Gaps in Material Qualification Requirement and Acceptance for Severe to Extreme Sour-Sweet Corrosive HPHT Environments Impacting Completion Design

2021 ◽  
Author(s):  
Sandeep Dhawan ◽  
Syed Munib Ullah Farid
Keyword(s):  
Fracture Toughness ◽  
Material Selection ◽  
Critical Stress Intensity Factor ◽  
Material Strength ◽  
Corrosive Environment ◽  
Worst Case ◽  
Secondary Failure ◽  
Minimum Requirements ◽  
Sour Service ◽  
Group 1

Abstract Severe to extreme sour-corrosive environment assisted cracking (EAC) phenomenon are complex. Mandatory test qualification requirements and acceptance criteria is non-existent, in relevant API and NACE standards for fracture toughness of the CRA's. This paper, perhaps an industry first, attempts to highlight some of these gaps and how it translates into material strength uncertainties thereby impacting tubing design and risk assessment. The materials in this context are high strength group 1 to 4 corrosion resistant alloys of API 5CRA. Fracture toughness or critical stress intensity factor is a measure of resistance to failure due to crack propagation - a key parameter for HPHT tubing material selection and design. This material aspect of fracture toughness can be influenced by several factors like Microstructure, Strength, Hardness, Heat treatment, Anisotropy etc. Low temperature is generally considered as worst case, nevertheless at higher temperatures, well environment driven embrittlement can have a serious impact on the fracture toughness value. Therefore, with several factors influencing, its characterization is important to define the burst envelope of the tubing when exposed to severe to extreme sour-sweet corrosive environment typical of HPHT wells. A unique approach is followed to determine the brittle burst tri-axial envelope of selected tubing based on minimum fracture toughness value of the CRA material, referred to as KIMAT for SSC (or EAC) as prescribed by the mill. Proportional radial scaling is proposed to generate scaled down von-mises brittle-burst envelope. The tubing loads and the safety factors are analyzed to the shrunken envelope to visualize the risks of tubular failure under sour-sweet corrosive environment. The analysis includes varying crack depths of 5% and 3%. In addition, a minimum KIMAT for SSC (or EAC) value required to achieve full scale VME is investigated to determine specific material property requirements. TM0177 NACE D covers methods to measure fracture toughness KIMAT for sour service at ambient temperature only and does not address the context of EAC exposure at ambient or elevated conditions i.e., KIMAT for EAC.This implies that a methodology for evaluation of EAC risk is not available as yet. Guidance on the potential for corrosion to cause cracking of CRAs is given in Table B.1 of ISO 15156-3 with primary and secondary failure mechanisms. However, a quantitative test to cover the risk of cracking of materials by specifying minimum required KIMAT for EAC for each group type in 5CRA is non-existent. Even KIMAT for sour service minimum requirements with SSC as primary failure mechanism, e.g., group 1 CRA, does not currently exist. Consequently, KIMAT for EAC minimum requirements are considered as far-fetched. Additionally, mills prescribed KIMAT for SSC lacks basis due to gaps in the minimum fracture toughness requirement stipulations for group 1 to 4 CRA materials listed at API 5CRA. Therefore, this paper provides risk insights and potential of tubing failure that can lead to serious integrity issues on a HPHT well. A joint industry program or joint API/NACE task group is proposed as a logical next step.

VALLOUREC VM 85 13Cr

Alloy Digest ◽  
2016 ◽  
Vol 65 (4) ◽  
Keyword(s):  
Fracture Toughness ◽  
Corrosion Resistance ◽  
Carbon Steel ◽  
Yield Strength ◽  
Physical Properties ◽  
Tensile Properties ◽  
Alloy Carbon ◽  
Sour Service ◽  
Minimum Yield

Abstract Vallourec VM 85 13Cr (minimum yield strength 85 ksi, or 586 MPa) is a low alloy carbon steel for use in oil country tubular goods as a material suitable for sour service. This datasheet provides information on composition, physical properties, hardness, and tensile properties as well as fracture toughness. It also includes information on corrosion resistance as well as forming. Filing Code: CS-198. Producer or source: Vallourec USA Corporation.

