INTERNATIONAL STANDARDS AND RECOMMENDED PRACTICES FOR ASSURING STRUCTURAL RELIABILITY ON OCTG PRODUCTS
F. Daguerre, M. Merliahmad, M. Tivelli
Technica Technicall Assistance Assistance - South South East Asia Asia
Introduction Conceptual Vision Well Challenges
Failure – Lack of Structural Failure Struct ural Reli ability ityy Structu ral Reliabil Relia Reliabilit bility
Well Design (Load cases – Environment …)
Exploration Drilling (Associated services)
Casing + Cementing
Completion Production etc
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Introduction Conceptual Vision Well Challenges Well Design
Corrosion& Cracking Resistance
(Load cases – Environment …)
Mult ltia iaxi xial al Lo Load ads s Mu Exploration Drilling (Associated services)
Casing + Cementing
Thermal profile Fluid dynamics Interaction fluids & materials
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o r n s k o i i n t l e i g e d c a x i C n n L p r o n e i f t e m a C o a c e d t r a i t n g M r n f o i i o n Product c k e y r s P o Performance W
Mechanical Properties
Structural Performance
Dimensions
Working Conditions
Completion Production etc
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Introduction From needs to requirements Well Challenges Well Design (Load cases – Environment …)
Corrosion& Cracking Resistance
•API 5CT/ISO 11960
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Exploration Drilling (Associated services)
Casing + Cementing
•NACE MR0175 /ISO15156
•API 5C3 / ISO 10400
o r n s k o i i n t l e i g e d c a x i C n n L p r o n e i f t e m a C o a c e d t r a i t n g M r n f o i i o n Product c k e y r s P o Performance W
•API 5C5 / ISO13679 •Proprietary specs.
Mechanical Properties
Structural Performance
Dimensions
Working Conditions
Completion Production etc
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Introduction From needs to requirements Well Challenges Well Design (Load cases – Environment …)
Corrosion& Cracking Resistance
•API 5CT/ISO 11960
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Exploration Drilling (Associated services)
Casing + Cementing
•NACE MR0175 /ISO15156
•API 5C3 / ISO 10400
o r n s k o i i n t l e i g e d c a x i C n n L p r o n e i f t e m a C o a c e d t r a i t n g M r n f o i i o n Product c k e y r s P o Performance W
•API 5C5 / ISO13679 •Proprietary specs.
Mechanical Properties
Structural Performance
Dimensions
Working Conditions
Completion Production etc
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Material Performance Material Properties
•API 5CT/ISO 11960
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Material Performance Material Properties
•API 5CT/ISO 11960 Ys Range [ksi]
40 45 50 55 60 65
Group I
H40
70
75
80
85
90
95
100 105 110 115 120 125 130 135 140 145 150
Max HRC
J55 - K 55 N80 Type1 & N80Q Group II
22
M65
23
L80
25,4
C90 C95 T95 Group III
P110
Group IV
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25,4
Q125
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Material Performance Material Properties
•API 5CT/ISO 11960 6.2 Heat Treatment 7.1 Chemical Composition 7.10. Hardenability 7.11 Grain size
Corrosion& Cracking Resistance
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Mechanical Properties
Structural Performance
Dimensions
Working Conditions
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Material Performance
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Material Performance
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Material Performance Material Properties
•API 5CT/ISO 11960 Corrosion& 6.2 Heat Treatment Cracking Resistance 7.1 Chemical Composition W o s 7.10. Hardenability r n k o i i n t i g l e e d 7.11 Grain size c a x i n n r p L C
o n e i t e m a C o a e c f d t r g a i t n M r n f o i i o n Product c k e y r s P o Performance W
Mechanical Properties
Structural Performance
Dimensions
Working Conditions
7.2 Tensile properties 7.3-7.-6 Charpy V-notch test 7.8 Hardness variation 7.14 Sulfide stress cracking DMF 4th Petroleum Forum
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Material Performance Sulfide Stress Cracking Resistance
•NACE MR0175 /ISO15156-2
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Material Performance Sulfide Stress Cracking Resistance
•NACE MR0175 /ISO15156 Corrosion& Cracking Resistance
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Mechanical Properties
Structural Performance
Dimensions
Working Conditions
In
environments containing H2S, hydrogen embrittlement, Sulfide Stress Cracking could suddenly occur DMF 4th Petroleum Forum
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Material Performance Sulfide Stress Cracking Resistance Factors interacting in the performance of steels 1. Chemical composition, method of manufacture, product form, strength, hardness of the material and its local variations, amount of cold work, heat-treatment condition, microstructure, microstructural uniformity, grain size and cleanliness of the material; 2.
