Corrosion resistant alloys for oil and gas industry

Inconel Ni-Cr-Fe Alloys Incoloy Fe-Ni-Cr Alloys Monel Ni-Cu alloys

Heanjia Super-Metals Co., Ltd was established in 1984 in Beijing, China. With the background in metal manufacturing and development, we continue to deliver solutions to your stringent material problems by our international quality Inconel, Incoloy and Monel alloys.

Presently, Heanjia Super-Metals is a global leader in the manufacture and supply of heavy nickel and high temperature performance alloys employed for the composite and sophisticated engineering operations. They are well engineered to provide great combination of heat resistance, elevated temperature corrosion resistance, hardness and strength and are employed in the high tech industries and applications across the globe. We offer the industrial level supply of nickel based alloys and product forms in the international markets. We manufacture nickel alloys in standard mill forms, plate, sheet, strip, pipe, bar, rod, wire and many others. We have manufacturing and testing units in China and sales office in Seattle, America.

Reach us by dropping an email at [email protected] or call: 12068907337 or visit www.super-metals.com for any related information about our products.

Natural gas is one of the biggest energy sources in the world. Moreover, the new gas recovery is performed by intense formations that include aggressive conditions for downhole tubes and other well parts. Traditionally, the selection of metals for oil and gas industry was a relatively easy proposition. The standard grades of low alloy and carbon steels were stated for drilling and manufacturing tubes of stainless steels and nickel alloys for regular use in industrial applications.

In the modern time, the choice of materials for drilling and wells accomplishment can be a stringent task including the potential economy and protection risks. This has given rise to consider the various aspects:

1. Deeper wells including elevated temperatures and pressures 2. Improved recovery procedures like steam or carbon dioxide introduction 3. Higher weight considerations, particularly offshore 4. Requirement for higher corrosion resistance in wells where hydrogen sulfide, carbon dioxide and chlorides are present

The selection of materials particularly for sour gas wells involving H2S gas is particularly vital. Conditions in sour wells are vigorously corrosive to metals and H2S is deadly. In few sour conditions, corrosion can be monitored by using inhibitors along with carbon steel tubes. Although inhibitors include large cost and may be inconsistent, particularly at the elevated high temperatures. The corrosion potential to the tubing wall increases string weight and decreases interior dimensions. The recommended alternative for life cycle economy and protection is the application of a corrosion resistant alloy for tubes and other well parts.

The resistant alloy prevents inhibitors, decreases weight, enhances protection, discards or reduces work overs and decreases downtime.

For several years, Heanjia Super-Metals has been the global leader in the development and usage of corrosion resistant alloys.

Monel, Inconel and Incoloy alloys are produced for use in the diverse applications such as drill collars, piping equipments and valves, heat exchangers, process vessels and pyrolysis furnaces. We have in house production and research labs in China and branch office in USA. The facilities are unsurpassed in manufacturing the high functional alloys. These are fully integrated for full line control and traceability from acquisition of raw materials by melting, hot processing, cold processing and delivery of end products. Tight quality controls are followed in all processes by our extensive experience in meeting the sophisticated material needs in aerospace and nuclear sectors. Flawless materials recognize and cautiously maintained computer records offer full production traceability. Material Selection

Material selection for deep service in sour well is administrated by a bunch of complex factors. Service temperature may be high up to 800oC or 1470oF. The warm gas is of attacking nature and the marine conditions also cause aggressive issues. The high temperature strength, corrosion resistance, easy fabricability and readily available welding products equivalent the base materials are essential factors. Choosing material for any application, the objective is to employ a material that functions best while being cost effective. The material should offer the necessary physical and mechanical characteristics while resisting the specific conditions of oil wells. Feasible variations in the well conditions with the passage of time should be considered for example, chloride magnitude.

Other essential surrounding conditions are dissolved acid gases such as carbon dioxide and hydrogen sulfide in the liquid phase, chloride ions from salt or brine, temperature and pressure. In some productions, the availability of elemental sulfur is an additional aspect. The magnitude of dissolved gases depends on partial pressure of gasses over the liquid phase and temperature. Bottom hole pressure usually increases with depth of well and temperature can be up to 500oF or above.

Downhole tubular materials and other components for oil and gas production are introduced in various grades and chemistries. With increase in corrosion resistance, complication of material also increases from carbon steel to martensitic stainless steel, duplex stainless steel, austenitic steels and nickel based alloys of different chemistries. The nickel alloys employed for oil country tubular materials, possess the magnitude of nickel, chromium and molybdenum as the basic factors of corrosion resistance.