VALLOUREC VM 90 13CR

Alloy Digest ◽  
2016 ◽  
Vol 65 (3) ◽  
Keyword(s):  
Fracture Toughness ◽  
Corrosion Resistance ◽  
Carbon Steel ◽  
Yield Strength ◽  
Physical Properties ◽  
Tensile Properties ◽  
Alloy Carbon ◽  
Sour Service ◽  
Minimum Yield

Abstract Vallourec VM 90 13CR (minimum yield strength 90 ksi, or 620 MPa) is a low alloy carbon steel for use in oil country tubular goods as a material suitable for sour service. This datasheet provides information on composition, physical properties, hardness, and tensile properties as well as fracture toughness. It also includes information on corrosion resistance as well as forming. Filing Code: CS-197. Producer or source: Vallourec USA Corporation.

CARELSO 60/65

Alloy Digest ◽  
2011 ◽  
Vol 60 (10) ◽  
Keyword(s):  
Fracture Toughness ◽  
Tensile Properties ◽  
Pressure Vessel ◽  
Heat Treating ◽  
Steel Alloy ◽  
Vessel Material ◽  
Sour Service

Abstract CarElso 60/65 is a steel alloy with special melt practice producing a pressure vessel material with resistance to mild sour service. This datasheet provides information on composition and tensile properties as well as fracture toughness. It also includes information on forming, heat treating, and joining. Filing Code: SA-635. Producer or source: Industeel USA, LLC.

VALLOUREC VM 125 13Cr SS

Alloy Digest ◽  
2016 ◽  
Vol 65 (11) ◽  
Keyword(s):  
Fracture Toughness ◽  
Corrosion Resistance ◽  
Physical Properties ◽  
Tensile Properties ◽  
Martensitic Steel ◽  
Chloride Content ◽  
Sour Service

Abstract Vallourec VM 125 13Cr SS is a 13Cr super martensitic steel for use in oil country tubular goods as a material suitable for sour service. The CY version offers corrosion and SCC resistance on a greater usage domain than API L80-13Cr in terms of temperature and chloride content. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties as well as fracture toughness. It also includes information on corrosion resistance as well as forming. Filing Code: SS-1254. Producer or source: Vallourec USA Corporation.

scholarly journals Studies of Fracture Toughness in Concretes Containing Fly Ash and Silica Fume in the First 28 Days of Curing

Materials ◽  
2021 ◽  
Vol 14 (2) ◽  
pp. 319
Author(s):  
Grzegorz Ludwik Golewski ◽  
Damian Marek Gil
Keyword(s):  
Fracture Toughness ◽  
Stress Intensity Factor ◽  
Stress Intensity ◽  
Fly Ash ◽  
Critical Stress ◽  
Critical Stress Intensity Factor ◽  
Early Age ◽  
Strength Parameters ◽  
Cement Binder ◽  
Mineral Additives

This paper presents the results of the fracture toughness of concretes containing two mineral additives. During the tests, the method of loading the specimens according to Mode I fracture was used. The research included an evaluation of mechanical parameters of concrete containing noncondensed silica fume (SF) in an amount of 10% and siliceous fly ash (FA) in the following amounts: 0%, 10% and 20%. The experiments were carried out on mature specimens, i.e., after 28 days of curing and specimens at an early age, i.e., after 3 and 7 days of curing. In the course of experiments, the effect of adding SF to the value of the critical stress intensity factor—KIcS in FA concretes in different periods of curing were evaluated. In addition, the basic strength parameters of concrete composites, i.e., compressive strength—fcm and splitting tensile strength—fctm, were measured. A novelty in the presented research is the evaluation of the fracture toughness of concretes with two mineral additives, assessed at an early age. During the tests, the structures of all composites and the nature of macroscopic crack propagation were also assessed. A modern and useful digital image correlation (DIC) technique was used to assess macroscopic cracks. Based on the conducted research, it was found the application of SF to FA concretes contributes to a significant increase in the fracture toughness of these materials at an early age. Moreover, on the basis of the obtained test results, it was found that the values of the critical stress intensity factor of analyzed concretes were convergent qualitatively with their strength parameters. It also has been demonstrated that in the first 28 days of concrete curing, the preferred solution is to replace cement with SF in the amount of 10% or to use a cement binder substitution with a combination of additives in proportions 10% SF + 10% FA. On the other hand, the composition of mineral additives in proportions 10% SF + 20% FA has a negative effect on the fracture mechanics parameters of concretes at an early age. Based on the analysis of the results of microstructural tests and the evaluation of the propagation of macroscopic cracks, it was established that along with the substitution of the cement binder with the combination of mineral additives, the composition of the cement matrix in these composites changes, which implies a different, i.e., quasi-plastic, behavior in the process of damage and destruction of the material.

