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CGE 654 - Lect 8 - Material Selection
CGE 654 - Lect 8 - Material Selection
Well
Completion
Material Selection
Outlines
Materials for well completion equipment
Engineering standards
Material selection requirements and criteria
Types of materials
Materials failure
Corrosion management and methods of prevention
Material Selection
Introduction
Proper selection of completion materials is a key
factor in ensuring completion longevity.
Selection of material is particularly critical where
tubing, casing and other well-completion
components are exposed to corrosive conditions.
Several specifications and standards have been
developed for material description and selection for
well completions.
Faculty of Chemical Engineering
Material Selection
Materials for well completion equipment
Tubulars
Carbon steel
Stainless steel (13Cr, 22Cr, Inconel)
Special alloys
Composite materials (GRE, Fiber glass)
Material Selection
Materials selection requirements
Materials selection should be optimized and provide acceptable
safety and reliability.
Requirements??
Material Selection
Corrosivity
Access for
maintenance
and repair
Requirements
Inspection
and corrosion
monitoring
Resistance to
brittle fracture
Failure
probabilities,
failure modes and
failure
consequences
Material Selection
Material selection criteria
Material selection criteria for oilfield equipment:
Mechanical properties (function)
Operating environment
Cost
Availability
Material Selection
Standards for Materials
AISI classifications (American Iron and Steel Institute)
API Standard (American Petroleum Institute)
ASTM Standard (American Society for Testing and
Materials)
ASME Code Specifications (American Society of
Mechanical Engineers)
NACE Publications (National Association of Corrosion
Engineers)
Faculty of Chemical Engineering
Material Selection
Materials Standards and Specifications
the standard number "5" in titles refers to tubular goods (5A, 5AX, 5AC)
'5L' covers various grades of pipeline (5L, 5LX, 5LS)
Material Selection
Materials Standards and specifications(cont)
ASTM (American Society for Testing and Materials)
cover all metals and alloys include specifications, methods of tests,
recommended practices
Material Selection
Materials Standards and specifications(cont)
The equipment for standard use - usually complies with API L80 regulation.
Material Selection
Materials Standards and specifications(cont)
Elastomers materials deteriorate over time at temperatures
above 275C, and lose all sealing capacity.
Special steels that do not come under the API categories are
used in hostile environments that require high mechanical
resistance or resistance to hydrogen sulphide.
CGE 654
Well
Completion
Tubular
Material Selection
Metals
Nearly all metals and alloys exhibit a crystalline structure
Strength - they are rarely used in engineering application
Alloys, a combination of several elemental metals are stronger
with more engineering usefulness.
Material Selection
Steels
Material Selection
Material Selection
Cast Iron
Material Selection
Stainless Steel
Steel will quickly rust in the presence of moisture and oxygen.
The addition of chromium gives steel the stainless quality.
Stainless steel must contain approximately 12% chromium or
more.
Stainless steel is classified by AISI based on its microstructure.
The 200 and 300 series stainless steels are austenitic, while
the 400 series are ferritic or martensitic.
There are several grades in each class.
Material Selection
Material Selection
Nickle Based Alloy
Monel consists of approximately 70% nickel and 30% copper
and exhibits good resistance against H2S (except at high
temperatures), CO2, O2, and chloride corrosion while
maintaining a high degree of ductility and strength.
Material Selection
Miscellaneous Alloys and Coatings
Due to the shortages and limitations of many H2S service alloys, various
other metal compounds are being used for equipment manufacture.
Hasteloy a nickel and molybdenum alloy.
Highly corrosion resistant.
Stellites cobalt, chromium and tungsten alloys.
For anti wear application.
Colomonoys nickel and boron alloys.
For anti wear coating.
Cemented carbides containing tungsten carbide.
For anti wear coating.
Material Selection
CGE 654
Well
Completion
Material Selection
Elastomer
Each of the monomers which link to form the polymer is usually made of
carbon, hydrogen, oxygen and/or silicon.
Material Selection
Elastomer
Material Selection
Examples of Elastomers
Unsaturated rubbers that can be cured by sulfur vulcanization:
Natural Rubber (NR)
Synthetic Polyisoprene (IR)
Butyl Rubber(copolymer of isobutylene and isoprene, IIR)
Halogenated butyl rubbers (Chloro Butyl Rubber: CIIR; Bromo
Butyl Rubber: BIIR)
Polybutadiene (BR)
Styrene-butadiene Rubber (copolymer of polystyrene and polybutadiene, SBR)
Nitrile Rubber (copolymer of polybutadiene and acrylonitrile,
NBR), also called Buna N rubbers
Material Selection
Examples of Elastomers(cont)
Saturated Rubbers that cannot be cured by sulfur vulcanization:
EPM (ethylene propylene rubber, a copolymer of ethylene and propylene) and
EPDM rubber (ethylene propylene diene rubber, a terpolymer of ethylene,
propylene and a diene-component)
Epichlorohydrin rubber (ECO)
Polyacrylic rubber (ACM, ABR)
Material Selection
Examples of Elastomers(cont)
Various other types of elastomers:
Thermoplastic elastomers (TPE), for example Elastron, etc.
