SPIRAL STEEL TUBE FORMED BY A PLURALITY OF WELDED STRIPS AND METHOD FOR FORMING A SPIRAL STEEL TUBE

专利摘要:
spiral steel tube formed by a plurality of welded strips and method for forming a spiral steel tube embodiments of the present description are directed to spiral steel tubes and methods for producing spiral steel tube. in some embodiments, the final microstructures of spiral steel tubes across all base metal regions, weld joints and heat-affected areas can be homogeneous. in addition, the final microstructure of the spiral steel tube can be a mixture of tempered martensite and bainite.
公开号:BR102014006157B1
申请号:R102014006157-6
申请日:2014-03-14
公开日:2020-03-17
发明作者:Martín Valdez；Gonzalo Gomez；Jorge Mitre；Bruce A. Reichert
申请人:Tenaris Coiled Tubes, Llc；
IPC主号:

专利说明:

"SPIRAL STEEL TUBE FORMED BY A WELDED STRIP PLURALITY AND METHOD FOR FORMING A SPIRAL STEEL TUBE" INCORPORATION BY REFERENCE TO ANY PRIORITY REQUESTS [0001] Any and all claims for which a foreign or domestic priority claim is identified in the Order Information Sheet as filed with this order is hereby incorporated by reference under 37 CFR 1.57.
RELATED ORDER
[0002] This order is related to the Holder's codependent order entitled SPIRAL TUBE WITH VARIABLE MECHANICAL PROPERTIES FOR HIGHER PERFORMANCE AND METHODS TO PRODUCE THE SAME BY A CONTINUOUS HEAT TREATMENT, Serial No. US13 / 229517, deposited and 9 September 2011 and published as US 2012/0186686 Al on July 26, 2012, the integrity of which is hereby incorporated by reference.
BACKGROUND
Description of Related Art [0003] In recent years, the use of spiral tubing has been expanded to applications that require high pressure and well-understood operations. As a consequence, there is a need to produce a spiral pipe with high tension properties in order to resist: i) axial loads in the suspension or bundling of long strips, and ii) high pressures applied during the process.
[0004] Standard production of spiral tubing uses a crude material, hot twisted strips with mechanical properties achieved through microstructural refinement during rolling. This refinement is achieved with the use of different additions of microalloys (Ti, N, V), as well as an appropriate selection of hot rolling processing conditions. The goal is to control material recrystallization and grain growth to achieve an ultra-fine microstructure. The material is limited in the use of solid solution alloy elements and precipitation hardening, since refinement is the only mechanism that allows high strength and hardness, simultaneously.
[0005] This raw material is specified for each supplier and may require variable mechanical properties in hot rolled steel in order to produce spiral tubes with variable mechanical properties, as well. As the properties increase, the cost of production and, consequently, the cost of raw material also increases. It is known that the strip-to-strip welding process used during the assembly of the "extended strip" that will be formed / welded by electrical resistance welding (SRE) in the spiral pipe, deteriorates the joint area. Therefore, the spiral pipe with increased properties tends to have a relatively lower performance in the area of strip welds. This deterioration is caused by the fact that the welding processes destroy the refinement introduced during hot rolling, and there is no post-weld heat treatment capable of regenerating the properties of both resistance to stress and hardness. In general, the resistance to tension is restored, but the hardness and its associated fatigue life are deteriorated in this zone. The current industrial route can produce a spiral pipe with high strength only at a high cost and with low performance of the strip weld joints in relation to the tubular body.
[0006] An alternative to produce the spiral pipe is through heat treatment of full body. This treatment is applied to a material that has formed a tube in the so-called "green" state because its properties will still be defined by the heat treatment conditions. In this case, the main variables affecting the properties of the final product are steel chemistry and heat treatment conditions. Therefore, with the appropriate combination of steel composition with welding material and heat treatment, the spiral pipe could be produced with uniform properties along the length, eliminating the weak connection of the strip-to-strip joint that is critical in pipes conventional, high-strength spiral coils. This general concept has been described previously, but has never been successfully applied to the production of high-strength spiral tubing (yield strength in the range of 551.6 MPa to 965.3 MPa [80-140 ksi]). The reason is that heat treatment at a high line speed (necessary to achieve high productivity) will generally result in the need for complicated and extended installations. This process could be simplified if the appropriate chemistry and heat treatment are selected.
[0007] The selection of the chemistry that is compatible with a reasonably sized industrial heat treatment installation requires an understanding of the various variables that affect the performance of the spiral pipe measured as: a) Axial Mechanical Properties, b) Microstructure Uniformity and Properties , c) Hardness, d) Fatigue resistance, e) Sulfide stress fracture resistance, among others.
SUMMARY
[0008] Below is described the chemistry designed to produce a heat-treated spiral pipe which is mostly outside the current limits for spiral pipes, as defined by the API 5ST standard. (Max.C: 0.16%, Max.Mn: 1.2% (CT70-90) Max.Mn: 1.65 (CT100-110), Max.P: 0.02% (CT70-90) Max .P: 0.025 (CT100-CT110), Max.S: 0.005, Si.Max: 0.5).
[0009] Modalities of this description are for a spiral steel tube and methods for producing the same. The tube, in some embodiments, may comprise an elastic limit greater than about 551.6 MPa (80 Ksi). The composition of the tube may comprise 0.16-0.35% p carbon, 0.30-2.00% p manganese, 0.10-0.35% p silicon, up to 0.005% p sulfur, up to 0.018% p phosphorus, the rest being iron and unavoidable impurities. The tube may also comprise may also comprise a final microstructure comprising a mixture of tempered and bainite martensite, in which the final microstructure of the spiral tube comprises more than 90% volume of tempered martensite, in which the microstructure is homogeneous in the tubular body. electric resistance welding line and strip end joints.
