill, T. Pendlington, G. Elliot ................................................... 138
“Influence of Cathodic Protection on Stress Corrosion Cracking
of Martensitic Stainless Steels in Sea Water”
H. Kiesheyer, G. Lennartz ............................................................................................. 151
“H,S Cracking Resistance of 420 Stainless Steel Tubulars”
L.J. Klein ........................................................................................................................ 153
“9Cr- 1Mo and 13Cr Tubulars for Sour Service”
L.J. Klein, R.M. Thompson, D.E. Moore ...................................................................... 159
“Stress Corrosion Behavior of 13 Cr Martensitic Stainless Steels
in C0,-H,S-Cl- Environment”
H. Kurahashi, T. Kurisu, Y. Sone, K. Wada, Y. Nakai ................................................... 171
“Stress Cracking of 13 Cr Steels in C0,-H,S-Cl- Environments"
H. Kurahashi, T. Kurisu, Y. Sone, K. Wada, Y. Nakai ................................................... 179
“Polarization Behavior of High-Alloy OCTG in CO, Environment
as Affected by Chlorides and Sulfides”
K. Masamura, S. Hashizume, J. Sakai, I. Matsushima ................................................... 188
McElmo Dome CO, Source Facilities Corrosion Control”
“
M.H. Nguyen ................................................................................................................. 195
“Behavior of Different Martensitic Stainless Steels Under Oil and Gas Corrosive
Environments”
B.J. Orlans-Joliet, F. Blanchard, G.C. Guntz, J.-J. Servier ............................................ 202
“Effect of Environmental Factors and Yield Strength on SCC Property
of AISI 420 Stainless Steel”
S. Sakamoto, A. Kawakami, H. Asahi, A. Nakamura ................................................... 207
“Development of Resistant OCTG and Its Application to Corrosive Wells”
M. Tanimura ................................................................................................................... 226
“Sulfide Stress Cracking Failures of 12Cr and 17-4PH Stainless Steel
Wellhead Equipment”
R.M. Thompson, G.B. Kohut, D.R. Canfield, W.R. Bass .............................................. 237
“Evaluation of SSC Resistance on Super 13CR Stainless Steel in Sour Applications”
M. Ueda, T. Kushida, T. Mori ........................................................................................ 245
“Austenitizing Temperature Effect on SCC Resistance of 410 Stainless Steel”
D.D. Vitale, H.E. Ebert.........................................................2.6.2. ......................................
“Sulfide Stress Cracking Resistance of Weld Repairs in Wellhead Alloys”
M. Watkins, E.L. Von Rosenberg .................................................................................. 274
“Pitting and Stress Cracking of 12 CR-NI-MO Martensitic Stainless Steels
in Chloride and Sulfide Environments”
Y. Yoshino, A. Ikegaya ................................................................................................... 279
“The Application & Field Experience of High Strength 12% Cr
Centrifugally Cast Pipe for Gas Gatherystem”
A. Yoshitake, M. Teraoka, T. Torigoe, S. Amako ......................................................... 288
iv
Section 2 Austenitic Stainless Steels
“Sulfide Stress Cracking of AISI 304 Stainless Steel Springs in Sour Water”
B. Craig, B. Hodgson ..................................................................................................... 297
“Sulfide Stress Cracking Resistance of Nitrogen Strengthened Stainless Steels”
R.R. Gaugh ..................................................................................................................... 299
“Effects of Residual Stress on Stress Corrosion Cracking
of Non-Magnetic Drill Dollars”
D.S. Kopecki ................................................................................................................... 308
“A Criterion for Evaluating and Predicting the Sour Resistance of High Alloys”
T. Murata, R. Matsuhashi, M. Sakakibara, M.O nayama ............................................... 318
“The Stress Resistance of Non-Magnetic Stainless Steels
Used in Oil Exploration”
P. G. Smith, J.E. Truman, H.T. Gisborne, G. Oakes ....................................................... 328
Section 3 Duplex Stainless Steels
“Materials Failures in Sour Gas Service”
S.W. Ciaraldi .................................................................................................................. 343
“Evaluation and Application of Highly Alloyed Materials
for Corrosive Oil Production”
B.D. Craig ...................................................................................................................... 351
“Evaluation of the Resistance of Some Highly Alloyed Stainless Steels
to Stress Corrosion Cracking in Hot Chloride Solutions
under High Pressures of CO, and H,S”
J.L. Crolet, M.R. Bonis .................................................................................................. 363
“Special Stainless Steels for Application of Natural Gas Exploitation Systems;
Resistance to Stress Corrosion in Environments Containing
Chlorides and H,S of Austenitic and Austeno-Femtic Grades”
A. Desestret, E. Mirabal, D. Catelin, P. Soulignac ........................................................ 375
