Sour Service Testing

2017 Pipeline Materials Workshop – Steels for Sour Service
June 1, 2017 University of Alberta, Edmonton, AB
Large-Scale Sour-Service Testing

Rationale, Challenges and Experience
Todd A. Zahacy
C-FER Technologies, Edmonton
2017 Pipeline Materials Workshop (5th Annual)
Steels for Sour Service
June 1, 2017
Edmonton, Alberta
University of Alberta
8th Flr. Donadeo ICE Building, Fred Pheasey Commons
2017 Pipeline Materials Workshop – Steels for Sour Service – June 1, 2017 - University of Alberta, Edmonton, AB 1
Outline
• Why large-sale and full-scale sour service testing?
– Benefits and Rationale
– Challenges
• Experience - examples
– Glycol separator
– Coiled tubing (CT)
– Threaded tubulars - pipe body and connection
• Observations OCTG by other Researchers
• Current activity and near-term plans
– High-pressure, high-temperature wellbores, line pipe and subsea
equipment
©C-FER Technologies 2017 Page 1 / 14

Sour-service Testing Options

Standard and Index Tests
• Standard and Index Tests • Advantages
– NACE TM0177 (Methods A, B, C & D) – Standard, repeatable test procedures
– Slow Strain-Rate Tests (SSRT) or – Broad acceptance
Constant Extension Rate Tensile
(CERT) Tests – Relatively low cost
– Mini-pipe tests – Broad applicability
• Typical uses • Challenges & potential shortcomings
– Certification of materials for sour – Application to field service
service • Manufactured, installed components under
– Ranking & identification of suitable service-life environmental and load
materials conditions
– Inputs for design – environmental, – Applicability to predicting long-term
defect and load limits performance and service life
• Generally need to consider the
results of two or more different tests
Why Large-scale Sour-Service Tests?

Benefits and Rationale
• Examine combinations of key factors
– Capture design, manufacturing and service
environment conditions and loading
(combined loading, through-body stresses)
– Synergistic damage effects C-FER Technologies (2005) – C-FER Project D060
• Full-body test specimens SSRT Coiled Tubing Specimen
– Large material areas and volumes

– Material variabilities (uniformity of strength
and hardness, inclusions, residual stress,
stress relief)
– Surface finish, stress concentrations/risers,
welds
– Manufacturing (welds, threaded connections)
– Through-body dimensional irregularities (wall
thickness, eccentricity)
• Examine impacts of use and ‘damage’ C-FER Technologies (1995) – C-FER Project 95029
C-FER Technologies (1998) – C-FER Project 98061
– Surface damage, dents and gouges
External 2° cracks Coiled Tubing post-SSRT
– Examine post field and in-service effects

Why Large-scale Sour-Service Tests?

Challenges
• Complex tests
– Loading (mechanical loads, pressure,
temperature)
– Instrumentation and control
– Front-end systems engineering, setup and
commissioning
– Time and cost
– Safety
• Potential complications
– Control of fluids, temperature, pressure –
generally remote
– Sampling
– Large volumes
– Contamination C-FER
C-FER Technologies
Technologies (2008)
(2008) – C-FER
– C-FER Project
Project C024C024
– Number of tests for repeatability of results

• Data processing and interpretation
– Comparison of results to index test results
Sour-service ‘Special Environments Lab’ (SEL)

• Fume hoods
– Two conventional laboratory fume hoods
– Used for smaller specimen test programs and low
pressure tests
– e.g., Coiled Tubing SSRT, thermal plastic cyclic strain
and sour fluid mini-pipe tests
• Containment vessels
– Two large Special Environments Chambers (SECs)
– In-ground primary chamber 12 m (39.4_ft) deep by
2.5_m (8.2 ft)
– Horizontal secondary chamber for containment and
to house test equipment, test source fluids and
controls
– Working pressure of 1.4 MPa (200 psi) to contain
releases
– All testing equipment inside the SECs is remotely
operated with pressure rated feed-thrus through the
vessel walls 12m
• SEL room
– Maintain two barriers at all times between toxic test
fluids and personnel
– Room operated at vacuum
– Self-Contained Breathing Apparatus (SCBA) system
– Sensors and alarms, auto shut-off
– Chemical scrubbers and ventilating systems
2.4m