H2S Partial pressure in gas or equivalent concentration in water phase.
3. Acidity (in situ pH) of the water phase. 4. Chloride ion concentration in the water phase 5. Presence of sulfur or other oxidants 6. Exposure to non-production fluids 7. Exposure to temperature 8. Total tensile stress: applied stress plus residual stress. 9. Exposure time. DMF 4th Petroleum Forum
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Material Performance Sulfide Stress Cracking Resistance H2S pp > 0,3Kpa (0,05psi)
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Material Performance Material Properties
•API 5CT/ISO 11960
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Material Performance Material Properties
•API 5CT/ISO 11960 Risk Concern ?
•Supplementary Requirements
•Product specification Level
Improve Structural Reliability
•Mechanical Properties •Statistical testing •NDT acceptance criteria •Inspection Frequencies
Statistical analysis of impact testing SR16. Impact testing (Charpy V-notch) for pipe H.2.2 Grade N80Q, PSL-3 (6.2.2). Only N80Q shall be furnished for PSL-3. H.4. PSL2 C90, T95, Q125. Chemical composition shall be Type 1. H.5 Yield strength - Q125, PSL-3. The maximum yield strength shall be 140 ksi H.6.1. PSL2. Charpy, minimum 75% shear area. H.7. PSL2 L80 Type 1: Hardenability 90%. PSL3 C90 & T95: 95% H.9 Sulfide stress-cracking - PSL-3. Method A testing with a load of 90% SMYS. SR12.
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Material Performance Structural Performance
Corrosion& Cracking Resistance
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Mechanical Properties
Structural Performance
Dimensions
Working Conditions
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Material Performance Structural Performance
•API 5C3 / ISO 10400 Corrosion& Cracking Resistance
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o r n s k o i i n t i g l e e d c a x i C n n L p r o n e i f t e m a C o a e c d t r g a i t n M r n f o i i o n Product c k e y r s P o Performance W
Mechanical Properties
Structural Performance
Dimensions
Working Conditions
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Material Performance Structural Performance
•API 5C3 / ISO 10400 Classical
approach, deterministic, smooth body continuous mechanics
Statistical
approach, realizing the variability of product parameters
depending no actual process control capabilities Influence
of imperfections and material fracture toughness in the
product rupture.
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Material Performance Structural Performance
•API 5C3 / ISO 10400
6 Triaxial yield of pipe body
7 Ductile rupture of the pipe body
8 External pressure resistance
9 Joint strength
Annex B (inf.) Discussion of equations for ductile rupture
Annex D (inf.) Discussion of equations for fracture
Annex F (inf.) Development of probabilistic collapse performance properties
Annex G (inf.) Calculation of design collapse strength from collapse test data
Annex K (inf.) Tables of calculated performance properties in SI units
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Material Performance Structural Performance
•API 5C3 / ISO 10400
6 Triaxial yield of pipe body Internal Yield
+
Internal Pressure
_ Ys
Ys
Compression
+
Tension
External Yield
_ External Pressure 23 May 2011
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Material Performance Structural Performance
•API 5C3 / ISO 10400
Annex F (inf.) Development of probabilistic collapse performance properties
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Material Performance Structural Performance
•API 5C3 / ISO 10400
7 Ductile rupture of the pipe body Annex B (inf.) Discussion of equations for ductile rupture Annex D (inf.) Discussion of equations for fracture
Final
failure must consider the imperfection acceptance levels
Annexes
K and L: Burst for P110 at 12,5 % and at a 5 % NDT inspection level. Supplementary
requirements, like SR2, or PLS 2 /3 in API 5CT – ISO 11960 for a higher structural reliability becomes evident. Rupture
could be ductile or fragile, with different mechanisms and quite different load levels. H2S
will affect the actual toughness and then special formulas are to be considered. Several work is ongoing in this regards. DMF 4th Petroleum Forum
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Material Performance Structural Performance
•API 5C5 / ISO 13679 Corrosion& Cracking Resistance
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Mechanical Properties
Structural Performance
Dimensions
Working Conditions
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Material Performance Structural Performance
•API 5C5 / ISO 13679 For API connections, round and buttress, the main characteristics are covered in API TR 5C3 / ISO TR 10400 and tabulated in Annexes K and L. The type of conditions in which they are used and their limitations to “low pressure, no critical services” are widely recognized. API 5C5 / ISO 13679, that establishes minimum design verification testing procedures and acceptance criteria for casing and tubing premium connections
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Material Performance Structural Performance
•API 5C5 / ISO 13679 It categorizes test severity into four test classes. Cal
I, for liquid service, testing at room temperature without external pressure and bending optional. Cal
II adds thermal cycling with a cumulative exposure of 5 h to gas at 135 °C. Cal
III, for gas and liquid service, includes external pressure in the cycling testing. Cal
IV, for most severe application includes bending, and thermal/pressure-tension cycling with cumulative exposure of about 50 h to gas at 180 °C.