Downhole tubular alloys

Heanjia SuperMetals produces oil country tubular materials that are significant for use in vigorous oil and gas industrial conditions. These high alloys offer protective and cost-effective production with extensive temperatures, pressures and magnitude of H2S.

Hastelloy C276, Incoloy 825 are commonly used for the suitable pair of corrosion resistance and affordability. These alloys are introduced in the extensive range of corrosion resistive forms for downhole accessories and surface devices.

Incoloy 825, is a nickel-chromium alloy with copper and molybdenum contents, offers resistance to oxidation and reduction media, chloride ion stress corrosion cracking, pitting and intergranular corrosion. An addition of molybdenum is particularly significant in improving resistance of alloy in sour well conditions. Incoloy 825 is a solid solution alloy that is reinforced by cold processing to the lowest yield strengths, it is suitable for applications in conditions where stainless steels are prone to chloride induced stress cracking, pitting or crevice attack. On the base of particular strength and temperature, it is extremely resistant to stress corrosion cracking at partial pressure of hydrogen sulfide gas up to 1000 psi. It is used up to 1750oC.

Hastelloy C276 or Inconel C276 is a nickel-molybdenum-chromium alloy with inclusions of iron and tungsten. It is employed in highly vigorous sour well conditions containing free sulfur. It is commercially introduced in oil country tubular materials, providing highest resistance to conditions including hydrogen sulfide. The solid solution alloy can be cold processed to high strength levels and is offered with smallest yield strength of 150,000 psi or 1034 Mpa. On the base of blend of specific yield strength, temperature and free sulfur presence, Hastelloy C276 is prevents cracking at H2S partial pressures up to 10,000 psi or 70 Mpa. It is resistant to sour conditions at temperatures about 500oF or 260oC.

High strength in tubes is received by cold processing, but components of heavy or non-uniform cross section cannot be reinforced by cold processing. The parts need to be constructed of an alloy that can be reinforced by precipitation hardening heat processing.

Heanjia Super-Metals (HSM) has the widest range of high performance and corrosion resistant alloys for the industrial operations. These are made to the high standards of quality and functionality applied to CRA tubing and casing and are made in a complete range of standard mills forms such as pipes, tubing, rounds, flats, hexagons, wire, plate, sheet, strip etc. From the wide product line the most suitable alloy can be chosen in the desired form for virtual downhole or well top part.

Nickel-Copper alloy Monel 400 has medium strength and excellent corrosion resistance and is particularly resistant to marine and brine water.

Monel K500 is a high strength, age hardenable form of Monel 400.

Inconel 600 is a solid solution Nickel-Chromium alloy having high strength and corrosion resistance in the different conditions.

Inconel 625, a solid solution NiCrMoNb alloy has good strength and excellent resistance to general corrosion, pitting and crevice attack and stress corrosion cracking.

Inconel 718 is an age hardenable nickel-chromium-iron alloy comprising of critical magnitudes of niobium, molybdenum, titanium and aluminum, with outstanding corrosion resistance and very high strength.

Inconel 725 is an age hardenable NiCrMoNb alloy with outstanding corrosion resistance of Inconel 625 such as resistance to H2S, with great strength received by heat processing instead cold processing.

Inconel X750 is a nickel-chromium alloy having properties identical to Inconel 600 however made age hardenable by inclusions of aluminum and titanium for larger strength as well as corrosion resistance. Incoloy 800 is a solid solution Nickel-chrome alloy providing excellent strength and prevents general corrosion in various conditions. It is enhanced to Incoloy 800H and 800HT grades for providing higher strength at temperatures above 1100oF or 590oC.

Alloys for destructive corrosive conditions facing components

Components Alloys Bellows expansion joints Incoloy 825, Nickel-copper alloy 400, Inconel 625, Inconel X750 Downhole tubing, casing and couplings Incoloy 825, Inconel C276 Drill collars Monel K500 Drill Pipe Incoloy 825 Fasteners Monel K500, Inconel X750, Inconel 725, Inconel 686 Fittings Incoloy 825, Inconel 625 Filters & separation Monel K500, Incoloy 825 Flare booms Inconel 625 Flare stack edges Incoloy 800Ht Hangers Incoloy 925, Inconel 718, Inconel 725 Heat exchangers Incoloy 825, Incoloy 800HT, Inconel 625, Monel 400 Instrumentation tubing Incoloy 825, Monel 400, Inconel 625 Landing nipples Incoloy 925, Inconel 725 Packers Incoloy 925, Inconel 718, Inconel 725 Polished bore receptables Inconel 718, Inconel 725, inocloy 925 Pumps Inconel 718, Monel 400, monel K500, Incoloy 925 Rig leg cladding Monel 400, Inconel 625, Incoloy 825, Side pocket mandrels Inconel 725 Springs Inconel X750, Inconel 725, Sucker rods Inconel 718, Monel 400, Monel k500 Tubing calipers Monel 400, Monel K500 Valves Incoloy 825, Inconel 718, Monel 400, Monel k500 Wire lines Incoloy 825 Chemistry of Nickel alloys for oil and gas industrial operations

