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InterCorr JIP 2005: New Limits for Sour Service NACE MR0175/ISO 15156, Deep Water & Dynamic Designs

InterCorr JIP 2005: New Limits for Sour Service NACE MR0175/ISO 15156, Deep Water & Dynamic Designs. Dr. Russell D. Kane Dr. Julio G. Maldonado InterCorr International, Inc. 14503 Bammel North Houston, Suite 300 Houston, Texas 77014 e-mail: rkane@intercorr.com. Background - 1.

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InterCorr JIP 2005: New Limits for Sour Service NACE MR0175/ISO 15156, Deep Water & Dynamic Designs

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  1. InterCorr JIP 2005:New Limits for Sour ServiceNACE MR0175/ISO 15156, Deep Water & Dynamic Designs Dr. Russell D. Kane Dr. Julio G. Maldonado InterCorr International, Inc. 14503 Bammel North Houston, Suite 300 Houston, Texas 77014 e-mail: rkane@intercorr.com

  2. Background - 1 • The development of new and deeper water offshore locations proceeds at a rapid pace. • SSC Issues are becoming more critical due to: • increasing H2S levels of both newer and older reservoirs, special considerations have arisen for material selection. • Many of these completions are operating in water depths that subject materials to combinations of low temperatures down to 5 C and dynamic loading. • Unresolved questions persist regarding resistance to SSC of many commonly used materials. • In some cases, industry guidelines as found in NACE MR0175/ISO 15156 have not investigated the true limits of commonly utilized “sweet-service” materials (316 SS, 17-4PH and Monel K-500, etc.) • Concerns are also for commonly utilized materials (up to 110 ksi SMYS) such as high strength steels & modified 13Cr’s.

  3. Background - 2 • Evaluation of materials for sour service started in the 1950’s and continued through the 1990’s mainly for onshore, wellhead and downhole applications. • Service temperatures were predominantly higher than ambient temperature, with susceptibility to SSC decreasing with increasing temperature over the range of around room temperature to over 125 C. • These studies utilize standard test methods, conducted at 24 C, that were a “reasonable worst case” for this service. • It was learned that susceptibility to SSC is actually higher at a temperature somewhat below room temperature; however, there is only limited data on this phenomenon.

  4. Background - 3 • Furthermore, evaluations for SSC have primarily been conducted under conditions of static load (stress), with threshold stresses determined under this simple loading condition. • This type of analysis is fine for designs that are based on primarily static loading. • However, many companies are going to dynamic designs for offshore components such as risers and flow lines which are using dynamic designs to achieve production from deeper water locations. • The role of dynamic loading on threshold behavior has not been adequately examined to provide a rigorous design basis for dynamic designs.

  5. JIP Program Description • InterCorr has developed a new flexible joint industry program (JIP) format for evaluation of the abovementioned topics. • Under this new effort, InterCorr has identified three (3) specific focused studies on topics that address these major SSC concerns. • Each topic will be funded by multiclient support and each will have a fixed scope of work and deliverables which can be completed within a one-year project period. • These will run in calendar year 2005 (from 1st Quarter through 4th Quarter 2005). • Sponsors will have the ability to fund any or all projects identified below. • They will also have the ability to conduct additional tests on a proprietary basis at preferred rates – 15% less than commercial rate.

  6. Program Schematic Project 2005-A – Evaluation of SSC Resistance of “Sweet” Materials in H2S Environments for Development of Ballot Guidelines in MR0175/ISO 15156 InterCorr JIP 2005:New Limits for Sour ServiceNACE MR0175/ISO 15156 Deep Water & Dynamic Designs Project 2005-B – Appraisal of SSC at Low Temperature Project 2005-C – Evaluation of Cyclic (Non-Fatigue) Loading on SSC Behavior Optional Project Addendum – This fee will cover a limited number of additional tests conducted on a proprietary basis These will be performed at preferred rates (15% less than commercial rates).

  7. Program Budget • Project 2005-A (17-4 PH, 316 SS & Monel 400; Evaluation for MR0175/ISO 15156) • $54,000 total ($9,000 per company) • Project 2005-B (Influence of low temperature on SSC) • $36,000 total ($6,000 per company) • Project 2005-C (Evaluation of Cyclic loading on SSC) • $30,000 total ($5,000 per company) • Optional Project Addendum (for Interested Sponsors) • $5,000 per company Each project will be fully funded with a total of 6 companies; work will start when three (3) companies agree to participate. Companies that join after 90 days from program start-up will pay 15% more than original sponsors.

  8. Program Status - 2005 JIP* * Subject to receipt of final contract (P.O.) • Program start-up sponsorship level has been • obtained for all projects. • If more than 6 companies agree to participate, • additional tests will be identified based on • sponsor input

  9. Project 2005-A: MR0175/ISO15156 Limits • Budget: Six companies, $54,000 – Current funding – six companies. • Schedule: Procurement of materials by end of March with testing to start by first part of April 2005. • Scope:This project will provide an engineering data base on 17-4 PH SS, 316 SS, and Monel 400 (and other materials may be added as the funding level and interest allows). It will include H2S partial pressure, pH and temperature as variables. The data will be collated and formatted for balloting of exposure limits for these materials.