Example #1: Glycol Separator

(1995-1996)
• Decommissioned sour glycol separator pulled
from service (1.52 m u 5.72 m, Gr 70 steel,1973 -
_ _ _
1989) with ‘extensive cracking & blistering’

• Burst test to:
– Conduct an ‘Engineering Critical Assessment’ of
effect of flaws relative to vessels in service
• Included both service damage and manufactured thinned
wall section & a repaired ‘designer’ crack on ID
– Predict failure pressure and mode (fracture
mechanics)
– Measure crack propagation rates
• Monitored hydrogen permeation flux probes, strain &
acoustics
– Better predict the probability of failure
• Risk (insurance) and equipment & maintenance costs
• Several slow pressure ramp-up and hold periods,
NACE_TM0177 soln A (pH 2.7 – 3.5, @RT)
• Principle learnings:
– Vessel burst on the side opposite the identified C-FER Technologies (1995) – C-FER Project 95029
service-generated and manufactured flaws
– Unable to accurately predict both the burst location
and load (?)
Example #2: Coiled Tubing

(1998-2001, 2005-2006)
• Sour Underbalanced Drilling (UBD) and well 50 mm (2”) OD u 305 mm (12”) long, 4.6 mm (0.180”) wall
workovers using coiled tubing (CT)
– Up to 2% to 3% maximum plastic flexural strain;
running speed ~2 ft/s
• Canadian Industry Recommended Practice
(IRP 6.3, 1987) limited CT for sour UBD to
max 65 ksi
– Limited usage (well depths)
C-FER Technologies (2005) – C-FER Project D060
• Industry consortium to examine potential to
use higher grades 70 & 80 ksi
• Full-body CT specimen Slow Strain Rate Tests
(SSRTs, NACE TM0198-98)
– Large test area with manufactured surface finish,
geometry, material variability
– Inclusion of longitudinal welds
C-FER Technologies (1998) – C-FER Projects 98061, 99077
– Uniform axial strain (conservative since affects full
body, including ‘weak zones’ and surface defects) • Advantages of sour SSRTs:
– Pre-fatigued through 70 pre-fatigue bend cycles - Potential synergistic damage effects of dynamic cyclic
some strain-softening plastic loading and hydrogen embrittlement
– NACE TM0177 Method A (soln A, pH_2.7, OD - Relatively short duration tests, destructive (definite end)
@RT), target 1PH/s (tested 0.5 & 1000 PH/s)
and quantitative results (total elongation and stress at
C-FER Technologies (2008)
failure relative to in air)


Sample Results
• Objective:
– To obtain a comparative ranking of 70 and
80 grade CT materials based on reasonably
close simulation of field conditions
– ‘Fit-for-purpose testing’ 80 ksi, Air SSRT
• Observations:
– Nominal elongation 70 and 80 grade in air
exceeded 30%
– Significantly reduced elongation @SSR in
NACE A soln
– Sulfide Stress Cracking (SSC) plus some
blistering, Hydrogen Induced Cracking 80 ksi, Sour SSRT
(HIC) and stress-oriented (SOHIC) @mid-
wall perlite laminations C-FER
C-FER Technologies
Technologies (1998)
(1998) – NACE
– NACE 2001-01080
2001-01080
– All 1° cracks were brittle, 2° cracks were Micrograph

Micrograph (320x)
(500x)
C-FER Technologies illustrating
showing
(1998) – C-FER CTstress
Projects 98061 oriented
midsection withHIC
HIC
@defects (SOHIC)
cracks initiated and propagated along pearlite lamination
• better control on defects and linesC-FER Technologies (1998) – C-FER Projects 98061, NACE 2001-01080
elimination of heavy mid-wall perlite 2° Cracks Aligned with Surface Smuga-OttoDefects
Smuga-Otto etalal2001,
et 2001,NACE
NACE2001-01080
2001-01080
laminations

• SSRT Results Sample Results (NACE 2001-01080)
100,000
– Significant effect of strain rate GRADE 80
GRADE 80
• 1000 PH/s response exceeded
H2S ENVIRONMENT
AIR
90,000
air total strain
• 0.5 PH/s displayed significantly GRADE 70
AIR
80,000
reduced elongation (2/3 of
1_PH/s)
70,000
– Grade 80 CT displayed GRADE 70
significantly lower total relative H2S ENVIRONMENT
60,000
elongation at fracture (avg only
11.7% of air results) compared Stress
(psi) 50,000
with Grade 70 CT material (avg
34% of air) three times that 40,000
TEST 1 - GRADE 80, AIR
of Grade 80_ TEST 2 - GRADE 80, 100% H2S
• Potential use of Grade 70

