Proposal for a New Work Item

for API 5 CRATo 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

N0702261

(bal.)20.0-21.4

15.5-17.4

0.8 max

1.8 max

0.5 max

0.010 max

0.015 max

Si P Al Co Ta Cu B

0.8 max

0.025 max

0.5 max

1.0 max

0.2 max

0.5 max

0.006 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 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.

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

ConditionYield

Strength (ksi)

UTS (ksi)

Elongation (%)

Reduction of Area

(%)

Cold-Worked 187.3 195.0 15.1 58

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

Test Temperature

Impact Energy* (ft-lbf)

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