[0010] A spiral steel tube formed from a plurality of welded strips is described here, wherein the tube may include regions of base metal, weld joints, and their thermally affected zones, and may comprise a yield strength greater than about 551.6 MPa (80 ksi), a composition comprising iron and 0.17-0.35% p carbon, 0.30-2.00% p manganese, 0.10-0.30% p silicon, 0.010-0.040% p aluminum, up to 0.010% p sulfur and up to 0.015% p phosphorus, and a final microstructure comprising a mixture of tempered martensite and bainite, in which the final microstructure of the spiral tube comprises more than 90% volume of tempered martensite in the regions of base metal, of weld joints, and the thermally affected zones, in which the final microstructure throughout all regions of base metal, weld joints and thermally affected zones is homogeneous and in which the final microstructure comprises a uniform distribution of fine carbides throughout the regions of m base etal, solder joints and thermally affected areas.
[0011] In some embodiments, the composition additionally comprises up to 1.0% p chrome, up to 0.5% p molybdenum, up to 0.0030% p boron, up to 0.030% p titanium, up to 0.50% p copper, up to 0.50% p nickel, up to 0.1% p niobium, up to 0.15% p vanadium, up to 0.0050% p oxygen, and up to 0.05% p calcium.
[0012] In some embodiments, the composition may comprise 0.17 to 0.30% p carbon, 0.30 to 1.60% p manganese, 0.10 to 0.20% p silicon, up to 0.7% p chromium, up to 0.5% p molybdenum, 0.0005 to 0.0025% p boron, 0.010 to 0.025% p titanium, 0.25 to 0.35% p copper, 0.20 to 0.35% p nickel, up to 0.04% p niobium, up to 0.10% p vanadium, up to 0.0015% p oxygen, up to 0.03% p calcium, up to 0.003% p sulfur; and up to 0.010% p phosphorus.
[0013] In some embodiments, the tube may have a minimum elastic limit of 861.4 MPa (125 ksi). In some embodiments, the tube may have a minimum elastic limit of 965.3 MPa (140 ksi). In some embodiments, the tube may have a minimum elastic limit between 861.4 MPa and 965.3 MPa (125-140 ksi).
[0014] In some embodiments, the final microstructure may comprise at least 95% volume of tempered martensite in the base metal regions, weld joints and thermally affected areas. In some embodiments, the tube may have a final grain size below 20 pm in the base metal regions, weld joints and thermally affected areas. In some embodiments, the tube may have a final grain size below 15 pm in the base metal regions, weld joints and thermally affected areas.
[0015] In some embodiments, weld joints may comprise bias welds. In some embodiments, the fatigue life of biased welds can be at least about 80% of the base metal regions. In some embodiments, the percentage of hardness of a weld joint, including its thermally affected zone, can be 110% or less than the hardness of the base metal.
[0016] Also described here is a method for forming a spiral steel tube which can comprise providing strips having a composition comprising iron and 0.17-0.35% w carbon, 0.30-2.00% w manganese , 0.10-0.30% p silicon, 0.010-0.040% p aluminum, up to 0.010% p sulfur, up to 0.015% p phosphorus, and weld the strips together, forming a tube from the welded strips, where the tube comprises base metal regions, joint welds and their thermally affected zones, austenitize the tube at 900-1000 ° C, temper the tube to form a final microstructure while tempered with martensite and bainite, where the microstructure while tempered comprises at least 90 % martensite in the base metal regions, weld joints and thermally affected zones, and tempering the quenched pipe at 550-720 ° C, where quenching the quenched pipe results in an elastic limit greater than about 551.6 MPa (80 ksi), in which the microstructure along all the base metal regions, joins Weld s and thermally affected zones are homogeneous, and the microstructure comprises a uniform distribution of fine carbides throughout the base metal regions, weld joints and thermally affected zones.
[0017] In some embodiments, the strip weld may comprise bias soldering. In some embodiments, the formation of the tube may comprise the formation of an in-line joint. In some embodiments, the method may further comprise twisting the tube in a coil. In some embodiments, austenitization can form a grain size below 20pm in the base metal regions, weld joints and thermally affected areas.
[0018] In some embodiments, the composition may additionally comprise up to 1.0% p chrome, up to 0.5% p molybdenum, up to 0.0030% p boron, up to 0.030% p titanium, up to 0.50% p copper, up to 0.50% p nickel, up to 0.1% p niobium, up to 0.15% p vanadium, up to 0.0050% p oxygen and up to 0.05% p calcium.
[0019] In some embodiments, the composition may comprise 0.17 to 0.30% p carbon, 0.30 to 1.60% p manganese, 0.10 to 0.20% p silicon, up to 0.7% p chromium, up to 0.5% p molybdenum, 0.0005 to 0.0025% p boron, 0.010 to 0.025% p titanium, 0.25 to 0.35% p copper, 0.20 to 0.35% p nickel, up to 0.04% p niobium, up to 0.10% p vanadium, up to 0.00015% p oxygen, up to 0.03% p calcium, up to 0.003% p sulfur and up to 0.010% p phosphorus.
[0020] In some embodiments, the tempered tube may have an elastic limit greater than or equal to 861.8 MPa (125 ksi). In some embodiments, the tempered pipe may have a minimum yield strength of 965.3 MPa (140 ksi). In some embodiments, the tempered pipe may have a minimum yield limit between 861.8 and 965.3 MPa (125-140 ksi).
BRIEF DESCRIPTION OF THE FIGURES
[0021] Figures 1A-B illustrate TRC diagrams corresponding to STD2 (A) and STD3 (B) steels.