TEST 3 - GRADE 80, 60%H2S, 40% CO2
30,000 TEST 4 - GRADE 80, 100% H2S, NO PREFATIGUE
CT material for sour UBD and TEST 5 - GRADE 70, AIR

TEST 6 - GRADE 70, 100% H2S, HALF STRAIN RATE
well servicing 20,000
TEST 7 - GRADE 70, 100% H2S
– With considerations of exposure 10,000

TEST 8 - Grade 70, 100% H2S
time/cycles, material yield and TEST 9 - GRADE 70, 100% H2S, PRESOAK AT 0 STRESS
TEST 10 - GRADE 70, 100% H2S, PRESOAK AT YIELD

hardness control HRC22 (Luft 0
et al 2002, NACE 2002-02054)
_
Strain NACE 2001-01080
Smuga-Otto et al 2001, NACE 2001-01080


Sample Results (SPE 97604)
• Example of Low-Cycle Corrosion
Fatigue (LCCF) test results
– Decreasing pH reduces LCCF
cycle life
– Inhibitor significantly increases
LCCF cycle life (~2/3 of air but
~4_times without inhibitor)
– Applied stress had almost no effect
on LCCF cycle life
• For sour CT UBD applications
– A higher pH and with the use of
inhibitor, expect to improve LCCF
life of 70 and 80 Grade CT
materials
• Additional research is required on
CT steel chemistry, optimal SSRT
strain rate, and additional LCCF
tests for statistical results
Nowinka et al 2005, SPE 97604
Example #3: Casing with Premium Connection

(2007 – 2008)
• Full-scale combined load testing of
integral premium connection
– 5.5” OD, 23 lb/ft TenarisHydril
Wedge 513™, TN95SS grade
_
(98 ksi Sy, 25 HRC)

_ _
TenarisHydril Wedge 513™
– Test connection sealability (http://www.tenaris.com/en/Products/PremiumConnections/Geometries/IntegralFl
ush/Wedge513.aspx, May 2017)
• For sour service directional wellbores

– Curvature of 40°/30m
– 110°C (230°F), 22.75 MPa (3300 psi)
• Test
– 30 day test with NACE TM0177-96 Soln A,
pH 2.6 - 2.8 @PH2S = 1.52 MPa,
PCO2=_2.55 MPa _
Heseltine 2009; Herod et al 2009, Mat Sc & Tech


Example #3: Casing with Premium Connection

(2008)
• Pre-test hydrostatic test of connection
passed @24.8 MPa (3600 psi) _
• Difficulty saturating fluid and maintaining

pressure – increasing pressure
– suspected off-gassing due to unknown
reaction
– Two more saturation attempts before identified
successful procedure to achieve stable
pressure @22.0 - 23.4 MPa _
• 30 day hold @110-120°C, pH increased to

3.77 passed 30 day sealability test
• @End of test:
– Broke-out connection torque 18% higher
than make-up – acceptable
– Internal surface coated with unknown corrosion
product (‘sludge’), some small pits, no cracking
• Key learnings:
– Procedural
• Saturate NACE soln with H2S at room
temperature, control pressure as raise
temperature
C-FERTechnologies
C-FER Technologies(2008)
(2008)––C-FER
C-FERProject
ProjectC024;
C024;Heseltine
Heseltine2008
2009
• Maintain gas cap in specimen (e.g. 20%) to aid in
control and saturation
– Consider condition of received large-scale test
specimens (finish, coatings) Heseltine 2009; Herod et al 2009, Mat Sc & Tech
Thermal & HP/HT Materials and

Premium Connections
http://www.imperialoil.com/Canada-
English/Investors/Operating/Natural_Resources/I_O_NaturalResourcesFig5.asp, June 2006.
Heseltine 2009; Herod et al 2009, Mat Sc & Tech

2013 Primrose, Wolf Lake, and Burnt Lake Annual Presentation to the AER - Subsurface
Issues Related to the Resource, Evaluation and Recovery, January 2014 Materials Workshop – Steels for Sour Service – June 1, 2017 - University of Alberta, Edmonton, AB
2017 Pipeline 16
C-FER Technologies

