NACE 1F192-2013 Use of Corrosion-Resistant Alloys in Oilfield Environments (Item No 24010).pdf

1、 Item No. 24010 NACE International Publication 1F192 (2013 Edition) This Technical Committee Report has been prepared by NACE International Task Group (TG) 328,* “Materials, Welding and Fabrication of Corrosion-Resistant Alloys (CRAs)Corrosion Issues in Oil and Gas Production.” Use of Corrosion-Resi

2、stant Alloys in Oilfield Environments July 2013, NACE International This NACE International technical committee report represents a consensus of those individual members who have reviewed this document, its scope, and provisions. Its acceptance does not in any respect preclude anyone from manufactur

3、ing, marketing, purchasing, or using products, processes, or procedures not included in this report. Nothing contained in this NACE International report is to be construed as granting any right, by implication or otherwise, to manufacture, sell, or use in connection with any method, apparatus, or pr

4、oduct covered by Letters Patent, or as indemnifying or protecting anyone against liability for infringement of Letters Patent. This report should in no way be interpreted as a restriction on the use of better procedures or materials not discussed herein. Neither is this report intended to apply in a

5、ll cases relating to the subject. Unpredictable circumstances may negate the usefulness of this report in specific instances. NACE assumes no responsibility for the interpretation or use of this report by other parties. Users of this NACE report are responsible for reviewing appropriate health, safe

6、ty, environmental, and regulatory documents and for determining their applicability in relation to this report prior to its use. This NACE report may not necessarily address all potential health and safety problems or environmental hazards associated with the use of materials, equipment, and/or oper

7、ations detailed or referred to within this report. Users of this NACE report are also responsible for establishing appropriate health, safety, and environmental protection practices, in consultation with appropriate regulatory authorities if necessary, to achieve compliance with any existing applica

8、ble regulatory requirements prior to the use of this report. CAUTIONARY NOTICE: The user is cautioned to obtain the latest edition of this report. NACE reports are subject to periodic review, and may be revised or withdrawn at any time without prior notice. NACE reports are automatically withdrawn i

9、f more than 10 years old. Purchasers of NACE reports may receive current information on all NACE publications by contacting the NACE FirstService Department, 1440 South Creek Dr., Houston, Texas 77084-4906 (telephone +1 281-228-6200). Dedication This report is dedicated to Richard S. (Dick) Treseder

10、. Dick was the original chairman of the T-1F-21 work group that worked tirelessly for its conclusion. This report would not have been possible without his efforts and guidance. Dick died April 16, 1999, before the report could be completed. The succeeding chairman and other task group members knew D

11、ick as a good friend and are deeply indebted to him for his dedication and leadership. Dick was truly one of the pioneers in the area of corrosion and metallurgy in the oil and gas industry. He was a NACE Fellow and a NACE member for almost 52 years. We as an industry owe more to Dick than what we c

12、an convey here in this short dedication. _ *Chair Stuart Bond, TWI, Ltd., Cambridge, Cambridgeshire. NACE International 2 Foreword The use of corrosion-resistant alloys (CRAs) as a corrosion-control method in aggressive oil and gas production environments is now established; however, the complexity

13、of the corrosion effects associated with these severe conditions and the metallurgical complexities of the many alloys being offered have resulted in challenging materials selection problems for the corrosion engineer. Further consideration is also given to the performance of the materials in the we

14、lded condition for many applications, as weldments sometimes do not retain the same corrosion resistance as parent materials. The purpose of this technical committee report is to bring together state-of-the-art knowledge covering experiences in the application of CRAs and issues of welding, fabricat

15、ion, and assessment for successful operation in oil and gas production environments with specific consideration of corrosion and environmentally assisted cracking, and to highlight technology gaps impacting the industry. This report is intended to provide engineers worldwide who have knowledge of th

16、e characteristics of corrosion damage modes in oil and gas production with information to avoid repeated failures and the recurrence of concerns about CRA material selection. Some issues remain to be addressed, and these are highlighted as technology gaps. This report does not extend to refinery or

17、distribution applications. This technical committee report was originally prepared in 1992 by NACE Task Group T-1F-21, revised in 1993 by Work Group T-1F-21b, in 2000 by Work Group T-1F-21g, and in 2012 by Task Group (TG) 328. This report is published by NACE International under the auspices of Spec