[0022] Figures 2A-B illustrate TRC diagrams corresponding to BTi2 (A) and CrMoBTi3 (B) steels.
[0023] Figure 3 illustrates a cooling rate of an inner tube surface as a function of wall thickness to wall thickness (EP) for a spiral tube tempered from the outside with water sprinklers.
[0024] Figure 4 illustrates tension properties of BTi2 steel as a function of the maximum tempering temperature (Tmax). Peak tempering cycles were used in these Gleeble® simulations. On the right are the tensile properties of the same steel as a function of the retention time at 720 ° C (isothermal tempering cycles).
[0025] Figures 5A-B illustrate non-tempered martensite appearing in the central segregation band near the SRE line after annealing the seam (Post-welding heat treatment -TTPS). Figures 5A-B correspond to a conventional Grade 90 spiral tube.
[0026] Figures 6A-B illustrate a damage located in the central segregation band produced during the fatigue test of a Grade 110 spiral pipe.
[0027] Figures 7A-B illustrate a damage located in the central segregation band produced during the fatigue test with a high internal pressure 65.5 MPa (9500 psi) of a Grade 100 spiral pipe.
[0028] Figures 8A-B illustrate microstructures of base metal corresponding to the standard spiral tube (A) and a spiral tube produced from the modalities of the present description (B). In both cases, the spiral pipe has tension properties corresponding to a Grade 110 (yield strength of 758.4 MPa to 827.4 MPa (110 Ksi to 120 Ksi)).
[0029] Figures 9A-B illustrate microstructures of the SRE line corresponding to the standard spiral tube (A) and a spiral tube produced from the modalities of the present description (B). In both cases, the tension properties of the spiral pipe correspond to a Grade 110 (yield strength of 758.4 MPa to 827.4 MPa (110 Ksi to 120 Ksi).
[0030] Figures 10A-B illustrate microstructures corresponding to thermally affected areas of the SRE for the standard spiral tube (A) and a spiral tube produced from the modalities of the present description (B). In both cases, the tension properties of the spiral pipe correspond to a Grade 110 (yield strength of 758.4 MPa to 827.4 MPa (110 Ksi to 120 Ksi)).
[0031] Figures 11A-B illustrate microstructures corresponding to thermally affected areas of the bias weld for the standard spiral tube (A) and a spiral tube produced from the modalities of the present description (B). In both cases, the tension properties of the spiral pipe correspond to a Grade 110 (yield strength of 758.4 MPa to 827.4 MPa (110 Ksi to 120 Ksi)).
[0032] Figure 12 illustrates a fracture formed during service in the melting zone of a bias weld (growing from the inner face of the tube). The fracture is in the direction of the large slats of upper bainite.
[0033] Figure 13 illustrates variations in hardness (base metal hardness = 100%) over typical bias welds obtained with conventional processing according to the modalities of the present description. The melting zone (ZF) is approximately located in the area between «+/- 5 mm from the center of the weld.
[0034] Figures 14A-B illustrate microstructures corresponding to the intersection between the bias weld and the SRE line for the standard spiral tube (A) and a spiral tube produced from the modalities of the present description (B). In both cases, the tension properties of the spiral pipe correspond to a Grade 110 (yield strength of 758.4 MPa to 827.4 MPa (110 Ksi to 120 Ksi)).
[0035] Figure 15 illustrates a schematic drawing of a fatigue testing machine.
[0036] Figure 16 illustrates the fatigue life measured for SV samples in relation to those corresponding to MB samples. The results are average values under different test conditions and degrees of spiral tube (80, 90 and 110 for conventional tubes and 80, 90, 110, 125 and 140 for spiral tubes produced according to this description).
[0037] Figure 17 illustrates the improvement in fatigue life in spiral tubes produced with a modality of chemistry and processing conditions according to this description. The improvement is determined by comparing the fatigue life measured for a conventional spiral pipe of the same Grade tested under similar conditions. The results are averaged for each Grade under different test conditions. In the case of grades 125 and 140, which are not standard, the fatigue life comparison was performed against STD3 steel in grade 110.
[0038] Figures 18A-B illustrate samples of C rings after testing Grade 80 material, according to NACE TM0177 (90% SMYS, Solution A, 1 bar H2S). A: conventional process. B: modality of the described process.
DETAILED DESCRIPTION
[0039] The raw material of the spiral pipe is produced in a steel installation as hot rolled strips. Controlled winding is used to ensure high strength and good hardness through microstructural refinement. The strips are cut longitudinally to the width for producing tubes and then seamed end to end through a joining process (for example, Plasma Arc Welding or Friction Welding and Mechanical Mixing) to form a longer strip. Then the tube is formed using an SRE process. The performance of the final product is measured in terms of: a) axial mechanical properties, b) microstructure uniformity and properties, c) hardness, d) fatigue resistance, e) sulfide stress fracture resistance, among others. Using the traditional processing route, the properties of the spiral tubing result from the combination of the properties of the hot rolled strip and the modifications introduced during welding and tube forming operations. The properties then obtained are limited when the performance of the spiral tube is measured as listed above. The reason is that the welding process used to join the strips modifies the refined microstructure while wound in such a way that, even if post-weld heat treatments are applied, the final properties are still compromised. A reduced fatigue life and low sulfide stress fracture performance are associated with heterogeneities in the microstructure and the presence of fragile constituents through the welds. It was proposed that a new route should comprise at least a full body heat treatment. This route has been described in general terms, but never specified. The description describes the chemical and raw material characteristics that, combined with appropriate welding processes and heat treatment conditions, will result in a tempered and tempered product with high performance both in the tubular body and in the strip joint welds. This material is designed for spiral piping, since it is selected not only in terms of relative cost, but preferably in order to maximize the fatigue life under the particular conditions that apply to the operation of a spiral pipe (cycle fatigue) under flexion with simultaneous axial load and internal pressures).