  10. Project 2005-A: MR0175/ISO15156 Limits Experimental Program Details – 1: • Materials: 3 materials – 17-4PH SS, 316 SS, Monel K500 (all per NACE MR0175/ISO 15156) • Heats: 3 heats of each material will be selected in the upper range of sour service hardness. • Stress Levels:  1 per condition with triplicate specimens at 90 percent actual yield strength. • Specimens: NACE TM0177 (Method A) • Summary: Total of nine (9) specimens of each material per environmental condition.

  11. Project 2005-A: MR0175/ISO15156 Limits Experimental Program Details – 2: • Environmental conditions • H2S Partial Pressures:  1 condition per material (proposed range based on current limits and experience of sponsors) • 3.4 – 10 kPa (0.5 – 1.5 psia) H2S at pH 4.5 for 17-4 PH • 100 – 350 kPa (15 – 50 psia) at pH 3.5 for 316 • 100 – 350 kPa (15 – 50 psia) at pH 3.5 Monel K-500. • Chloride Content: 1 condition (5 to 15 percent). • Temperatures:  3 conditions (23 C to 125 C) as may be required to define performance. • Summary: Total of nine (9) specimens of each material x three (3) environmental conditions = 27 specimens of each material • Additional Conditions: In order to properly assess SSC limits up to an additional three tests will be utilized, if required – may also have to change test 2 or 3 conditions based on results of prior tests (i.e. three test contingency).

  12. Project 2005-A: MR0175/ISO15156 Limits Experimental Program Details – 3: • Data presentation: tabular data will be provided. Where possible plots will be provided if additional data is provided or developed. Where available data from literature source will be included for benchmarking and supplementing of the program data. Sponsor participation is requested. • Ballot items: MR0175/ISO 15156 ballot items will be prepared by InterCorr for sponsor review, modification, approval and submittal. • JIP Website: Data and ballots will be posted to a secure 2005 JIP website and archived for the sponsors. This will facilitate access and review. A discussion thread will be available for posting, review of comments, and pre-ballot development. • Schedule: Testing will begin in April and proceed through October 2005. Ballot development will take place during November and December 2005.

  13. Project 2005-A: MR0175/ISO15156 Limits • Discussion Items / Q & A: • Sponsors – If you have questions or comments regarding Project 2005-A in advance, please submit them to rkane@intercorr.com. They will be included with the final presentation slides posted to the InterCorr website to be used in the meeting.

  14. Project 2005-B: Appraisal of SSC at Low Temperature Experimental Program Details – 1: • This project will focus on the development of engineering data for SSC to support the use of common materials in subsea applications that require prolonged exposure to low temperatures. • It will utilize standard test methodologies (assessment of threshold stresses and KISSC) at specific levels of H2S concentration, pH and temperature. • Materials of greatest interest are high strength steels and modified 13Cr alloys used for casing, risers and flow lines. • However, the data may have implications for other materials in subsea applications.

  15. Project 2005-B: Appraisal of SSC at Low Temperature Experimental Program Details – 2: • Materials: 4 conditions (API T-95 Type I; AISI 4130-40 (HRC 22 max.)  13Cr L-80; and Modified 13Cr-110. • Test Temperatures: 2 conditions (5 C, 23 C) • Test Methods: NACE TM0177 Method A and Method D • Stress Conditions: Five stress conditions at each temperature • TM0177 Method A - 2 applied tensile stresses per condition – 90 percent actual yield stress; second stress condition to be selected to be the same stress or lower depending on results at 90 percent; • TM0177 Method D - 3 wedge loaded DCB specimens. • Summary: 4 material x 5 specimens = 20 specimens per temperature • TOTAL = 20 specimens x 2 temperatures = 40 specimens

  16. Project 2005-B: Appraisal of SSC at Low Temperature Experimental Program Details – 3: • H2S partial pressure: 1 condition for each material type • 100 kPa (15 psia) for steels • 10 kPa for (1.5 psia) for Modified 13Cr • Solution pH: 1 condition for each material type • 3.0 for steels • 3.5 for 13Cr • Chloride content: 1 condition (5 to 15 percent NaCl) • Environmental and materials conditions to be determined by sponsor input and available data for materials submitted. • Results: Data for F/NF at two stress levels and KISSC for each material and temperature will be compared to assess influence of temperature on SSC susceptibility.

  17. Project 2005-B: Appraisal of SSC at Low Temperature Experimental Program Details – 4: • Data presentation: tabular data will be provided. Where possible plots will be provided if additional data is provided or developed. Where available, data from literature sources will be included for benchmarking and supplementing of the program data. Sponsor participation is requested. • JIP Website: Data will be posted to a secure 2005 JIP website and archived for the sponsors. This will facilitate access and review. • Schedule: Testing will begin in June and proceed through September 2005. Results will be provided in a report in October 2005.