Thermal Cycle
Axially Confined
• Axially confined steel tubular (cemented
casing) during heating develops
compressive stresses (C)
• Depending on material, will eventually
yield (exceed elastic limit)
• On cool-down, experience high tensile
stresses (T) - may yield in tension
• C/T with each thermal cycle
V thermal Lx ,C Lx , H
Heat
Heavy Oil And Oil Sands Operations; IRP 3.2.1 WELL DESIGN, JUNE 2011 DRAFT, TC TH ! TC
REV 09JUNE11 (modified)
Premium Connection in Thermal-cycle Response

Stress Profile
177.8 mm, 38.7 kg/m (7”, 26 lb/ft) L80 Generic Premium Connection
• Connection is subjected to axial compression during heating and axial tension during
cooling
• Localized plastic stresses – compressive and tensile
1. Xie, J. (2011). Analysis of Strain Rate Impact on Makeup of Oilfield Premium Casing Connections. 2011 SIMULIA Customer Conference, May. pp 610-621.
2. Xie, J. and Tao, G. (2010). Analysis of Casing Connections Subjected to Thermal Cycle Loads. 2010 SIMULIA Customer Conference, Providence, RI, USA, May 125-27, pp. 679-694..

Different Strength Materials
• Low-strength (purple) and high-

strength (blue) materials
subjected to same thermal cycle
• Low-strength material
– Lower peak stress (capacity) than
high-strength material
– Experiences higher plastic strain
per cycle than high-strength
material
Drilling and Completions Committee (DACC). (2012). In Situ Heavy Oil Operations -
An Industry Recommended Practice (IRP) for the Canadian Oil and Gas Industry,
Vol. 03 – 2012. (modified)
Environmental Cracking
IRP 3.2.1 (2012 ) Well Design, Appendix F
Sulfide Stress Cracking (SSC)

Potential synergistic effects of elevated
temperature, plasticity, and corrosive
environment not well understood
– Experience has shown that controlling
hardness < 22_HRC (Rockwell C) can _
alleviate SSC
– Mitigate by controlling wellbore
environment and avoiding concurrent Szklarz, K.E. (2011). Cracking and Corrosion Issues with In Situ Thermal
conditions (stress, temp, pH, gases) Production of Heavy Oil. ATI Conference 2011 Proceedings, Lake Louise, AB.
Sept. 28. Paper 5H. (presentation and paper - modified).
* IRP 3 (2002) recommended minimum resistance to SSC >

90% of yield from NACE TM-0177-96 Method A test

Synergistic Thermo-mechanical Loading & Corrosion in

Thermal Wells (2008 – Present – Noetic led JIP)
• Motivation
– To develop a qualification protocol for assessment of
OCTG materials under combined thermo-mechanical
load cycles and environment-induced corrosion
• Additional objectives
– Improve the understanding of key variables
– Define Synergistic Representative Test (SRT)
– Identify forms of standard or intermediate material
tests that correlate with complex combined thermo-
mechanical (mini-pipe) test results
• Participants
– Operating companies and OCTG suppliers
• Activities – Phases 1 and 2
– Developed methodology & completed range of:
• ‘Simplified tests’ including thermal-mechanical tests and
sour service tests (NACE TM0177 Methods A)
• ‘Complex’ thermo-mechanical sour SSR (mini-pipe) tests C-FER Technologies (2013) – C-FER Projects C047
– Tested multiple materials using SRT at various levels C047
of severity with good repeatability
– Demonstrated synergistic mechanisms & observed
consistent fracture surfaces
Synergistic Impacts
Interim Results from Mini-pipe Tests (2013)
• L80 test results show significant loss
in ductility
– Reduction in plastic strain at parting
• Comments (Allen 2013):
– Evidence of synergies
– Damage mechanisms of combined
thermal-mechanical plastic strains and
SSC are complex
– Operators should consider these
impacts when selecting casing materials
Allen, M. (2013). Synergistic Damage: Combined impacts of sour exposure and mechanical loading on
production casing. SPE Thermal Well Integrity ATW, Nov. 17-19, Banff, AB.