[0040] This description relates to a high resistance spiral pipe (minimum elastic limit in the range of 551.6 MPa to 965.3 MPa (80-140 ksi) having an increased short cycle fatigue life compared to standard products, as defined by API 5ST.Additionally, the resistance to Fracture Stress by Sulphide (SSC) is also enhanced in this description.This exceptional combination of properties is achieved through an appropriate selection of chemistry and steel processing conditions. Industrial processing differs from the standard route in the application of a Full Body Heat Treatment (TTCC), as described in United States Order No. US2012 / 0186686 Al. This TTCC is performed after the spiral tube is formed by SRE (Welding by Electrical Resistance) and consists of at least one austenitization, quenching and tempering cycle. The description mentioned above is more specifically related to chemicals and processing steel pipe in meters for producing spiral quenched and tempered with the properties mentioned above. Although the generation of certain mechanical properties during heat treatment in a base material with a given composition is part of general knowledge, the particular application for spiral pipes uses raw material with specific chemistry in order to minimize the damaging effect of variables particular characteristics, such as segregation patterns, on the specific properties of this application.
[0041] One of the most important properties for the spiral tube is an increased resistance to short cycle fatigue. This is because, during standard field operation, spiral tubes are often rolled up and unrolled, introducing cyclic plastic deformations that eventually produce failures. During the short cycle fatigue process, the deformation is preferably located, on a microscopic scale, in regions of more malleable material. When brittle constituents are present near or in the stress concentration regions, fractures can easily become nuclear and spread. Therefore, a reduction in fatigue life is associated with heterogeneous microstructures (having more malleable regions that localize deformation) in combination with brittle constituents (which nucleus and / or propagate fractures). All of these microstructural characteristics appear in the Thermally Affected Zone in welds (ZAT). There are some types of tubular body microstructures that also have the mentioned features. This is because they are composed of a mixture of rigid and malleable constituents, for example, ferrite, perlite and bainite. In this case, the stress is located on the most malleable ferrite, close to the border with, where fractures are nucleated and propagated. High-resistance spiral tubes currently have this type of structure.
[0042] In order to avoid stress localization during low cycle fatigue, the microstructure needs to be not only homogeneous along the tubular body and joints, but also on the microscopic scale. For low carbon steels, a microstructure composed of tempered martensite, which is basically a ferrite matrix with a homogeneous and fine distribution of carbides, is ideal. Therefore, the objective of the chemical selection and processing conditions described in this description is to achieve, with the TTCC, a homogeneous microstructure (in the tubular body, soldered in the SRE line) made up of at least 90% tempered martensite, preferably more than 95 % tempered martensite.
[0043] Additionally, tempered martensite is more suitable for producing grades of ultra high strength than standard spiral tube microstructures (composed of ferrite, perlite and bainite), for which extremely costly alloy additions are required to reach a limit of elasticities greater than about 861.8 Mpa (125 Ksi).
[0044] In comparison with structures containing bainite, another important benefit of tempered martensite is its resistance to fracture by sulfide stress.
[0045] The chemistry of steel has been defined as the most suitable for the production of heat-treated spiral pipes using a TTCC, and can be described in terms of carbon concentration (% p C), Manganese (% p Mn), Silicon (% p Si), Chromium (% p Cr), Molybdenum (% p Mo), as well as microalloy elements such as Boron (% p B), Titanium (% p Ti), Aluminum (% p Al), Niobium (% p Nb) and Vanadium (% p V). Also, upper limits can be of unavoidable impurities like Sulfur (% p S), Phosphorus (% p P) and Oxygen (% p 0).
[0046] In order to produce a final structure composed of tempered martensite, the steel chemistry of this description differs mainly from the previous spiral tube technique because of the higher carbon content (see, for example, API 5ST, in which the amount maximum carbon allowed for spiral piping is 0.16%), which allows to obtain the desired microstructure through a TTCC composed of at least one austenitization, tempering and tempering cycle.
[0047] The terms "approximately", "about" and "substantially" as used here, represent an amount close to the defined quantity that still enables a desired function or achieves a desired result. For example, the terms "approximately", "about" and "substantially" may refer to an amount that is in the range of less than 10% of, in the range of less than 5% of, in the range of less than 1 % of, in the range of less than 0.1% of and in the range of less than 0.01% of the defined quantity.
[0048] Carbon is an element whose addition increases, without high costs, the strength of steel through an improvement in hardening and the promotion of precipitation of carbides during heat treatments. If carbon is reduced below 0.17%, hardening cannot be guaranteed and large fractions of bainite can be formed during heat treatments. This appearance of bainite makes it difficult to reach a yield strength above 551.6 Mpa (80 ksi) with the desired fatigue life and resistance to sulfide stress fracture. The current route for spiral piping is not suitable for heat treatment since the maximum amount of carbon allowed by API5ST is 0.16%. Conventional microstructures for spiral tubing show large fractions of bainite that compromise hardness, fatigue life and resistance to fracture by sulfide stress in the degrees of greatest strength, that is, spiral tubing with a minimum elastic limit above 758.4 MPa (110 Ksi).
[0049] On the other hand, steels with more than 0.35% carbon will have poor weldability, being susceptible to brittle constituents and fractures during post-weld heat treatment welding operations. In addition, higher carbon content can result in significant amounts of austenite retained after tempering, which becomes brittle constituents under tempering. These brittle constituents impair fatigue life and resistance to sulfide stress fracture. Therefore, the C content of the steel composition varies within a range of about 0.17% to about 0.35%, preferably from about 0.17% to about 0.30%.
