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This paper discusses a study wherein the SSC resistance of 13Cr bar stock quenched and tempered to 22 HRC maximum hardness was tested and evaluated beyond the maximum H2S limit of 10 kPa (1.5 psi) established in NACE MR0175/ISO 15156-3 for use in sour service.
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This paper discusses two case histories in which 41XX low-alloy steel, quenched and tempered to 22 HRC maximum hardness, was used in longer-term downhole completion tools.
The focus of this paper is the welding metallurgy and weld metal properties of N07022 alloy. Evaluation of the N07022 weld metal microstructure will be discussed. Sour gas testing of N07022 weld overlay material will be highlighted. Mechanical properties will be presented.
This standard is now undergoing a critical review to determine how it should change to meet the future needs of the Oil & Gas Industry better. Where are we headed with NACE MR0175/ISO 15156? The results of our collective initial efforts are presented.
Petroleum and natural gas industries — Materials for use in H2S-containing environments in oil and gas production —
Part 1: General principles for selection of cracking-resistant materials
TECHNICAL CIRCULAR 1
Published 2021-12-09
Part 2: Cracking-resistant carbon and low-alloy steels, and the use of cast irons
Part 3: Cracking-resistant CRAs (corrosion-resistant alloys) and other alloys
Traditionally, sour severity of high-pressure, high temperature (HPHT) oil and gas production wells were assessed by H2S partial pressure (PH2S): The mole fraction of H2S in the gas (yH2S) multiplied by the total pressure (PT). While PH2S is appropriate for characterizing the sour severity of wellbores operating at low total pressures (e.g., PT < 35 MPa) and/or for highly sour systems (e.g., yH2S > 1 mol%), PH2S usually over-predicts the actual sour severity of HPHT systems, leading to sub-optimal material selection options.
13Cr-5Ni-2Mo type Super Martensitic stainless steels referred to as SMSS-13Cr type grades can provide good general corrosion resistance such as in high CO2 environments combined with higher strengths and excellent toughness2 making them a prospective material choice for long term downhole completion equipment depending on actual well conditions. One of the main limiting factors for the use of SMSS-13Cr type grades is the Sulfide Stress Cracking (SSC) resistance in presence of H2S in downhole well conditions. Therefore, a good understanding of this behavior is essential to facilitate the material selection process.
Steel pipelines are sometimes subjected to demanding sour environments resulting from the presence of high H2S contents. Pipeline materials, therefore, must be resilient against sulfide stress cracking (SSC) which is caused by H2S. Beginning in the 1980s, thermo-mechanically controlled processed (TMCP) steels have been widely used for the manufacturing of large-diameter sour service pipelines. The failure of the Kashagan pipelines in 2013 raised concern regarding the use of TMCP steels in sour environments. These concerns arise from the potential for local hard zones (LHZs) to be produced on the surface of the line pipe during TMCP processes, ultimately leading to through-wall SSC failures. In the present study, several X60 - X65 TMCP steels (both with and without LHZs) have been tested under different Region 3 (R3) conditions in the NACE MR0175/ISO15156-2 pH-H2S partial pressure diagram. It can be concluded that the presence of LHZs increases TMCP steels’ sour cracking susceptibility; however, TMCP steels without LHZs pass the SSC tests at even the most severe R3 environments. Traditional HRC or HV10 testing are not able to detect LHZs, and so lower load HV 0.5 or HV 0.1 tests are necessary. For TMCP steels, the current R3 may be further divided into R3-a and R3-b sub-regions. The sour cracking severity of R3-a is less than that of R3-b. Additional actions, like enhanced mill qualification of the TMCP plate, should be considered to ensure that no LHZs exist in steels to be utilized in R3-b environments.
Stainless steel UNS S17400 (17-4PH) has been successfully used in oilfield services outside the traditional NACE MR0175/ISO 15156 limits for permanent equipment. The exact operational envelops of 17-4PH (HH1150), including the tensile threshold stress, sour gas partial pressure, temperature, and exposure time that enable the crack-free usage of 17-4PH (HH1150) are not well established. For service equipment, NACE MR0175/ISO15156 currently provides exemptions from the tight environmental restrictions of permanent equipment, but instead limits the maximum applied stress to a debatable 60% of the specified minimum yield strength (SMYS). In this investigation, the sulfide stress-corrosion cracking of 17-4PH is revisited through 51 new NACE TM0177 Methods A tests conducted over 240 hours minimum (480hrs in certain cases). Under unrestricted sour gas partial pressures, the threshold tensile stress below which cracking does not occur is between 45% and 60% of the SMYS at ambient temperature. Alloy 17-4PH is also less susceptible to sulfide stress cracking as temperature increases from 70°F (21°C) to 350°F (177°C). Risk of sulfide stress cracking is also greatly mitigated when delta ferrite is controlled. With reduced delta ferrite, as provided by two out of three tested heats, and reverted austenite promoted by both chemical composition and longer aging treatments, no cracking is seen at 60% stress level up to 45psi H2S (0.31MPa); at 45% stress level, this value is increased to 120psi (0.83MPa) based on newly-collected test data.