  18. Project 2005-B: Appraisal of SSC at Low Temperature • Discussion Items / Q & A: • Sponsors – If you have questions or comments regarding Project 2005-B in advance, please submit them to rkane@intercorr.com. They will be included with the final presentation slides posted to the InterCorr website to be used in the meeting.

  19. Project 2005-C – Evaluation of Cyclic (Non-Fatigue) Loading on SSC Behavior Experimental Program Details – 1: • This project will assess the impact of cyclic stresses on the threshold for SSC of a selected group of materials including a high strength steel, and a modified 13Cr alloy. • It will document and provide engineering data to assess dynamic designs where hydrogen charging is obtained from H2S corrosion. • NOTE: Such results may also provide insights into the effects of hydrogen charging from external cathodic protection under dynamic loading conditions, as well; however, this is not the specific intent of this project.

  20. Project 2005-C – Evaluation of Cyclic (Non-Fatigue) Loading on SSC Behavior Experimental Program Details – 2: • Materials: 2 conditions: API T-95 Type 1 and Modified 13Cr-110 completion steels  • Test Method: NACE TM0198 slow strain rate specimen  • Stress Conditions: 3 tests SSR Cyclic load - 10% of mean stress on each material; duplicate tests • 250 cycles maximum • maximum stress is to be 90 percent of actual yield or lower as needed to characterize materials and the impact of cyclic load • For example (three max. stresses: 90, 80, or 70 percent of actual yield strength depending on initial results. • Specimens at each condition to be tested without cyclic loading. • Temperatures: 2 conditions (5 C, 23 C) • Summary: 2 materials x 3 stresses x 2 (cyclic and static conditions) = 12 specimens per temperature • TOTAL = 12 specimens x 2 temperatures = 24 specimens

  21. Project 2005-C – Evaluation of Cyclic (Non-Fatigue) Loading on SSC Behavior Experimental Program Details – 3: • H2S Partial Pressures: 1 condition per material • 100 kPa (15 psia) for steel • 10 kPa (1.5 psia) for Modified 13Cr • Solution pH: 1 condition per material • pH 3.0 for steel • pH 3.5 for Modified 13Cr • Chloride Content: 1 condition • 5 percent NaCl • Environmental conditions to be determined by sponsor input and available data for materials submitted. Materials to be selected from 2005-B • Results: F/NF data for three stress conditions (with and without load cycling) for each material and temperature will be compared to assess influence of cyclic loading on SSC susceptibility.

  22. Project 2005-C – Evaluation of Cyclic (Non-Fatigue) Loading on SSC Behavior Experimental Program Details – 4: • Data presentation: Tabular data will be provided. Where possible plots will be provided if additional data is provided or developed. Where available, data from literature sources will be included for benchmarking and supplementing of the program data. Sponsor participation is requested. • JIP Website: Data will be posted to a secure 2005 JIP website and archived for the sponsors. This will facilitate access and review. • Schedule: Testing will begin in July and proceed through October 2005. Results will be provided in a report in November 2005.

  23. Project 2005-C – Evaluation of Cyclic (Non-Fatigue) Loading on SSC Behavior • Discussion Items / Q & A: • Sponsors – If you have questions or comments regarding Project 2005-C in advance, please submit them to rkane@intercorr.com. They will be included with the final presentation slides posted to the InterCorr website to be used in the meeting.

  24. Program Benefits • The initial benefit of this new flexible JIP format is that participating companies will pay only a portion of the total cost of these projects. • The program will set specific one year goals for funding and deliverables and the final scope of the work will be reviewed and approved by the companies that participate. Suggestions for 2006 programs are welcome. • All reporting will be paperless providing data in electronic format and a secure JIP website which will be used to archive the program data and deliverables for easy access by participating companies. • Additionally, InterCorr will utilize the secure website to develop any ballot items for MR0175/ISO 15156. • Sponsors may fund individual and multiple projects. • The results from this program will be held in confidence among the sponsoring companies for a period of at least two years or until approval is given from the sponsors. • Companies desiring to join the program after program start-up will have to pay 15 percent higher fees than those paid by the original sponsors. This arrangement gives the initial program sponsors maximum leveraging of their sponsorship fee.

  25. Program Management • This program will involve Dr. Russell D. Kane, InterCorr Vice President, as the program manager. He has extensive experience with evaluation of materials for sour service applications and development of the NACE MR0175 document. He will work with Dr. Julio G. Maldonado and Dr. Elizabeth Trillo who have extensive experience with SSC and laboratory corrosion testing. • Principal Investigators for the various tasks will be as follows: • 2005-A MR0175/ISO 15156 Limits – Dr. Russell D. Kane • 2005-B Low Temperatures – Dr. Elizabeth Trillo • 2005-C Cyclic Loading – Dr. Julio G. Maldonado • Periodic meetings will be held with the program sponsors through organized teleconferences currently planned for July 2005, October 2005 and December 2005. Monthly program updates will be provided by posting to the discussion thread. • For further information, questions, or suggestions for additional sponsors, please contact Dr. R.D. Kane at 281-444-2282 Ext. 32 or email at rkane@intercorr.com

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