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H2S, CO2 and High Chloride Downhole Environment Modelling and Fitness for Purpose Testing of UNS S39274, UNS N08535 and UNS N06255 Corrosion Resistant Alloys

Aker BP is planning to drill four high-pressure, high-temperature wells in a gas field. The produced fluids are primarily composed of gas condensate with formation water. The operator anticipates a chloride environment greater than 120,000 mg/L in these four wells. ISO 15156 specifies a chloride limit of 120,000 mg/L for super duplex alloys for downhole applications. The objectives of this study are to determine the chemistry inside these four wells, to identify the test parameters representative of the downhole environment, and to assess if UNS S39274, UNS N08535 and UNS N06255 are suitable tubing materials. Thermodynamic modeling based on the anticipated production rate from each well was employed for the determination of downhole chemistry. Results show that chloride concentration can reach 308,000 mg/L. Scaling of halite, barite, calcite, and aragonite was also predicted to occur at certain depths inside the well. The parameters used for fitness-for-purpose testing were selected based on chloride conditions with and without halite scaling. The performance of UNS S39274, UNS N08535 and UNS N06255 was assessed using four-point bend tests, crevice corrosion tests, and slow strain rate tests in the simulated downhole environment with 0.025 bar pH2S, 16.6 bar pCO2 and high chloride concentration. No cracking was observed on UNS S39274 and UNS N06255 four-point bend specimens. However, one out of twelve UNS N08535 specimens tested exhibited a crack at a location outside the inner roller of the four-point bend jig. The corrosion rates of UNS S39274, UNS N08535, and UNS N06255 based on mass loss are 0.18 mpy, 0.23 mpy, and 0.09 mpy, respectively. Slow strain rate test results showed no significant loss in ductility, and no secondary cracking when specimens were tested in downhole high chloride conditions. The overall results of the study indicated that these corrosion resistant alloys are able to withstand chloride concentrations beyond the specified limits when H2S partial pressure is low.
Product Number: 51324-20838-SG
Author: Noelle Easter C. Co; Ravi M. Krishnamurthy; Kenneth George; Bjørn-Andreas Hugaas; Ragnar Marcelius Fredriksen
Publication Date: 2024
$40.00
$40.00
$40.00