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

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). LRO Strengthening of Alloy C-22HS.

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

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  1. Proposal for a New Work Itemfor API 5 CRATo Include Alloy C-22HS (UNS N07022) at PLS -2 Ed Hibner, Consultant to Haynes International, Inc.

  2. Compositions of Alloy C-22HS (UNS N07022)

  3. 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

  4. LRO Domains in C-22HS. The Ni2( Mo,Cr) domains have the Pt2Mo crystal structure. The domains are approximately 10 nm in size.

  5. For Oil and Gas ApplicationsAlloy 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.

  6. 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

  7. Average Room Temperature Tensile Properties - Tube

  8. Charpy Impact Testing1” Diameter Bar, 44% Cold Worked (CW)

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. 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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