Thermoplastic Vulcanizates (TPV), for example Santoprene TPV
Thermoplastic Polyurethane (TPU)
Thermoplastic Olefins (TPO)
The proteins resilin and elastin
Polysulfide Rubber
Material Selection
Elastomers
Highly saturated nitriles
Highly or Fully Saturated Nitrile Rubbers are designed specifically
for applications with H2S production or high temperatures.
Most elastomers are cured using a sulfur vulcanization process,
exposure to H2S downhole results in the further hardening and the
eventual failure of the elastomer.
Produced by selectively saturating (hydrogenating) most of the
butadiene portion of the acrylonitrile-butadiene polymer.
CGE 654
Well
Completion
Corrosion
Material Selection
Corrosion
Corrosion is defined as the destruction of a metal by a chemical or
electrochemical reaction.
Corrosion occurs when a metal in contact with water forms a
corrosion cell.
The corrosion cell has four components,
Material Selection
Corrosion
Material Selection
Corrosion
How??? Why???
Corrosion is the electromechanical reaction of metal or metal alloy
due to reaction with its environment
Pure metals do not exist in nature, only as ores or oxides of metal; the
most stable state
Corrosion is the reversion of the pure metal to its stable state (ore)
Fe Fe2+ + 2e
Cathodic reaction :
O + 4e + 2H2O 4OH
Material Selection
Corrosion
How??? Why???
Corrosion cells are created on metal surfaces in contact with an
electrolyte because of energy differences between the metal and the
electrolyte.
Different area on the metal surface could also have different potentials
with respect to the electrolyte.
These variations could be due to i) metallurgical factors, i.e.,
differences in their composition, microstructure, fabrication, and field
installations, and ii) environmental factors. Carbon and low alloy steels
are the most widely used material in the oilfield.
Stainless steels (Fe-Cr-Ni), and nickel-base corrosion resistant alloys
(CRA), such as Incoloys (Ni-Fe-Cr), Inconels (Ni-Cr), Hastelloys (Ni-CrMo-Fe-Co) etc., are also used in highly corrosive environments.
Faculty of Chemical Engineering
Material Selection
Types of corrosion
Uniform corrosion
Uniform removal of metal from a surface
May be observed in tubing and sucker rods
Acidizing treatment
Galvanic corrosion
Occurs when two dissimilar metals are connected electrically and are in contact with
an electrolyte solution
Eg: When a new section of pipe is added to an older section. The new pipe becomes
anodic and corrodes preferentially.
Intergranular corrosion
Localized corrosion along grain (metals&alloy) boundaries
Dealloying
Occurs when one or more components of an alloy are more susceptible to corrosion
than the rest.
Eg: The removal of zinc from brass, known as dezincification.
Material Selection
Types of corrosion(cont)
Crevice and pitting corrosion
Crevice corrosion - occur in crevices (stagnant, shielded areas) such as those formed under
gaskets, washers, insulation material, fastener heads, surface deposits, disbonded coatings,
threads, lap joints and clamps.
Pitting corrosion - "self nucleating" crevice corrosion, starting at occluded cells.
Hydrogen damage
Brittle mechanical fracture caused by penetration and diffusion of atomic hydrogen into the
crystal structure of an alloy
Occurs in corrosive environment under constant tensile stress
Erosion corrosion
Also known as flow-enhanced corrosion
Takes place in flowing systems where turbulence occurs, typically in pipe bends (elbows), tube
constrictions, and other structures that alter flow direction or velocity.
Mechanism - The continual flow of water, which removes any protective film or metal oxide
from the metal surface.
Material Selection
Types of corrosion(cont)
Material Selection
Types of corrosion(cont)
Material Selection
Cost of corrosion
Plant Downtime
Loss of Product
Loss of Efficiency
Contamination
Over design
Environmental Issues
Material Selection
Legislation
(Legal Liability)
Prudent
Operator
Ensure Asset
Integrity
Corrosion
Management
Ensure Health
and Safety
Manage
production
Maintenance
Material Selection
Coatings
Alloying
(metallurgy).
Methods of
prevention
Cathodic
protection
Faculty of Chemical Engineering
Inhibitors
Material Selection
Coatings
Inorganic, organic or
metallic coatings alter the
corrosion process by
changing the nature of the
metal solution interface.
Inhibitors
Alloying (metallurgy)
Another method of
corrosion control - any
chemical that reduces the
tendency for corrosion.
Cathodic protection is
Cathodic protection of
metals is simply the addition
of direct current applied to a
metal in reverse of the
natural flow (the anode
becomes the cathode, the
cathode becomes the
anode).
Cathodic Protection
Physical characteristics
solubility, emulsion,
foaming, compatibility,
thermal stability.
Selection of inhibitors
static corrosion test, wheel
test, flow test, misc tests.
Material Selection
Example: Material selection for well
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