18、ific Technology Group (STG) 32, “Oil and Gas ProductionMetallurgy.” NACE technical committee reports are intended to convey technical information or state-of-the-art knowledge regarding corrosion. In many cases, they discuss specific applications of corrosion mitigation technology, whether considere

19、d successful or not. Statements used to convey this information are factual and are provided to the reader as input and guidance for consideration when applying this technology in the future. However, these statements are not intended to be recommendations for general application of this technology,

20、 and must not be construed as such. Contents 1. Introduction 3 1.1 Definition of CRA:. .3 1.2 Coverage of Report:. .3 1.3 Organization of Report:. 3 1.4 Use of SI and English Units:. .3 1.5 Limitations of Use:. 4 1.6 Updating:. 4 2. General 4 2.1 Definitions:. 4 2.2 Acronyms:5 2.3 Materials Selectio

21、n and DesignSome Factors Considered During Design 5 2.4 Failure Modes 6 2.5 Failure Avoidance: .7 3. Processes Used for Manufacture 8 3.1 Melting and Casting: 8 3.2 Forging/Hot Working 9 3.3 Welding: 9 3.4 Cladding 12 3.5 Summary of Relevant Material Properties and Applications of Clad Components .

22、15 3.6 CRA Buttering 17 3.7 Powder Metallurgy . 18 4. Materials 19 4.1 Austenitic Stainless Steels 19 4.2 Superaustenitic Stainless Steels . 20 4.3 Ferritic Stainless Steels . 22 4.4 Martensitic Stainless SteelsStandard 13% Cr Stainless Steels (UNS S41000/UNS S42000 Types 410/420) 22 NACE internatio

23、nal 3 4.5 Weldable Supermartensitic Low-Carbon Stainless Steels . 24 4.6 Duplex Stainless Steels . 25 4.7 Precipitation-Hardenable Stainless Steels . 28 4.8 Solid-Solution Ni-Based Alloys 29 4.9 Precipitation-Hardenable Ni-Based Alloys . 30 4.10 Cobalt-Based Alloys 33 4.11 Ni-Copper Alloys 33 4.12 Z

24、irconium Alloys 34 4.13 Titanium Alloys 34 4.14 Copper-Beryllium Alloys 36 5. Testing Methods and Specific Issues for Welds 37 6. Application Limits for Welded CRAs 39 7. Summary of Generic Current State-of-the-Art and Technology Gaps . 40 8. Specific Equipment 41 8.1 Tubing, Casing, Liners . 41 8.2

25、 Downhole Packers/Safety Valves/Other Accessories 44 8.3 Wireline Equipment . 44 8.4 Wellheads/Trees/Valves 44 8.5 Flowlines/Production Risers 46 8.6 Valves 49 8.7 Pumps . 50 8.8 Vessels 51 8.9 Compressors . 51 8.10 Bolting 52 8.11 Instrumentation 52 8.12 Heat Exchangers . 52 References 53 Bibliogra

26、phy for Weldable Supermartensitic Stainless Steels 59 Section 1: Introduction 1.1 Definition of CRA: A corrosion-resistant alloy (CRA) is commonly defined as an alloy with an inherently low corrosion rate in the operating environment of interest, typically much lower than carbon and low-alloy steels

27、 (e.g., 1 to 2 orders of magnitude less). However, they are sometimes subject to localized corrosion (crevice and pitting corrosion) or environmentally assisted cracking, which often determines their envelope of application. Processing and welding of these alloys sometimes significantly influences t

28、heir corrosion resistance, and thus it is important that the final product form and manufacturing route are considered in the assessment of the suitability of the alloy for the intended operating environment. In addition, the mode of operation of the equipment commonly determines the acceptable exte

29、nt of material degradation. For example, downhole tools and equipment operating for short periods of time in harsh conditions sometimes use a lower-grade alloy on a fitness-for-purpose consideration in contrast to permanently installed equipment, provided they retain suitable performance in normal o

30、perating conditions. 1.2 Coverage of Report: This report covers a wide range of corrosion mechanisms, including stress corrosion cracking (SCC), forms of hydrogen embrittlement (HE), general corrosion, pitting and crevice corrosion, corrosion fatigue, and liquid metal cracking. The oil and gas secto

31、r is continuing to develop more demanding wells which are corrosive to carbon steel because of the composition of the fluids produced, the production temperature, and the pressure in these wells; as a result, CRAs are used for successful completion and operation. However, such alloys present a range