scholarly journals Comparison of 2507 Duplex and 28 % Cr- Austenitic Stainless Steel Corrosion Behavior for High Pressure and High Temperature (HPHT) in Sour Service Condition with C-ring Experiment

2021 ◽  
Author(s):  
Harris Prabowo ◽  
Badrul Munir ◽  
Yudha Pratesa ◽  
Johny W. Soedarsono
Keyword(s):  
High Pressure ◽  
Stainless Steel ◽  
High Temperature ◽  
Austenitic Stainless Steel ◽  
Corrosion Behavior ◽  
Material Selection ◽  
Stress Cracking ◽  
Sulfide Stress ◽  
Sulfide Stress Cracking ◽  
Sour Service

The scarcity of oil and gas resources made High Pressure and High Temperature (HPHT) reservoir attractive to be developed. The sour service environment gives an additional factor in material selection for HPHT reservoir. Austenitic 28 Cr and super duplex stainless steel 2507 (SS 2507) are proposed to be a potential materials candidate for such conditions. C-ring tests were performed to investigate their corrosion behavior, specifically sulfide stress cracking (SSC) and sulfide stress cracking susceptibility. The C-ring tests were done under 2.55 % H2S (31.48 psia) and 50 % CO2 (617.25 psia). The testing was done in static environment conditions. Regardless of good SSC resistance for both materials, different pitting resistance is seen in both materials. The pitting resistance did not follow the general Pitting Resistance Equivalent Number (PREN), since SS 2507 super duplex (PREN > 40) has more pitting density than 28 Cr austenitic stainless steel (PREN < 40). SS 2507 super duplex pit shape tends to be larger but shallower than 28 Cr austenitic stainless steel. 28 Cr austenitic stainless steel has a smaller pit density, yet deeper and isolated.

scholarly journals Effect of Slag Particle Size on Fracture Toughness of Concrete

2019 ◽  
Vol 9 (4) ◽  
pp. 805 ◽  
Author(s):  
Chung-Ho Huang ◽  
Chung-Hao Wu ◽  
Shu-Ken Lin ◽  
Tsong Yen
Keyword(s):  
Fracture Toughness ◽  
Particle Size ◽  
Compressive Strength ◽  
Stress Intensity ◽  
Fracture Energy ◽  
Critical Stress ◽  
Critical Stress Intensity Factor ◽  
Cementitious Material ◽  
Test Results ◽  
Unique Effect

The effects of particle size of ground granulated blast furnace slag (GGBS) on the fracture energy, critical stress intensity, and strength of concrete are experimentally studied. Three fineness levels of GGBS of 4000, 5000, 6000 cm2/g were used. In addition to the control mixture without slag, two slag replacement levels of 20% and 40% by weight of the cementitious material were selected for preparing the concrete mixtures. The control mixture was designed to have a target compressive strength at 28 days of 62 MPa, while the water to cementitious material ratio was selected as 0.35 for all mixtures. Test results indicate that using finer slag in concrete may improve the filling effect and the reactivity of slag, resulting in a larger strength enhancement. The compressive strength of slag concrete was found to increase in conjunction with the fineness level of the slag presented in the mixture. Use of finer slag presents a beneficial effect on the fracture energy (GF) of concrete, even at an early age, and attains a higher increment of GF at later age (56 days). This implicates that the finer slag can have a unique effect on the enhancement of the fracture resistance of concrete. The test results of the critical stress intensity factor (KSIC) of the slag concretes have a similar tendency as that of the fracture energy, indicating that the finer slag may present an increase in the fracture toughness of concrete.

Fracture Toughness Testing and Validation of Pipeline Girth Weld Flaw Acceptance Criteria for Sour Service Under Large Strain

2011 ◽  
Author(s):  
You You Wu ◽  
Wen Guo Yuan ◽  
Tse Ven Steven Chong ◽  
Jens P. Tronskar
Keyword(s):  
Fracture Toughness ◽  
Oil And Gas ◽  
Large Strain ◽  
Axial Strain ◽  
Laboratory Data ◽  
Local Buckling ◽  
Acceptance Criteria ◽  
Service Environment ◽  
Girth Welds ◽  
Sour Service

Fracture toughness is one of the most important input parameters for assessment of pipeline girth weld failure capacity. For many new subsea pipeline projects there is a need to develop flaw acceptance criteria for pipeline installation considering the operation phase which may involve the transport of sour oil and gas and where the pipeline is exposed to large axial strain due to local buckling. Engineering Critical Assessment (ECA) performed using laboratory data based on conservative KISSC testing gives small acceptable flaw sizes which may be below the workmanship criteria for pipeline laying. DNV has conducted extensive research based on the requirements of DNV-OS-F101 and DNV-RP-F108, aiming to establish a method to develop J-R curves applicable for ECA of pipeline girth welds in sour service environment and a methodology to validate the ECA by segment testing in a laboratory-simulated sour service environment as per DNV-RP-F108.