“Properties of and Experience with Welded Joints in Stainless Alloys”
H. Eriksson, P. Norberg, S. Bernhardsson ..................................................................... 397
“Corrosion and Age Hardening Studies of Some Cast Stainless Alloys
Containing Ferrite”
J.W. Flowers, F.H. Beck, M.G. Fontana ........................................................................ 407
“The Effect of Cathodic Protection on Duplex Stainless Steels in Sea Water”
R. Francis, G. Byrne, G.R. Warburton ........................................................................... 420
“The Corrosion of Duplex Stainless Stels in Sour Service”
R. Francis, G. Byrne ...................................................................................................... 434
“Corrosion Behaviors of Duplex Stainless Steel for Wet CO, Environment”
A. Ikeda, M.M iura, S. Mukai, M. Ueda, K. Koso ........................................................ 447
“Effect of Alloying Element and Ferrite-Austenite Ratio on SCC Resistance
of Duplex Stainless Steels in Sour Gas Environment”
Y. Ishizawa, T. Inazumi .................................................................................................. 464
V
“Production Technology and Corrosion Properties of Duplex Stainless Steel Line Pipe
by HF-ERW Process”
H. Kashimura, M. Onoyama, Y. Watanabe, T. Fujikawa ............................................... 474
“Full Scale Testing of Duplex Stainless Steel Pipes in Simulated Sour Environments”
Y. Kobayashi, Y. Isluzawa, J. Sakai, M. Itoh, T. Taira, H. Amp ................................... 483
“Duplex Stainless Steel Pipelines and Piping on the North Slope”
A.C. Madsen, F.O. Mueller, R. Geisert., J.B. Lee, H.J. Choi ....................................... 494
Corrosion Behavior of 25 Pct Cr Duplex Stainless Steel in C0,-H,S-Cl- Environments”
S. Mukai, H. Okamoto, T. Kudo, A. Ikeda ................................................................... 501
“Stress Corrosion Cracking Susceptibility of Duplex Stainless Steels
in Sour Gas Environments”
P.R. Rhodes, G.A. Welch, L. Abrego ............................................................................. 518
“Investigation of the Stress Corrosion Cracking of Duplex Stainless Steel Weldments
in Sour Conditions”
M.J. Schofield, R. Bradshaw, R.A. Cottis ..................................................................... 557
“Optimizing Welding Condition for Excellent Resistance
in Duplex Stainless Steel Linepipe”
K. Tamaki, K. Yasuda, M. Kimura, H. Kawasaki, T. Uegaki ........................................ 567
“Corrosion Resistance of Duplex Stainless Steel Weldments”
H. Tsuge, Y. Tarutani, T. Kudo ...................................................................................... 574
“Performance of High Resistant Duplex Stainless Steel in Chloride
and Sour Environments”
M. Ueda, H. Okamoto, T. Kobayashi, K. Kondo, K. Ogawa, T. Kudo ......................... 588
“Influence of Thermal History on Corrosion Resistance
of Duplex Stainless Steel Linepipe”
K. Ume, N. Seki, Y. Naganawa, T. Hyodo, K. Satoh, Y. Kuriki ................................... 609
“Effect of Heat Treatment and Microstructure on the Corrosion
and SCC of Duplex Stainless Steels in H,S/Cl- Environments”
S. Mark Wilhelm, R.D. Kane ......................................................................................... 621
“Performance of Duplex Stainless Steel Pipes in Sour Gas Wells”
G. Wilken ....................................................................................................................... 630
VOLUME II
Section 4 Precipitation-Hardened Nickel Alloys
“Cast Nickel Alloys for Sour Service”
R. Badrak ....................................................................................................................... 641
“Effect of Sulfur on Cracking Behavior of CRA’s in Simulated
Downhole Environments”
W. Coyle ........................................................................................................................ 653
vi
“Evaluation and Qualification of a Precipitation-Hardened Material
for Deep, Hot, Sour Environments”
T.A. DeBold, N.B. Schmidt, M.F. Bluem, S.R. Herman ............................................... 666
“Failure of Monel Ni-Cu-A1 Alloy K-500 Bolts in Seawater”
K.D. Efird ...................................................................................................................... 676
“Stress Corrosion Cracking and Hydrogen Embrittlement of High-Strength
Nonmagnetic Alloys in Brines”
J.G. Erlings, H.W. deGrmt, J.F.M. van Roy ................................................................. 680
“Development of Large Nickel-Base Alloy 925 Composite Block Trees
for Extreme Corrosion, Fire-Resistant Applications on Offshore Platforms”
T. Haeberle, P.J. Kovach ................................................................................................ 687
“Hydrogen Embrittlement of INCOLOY Alloy 925, MONEL Alloy K-500,
and INCONEL Alloy 625 by Slow Strain Method‘’
J.A. Harris, E.F. Clatworthy .......................................................................................... 695
“Behavior of Age-Hardenable Alloy UNS NO7725 for Oil Field Applications”
E.L. Hibner .................................................................................................................... 701
“Precipitation-Hardened, Nickel-Base Alloys for Sour Gas Environments”