Alloy Monel Monel Monel Inconel Inconel Inconel Inconel Hastelloy Inconel Incoloy Incoloy 825 Inconel 925 400 R405 K500 600 625 718 725 C276 X750 800 UNS N0440 N04405 N05500 N06600 N06625 N07718 N07725 N10276 N07750 N08800 N08825 N09925 Element 0 Nickel 63 63 63 72 58 50 to 55 44 57 70 30 to 35 38 to 46 42 to 46 Chromium - - - 14.9 to 20 to 23 19 to 22.5 21 to 23.5 14.5 to 16.5 14 to 17 19 to 23 19.5 to 23.5 19.5 to 22.5 17 Iron 2.5 2.5 2 6 to 10 5 9 18 to 21 4 to 7 5 to 9 39.5 22 22 Copper 28 to 28 to 27 to .5 - - 1.5 to 2.5 - .50 0.75 1.5 to 3 1.5 to 3 34 34 33 Molybdenum - - - - 8 to 10 7 to 9.5 6 to 8 15 to 17 - - 2.5 to 3.5 2.5 to 3.5 Niobium - - - - 3.15 to 2.75 to 4 .50 - .70 to - - 0.5 4.15 1.20 Aluminum - - 2.30 to - .40 0.35 - - .40 to 1 .15 to .2 .1 to .5 3.15 .60 Titanium - - .35 to -- .40 1 to 1.7 - - 2.25 to .15 to .6 to 1.2 1.9 to 2.3 .85 2.75 .60 Sulfur .024 .025 to .01 .015 .015 0.010 .03 .03 .01 .0015 .03 .03 .060 Tungsten ------1.5 3 to 4.5 - - - - Cobalt - - - - 1 - 5 25 1 - - - Carbon .3 .3 .25 .15 .10 .03 .015 .01 0.08 1.10 .05 .03 Manganese 2 2 1.5 1 .50 .35 1 1 1 1.5 1 1 Silicon .5 .5 .5 .5 .50 .20 1 .08 .50 1 .5 0.5 Phosphorous - - - - .015 .015 .04 .04 - - - .03 Boron ------Vanadium ------.35 - - - - Nitrogen ------

Physical properties of chosen Nickel alloys

Alloy Densiy Young’s Magn Specific heat CTE Thermal Electric resistivity modulus etic conductivity perm eabilit y Lb/in3 g/cm3 10(6) psi GPa - Btu/lb.oF J/Kg.oC 10(- 10(- Btu.inc W/m. Ohm. Micro 6)/oF 6)/oC h/ft2.h. C Cmil/ft ohm.m oF Monel 400 .318 8.80 26 179 - .102 427 8.8 15.8 151 21.8 329 .547 Monel R405 .318 8.80 26 179 1.002 .102 427 8.7 15.7 151 21.8 307 .510 Monel K500 .305 8.44 26 179 1.010 .100 419 8.3 14.9 121 17.5 370 .615 Inconel 600 .306 8.47 31.1 221 1.000 .106 444 7.9 14.2 103 14.9 620 1.03 6 Inconel 625 .305 8.44 30.1 208 1.001 .098 410 7.4 13.3 68 9.8 776 1.29 1 Inconel 718 .296 8.19 29 200 <1.00 .104 435 8 14.4 79 11.4 751 1.25 1 Inconel 725 .300 8.30 29.6 204 <1.00 - - 7.5 13 - - 688 1.14 1 Inconel X750 .299 8.28 31 214 - .103 431 7.5 13.5 83 12 731 1.22 Hastelloy C276 .321 8.89 29.8 205 1.000 .102 427 7.2 13 68 9.8 739 1.23 2 Incoloy 800 .287 7.94 28.5 197 1.014 .11 460 9. 16.2 80 11.5 595 .989 Incoloy 825 .294 8.14 29.8 205 1.005 .105 440 8.5 15.3 77 11.1 678 1.13 Incoloy 925 .292 8.08 29.2 201 1.001 .104 435 8.2 14.8 - - 701 1.17

