New Technology of CRA Linepipe

Masakatsu Ueda Sumitomo Metal Industries, Ltd.

- CONTENTS 1. Why choose CRA for linepipes ? 2. Previous technology of CRA linepipes 3. New technology of CRA linepipes 4. Future development works 5. Conclusion

Norway-Japan SeminarMilestones in onshore/offshore pipeline research,

May, 27, 2003

Why choose CRA for linepipes

Characteristic on Oil & Gas Wells Oil wells: In their early days, - Not to be highly corrosive with protective oil film over the carbon steel surface. - As time passes, to produce increasing amounts of water and to be rather corrosive. Gas wells: - Not to have the same benefit of protective oil film - To have the condensation of water from vapor in the gas. - pH of the condensed water is typically between 3.5 and 4.5 and corrosion rates of carbon steel can be very high, sometimes several mm per year.

The use of CRA linepipes - To have higher reliability than carbon steel with inhibition. - To have lower life cycle cost and much less environmental impact

Examples of practical problems - The well design is unsuitable for injecting inhibitor - The corrosion rate is too high, even with inhibitor injection. - The cumulative cost of purchasing inhibitor year on year can become excessive. - High reliability is required in the inhibitor injection system which cannot always be guaranteed. - The environmental disposal issues with inhibitors are too demanding.
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The use of chemical inhibitor additions to well fluids

Previous technology of CRA linepipes

For CO2 + slightly H2S Environments (Strength grade: up to X65) Duplex Stainless Steel(DSS) pipes UNS S31500: 18Cr-5Ni-3Mo UNS S31803: 22Cr-5.5Ni-3Mo-0.1N

High

Temperature

C O

Duplex stainless steel or Clad

H ig h

Carbon steel with inhibitor Installed length (km) H2S High 1,200 1,000 800 600 400 200 0

Clad pipes with cladding layer of stainless steel UNS S31603: 18Cr-12Ni-3Mo(AISI 316L)

Fig. Applicable Environments for CRA linepipes (1975 to 1990 year)

DSS

Clad

1975

1980

1985

1990

1995

2000 3

Fig. Cumulative Use(km) of DSS and Clad pipes

Key technology to prevent corrosion

For CO2 Corrosion (General and Localized Corrosion) at elevated temp.
Higher Cr content in steels, Higher corrosion resistance due to Cr enrichment on surface film film

Key technology to prevent corrosion

For H2S Corrosion (Stress Corrosion Cracking: SCC) at room temp. Higher Cr , Ni and Mo contents in steels, Higher SCC resistance due to forming stable dual surface film Corrosion mechanism

Stable surface film formation

- Prevention of localized corrosion Forming stable surface film by Higher Cr, Ni and Mo content 5

New technology of CRA linepipes

Strength grade: up to X80 Weldable Super 13Cr Martensitic Stainless Steel seamless linepipes (1) Superior corrosion resistance to CO2 and slightly H2S environments (2) Quite cheap to DSS and Clad Improved-Duplex Stainless Steel(DSS) and Clad pipes Corrosion resistance to (1) Seawater & Slightly H2S for DSS (2) Highly H2S for Clad
DSS
Super 13Cr MSS

High

DSS
H ig h

Temperature

Super 13Cr MSS

C O

Clad

C steel + inhibitor H2S High 1,200 Installed length (km) 1,000 800 600 400 200 0

Fig. Applicable Environments for CRA linepipes (from 1990 year)

Super 13Cr MSS(66%)

Clad(28%) DSS(6%)

Clad

1975 Fig. % share in 2000 t0 2002

1980

1985

1990

1995

2000

Fig. Cumulative Use(km) of Super 13Cr MSS, DSS and Clad pipes 6

Weldable Super 13Cr Martensitic Stainless Steels Seamless Linepipes - Material development The development of weldable Super 13Cr MSS has been carried out by parallel activities of the following technical development together with Norwegian oil company, Statoil in 1993 to 1995 years; 1) Base metal Alloy design of base metal to keep corrosion resistance for CO2 and slightly H2S Ultra low Carbon MSS to adjust Cr, Ni, Mo, Ti contents 2) Welding wire Alloy design of weld metal to keep YS and toughness with low H content Super DSS to adjust Cr, Ni, Mo and N contents 3) Welding procedure High speed welding technique, Pulsed MIG welding method has been developed by Statoil
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Weldable Super 13Cr Martensitic Stainless Steel Seamless Linepipes - Alloy design concept Key technology - Ultra low Carbon : less than 0.01% - Welding material : Super duplex stainless steel(DP3W) X80 weldable, with over matching welding materials

Weldable Super 13Cr Martensitic Stainless Steel Seamless Linepipes - Mechanical properties Welding procedure (GTAW: 1.2kJ/mm)

Tensile strength (satisfy X80 Spec.) Hardness distribution

(almost the same from base metal to weld metal)

Toughness (Excellent)

Weldable Super 13Cr Martensitic Stainless Steel Seamless Linepipes - Corrosion resistance For CO2 at elevated temp.: General & localized corrosion For H2S at room temp.: Sulfide Stress Corrosion Cracking

Super 13Cr weldment

3.0MPa CO2 + 0.001MPa H2S, 5%NaCl, 100%YS, 336h

SSRT: 3.0MPa CO2 + x H2S

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Future development works

- Weldable super 13Cr martensitic stainless steel seamless linepipes m Optimization of Application technology Intergranular Stress Corrosion Cracking at Elevated Temperature SCC mechanism on HAZ of super 13Cr MSS in CO2 environments at elevated temperature will be made clear, though the SCC can be prevented by the application of post weld heat treatment( PWHT). The SCC in no PWHT conditions occurs on the HAZ of intact root surface, but does not as the intact root surface is machined. Hydrogen Emblittlement 1) Pre-service The combination of a high strength material, the presence of various different microstructure around the weld and not very well known stress/strain distributions in the weld area will be investigated for a more fundamental approach. 2) In-service Sacrificial anodes, overprotection to lead to the development to leaks around anode attachments and moderate cathodic protection technique will be investigated for preventing hydrogen emblittlement. Welding Procedure The development of chemically matching weld consumables and various girth welding processes will be investigated for welding faster and cheaper.
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- Conclusion CRA linepipes have some benefits of higher corrosion resistance, lower life cycle cost, and much less environmental impact than carbon steel with inhibition. Weldable super 13Cr martensitic stainless steel seamless linepipes of X80 grade with super duplex stainless weld metal have been developed by new technology of ultra low carbon and alloy design of Cr, Ni, Mo and Ti for CO2 and slightly H2S environments. And the application of these pipes has been substantial with approximately 650 km and 66% share of CRA linepipes in between 2000 and 2002. As future development works, optimization of application technology will be investigated for the weldable super 13Cr martensitic stainless steel seamless linepipes.

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