[0050] The addition of manganese improves hardening and resistance. Mn also contributes to sulfur deoxidation and control during the steelmaking process. If the Mn content is less than about 0.30%, it can be difficult to achieve the desired resistance level. However, as the content of Mn increases, large segregation patterns can be formed. Areas of Mn segregation will tend to form brittle constituents during heat treatment that impair hardness and reduce fatigue. In addition, these segregated areas increase the material's susceptibility to sulfide stress fracture (SSC - sulfide stress cracking). Accordingly, the Mn content of the steel composition varies within the range of 0.30% to 2.0%, preferably from 0.30% to 1.60%, and more preferably from 0.30% to 0.80 % in application for which an enhanced sulfide stress fracture resistance is used.
[0051] Silicon is an element whose addition has a deoxidizing action during the steel making process and also increases the strength of the steel. In some embodiments, if Si exceeds about 0.30%, the hardness may decrease. In addition, large segregation patterns can be formed. Therefore, the Si content of the steel composition ranges from about 0.10% to 0.30%, preferably about 0.10% to about 0.20%.
[0052] The addition of chromium increases the hardening and resistance to tempering of the steel. Cr can be used to partially replace Mn in the steel composition in order to achieve high strength without producing large segregation patterns that impair the fatigue life and resistance to sulfide stress fracture. However, Cr is a costly addition that makes spiral piping more difficult to produce because of its effects on hot formed loads. Therefore, in some modalities Cr is limited to about 1.0%, preferably to about 0.7%.
[0053] Molybdenum is an element whose addition is efficient in increasing the strength of the steel and, additionally, aids in slowing the softening during tempering. Tempering resistance allows the production of high strength steels with reduced Mn content, increasing the fatigue life and resistance to fracture by sulfide stress. The addition of Mo may also reduce phosphorus segregation at grain boundaries, improving resistance to intergranular fracture. However, this iron binder is expensive, making it desirable to reduce the maximum Mo content in the steel composition. Therefore, in certain embodiments, the maximum amount of Mo is about 0.5%.
[0054] Boron is an element whose addition is highly efficient in increasing the hardening of steel. For example, B can improve hardening by inhibiting the formation of ferrite during tempering. In some embodiments, B is used to achieve good hardening (that is, as a tempered structure composed of at least 90% martensite) in steels with reduced Mn content to improve the fatigue life and resistance to fracture by sulfide stress. If the content of B is less than about 0.0005% w, it can be difficult, in these modalities, to obtain the desired hardening of the steel. However, if the B content is too high, coarse boron carbides can be formed at the grain boundaries, adversely affecting toughness. Thus, in one modality, the concentration of B in the composition is less than about 0.0030% and, in another modality, the content of B is around 0.0005% to 0.0025%.
[0055] Titanium is an element .which addition is efficient in increasing the efficiency of B in steel, by fixing nitrogen impurity with titanium nitrides (TiN) and inhibiting the formation of boron nitrides. If the Ti content is very low, it may be difficult, in some modalities, to obtain the desired effect of boron from ‘steel hardening. On the other hand, if the Ti content is greater than 0.03% w, coarse titanium nitrides and carbides (TiN and TiC) may be formed, adversely affecting the. ductility and tenacity. Thus, in certain modalities, the Ti concentration can be limited to about 0.030%. In other embodiments, the Ti concentration can vary from about 0.010% to about 0.025%.
[0056] Considering that the production of spiral pipes with low mechanical properties benefits from low tempering resistance, the addition of B and Ti increases the hardening without increasing the resistance to tempering. Therefore, it allows the production of Grade 551.6 MPa (80 ksi) without long immersion times during tempering, with the subsequent increase in productivity. As one of the limitations for the production of a spiral pipe in a heat treatment line is the length of the line to properly immerse the material during tempering, the use of B and Ti is particularly relevant for the production of a low yield strength in the spiral pipe.
[0057] Copper is an element that is not required in certain modalities of steel composition. However, in some spiral piping applications, Cu may be required to increase resistance to atmospheric corrosion. Therefore, in certain embodiments, the Cu content of the steel composition can be limited to less than about 0.50%. In other embodiments, the Cu concentration can vary from about 0.25% to about 0.35%.
[0058] Nickel is an element whose addition increases the strength and toughness of steel. If Cu is added to the steel composition, Ni can be used to avoid hot rolling defects known as lack of heat. However, Ni is very expensive and, in certain embodiments, the Ni content of the steel composition is limited to less than or equal to about 0.50%. In other embodiments, the Ni concentration can vary from about 0.20% to about 0.35%.
[0059] Niobium is an element whose addition to the steel composition can refine the austenitic grain size during reheating in the austenitic region, with the subsequent increase in both strength and toughness. The Nb can also precipitate during tempering, increasing the strength of the steel by hardening by particle dispersion. In one embodiment, the Nb content of the steel composition can vary within the range of about 0% to about 0.10%, preferably about 0% to about 0.04%.
[0060] Vanadium is an element whose addition can be used to increase the steel's resistance to carbide precipitations during tempering. However, if the V content of the steel composition is greater than about 0.15%, a large fraction of the volume of vanadium carbide particles may be formed, with a concomitant reduction in the toughness of the steel. Therefore, in certain embodiments, the content of V is limited to about 0.15%, preferably a. about 0.10%.
[0061] Aluminum is an element whose addition to the steel composition has a deoxidizing effect during the steel making process and additionally refines the grain size of the steel. In one embodiment, if the Al content of the steel composition is less than about 0.010%, the steel may be susceptible to oxidation, exhibiting high levels of inclusions. In other embodiments, if the Al content of the steel composition is greater than about 0.040%, coarse precipitates may be formed, impairing the toughness of the steel. Therefore, the Al content of the steel composition can vary within the range of about 0.010% to about 0.040%.
