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Development of a New CRA Grade for High Pressure High Temperature Application

In High Pressure High Temperature “HPHT” wells (pressure above 10000psi/690bar temperature above 300°F/150°C which contain CO2 (sweet corrosion) and H2S (sour service) the oil & gas operators need to select materials which are resistant in corrosive atmosphere during the well lifetime. At the same time high strength grades are usually required to meet collapse and burst properties. The aim of the end users is to get the specific grade which can resist to corrosion while minimizing the cost which involves qualification with corrosion tests.The API 5CRA standard defines corrosion resistant alloy (CRA) grades for casings and tubings from group 1 named “Super 13Cr 13-5-2” (suitable up to 356°F/180°C) to group 2 “Duplex” grades 22-5-3 (450°F/232°C) or “Super Duplex” 25-7-4 (482°F/250°C) and higher grades.Therefore when the well temperature is above 356°F/180°C duplex grades or higher are commonly selected as these materials have a larger application domain at higher temperature range.A new proprietary grade chemistry was developed to provide good corrosion performances up to 230°C 125ksi (862MPa) grade material and high impact toughness. From a metallurgical standpoint achieving targeted mechanical and corrosion performances has ended up in a multi-phases material (martensite delta ferrite and austenite). Most of the performances are mainly controlled by the phases balance which alloy optimization has enabled consistent control by heat treatment.Stress corrosion cracking performances were assessed and compared to Super 13Cr and Super Duplex materials showing significant benefice of chromium under high temperature. Potentiodynamic electrochemical measurements in H2S environment were performed at 24°C in order to evaluate pitting performance and assess risk of sulfide stress corrosion cracking confirming higher sulfide stress corrosion performance compared to S13Cr materials. X-ray Photoelectron Spectroscopy (XPS) characterizations provide deep knowledge about it passive film compositions underlining the beneficial effect of high chromium within the grade.This solution offers to Oil and Gas operators a cost effective designed seamless tubes for high temperature well reservoir condition as alternative to duplex materials.

Product Number: 51319-12782-SG
Author: Cécile Millet
Publication Date: 2019
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$20.00
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