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51315-5812-Laboratory Test to Prospect Service Life Extension of AISI 304 Flexible Pipe Carcass at Sour Service

Product Number: 51315-5812-SG
ISBN: 5812 2015 CP
Author: Merlin Bandeira
Publication Date: 2015
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At Campos basin in Brazil flexible pipes are widely used in offshore applications for transportation of oil and gas. The first oil production at this basin started 35 years ago and today it is responsible for more than 80% of Brazilian oil production. The carcass material selection has to consider the corrosion resistance according to the pipe fluid. Primary objective of the carcass is to support external hydrostatic pressure due to water depth not having or being able to act as a sealing barrier to produced fluids. Thus to test these components and its suitability to support field conditions it would not be required to reprove localized corrosion that do not interact with others and does not compromise the failure mode of the component. Field conditions changed recently in Campos basin as the water injection caused some souring of the reservoir and and now small amounts of H2S associated with CO2 in the range of 0.1 to 0.4% have also to be considered. Therefore a study to assess carcass corrosion resistance to Sulfide Stress Cracking (SSC) and crevice susceptibility is needed. First production lines used in Campos Basin used AISI 304 as carcass material and therefore a test program comprising this material and 316L was launched. All tested samples came from flexible lines that had operated in Campos Basin for several years. They were inspected before the test and showed no sign of localized corrosion. Test conditions included 60.000 to 100.000ppm of Cl- up to 23%H2S and balance of CO2 at 60 and 80oC pH range from 4 to 5.5 with immersion time of 30 days. C-ring test were used to evaluate carcass SSC susceptibility. Initially two load levels were used: one well above the carcass material elastic limit and other around 90% of carcass material yield strength. In order to evaluate crevice susceptibility a crevice former device was introduced on each SSC sample at the region of highest strain. Results showed no SSC or crevice corrosion failure at 60 and 80oC at all pHs tested for 316 even when loaded with tensions above the material yield strength. In the case of 304 carcasses there were pit corrosion at 80oC tests.References1-NACE Standard TM 0177-2005: Laboratory Testing of Metals for Resistance to Sulfide Stress Cracking and Stress Corrosion Cracking in H2S Environments2-Banke L Flexible Pipe End Fitting - PhD Thesis – Department of Naval and Offshore Engineering Technical University of Denmark January 2000.3-API SPECIFICATION 17J / ISO 13628- Specification for Unbonded Flexible Pipe Third Edition 2008.4-Petrobras Standard NI 2409 – Flexible pipe 2003.5- M.C.E. Bandeira A.F.V.A. Beserra O. R. Mattos et al. “ Adaptation of NACE standard TM 0177 C-ring test for flexible pipe carcass” Corrosion/2013 paper no 2680 (Orlando FL: NACE 2013).
At Campos basin in Brazil flexible pipes are widely used in offshore applications for transportation of oil and gas. The first oil production at this basin started 35 years ago and today it is responsible for more than 80% of Brazilian oil production. The carcass material selection has to consider the corrosion resistance according to the pipe fluid. Primary objective of the carcass is to support external hydrostatic pressure due to water depth not having or being able to act as a sealing barrier to produced fluids. Thus to test these components and its suitability to support field conditions it would not be required to reprove localized corrosion that do not interact with others and does not compromise the failure mode of the component. Field conditions changed recently in Campos basin as the water injection caused some souring of the reservoir and and now small amounts of H2S associated with CO2 in the range of 0.1 to 0.4% have also to be considered. Therefore a study to assess carcass corrosion resistance to Sulfide Stress Cracking (SSC) and crevice susceptibility is needed. First production lines used in Campos Basin used AISI 304 as carcass material and therefore a test program comprising this material and 316L was launched. All tested samples came from flexible lines that had operated in Campos Basin for several years. They were inspected before the test and showed no sign of localized corrosion. Test conditions included 60.000 to 100.000ppm of Cl- up to 23%H2S and balance of CO2 at 60 and 80oC pH range from 4 to 5.5 with immersion time of 30 days. C-ring test were used to evaluate carcass SSC susceptibility. Initially two load levels were used: one well above the carcass material elastic limit and other around 90% of carcass material yield strength. In order to evaluate crevice susceptibility a crevice former device was introduced on each SSC sample at the region of highest strain. Results showed no SSC or crevice corrosion failure at 60 and 80oC at all pHs tested for 316 even when loaded with tensions above the material yield strength. In the case of 304 carcasses there were pit corrosion at 80oC tests.References1-NACE Standard TM 0177-2005: Laboratory Testing of Metals for Resistance to Sulfide Stress Cracking and Stress Corrosion Cracking in H2S Environments2-Banke L Flexible Pipe End Fitting - PhD Thesis – Department of Naval and Offshore Engineering Technical University of Denmark January 2000.3-API SPECIFICATION 17J / ISO 13628- Specification for Unbonded Flexible Pipe Third Edition 2008.4-Petrobras Standard NI 2409 – Flexible pipe 2003.5- M.C.E. Bandeira A.F.V.A. Beserra O. R. Mattos et al. “ Adaptation of NACE standard TM 0177 C-ring test for flexible pipe carcass” Corrosion/2013 paper no 2680 (Orlando FL: NACE 2013).
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