Mechanical properties for tubes

Alloy Yield strength Tensile strength Elongation Hardness Rockwell Ksi Mpa Ksi Mpa % Highest for sour well operations Inconel C276 125 862 130 896 13 C45 Incoloy 825 110 758 130 896 16 C35 Incoloy 925 110 758 140 965 18 C38

Mechanical properties for age hardenend rods or bars

Alloy Yield strength Tensile strength Elongation Hardness Ksi Mpa Ksi Mpa % Rc Monel K500 95 655 130 896 20 C35 Inconel 718 120 827 150 1034 20 C40 Inconel 725 120 827 150 1034 20 C40 Inconel X750 110 758 165 1138 20 C35

Mechanical properties for annealed corrosion resistant alloys

Alloy Yield strength Tensile strength Elongation Hardness Ksi Mpa Ksi Mpa % Rc Monel 400 35 214 80 552 40 B65 Inconel 600 45 310 95 655 40 B80 Inconel 625 80 552 135 931 45 B95 Inconel C276 60 414 115 793 50 B90 Incoloy 800 35 214 85 586 45 B70 Incoloy 825 45 310 100 690 45 B85

Specifications for Nickel alloys

Alloy UNS NACE ASTM ASME SAE AMS BS DIN W. Nr. VdTuV Monel 400 N04400 Mr-01-75 B127, B 163- 165, B 366, SB 127, SB 163- 165, SB 4544, 4574, 4575, 3072 – 17743, 2.4360 263 B 564, 725, B730, B751, 366, SB 564, SB 751, SB 4675, 4730, 4731, 3076 17750 B775, B829 775, SB 829 7233 – 54 Monel R405 N04405 MR-01-75 B 164 SB 164 4674, 7234 - - - - Monel K500 N05500 MR-01-75 B 865 - 4676 3072 – 17743, 2.4375 - 3076 17752 – 54 Inconel 600 N06600 MR -01 -75 B163, B 166 – 168, B 366, SB 163, SB 166 168, SB 5540, 5580, 5665, 3072 – 17742, 2.4816 305 B516 – 517, B564, B751, 366, SB 566 – 517, SB 5687, 7232 3076 17750 B775, B829 564, SB 751, SB 775, SB – 54 839 Inconel 625 N06625 MR -01 – 75 B 366, B 443 – 444, B SB – 366, SB 443, 444, SB 5581, 5599, 5666, 3072, 17744, 2.4856 499 446, B564, B704 – 705, 446, SB 564, SB 704 – 5837, 5869 3074, 117750 B751, B 775, B829 705, SB – 751, SB – 775, 3076 – 52 SB – 829 Inconel 718 N07718 MR – 01 – 75 B 637, B 670 SB – 425, SB – 637 5589, 5590, 5596, - - 2.4668 - 5597, 5662, 5664, 5832, 5962 Inconel 725 N07725 MR – 01 – 75 B 802 SB 443, 444, SB – 446 - - - - - Inconel X750 N07750 MR – 01 – 75 B 637 SB 637 5542, 5582, 5583, HR505 - 2.4669 - 5598, 5667 – 5671, 5698, 5699, 5747 Hastelloy C276 N10276 MR – 01 – 75 B 366, B 564, B 574, 575, SB 366, SB 582, SB 619, - - 17744, 2.4819 400 – B 619, B 622, B 626, B SB 622, SB 626, SB 751, 17750 12.98 751, B 775, B 829 SB 775, SB 829 – 52 Incoloy 800 N08800 MR – 01 – 75 B 163, B 366, B 407 – SB 163, SB 366, SB 407 – 5766, 5871 3072 – 470 1.4876 412 409, B 514, 515, B 564, B 409, SB 514, 515, SB 564, 3076 751, B 775, B829 SB 751, SB 775, SB 829 Incoloy 825 N08825 MR – 01 – 75 B 163, B 366, B 423 – SB 163, SB 366, SB 423 – - - - - - 425, B 564, B 704, 705, B 425, SB 564, SB 704, 705, 751, B 775, B829 SB 751, SB 775, SB 829 Incoloy 925 N09925 MR – 01 – 75 - SB 423 – 425, SB 564 - - - - -

