API 5CRA Long Presentation for Inclusion of Alloy C 22HS b by HC121104194937

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									Proposal for a New Work Item
       for API 5 CRA
  To Include Alloy C-22HS
   (UNS N07022) at PLS -2


   Ed Hibner, Consultant to
   Haynes International, Inc.
Compositions of Alloy C-22HS (UNS N07022)


Alloy     Ni       Cr     Mo      W     Fe    Mn     C       S
           61     20.0-   15.5-   0.8   1.8   0.5   0.010   0.015
N07022
         (bal.)   21.4    17.4    max   max   max   max     max




          Si       P       Al     Co    Ta    Cu     B
          0.8     0.025   0.5     1.0   0.2   0.5   0.006
          max     max     max     max   max   max   max
  LRO Strengthening of Alloy C-22HS

•Many C-type alloys are known to strengthen significantly
under Long Range Ordering:
   •Strengthening is due to formation of long rang
   ordered domains (LRO) of Ni2( Mo,Cr)
   •Ductility remains high after LRO strengthening
LRO Domains in C-22HS. The Ni2( Mo,Cr) domains
        have the Pt2Mo crystal structure.
  The domains are approximately 10 nm in size.
          For Oil and Gas Applications
Alloy C-22HS Exhibits the Following Advantages

 •Very, very High Yield Strength Levels, While Still Exhibiting High
 Fracture Toughness and Ductility
 •Superior Resistance to Corrosion and Hydrogen Embrittlement
 •Currently Approved and Waiting for Publication in MR0175/ ISO
 15156-3 at NACE Level VII Environment with Elemental Sulfur
 at 204 °C (400)°F.
     •Approved Conditions: Annealed + Aged, Annealed + Cold Worked, and
     Annealed + Cold Worked + Aged.

 •MR0175/ ISO 15156-3 Ballot has been Submitted for C-22HS for
 Resistance Limits to 25% NaCl + 1,000 psi (7000 kPa) CO2 +
 1,000 psi (7000 kPa) H2S at 550°F (288°C), for Annealed + Cold
 Worked, and Annealed + Cold Worked + Aged Conditions.
        Alloy C-22HS is Included in
           MR0175/ ISO15156-3
        in the Following Locations
 Table A.33 — Environmental and materials limits for age-
  hardened nickel-based alloys (III) used for any equipment or
  component, in the annealed + age hardened material condition.
 Table A.14 — Environmental and materials limits for annealed
  and cold-worked, solid-solution nickel-based alloys used as any
  equipment or component, in the annealed + cold worked and in
  the annealed + cold worked + age hardened material conditions.
 Table A.12 — Materials types of solid-solution nickel-based
  alloys, as category 4f for UNS N07022, for material in the
  annealed + cold worked and in the annealed + cold worked + age
  hardened material conditions.
 Table D.3 — Chemical compositions of some solid-solution
  nickel-based alloys
 Table D.9 — Chemical compositions of some precipitation
  hardened nickel base alloys
 Average Room Temperature Tensile
         Properties - Tube
                Yield                       Reduction
                         UTS     Elongation
 Condition    Strength                       of Area
                         (ksi)      (%)
                 (ksi)                         (%)
Cold-Worked    187.3     195.0     15.1        58
      Charpy Impact Testing
1” Diameter Bar, 44% Cold Worked (CW)

                  Impact Energy* (ft-lbf)
       Test
    Temperature
                           CW

      RT (67°F)            146

       -75°F               153

       -320°F              113
Established Manufacturing Plan for OCTG Products to
     be Considered for API 5 CRA Applications

•Air Melt, AOD, ESR, Forge, Anneal, Trepan are Steps
for all C-22HS Products
•Variant is that Large Runs get Extruded and Annealed,
and Small Runs (accessories) would be Forged to
Smaller Diameters and Just Trepanned Prior to Honing.
•All Routes are Honed, ID Inspected, Pilgered, and NDT
Tested
•Final tubing and coupling stock condition will be in the
cold-worked condition.
Manufacturing History for OCTG Products to be
   Considered for API 5 CRA Applications
 •Haynes International has Melted 48 Commercial Heats of Alloy C-
 22HS (1.5 Heats for Cold Worked Bar and 46.5 Heats for Tubing and
 Coupling Stock)
 •Oil and Gas Wells 2 (One Shipped and Currently Being Installed
 and One in Manufacturing)
 •OCTG Sizes: 3.5” O.D. x 0.430” Wall (160ksi min. Yield Strength),
 49,300 ft. and 775,400 lbs.
 •Coupling Stock: 4.167” O.D. x 0.833” Wall (160ksi min. Yield
 Strength), 670 ft. and 21,800 lbs.
 •Coupling Stock: 4.25” O.D. x 0.950” Wall (160ksi min. Yield
 Strength), 810 ft. and 29,800 lbs.
 •Accessory: 3.5” O.D. x 0.920” Wall (160ksi min. Yield Strength), 40
 ft. and 850 lbs.
                     Conclusions
Haynes International has a well established route of production for
Alloy C-22HS Oil Country Tubular Products and has delivered one
major tubing string with coupling stock and accessories which will be
in production first quarter 2012 .

A second major Alloy C-22HS tubing string with coupling stock is in
Manufacturing and will be delivered by the time that work begins on
inclusion of Alloy C-22HS in API 5 CRA at PLS-2 level .

Haynes International has decades of experience in production of
OCTG’s and Coupling Stock for a complete range of Ni-Cr-Mo alloys.
This includes alloys such as Alloys G-3, G-50 and C-276, of which
Alloys G-3, G-50 and C-276 were invented by Haynes International.
             Recommendation
Establish a New Work Item or Incorporate in an Existing
Work Item for Inclusion of Hastelloy Alloy C-22HS (UNS
N07022) in API 5 CRA at the PLS-2 Level.
Recommend Ed Hibner, Haynes International, Inc.
Consultant and Brett Puckett of Shell to Chair the Working
Group if assigned a new Work Item.
Manufacturing History for Bar Products for Oil
            Patch Applications
•Haynes International has Melted 1.5 Commercial Heats of Alloy C-
22HS for Cold Worked Bar
•Oil and Gas Wells 2 (One Shipped and Currently Being Installed
and One in Manufacturing)
•Bar Diameter Range from 0.5” dia. to 3.625” dia.
•Applications Include:
    •MDW Tool Inserts
    •Wireline Tool Battery Housings
    •Sample Bottles
    •Wireline Tensile Bars

								
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