[0062] Sulfur is an element that reduces the toughness and workability of steel. As a consequence, in some embodiments, the S content of the steel composition is limited to a maximum of about 0.010%, preferably about 0.003%.
[0063] Phosphorus is an element that causes the toughness of steel to decrease. As a consequence, the P content of the steel composition is limited to a maximum of about 0.015%, preferably about 0.010%.
[0064] Oxygen can be an impurity in the steel composition that is present primarily in the form of oxides. In a steel composition modality, as the O content increases, the steel's impact properties are impaired. As a consequence, in certain embodiments of the steel composition, a relatively low O content is desired, less than or equal to about 0.0050% w; preferably less than or equal to about 0.0015% w.
[0065] Calcium is an element whose addition to the steel composition can increase toughness by changing the shape of the sulphide inclusions. In one embodiment, the steel composition may comprise a minimum Ca to S content ratio of Ca / S> 1.5. In other embodiments of the steel composition, excessive Ca is unnecessary and the steel composition may comprise a maximum Ca content of about 0.05%, preferably about 0.03%.
[0066] The contents of unavoidable impurities, including, without limitation N, Pb, Sn, As, Sb, Bi and the like are preferably kept as low as possible. However, properties (e.g. strength, toughness) of steels formed from the steel composition modalities of the present description may not be substantially impaired as these impurities are kept below selected levels. In one embodiment, the N content of the steel composition can be less than about 0.010%, preferably less than or equal to about 0.008%. In another embodiment, the Pb content of the steel composition may be less than or equal to about 0.005%. In an additional embodiment, the Sn content of the steel composition can be less than or equal to about 0.02%. In an additional embodiment, the As content of the steel composition may be less than or equal to about 0.012%. In another embodiment, the Sb content of the steel composition may be less than or equal to about 0.008%. In an additional embodiment, the Bi content of the steel composition may be less than or equal to about 0.003%.
[0067] The selection of a specific steel chemistry from this description will depend on the specification of the final product and restrictions of the industrial installation (for example, when introducing heat treatment lines, it is difficult to achieve long immersion times during tempering). The addition of Mn will be reduced when possible because it impairs the life of fatigue and resistance to fracture by sulfide stress through the formation of large segregation patterns. 0 Cr and, to a lesser extent, Mo will be used to replace Mn, and the full body heat treatment is kept as simple as possible. Both elements increase carbide stability and resistance to softening, which can lead to long immersion times during tempering. Therefore, these elements are preferred for grades of higher strength (eg Grade 110 and higher), for which resistance to tempering is desired, and avoided at lower grades (Grade 80), for which industrial heat treatment lines impractical would be necessary.
[0068] In the case of Minor Degrees (Grade 80), additions of microligrants B and Ti will be preferred in combination with suitable contents of C. These elements allow to achieve good hardening without the use of large additions of Mn. In addition, B and Ti do not increase resistance to tempering. Therefore, a simple and short tempering treatment can be used to achieve the desired resistance level.
[0069] The industrial processing route corresponding to this description is described in the following paragraphs, focusing on the conditions of the Full Body Heat Treatment (TTCC).
[0070] The raw material for spiral tubing is produced in a steel mill as hot-rolled strips with a wall thickness that can vary from about 0.20 centimeters to 0.76 'centimeters (0.08-0.30 inches). Controlled rolling can be used for the steel supplier to refine the microstructure while being rolled. However, an important microstructural refinement of the strips while laminated is not necessary because, in this description, the microstructure and mechanical properties are mostly defined by the final TTCC. This flexibility in the hot rolling process helps to reduce the cost of raw material and allows the use of steel chemicals not available when complex hot rolling procedures can be used (in general, controlled rolling can only be applied to carbon micro alloy steels. ).
[0071] The steel strips are cut lengthwise to the width of pipe production. Then, the strips are joined end to end through a welding process (for example, Plasma Arc Welding or Friction Welding and Mechanical Stirring) to form a larger strip that allows to reach the tubular length. These welded strips are transformed into a tube using, for example, electrical resistance welding. External diameters of spiral tubes are between 0.25 cm and 1.27 cm (1-5 inches). Tube lengths are about 4572 m (15,000 feet), but lengths can be between about 3048 m and about 12192 m (10,000-40,000 feet).
[0072] After forming the tube, the Full Body Heat Treatment (TTCC) is applied. The purpose of this heat treatment is to produce a final homogeneous microstructure composed of at least 90% tempered martensite, the rest being bainite. This microstructure, having a uniform carbide distribution and grain size below 20 pm - preferably below 15 pm - ensures good combinations of strength, ductility, toughness and low cycle fatigue life. Additionally, as mentioned earlier, due to the appropriate selection of steel chemistry, this type of microstructure is suitable to improve the resistance to Fracture by Sulfide Stress (FES) in comparison with conventional structures, composed of ferrite, perlite and large volumetric fractions of bainite. higher.
[0073] The TTCC is composed of at least one austenitization and quenching cycle (Q) followed by a tempering treatment (T). Austenitization is carried out at temperatures between 900 ° C and 1000 ° C. During this stage, the total residence time above equilibrium temperature Ae3 should be selected to ensure complete dissolution of iron carbides without excessive austenitic grain growth. The target grain size is below 20 pm, preferably below 15 pm. Tempering must be carried out by controlling the minimum cooling rate in order to achieve a final microstructure while tempered, composed of at least 90% martensite along the pipe.