M. Igarashi, S. Mukai, T. Kudo, Y. Okada, A. Ikeda .................................................... 709
“Failures of Nickel Copper Bolts in Subsea Applications”
M.W. Joosten, L.H. Wolfe ............................................................................................. 716
“Heat Treatment and Environmental Embrittlement of High-Performance Alloys”
J. Kolts ........................................................................................................................... 722
“Alloy 7 18 for the Oil and Gas Industry, Superalloy 7 18 Metallurgy
and Applications
J. Kolts ........................................................................................................................... 733
“Alloy 7 18 -All0y Optimization for Applications in Oil and Gas Production”
O.A. Onyewuenyi ........................................................................................................... 749
Section 5 Solid Solution NickeVCobalt-Base Alloys
“Corrosion-Resistant Alloys for Hot, Deep Sour Wells: Properties,
Experience, and Future Trends”
A.I. Asphahani, J.C. Prouheze, G.J. Petersen ................................................................ 769
“Stress-Cracking Resistance of Stainless Alloys in Sour Environments”
H.E. Chaung, M. Watkins, G.A. Vaughn ....................................................................... 779
“Laboratory Testing of Nickel Alloys for H,S Service”
J.A. Harris, T.F. Lemke .................................................................................................. 786
“Environmental Cracking Evaluation of Resistant Alloys
in H,S-C0,-CL- Environment by Slow Strain Rate Tensile Test”
A. Ikeda, M. Ueda, H. Tsuge ......................................................................................... 791
“Laboratory Evaluation of Corrosion Resistant Alloys for the Oil and Gas Industry”
J. Kolts ........................................................................................................................... 810
“Temperature and Texture Effects on Properties of CRA’s”
S.E. Mahmoud, C.W. Petersen ...................................................................................... 828
vii
“The Use of Strain Rate Testing to Determine the Effect of Elemental Sulfur
on Stress Corrosion Cracking of Nickel-Base Alloys”
C.J. Martin, H.S.A hluwa, F. Blanchard, J. Skogsberg .................................................. 841
“Developmento f High-Alloy Tubular Goods for Sour Wells”
H. Ogawa, K. Denpo, K. Ina, K. Shitani, A. Miyasaka, H. Asahi, S. Sakamoto,
M.O noyama ................................................................................................................. 855
“Critical Contents of Nickel and Chromium Required for SCC Resistance
of High Alloy OCTG”
J.I. Saki, M.H onda, K. Masamura, I. Matsushima, Y. Ishizawa ................................. 861
“Laboratory and Field Evaluations of Clad Christmas Tree Equipment“
.................................................................................................
W.J. Sisak, J.R. Gordon 871
“The Effect of Elemental Sulfur on Stress Cracking of Nickel Base Alloys”
N. Sndhar, S.M.C orey .................................................................................................. 877
“Influence of Elemental S on Corrosion Behavior of CRA
in H,S-C0,-Cl- Environment”
M. Ueda, T. Kudo .......................................................................................................... 888
‘‘Wireline Materials for Sour Service”
G.A. Vaughn, H.E.C haung ........................................................................................... 905
Section 6 Other Alloys
“Corrosion and Stress Corrosion Cracking of Aluminum Alloy Drillpipe
in a Water-Based, Low-Solids, Nondispersed Drilling Mud”
S.W. Ciaraldi, D.R. Grimes, H.F. Nichols, S.O. Moore..............................................9..1.5
“Yellow Metal (UNS C69100) for Sour Service”
...................................................................................
T. Clark, W. In&, C.M. Fowler 923
“Performance of a Beryllium Copper Nonmagnetic Drill Collar Alloy”
F. Dunlevey .................................................................................................................... 936
“Corrosion and Hydrogen Embrittlement Behavior of Titanium
in Aqueous Sulfidic Solutions”
Z. A. Foroulis .................................................................................................................. 943
“Engineering Incentives for Utilizing Ti-3Al-8V-6Cr-4Zr-4Mo Alloy Tubulars
in Highly Aggressive Deep Sour Gas Wells”
D.R. Klink, R.W. Schutz ................................................................................................ 952
“Stress Corrosion Behavior of Ti-3Al-8V-6Cr-4Zr-4Mo Alloy
Under Deep Sour Gas Well Conditions”
R.W. Schutz, M.X iao, T.A. Bednarowicz ..................................................................... 964
“Stress Cracking Behavior of Ti-38-6-44 In Sour Gas Environments”
.............................................................................................
D.E. Thomas, S.R. Seagle 982
“The Chloride Stress Corrosion Cracking Behavior of Beryllium Copper
and Other Nonmagnetic Drill Collar Alloys”
J.C. Turn Jr. ................................................................................................................... 989
viii