Fracture Toughness Properties of SA540 Steels for Nuclear Bolting Applications

1977 ◽  
Vol 99 (3) ◽  
pp. 419-426
Author(s):  
R. R. Seeley ◽  
W. A. Van Der Sluys ◽  
A. L. Lowe
Keyword(s):  
Fracture Toughness ◽  
Impact Energy ◽  
Nuclear Reactor ◽  
Charpy Impact ◽  
Nuclear Regulatory Commission ◽  
Charpy Impact Energy ◽  
Energy Correlation ◽  
Impact Properties ◽  
Minimum Requirements ◽  
Regulatory Commission

Large bolts manufactured from SA540 Grades B23 and B24 are used on nuclear reactor vessels and require certain minimum mechanical properties. A minimum fracture toughness of 125 ksi in. (137 MPa m) at maximum operating stresses is required by the Nuclear Regulatory Commission for these bolts. This minimum toughness property was determined by a stress analysis of a bolt. Minimum required Charpy impact properties were calculated by a fracture toughness-Charpy impact energy correlation and the minimum calculated fracture toughness. The fracture toughness, yield strength and Charpy V notch impact properties were determined for five commercial heats of SA540 steels. Correlations between the fracture toughness and Charpy impact properties of these materials were evaluated. The toughness-impact energy correlation used to set the minimum required Charpy impact properties was found to be unduly conservative, and a different correlation of these properties is suggested. The SA540 steels investigated exhibited fracture toughness properties in excess of the NRC minimum requirements.

Nondestructive Evaluation of Metal Strength, Toughness, and Ductility Through Frictional Sliding

2019 ◽  
Author(s):  
Steven Palkovic ◽  
Parth Patel ◽  
Soheil Safari ◽  
Simon C. Bellemare
Keyword(s):  
Fracture Toughness ◽  
Tensile Stress ◽  
Pressure Vessels ◽  
Surface Measurement ◽  
Material Strength ◽  
Stress Strain ◽  
Frictional Sliding ◽  
Structural Applications ◽  
Toughness Testing ◽  
Welding Processes

Abstract Traditional assessment of mechanical properties requires the removal of a standardized specimen for destructive laboratory testing. A nondestructive in-situ method is a cost-effective and efficient solution for applications where sample cutouts are not feasible. This work describes developments in contact mechanics that use frictional sliding to evaluate the material strength and toughness of steel pressure vessels and pipelines. Hardness, Strength, and Ductility (HSD) testing is a portable implementation of frictional sliding that provides a tensile stress-strain curve for assessment of the yield, ultimate tensile strength (UTS), and strain hardening exponent for power-law hardening metals. HSD testing incorporates four styluses of different geometry that generate grooves on the surface of a material as they travel. The measured geometry of these grooves along with the normal reaction forces on the stylus are correlated to representative tensile stress-strain values through finite element analysis (FEA) simulations. These principles have been extended to account for nonlinear strength behavior through the thickness of seam-welded steel pipes by using a combination of the HSD surface measurement, microstructure grain size, and chemistry. Frictional sliding tests are also used to assess material variation across a welded seam to identify different welding processes and the effectiveness of post-weld-heat-treatments (PWHT). A second implementation of frictional sliding is Nondestructive Toughness Testing (NDTT), which provides an NDE solution for measuring fracture toughness by using a wedge-shaped stylus with an internal stretch passage to generate a Mode I tensile loading condition on the surface of a sample. The test produces a raised fractured surface whose height provides an indication of the materials ability to stretch near a propagating crack and is correlated to the crack-tip-opening-displacement (CTOD) measured from traditional laboratory toughness testing. Experiments on pipeline steel indicate that NDTT can provide an index of fracture toughness to benchmark materials tested under similar conditions. Implementation of these new instruments to gather data for integrity management programs, fitness for service assessments, and quality control of new manufacturing will help to reduce risk and uncertainty in structural applications.

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