[0074] Tempering is carried out at temperatures between 550 ° C and 720 ° C. A heat treatment above 720 ° C can lead to a partial transformation from martensite to a carbon-rich austenite. This constituent should be avoided because it tends to turn into brittle constituents, which can impair tenacity and fatigue life. On the other hand, if the quench is carried out below 550 ° C, the recovery process of the displaced structure while quenched is not completed. Consequently, the toughness can again be extremely reduced. The tempering cycle must be selected, within the temperature range mentioned above, in order to achieve the desired mechanical properties. The minimum yield strength can vary from 551.6 MPa to 965.3 MPa (80-140 ksi). An appropriate temperature residence time must be selected in order to guarantee a homogeneous distribution of carbides both in the base tube and in the weld areas (SRE line and strip to strip joints). In some cases, in order to improve the combination of strength and toughness, more than one cycle of austenitization, tempering and tempering can be carried out. After the TTCC, the tube can be subjected to a size adjustment process, in order to guarantee specified dimensional tolerances, free of tension, and wound in a spiral.
Examples: Example A: Selection of chemistry to improve hardening [0075] As mentioned earlier, the microstructure of this description is composed of at least 90% tempered martensite with a homogeneous distribution of fine carbides, the rest being bainite. This microstructure allows the production of a spiral tube with the desired combination of high strength, extended low cycle fatigue life and enhanced sulfide stress fracture resistance.
[0076] The tempered martensite is obtained by at least one tempering and tempering heat treatment, carried out after the pipe is formed by SRE. The heat treatment can be repeated two or more times if further refinement is desired to improve the resistance to fracture by sulfide stress. This is due to the fact that subsequent austenitization and tempering cycles reduce not only the previous austenitic grain size but also the martensite block and package sizes.
[0077] To obtain the target microstructure with good hardening, at least 90% martensite can be formed at the end of the tempering process. Proper chemical selection is essential to achieve such a volumetric fraction of martensite. The selection of suitable steel compositions was based on experiments carried out with a Gleeble® 3500 thermodynamic simulator and industrial tests were carried out later to confirm the laboratory findings.
[0078] Some of the steel chemicals analyzed in the laboratory are listed in Table A1. For all these chemicals, dilatometry tests were performed on Gleeble® to build Continuous Cooling Transformation (TRC) diagrams. The TRC diagrams were used, in combination with metallographic analysis of the samples obtained from the simulations, to determine the minimum cooling rate to have more than 90% martensite. This critical cooling rate, mainly dependent on steel chemistry, will be referred to as CR90.
Table A1: Chemical composition of steels studied experimentally. Element concentrations are in weight percent (% w).
[0079] Examples of the obtained TRC diagrams are shown in Figures 1-2. In all cases, austenitization was carried out at 900-950 ° C in order to obtain an austenitic grain size (TGA) of 10-20 μιη. STD1, STD2 and STD3 steels have chemicals within the API 5ST specification, but outside the range of this description due to their low carbon addition (Table A1). CR90 critical cooling was greater than 100 ° C / s, for STD1 and STD2, and about 50 ° C / s, for STD3.
[0080] Figures 1A-B show TRC diagrams corresponding to STD2 (A) and STD3 (B) steels. In bold are shown the critical cooling conditions to produce a final microstructure composed of about 90% martensite, the rest being bainite. Figures 2A-B show the TRC diagrams corresponding to BTi2 and CrMoBTi3 steels. In bold are shown the critical cooling conditions to produce a final microstructure composed of about 90% martensite, the rest being bainite. The first is a B-Ti microalloyed steel (see Table A1). CrMoBTi2 is a medium carbon steel with additions of Cr and Mo, also microalloyed with B-Ti. The measured critical cooling rates (corresponding to the cooling curves shown in bold in the TRC diagrams) were 25 ° C / s and 15 ° C / s for BTi2 and CrMoBTi3, respectively.
[0081] In Figure 3, the average cooling rate of tubes treated in an installation of quenching heads (water sprinklers cooling the tube from the external surface) is shown. The values are shown as a function of the pipe wall thickness (EP). The shaded area in the diagram corresponds to the typical range of wall thickness for spiral pipe applications. Of course, when selecting suitable steel chemicals to have more than 90% tempered martensite, the critical cooling rate of the alloy must be equal to or less than 30 ° C / s. Otherwise, more than 10% bainite will be formed during the quenching of the thickest tube (EP = 0.76 cm (0.3 inches)) in the installation mentioned above.
[0082] STD1, STD2 and STD3 have critical cooling rates above 30 ° C / s. Therefore, these steels are not suitable for this description. On the other hand, the hardening is suitable for BTi2 and CrMoBTi3 steels. The improvement in hardening is due to an increased carbon content and the addition of B-Ti.
[0083] Table A2 shows the critical cooling rates measured for the steels in Table Al. STD1, STD2 and STD3 are chemicals currently used for Grade 80, 90 and 110 spiral tubes; and comply with API 5ST. However, even the most connected STD3 has a critical cooling rate to guarantee more than 90% tempered martensite in tubes with EP in the range of interest. It is clear that standard materials are not suitable for producing the microstructure targeted in this description and the hardening must be improved. In low alloy steels, the most important element affecting hardening is carbon. Consequently, C was increased above the maximum specified by API 5ST (0.16% w) to have critical cooling rates of no more than 30 ° C / s. In this description, the addition of carbon is in the range of 0.17% to 0.35% (the maximum level has been selected to ensure good weldability and toughness). As mentioned earlier, the rest of the chemistry must be adjusted to have CR90 values equal to or less than 30 ° C / s.
Table A2: Critical cooling rates to have more than 90% martensite (CR90) measured for the analyzed steels. Values determined from Gleeble® dilatometric tests and metallographic analyzes.