32、 of technical challenges in fabrication and assessment for selection in new fields, which are often close to limits of known applicability in extreme cases, or that possibly have reduced corrosion or cracking resistance as a result of issues arising in manufacturing and welding practices. This repor

33、t is written for the engineer who has knowledge of the characteristics of corrosion systems encountered in oil and gas production, and who has experience with oilfield applications of CRAs. 1.3 Organization of Report: This report is organized to allow information on a specific subject to be found wi

34、thout reading the entire report. However, it is desired that the reader consider both the general information and that provided specifically by alloy type, before referring to the information on performance experiences. NACE international 4 1.4 Use of SI and English Units: Measurements in this repor

35、t follow the NACE International Publication Style Manual (Fifth Edition, 2008). Some measurements are listed in U.S. customary units followed by the Systeme Internationale (SI) conversion, while others are listed in SI units first. In accordance with the Style Manual, the actual measurements recorde

36、d are shown first followed by the conversion. 1.5 Limitations of Use: This NACE technical committee report does not present standardized materials selection methods or materials specifications. This report presents information on current industry practices only and is not to be interpreted as recomm

37、ending use of the materials listed herein. In addition, comment on the influence of welding and joining techniques on the CRA materials does not remove any requirements to undertake qualification and acceptance tests for the appropriate application as determined by the prevailing standards and end c

38、lient requirements pertaining to the same. This report aims to highlight major considerations for the materials/corrosion engineer in the oil and gas production sector and to identify current technology gaps that industry wants to address to support the demands for applications in increasingly harsh

39、 environments of pressure, temperature, and corrosiveness. 1.6 Updating: Users of this report are encouraged to provide information on experiences of materials performance both in terms of failures and detailed documented information on satisfactory operation in more aggressive conditions. Also, ide

40、ntification of additional technology gaps is likely to be useful to focus development of activities in the future. Please advise STG 32 by sending correspondence to NACE International to allow suggested revisions to be reviewed by TG 328, which is assigned this responsibility under STG 32. Section 2

41、: General 2.1 Definitions: The definitions used in this version are based on those in NACE/ASTM(1) G193 “Standard Terminology and Acronyms Relating to Corrosion.” Therefore, the previous version has now been modified and the section that gave individual definition of terms has been reduced significa

42、ntly. However, below are listed terms with specific meaning in this report when it is necessary to clarify for the reader. Note ISO 80442 has not been cited as an existing International Standard with additional corrosion terminology. Activation: The changing of a passive surface of a metal to a chem

43、ically active state. Active Metal: A metal ready to corrode, or being corroded. Active Potential: The potential of a corroding material. Air Induction Melting (AIM): A process for melting and refining metals in which the metal is exposed to air and melted by induction heating. Anion: A negatively ch

44、arged ion that migrates through the electrolyte toward the anode under the influence of a potential gradient (expands definition). Argon-Oxygen Decarburization (AOD): A refining process used in the production of stainless steels and nickel-based alloys in which an argon-oxygen mixture is blown into

45、the molten metal bath. Cation: A positively charged ion that migrates through the electrolyte toward the cathode under the influence of a potential gradient (expands definition). Duplex Stainless Steel: A stainless steel whose microstructure at room temperature consists primarily of a mixture of app

46、roximately equal proportions of austenite and ferrite. Electroslag Remelting (ESR): A consumable-electrode remelting process in which heat is generated by passage of current through a conductive slag. Hydrogen Embrittlement (HE): A loss of ductility of a metal resulting from absorption of hydrogen.

47、Hydrogen Stress Cracking (HSC): Cracking that results from the presence of hydrogen in a metal in combination with tensile stress. It occurs most frequently with high-strength alloys (also called hydrogen-induced stress cracking, HISC). (1) ASTM International (ASTM), 100 Barr Harbor Dr., West Consho

48、hocken, PA 19428-2959. NACE international 5 KISCC: Abbreviation for critical value of the plane strain stress intensity factor that will produce crack propagation by stress corrosion cracking of a given material in a given environment. KISSC is used for cracking in sour media. Martensite: Metastable

49、 body-centered tetragonal phase of iron supersaturated with carbon, produced from austenite by shear transformation during quenching or deformation. Quenching: Rapid cooling of metals (often steels) from a suitably elevated temperature. This generally is accomplished by immersion in water, oil, polymer solution, or salt, although forced air or liquid sprays are often used. Sensitizing Heat Treatment: A heat treatment, whether accidental, intentional, or incidental (as during welding), that causes precipitation of constituents (usually