Observations OCTG by other Researchers

Greer et al (NACE 69,1996)(1)
• Conducted NACE TM0177 Method A tests and
full-size pipe body tests on C110 (+ ‘upper “The fundamental advantage of prototype testing is that the
C100’) and C90 casing manufacture and geometry of the test specimen and the field used
– Casing test specimens placed in test holes product are basically the same, and loading by capped end pressure
– Included ‘proprietary’ (premium?) connections in 8_ft creates loads in the pipe and connection conducive to SSC. The
(2.4 m) specimens significant exposure area in the single prototype test is many orders
– Believe were not confined axially or radially of magnitude greater than that of many extensive laboratory
• NACE TM0177 Method A most samples specimens, giving a meaningful lower bound to test results.
passed (exception was higher hardness C110
The methodology of the prototype test sample is superior to that of
material)
the NACE TM0177 Method A sample because many sulfide stress
• Casing body tests all C110 specimens failed cracks initiate at metallurgical discontinuities in the pipe. The
<30 days @<= 80% of min yield stress with mix preponderance of such discontinuities are associated with the
of HIC and SSC; C90 passed 90% Vymin internal and external surfaces of the pipe, and Method A samples
• Found that the von Mises stress thresholds machined from pipe result in the exclusion of such discontinuities
from the C110 pipe tests were consistently less because of the machining process. The larger surface area which is
than the threshold values (80% of min yield) exposed in the prototype test allows a more accurate determination
from NACE Method A of the true threshold stress of the material.” (Greer et al 1996)
• Concluded that NACE Method A (axial samples)
did not provide a lower bound threshold stress
compared to the pipe body tests (principally 1. Greer, J.B., Elliott, G., and Shivers, R.M. (1996). Prototype Sulfide Stress Cracking Testing of High Strength
Oil Country Tubular Goods. 1996 NACE International Annual Conference and Exposition, NACE 96-69.
hoop)
Observations OCTG by other Researchers

Kane 2006 (NACE 2006-06131) & Moore (SPE 97578 2005)
• API research program to evaluate: • Concluded that more full-scale testing in sour
– ISO DIS 10400 Failure Assessment Diagram (FAD) environments was needed
through large-scale testing • Suggested may be possible to use intermediate
– Which models best simulate the brittle burst of pipe in sour mini-pipe tests (guide future full-body tests)
environments?
SPE 97578
• Test program NACE 2006-06131
NACE 2006-06131
– Full-scale burst testing of 95 grade 7.75” casing, 0.595”
wall
– Manufactured seamless pipe containing longitudinal flaws
(10.5-14.3% of through wall)
– No confinement @ambient temperature
– Also conducted NACE TM0177 Method D DCB and Crack
Tip Opening Displacement (CTOD) tests
• Air and non-H2S NACE Soln B on OD
– Failed at the imperfections
– Failed at consistent burst pressure values (19.8_ksi_±0.2%)
– Good match with FAD calculated burst pressure values
• NACE Soln A burst specimens (ID/OD or OD, Sample 2H - Pipe Failure 99° from10.48% man-made flaw
held for varying times and pressure loading Test condition: H2S (OD) - Water (ID)
profiles) NACE 2006-06131

– Burst at lower pressures with wide scatter (12.0_ksi_±37%) 1. Kane, R.D. (2006). Full Scale Testing of Pipe Containing Surface Imperfections in H2S and Non-H2S
Environments. 2006 NACE Corrosion NACExpo, 61st Annual Conference and Exposition, NACE 2006-06131.
– Failed at location about 90-99° circumferentially away from 2. Moore, P.W. and Maldonado, J.G. (2005). Review of the Recent API PRAC Project Attempt to Evaluate the
the flaw self-initiating cracks ISO DIS 10400 Failure Assessment Diagram Through Full Scale Testing of Pipe Containing Surface
Imperfections. SPE HP/HT Sour Well Design ATW, May 17-19, The Woodlands, TX. SPE 97578.
– Multiple cracking modes (HIC, SOHIC, SSC) observed

Near-term & Go-forward Plans

• Large-scale tubular pipe body and
connection sour service tests for HP/HT
and thermal well applications
– Combined loading
– Pressure and thermal cycles
– Plastic cyclic loading and sour environment
– Compare results to standard NACE and
intermediate (mini-pipe) test results
• Large-scale line pipe
– Assess relationship between standard test
results and full-system behaviour
• Support for recent API HP/HT subsea
design guidelines (API TR 17TR8)
– e.g., validation testing/qualification of designs
• Interest has been received from the
different groups (generally end-users)
– On-going discussions
C-FER Technologies
C-FER 2013
Technologies (2015)
Summary
• Large or full-scale testing offers significant advantages for sour-
service performance of manufactured components, including:
– Large area/volume, material’s life-cycle path, surface finish and flaws
– Inclusion of component design, manufacturing, handling and operational
– Offers examination of combined loading and environmental effects
– Useful for examining damage and failures under in-service conditions (fit-for-
purpose) and for model and design validation
• Relative to standard material characterization, index or ranking tests,
large scale tests have several challenges
– Complex loading, large volumes, large loads, complex instrumentation and
control, safety, and cost
– Generally limited number of tests

