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Page3Page11Page29Page35PublicationNo.SMC-013Copyright©2003bySpecialMetalsCorporationINCONEL®,INCOLOY®,MONEL®,INCO-WELD®,625LCF®,725™,800HT®and925™aretrademarksoftheSpecialMetalsCorporationgroupofcompanies.Thedatacontainedinthispublicationisforinformationalpurposesonlyandmayberevisedatanytimewithoutpriornotice.Thedataisbelievedtobeaccurateandreliable,butSpecialMetalsmakesnorepresentationorwarrantyofanykind(expressorimplied)andassumesnoliabilitywithrespecttotheaccuracyorcompletenessoftheinformationcontainedherein.Althoughthedataisbelievedtoberepresentativeoftheproduct,theactualcharacteristicsorperformanceoftheproductmayvaryfromwhatisshowninthispublication.Nothingcontainedinthispublicationshouldbeconstruedasguaranteeingtheproductforaparticularuseorapplication.MANUFACTURINGANDQUALITYCONTROLAnoverviewofthefacilitiesandsystemsthatmakeuptheworld’sleadingproducerofcorrosion-resistantalloys.MATERIALSSELECTIONThecapabilitiesoftheindustry’sbroadestselectionofcor-rosion-resistantalloys.EFFECTSOFWELLENVIRONMENTSWhynickelalloysareneededtoresistcorrosioninaggressivewellfluids.CORROSIONTESTINGAcompilationofcorrosiondatainenvironmentsrele-vanttooilandgasdrillingandproduction.Part1:Part2:Part3:Part4:CORROSION–RESISTANTALLOYSFOROILANDGASPRODUCTION2PART1INCONELfiNi-CrAlloysINCONEL®Ni-Cr-FeAlloysINCONEL®Ni-Cr-MoAlloysINCOLOY®Fe-Ni-CrAlloysMONEL®Ni-CuAlloysINCO-WELD®WeldingProductsTheSpecialMetalsGroupofcompanieswascreatedin1998,whenSpecialMetalsCorporationofNewHartford,NewYorkacquiredIncoAlloysInternationalInc.,includingitsHuntingtonAlloysandWigginAlloysdivisions.Withahistoryofalloyinventionandproductiongoingbacksome100years,ournewcompanycontinuestoprovidesolutionstoyourdifficultmaterialsproblemsthroughsuchtime-testedproductsasourworld-recognizedINCONEL®,INCOLOY®andMONEL®alloys.Today’sSpecialMetalsisaworldleaderintheinvention,productionandsupplyofthehigh-nickel,high-performancealloysusedforthe“difficultjobsinengineering.”Thesealloysarehighlyengineeredtoofferasupe-riorcombinationofheatresistance,hightemperaturecorrosionresistance,toughnessandstrengthandareusedintheworld’smosttechnicallydemandingindustriesandapplications.SpecialMetalsoffersthelargestrangeofnick-el-basedalloysandproductforms,aswellascobalt-basedalloys,tomorethan10worldwidemarkets.Weproducenickelalloysinallstandardmillforms,fromlargeingotsandbilletstoplate,sheet,strip,tubing,barandwire,thelatterofwhichincludescoreandfillerwiresforweldingproducts.ThecompanyhasmanufacturingandresearchfacilitiesintheUSAandEurope,salesofficesinNorthAmerica,EuropeandAsia,andadistributionnetworkincludingmostoftheindustrializedcountriesoftheworld.ContactanyofourofficeslistedonthelastpageofthispublicationorvisittheSMCwebsite,(44MN)ofseparatingforce.Computer-controlledextru-sionpressesproduceseamlesstubularsofupto10in(250mm)outsidediameter.54Meltingfurnacesincludethisvacuum-inductionfurnacewithitssophisticatedcontrolsystem.Meltingundervacuumexcludescontaminantsandproducesalloysofprecisecomposition.Electroslagremeltingenhancesthestructureandpurityofthemetal.Theopera-tioniscarriedoutunderstrict,computerizedcontrol.312+236MANUFACTURINGANDQUALITYCONTROLNaturalgascontinuestobeoneoftheworld’smostabundantsourcesofenergy.Increasingly,therecoveryofnewgasisfromdeepformationsthatposehostileenvironmentsfordownholetubularsandotherwellcomponents.Inthepast,theselectionofmetallicmaterialsforoilandgaswellswasarelativelystraightforwardproposition.Standardgradesoflow-alloyandcarbonsteelswerespecifiedfordrillingandproductiontubularswithafewstainlesssteelsandnickelalloysincommonuseforspecialapplicationssuchasvalvesandinstrumentation.Today,materialsselectionfordrillingandcompletionofwellscanbeacomplextaskinvolvinghighfinancialandsafetyrisks.Thissituationisbroughtaboutbyseveralfactors,including1.deeperwellsinvolvinghighertemperaturesandpres-sures,2.enhancedrecoverymethodssuchassteamorCO2injec-tion,3.increasedweightconsiderations,especiallyoffshore,and4.theneedforgreatercorrosionresistanceinwellscontain-inghydrogensulfide(H2S),carbondioxide(CO2),andchlorides(Cl-).Materialsselectionisespeciallycriticalforsourgaswells-thosecontainingH2S.Environmentsinsourwellsareextremelycorrosivetometals,andH2Sishighlytoxic.Insomesourenvironments,corrosioncanbecontrolledbyusinginhibitorsalongwithcarbonsteeltubulars.However,inhibitorsinvolvecontinuinghighcostandmaybeunreli-able,especiallyathighertemperatures.Addingcorrosionallowancetothetubingwallincreasesstringweightandreducesinteriordimensions.Inmanycases,thepreferredalternativeintermsoflife-cycleeconomyandsafetyistheuseofacorrosion-resistantalloy(CRA)fortubularsandotherwellcomponents.547MANUFACTURINGANDQUALITYCONTROLAresistantalloyeliminatesinhibitors,lowersweight,improvessafety,eliminatesorminimizesworkovers,andreducesdowntime.Formanydecades,SpecialMetalshasbeentheworldwidele