Transcript API 5CRA Long Presentation for Inclusion of Alloy

Proposal for a New Work Item
for API 5 CRA
To Include Alloy C-22HS
(UNS N07022) at PLS -2
Ed Hibner, Consultant to
Haynes International, Inc.
Compositions of Alloy C-22HS (UNS N07022)
Alloy
Ni
Cr
Mo
W
Fe
Mn
C
S
N07022
61
(bal.)
20.021.4
15.517.4
0.8
1.8
0.5
0.010
0.015
max
max
max
max
max
Si
P
Al
Co
Ta
Cu
B
0.8
0.025
0.5
1.0
0.2
0.5
0.006
max
max
max
max
max
max
max
LRO Strengthening of Alloy C-22HS
•Many C-type alloys are known to strengthen significantly
under Long Range Ordering:
•Strengthening is due to formation of long rang
ordered domains (LRO) of Ni2( Mo,Cr)
•Ductility remains high after LRO strengthening
LRO Domains in C-22HS. The Ni2( Mo,Cr) domains
have the Pt2Mo crystal structure.
The domains are approximately 10 nm in size.
For Oil and Gas Applications
Alloy C-22HS Exhibits the Following Advantages
•Very, very High Yield Strength Levels, While Still Exhibiting High
Fracture Toughness and Ductility
•Superior Resistance to Corrosion and Hydrogen Embrittlement
•Currently Approved and Waiting for Publication in MR0175/ ISO
15156-3 at NACE Level VII Environment with Elemental Sulfur
at 204 °C (400)°F.
•Approved Conditions: Annealed + Aged, Annealed + Cold Worked, and
Annealed + Cold Worked + Aged.
•MR0175/ ISO 15156-3 Ballot has been Submitted for C-22HS for
Resistance Limits to 25% NaCl + 1,000 psi (7000 kPa) CO2 +
1,000 psi (7000 kPa) H2S at 550°F (288°C), for Annealed + Cold
Worked, and Annealed + Cold Worked + Aged Conditions.
Alloy C-22HS is Included in
MR0175/ ISO15156-3
in the Following Locations
 Table A.33 — Environmental and materials limits for agehardened nickel-based alloys (III) used for any equipment or
component, in the annealed + age hardened material condition.
 Table A.14 — Environmental and materials limits for annealed
and cold-worked, solid-solution nickel-based alloys used as any
equipment or component, in the annealed + cold worked and in
the annealed + cold worked + age hardened material conditions.
 Table A.12 — Materials types of solid-solution nickel-based
alloys, as category 4f for UNS N07022, for material in the
annealed + cold worked and in the annealed + cold worked + age
hardened material conditions.
 Table D.3 — Chemical compositions of some solid-solution
nickel-based alloys
 Table D.9 — Chemical compositions of some precipitation
hardened nickel base alloys
Average Room Temperature Tensile
Properties - Tube
Condition
Yield
Strength
(ksi)
UTS
(ksi)
Cold-Worked
187.3
195.0
Reduction
Elongation
of Area
(%)
(%)
15.1
58
Charpy Impact Testing
1” Diameter Bar, 44% Cold Worked (CW)
Test
Temperature
Impact Energy* (ft-lbf)
CW
RT (67°F)
146
-75°F
153
-320°F
113
Established Manufacturing Plan for OCTG Products to
be Considered for API 5 CRA Applications
•Air Melt, AOD, ESR, Forge, Anneal, Trepan are Steps
for all C-22HS Products
•Variant is that Large Runs get Extruded and Annealed,
and Small Runs (accessories) would be Forged to
Smaller Diameters and Just Trepanned Prior to Honing.
•All Routes are Honed, ID Inspected, Pilgered, and NDT
Tested
•Final tubing and coupling stock condition will be in the
cold-worked condition.
Manufacturing History for OCTG Products to be
Considered for API 5 CRA Applications
•Haynes International has Melted 48 Commercial Heats of Alloy C22HS (1.5 Heats for Cold Worked Bar and 46.5 Heats for Tubing and
Coupling Stock)
•Oil and Gas Wells 2 (One Shipped and Currently Being Installed
and One in Manufacturing)
•OCTG Sizes: 3.5” O.D. x 0.430” Wall (160ksi min. Yield Strength),
49,300 ft. and 775,400 lbs.
•Coupling Stock: 4.167” O.D. x 0.833” Wall (160ksi min. Yield
Strength), 670 ft. and 21,800 lbs.
•Coupling Stock: 4.25” O.D. x 0.950” Wall (160ksi min. Yield
Strength), 810 ft. and 29,800 lbs.
•Accessory: 3.5” O.D. x 0.920” Wall (160ksi min. Yield Strength), 40
ft. and 850 lbs.
Conclusions
Haynes International has a well established route of production for
Alloy C-22HS Oil Country Tubular Products and has delivered one
major tubing string with coupling stock and accessories which will be
in production first quarter 2012 .
A second major Alloy C-22HS tubing string with coupling stock is in
Manufacturing and will be delivered by the time that work begins on
inclusion of Alloy C-22HS in API 5 CRA at PLS-2 level .
Haynes International has decades of experience in production of
OCTG’s and Coupling Stock for a complete range of Ni-Cr-Mo alloys.
This includes alloys such as Alloys G-3, G-50 and C-276, of which
Alloys G-3, G-50 and C-276 were invented by Haynes International.
Recommendation
Establish a New Work Item or Incorporate in an Existing
Work Item for Inclusion of Hastelloy Alloy C-22HS (UNS
N07022) in API 5 CRA at the PLS-2 Level.
Recommend Ed Hibner, Haynes International, Inc.
Consultant and Brett Puckett of Shell to Chair the Working
Group if assigned a new Work Item.
Manufacturing History for Bar Products for Oil
Patch Applications
•Haynes International has Melted 1.5 Commercial Heats of Alloy C22HS for Cold Worked Bar
•Oil and Gas Wells 2 (One Shipped and Currently Being Installed
and One in Manufacturing)
•Bar Diameter Range from 0.5” dia. to 3.625” dia.
•Applications Include:
•MDW Tool Inserts
•Wireline Tool Battery Housings
•Sample Bottles
•Wireline Tensile Bars