Acknowledgements
• Thanks and recognition to:
– C-FER Technologies for its support and to my colleagues:
• Kirk Hamilton, Tim Roth, Jonathan Heseltine, Chris Lam, Mark Cuglietta and Cam
Matthews, for their assistance toward the preparation of this presentation
• Dr. Qishi Chen for identifying this opportunity to provide this presentation
– Industry end user and product supplier companies that have supported
us in our tubulars and pipelines research over 30-plus years
– 2017 Pipeline Material Workshop organizers and Dr. J. Barry Wiskel for
the opportunity to present and participate in this event
Thankyou
Large-Scale Sour-Service Testing
Rationale, Challenges and Experience
Todd Zahacy
C-FER Technologies, Canada

References
1. Cayard, M.S. and Kane, R.D. (1997). Serviceability of Coiled Tubing for Sour Oil and Gas Wells. SPE/ICoTA North
American Coiled Tubing Roundtable, 1-3 April, Montgomery, Texas. SPE-38410-MS.
2. Smuga-Otto, I., Nowinka, J., Wilde, G. and Skrzypek, H. (2000). Evaluation of Coiled Tubing Materials for Sour
Service Under Full Body Slow Strain Rate Test. Proceedings 2000 NACE NWAC, Feb. 29- Mar.2, Saskatoon, SK.
Pp. 85-99.
3. Smuga-Otto, I., Nowinka, J., Wilde, G. and Luft, H.B. (2001). Coiled Tubing Performance Evaluation for Sour
Service Under Variable Loading Conditions. CORROSION 2001, 11-16 March, Houston, Texas. NACE-01080.
4. Luft, H.B. and Wilde, G. (1999). Industry Guidelines for Underbalanced Coiled Tubing Drilling of Critical Sour Wells.
SPE/ICoTA Coiled Tubing Roundtable, 25-26 May, Houston, Texas. SPE-54483-MS.
5. Luft, H.B., Szklarz, K.E., Nowinka, J. and Skrzypek, H. (2002). Evaluating the Fitness-for-Purpose of Coiled Tubing
for Underbalanced Drilling of Sour Wells. CORROSION 2002, 7-11 April, Denver, Colorado. NACE-02054.
6. Luft, H.B. (2003). The Low Cycle Fatigue and Plastic Strain Response of Coiled Tubing in a Sour Environment
With and Without Corrosion Inhibitor Protection. SPE/ICoTA Coiled Tubing Conference and Exhibition, 8-9 April,
Houston, Texas. SPE-81723-MS.
7. Nowinka. J., Luft, B. and Szklarz, K. (2005). Qualification of Materials for Sour Wells with Various Test
Methodologies. SPE High Pressure/High Temperature Sour Well Design Applied Technology Workshop, 17-19 May,
The Woodlands, Texas. SPE-97604-PT.
8. Padron, T. (2010). Sour Serviceability of Higher-Strength Coiled Tubing: Final Results. SPE Projects, Facilities &
Construction. Vol. 5, No. 04 (December). SPE-130279-PA.
9. Szklarz, K.E. (2011). Cracking and Corrosion Issues with In Situ Thermal Production of Heavy Oil. ATI Conference
2011 Proceedings, Lake Louise, AB. Sept. 28. Paper 5H.
10. Been, J. and Crozier, B. (2012). Evaluation of Sour Corrosion as a Function of Pressure, Temperature and Tensile
Load Using Hydrogen Permeation in Mini-Pipe Specimens. CORROSION 2012, Mar. 11-15, Salt Lake City, Utah.
NACE-2012-1161.
References
11. Allen, M. (2013). Synergistic Damage: Combined impacts of sour exposure and mechanical loading on
production casing. SPE Thermal Well Integrity ATW, Nov. 17-19, Banff, AB.
12. Greer, J.B., Elliott, G., and Shivers, R.M. (1996). Prototype Sulfide Stress Cracking Testing of High Strength Oil
Country Tubular Goods. 1996 NACE International Annual Conference and Exposition, NACE 96-69.
13. Cernocky, E.P., Aaron, V.D., Paslay, P.R. and Wink, R.E. (2005). Combined Axial Tension/Compression and
Internal Pressure Testing of Mini-Pipe Specimens in H2S Environment to Determine Three Dimensional (Triaxial)
Stress States which Produce Crack Initiation Failure: Explanation of the New Test Fixture, Mini-Pipe Specimen,
and Preliminary Test Results. SPE High Pressure/High Temperature Sour Well Design Applied Technology
Workshop, 17-19 May, The Woodlands, Texas. SPE-97577-MS.
14. Moore, P.W. and Maldonado, J.G. (2005). Review of the Recent API PRAC Project Attempt to Evaluate the ISO
DIS 10400 Failure Assessment Diagram Through Full Scale Testing of Pipe Containing Surface Imperfections.
SPE HP/HT Sour Well Design ATW, May 17-19, The Woodlands, TX. SPE 97578.
15. Kane, R.D., Moore, P. and Maldonado, J.G. (2006). Full Scale Testing of Pipe Containing Surface Imperfections
in H2S and Non-H2S Environments. CORROSION 2006, 12-16 March, San Diego, California. NACE-06131.
16. Herod, S., Sivley,R., Romero, A., Kis, P. and Heseltine, J. (2009). Full Scale Combined Load Premium
Connection Testing in an H2S Environment. Materials Science & Technology 2009 Conference and Exhibition
(MS&T Partner Societies), Oct. 01, pp. 1664 - 1675.
17. Urband, B.E. and Garrison, B.V. (2003). The Effects of OCTG Connection Swaging and Stress Relieving on SSC
Resistance. CORROSION 2003, 16-20 March, San Diego, California. NACE-03111.
18. Huang, W. (2012). Sulfide Stress Cracking of Low Alloy Steels for Casing Application in Sour Environments. MSc.
Thesis, Department of Chemical and Materials Engineering, University of Alberta, Edmonton, AB.