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Validation Tests ISO 13679 – Galling Evaluation & Seal capacity under combined loads
E C N A T S I S E R G N I L L A G
Specimen preparation
Specimen 1
Specimen 2
Specimen 3
Thread-seal interference
H-L
L-L
H-H
Thread taper
PSBF
PSBF
NOM-NOM
PFBS
MU (A)
MU (A)
MU (A)
7.2.2
7.2.2
7.2.2
H/L
H/H
H/H
RRG (B) 7.2.4 L/H
Make and
Specimen 4
Specimen 5
Specimen 6
Specimen 7
H-L
L-H
L-H
PSBF
PSBF
PFBS
PFBS
MU (A)
MU (A)
MU (A)
MU (A)
MU (A)
7.2.2
7.2.2
7.2.2
7.2.2
7.2.2
H/H
H/L
H/H
H/L
H/L
RRG (B)
RRG (B)
RRG (B)
7.2.4
7.2.4
7.2.4
L/H
L/H
L/H
L-H H-L 8 SPECIMENS
Specimen 8
break properties
Amount thread compound/torque shown in each block
MBG (B)
MBG (B)
MBG (B)
MBG (B)
7.2.3
7.2.3
7.2.3
7.2.3
L/H
L/H
L/H
L/H
FMU (B)
FMU (B)
FMU (B)
FMU (B)
FMU (B)
FMU (B)
FMU (B)
FMU (B)
7.2.5
7.2.5
7.2.5
7.2.5
7.2.5
7.2.5
7.2.5
7.2.5
H/L
H/H
H/H
H/H
H/L
H/H
H/L
H/L
Bake
Bake
Bake
Bake
Bake
Bake
Bake
Bake
Bake
CAL II, III, IV
7.3.2
7.3.2
7.3.2
7.3.2
7.3.2
7.3.2
7.3.2
7.3.2
T/C pi/po
T/C pi/po
T/C pi/po
T/C pi/po
7.3.3
7.3.3
7.3.3
7.3.3
D E S N I D B A O M L O C
Series A
Series B
T/C pi w B
T/C pi w B
T/C p i w B
T/C pi w B
7.3.4
7.3.4
7.3.4
7.3.4
Thermal Cycle 7.3.5
Thermal Cycle 7.3.5
Thermal Cycle 7.3.5
Thermal Cycle 7.3.5
Structural tests
Failure test
Failure test
Failure test
Failure test
Failure test
Failure test
Failure test
Failure test
CAL
pih+T to F
C+po to F
T to F
po+C to F
T+pi to F
pi+C to F
po to F
pil+T to F
IV & III
7.5.1
7.5.2
7.5.3
7.5.6
7.5.7
7.5.8
Path No.
P1
P2
P3
P6
P7
P8
Series C
th
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FAILURE TESTS7.5.5 7.5.4 P4
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Material Performance Structural Performance
•API 5C5 / ISO 13679 20.0 Load Points Collapse Pressure
15.0
95% VMES 100% VMES (Yield)
10.0
i s k [
e r u s-3,000 s e r P
5.0 0.0 -2,000
-1,000
0
1,000
2,000
3,000
-5.0 -10.0 -15.0 -20.0
Test Failure
Axial L o ad [ki p s]
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Conclusions From needs to requirements
International
Standards and Recommended Practice assure the structural reliability. The
application of these documents a sound engineer judgment for each application.
Corrosion& Cracking Resistance
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o s r n k o i i n t i g l e e d c a x i C n n L p r requires o n e i f t e m a C o a e c d t r g a i t n M r n f o i i o n Product c k e y r s P o Performance W
Some
cases are not considered in these Mechanical documents, and as stated in API 5CT / ISO Properties 11960 introduction:
Structural Performance
Dimensions
Working Conditions
“Users of this International Standard should be aware that further or differing requirements may be needed for individual applications”.
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