Corrosion rate in hydrogen sulfide gas conditions

Alloy Hydrogen sulfide pressure Corrosion rate 300oF or 149oC 400of or 204oC Inconel 625 10 psi 69 kPa 0 mpy .000 mm/y .1 mpy .003 mm/y 50 psi 345 kPa 0.3 mpy .008 mm/y .4 mpy .010 mm/y 100 psi 690 kPa 0.1 mpy 0.003 mm/y .2 mpy .005 mm/y Incoloy 825 10 psi 69 kPa .1 mpy .003 mm/y .1 mpy .003 mm/y 50 psi 345 kPa .4 mpy .010 mm/y .5 mpy .0013 mm/y 100 psi 690 kPa .4 mpy .003 mm/y .5 mpy .013 mm/y Incoloy 925 10 psi 69 kPa .1 mpy .003 mm/y .1 mpy .003 mm/y 50 psi 345 kPa .4 mpy .0010 mm/y .5 mpy .013 mm/y 100 psi 690 kPa .1 mpy .003 mm/y .4 mpy .010 mm/y Inconel 718 10 psi 69 kPa 3 mpy .076 mm/y .3 mpy .008 mm/y 50 psi 345 kPa .7 mpy .018 mm/y 2.3 mpy .058 mm/y 100 psi 690 kPa .1 mpy .003 mm/y 1.2 mpy .030 mm/y Monel K500 10 psi 69 kPa 27 mpy .69 mm/y 1.1 mpy .28 mm/y 50 psi 345 kPa 78 mpy 1.98 mm/y 113 mpy 2.87 mm/y 100 psi 690 kPa 221 mpy 5.61 mm/y 169 mpy 4.29 mm/y

Stress corrosion cracking tests in elevated temperature sour conditions Alloy Material condition Yield strength Hardness, RC Test condition Time, Stress corrosion cracking 1000 psi Mpa days Inconel 625 Cold processed 128 883 37 A 15 no Inconel 625 Cold processed 177.1 1221 41 A 15 no Inconel 625 Cold processed 128 883 37 B 15 no Inconel 625 Cold processed 177.1 1221 41 B 15 no Inconel 625 Cold processed 125 862 30.5 C 42 no Inconel 625 Cold processed 160 1103 37.5 C 42 No Inconel 625 Cold processed 176 1214 41 C 42 no Inconel 718 Age hardened 120 827 30 C 42 No Inconel 718 Age hardened 134 924 38.5 C 42 No Inconel 718 Cold processed 197 1358 37.5 C 20 Yes Inconel C276 Cold processed 194.7 1342 43.5 A 15 No Inconel C276 Cold processed 194.7 1342 43.5 B 5 No Incoloy 825 Cold processed 131 903 30 A 15 Yes Incoloy 825 Cold processed 138 952 30 C 42 No Incoloy 825 Cold processed 147 1014 33 C 42 No Incoloy 925 Cold processed and aged 166 1145 40.5 A 15 yes Incoloy 925 Age hardened 133.5 783 38 B 15 yes Incoloy 925 Cold processed and aged 185.5 1279 46 B 15 yes Incoloy 925 Age hardened 114 786 38 C 42 No Incoloy 925 Cold processed 139 958 35.5 C 42 No Incoloy 925 Cold processed and aged 176 1214 43.5 C 42 No Incoloy 925 Cold processed and aged 185.5 1279 46 C 42 No

Test A: 15% NaCl + 200 psi or 1380 kPa H2S + 100 psi or 690 kPa Co + 1 g/l sulfur at 450f or 232oC

Test B : 25% NaCl + 200 psi or 1380 kPa H2S + 100 psi or 690 kPa Co + 1 g/l sulfur at 400of or 204oC Test C : 15% NaCl saturated with H2S + 1000 psi or 6.9 MPa gas phase of 1 % H2S, 50% carbon dioxide, 49 % N2 at 500of or 260oF

Test D : 25 % NaCl + 100 psi or 690 kPa H2S + 200 psi or 1380 kPa CO2 at 400oF or 204oC

Test E : similar to test D at 425oF or 218oC

Heanjia Super-Metals Co., Ltd

Headquarters

Yinling International, Wanjing West Road, Chaoyang District, Beijing.

Email: [email protected] Tel: 86- 134-2631-5876

HSM Factory

Wire Mesh Industrial Park, Anping County, Hebei Province, China

HSM Sales Office

3002 Harvard Ave E, Seattle Washington USA

Call: 12068907337

Email: [email protected]