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2017 Pipeline Materials Workshop – Steels for Sour Service

June 1, 2017 University of Alberta, Edmonton, AB

Large-Scale Sour-Service Testing

©C-FER Technologies 2017 Page 1 / 14

Sour-service Testing Options

Why Large-scale Sour-Service Tests?

• Full-body test specimens SSRT Coiled Tubing Specimen

– Large material areas and volumes

©C-FER Technologies 2017 Page 2 / 14

Why Large-scale Sour-Service Tests?

– Number of tests for repeatability of results

Sour-service ‘Special Environments Lab’ (SEL)

©C-FER Technologies 2017 Page 3 / 14

Example #1: Glycol Separator

1989) with ‘extensive cracking & blistering’

Example #2: Coiled Tubing

©C-FER Technologies 2017 Page 4 / 14

Example #2: Coiled Tubing

– All 1° cracks were brittle, 2° cracks were Micrograph

Example #2: Coiled Tubing

of Grade 80_ TEST 2 - GRADE 80, 100% H2S

•  Potential use of Grade 70

CT material for sour UBD and TEST 5 - GRADE 70, AIR

– With considerations of exposure 10,000

TEST 10 - GRADE 70, 100% H2S, PRESOAK AT YIELD

©C-FER Technologies 2017 Page 5 / 14

Example #2: Coiled Tubing

Example #3: Casing with Premium Connection

(98 ksi Sy, 25 HRC)

• For sour service directional wellbores

Heseltine 2009; Herod et al 2009, Mat Sc & Tech

©C-FER Technologies 2017 Page 6 / 14

Example #3: Casing with Premium Connection

• Difficulty saturating fluid and maintaining

• 30 day hold @110-120°C, pH increased to

Thermal & HP/HT Materials and

Heseltine 2009; Herod et al 2009, Mat Sc & Tech

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Premium Connection in Thermal-cycle Response

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Different Strength Materials

• Low-strength (purple) and high-

Sulfide Stress Cracking (SSC)

* IRP 3 (2002) recommended minimum resistance to SSC >

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Synergistic Thermo-mechanical Loading & Corrosion in

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Observations OCTG by other Researchers

Observations OCTG by other Researchers

profiles) NACE 2006-06131

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Near-term & Go-forward Plans

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