[0084] The following instructions for selecting suitable steel chemicals were obtained from the analysis of experimental results in Table A2: [0085] C-Μη steels: hardening depends mainly on the addition of carbon and manganese. About 2% Mn can be used to achieve the desired hardening when C is at the lower limit (CMnl steel). However, Mn is an element that produces strong segregation patterns that can decrease the life of fatigue. Therefore, the addition of Mn is decreased in formulations with more carbon. For example, when the carbon concentration is about 0.25%, 1.6% Mn is sufficient to achieve hardening (CMn2 steel).
[0086] B-Ti steels: these alloys are simple carbon steels microalloyed with boron and titanium. Due to the increase in hardening associated with the effect of boron, Mn can be further reduced. For carbon at the lower limit, about 1.6% Mn can be used to achieve hardening. When the carbon concentration is about 0.25%, 1.3% Mn is sufficient to achieve hardening (BTi2 steel).
[0087] Cr-Mo steels: these steels have additions of Cr and Mo which are useful to increase the resistance to tempering, which makes them suitable for Degrees of ultra-high resistance. Additionally, Cr and Mo are elements that improve hardening; then, the addition of Mn can be further reduced. However, Cr and Mo are costly additions that reduce the hot workability of steel and their maximum contents are limited to 1% and 0.5%, respectively. In an example with carbon at the lower limit, about 1% Mn can be used to achieve CR90 (CrMol). If the steel is also microalloyed with B-Ti, an additional reduction of Mn to 0.6% can be performed (CrMoBTil).
Example B: Chemistry selection for different degrees of spiral tube [0088] To analyze the tempering behavior of the steels shown in Table Al, simulations of industrial heat treatments were performed in Gleeble®. The simulations consisted of austenitization at 900-950 ° C, quenching at 30 ° C / s and tempering. In a particular case of STD1, STD2 and STD3 steels, higher cooling rates were used in order to reach at least 90% martensite during tempering. For STD1 and STD2, a tempering rate of about 150 ° C / s was used while, for STD3, the cooling was at 50 ° C / s. These higher cooling rates can be achieved in small samples on the Gleeble® when external cooling water is applied. After quenching, the samples were tempered using two types of cycles: -Cycle in peak form: Heating at 50 ° C / s to a maximum temperature (Tmax) that was in the range of 550 ° C to 720 ° C. Cooling at about 1.5 ° C / s to room temperature. These cycles had the intention of similar conditions of real tempering in induction furnaces, which are characterized by high rate of heating, no immersion time at maximum temperature and air cooling. -Isothermal cycle: Heating at 50 ° C / s to 710 ° C, immersion in this temperature for a time that varied from 1 min to 1 hour and cooling to about 1.5 ° C / s. this cycle was used to simulate tempering in an industrial line with several immersion inductors or with a tunnel oven.
[0089] In all cases, the tempering temperature ranged from 550 ° C to 720 ° C. Temperatures greater than 720 ° C have been avoided because unwanted re-austenitization occurs. On the other hand, if the tempering is performed below 550 ° C, the recovery of the displaced structure is not completed, and the material has brittle constituents that can impair fatigue life.
[0090] Peak-shaped tempering cycles are preferred to reduce the length of the line and to improve productivity. Therefore, the feasibility of obtaining a given grade with a specific steel chemistry was mainly determined by the tempering curve obtained using this type of cycles. If after a peak tempering at 720 ° C the resistance is still high for the Grade, an immersion in the maximum temperature can be performed. However, as immersion time increases, larger, more costly and less productive industrial lines may be necessary.
[0091] In Figure 4 (positioned on the left), the tempering curve measured for BTi2 steel is shown. Stress properties are shown as a function of the maximum tempering temperature. Peak-shaped thermal cycles were used in the simulations. From the figure, it is seen that Degrees 90 to 125 can be obtained by changing the maximum peak temperature from about 710 ° C to 575 ° C, respectively. With this chemistry, it is not possible to reach 965.3 MPa (140 Ksi) yield strength without reducing the tempering temperature below 550 ° C. for smaller cranes, 3 minutes of immersion at 710 ° C can be used to obtain Grade 80 (positioned to the right in Figure 4).
[0092] Based on the results obtained from the simulations in Gleeble®, Table BI was built. This Table shows, for each steel analyzed, the feasibility of producing different Degrees, which were in the range of 551.6 MPa to 965.3 MPa (80-140 Ksi) of minimum elastic limit. For example, in the case of BTi2, it is feasible to reach Degrees 90 to 125 using peak tempering cycles. However, 2 minutes of immersion at 720 ° C can be used in the case of Grade 80, which is why the corresponding "immersion" cell is indicated.
Table B1: Feasibility of industrially producing Grades 80 to 140 using the steel chemicals analyzed. When "immersion" appears in the cell, it means that more than 1 minute immersion at 720 ° C can be used to reach the Degree.
[0093] From the results obtained, it is clear that, in order to obtain the highest Degrees, greater additions of carbon and Cr-Mo can be used. Particularly, Grade 140 cannot be achieved with standard chemicals, as described in API5ST, due to the low carbon content. On the other hand, to achieve Grade 80, a simple chemistry with little added carbon and no addition of Cr or Mo is the best option. In this case, microalloying additions of B-Ti can be used to ensure good hardening (for example, a chemical like BTii is a good alternative).
[0094] It is important to mention that, in order to produce martensitic structures with standard steels (STD1, STD2 and STD3), it was necessary to use in the laboratory tempering rates higher than those achievable at the factory. Consequently, if we limit the cooling rate to that industrially achievable, none of the Degrees of spiral tube can be obtained with conventional steels using the TTCC processing route.
Example C: Chemistry selection to reduce negative segregation effects during solidification [0095] During steel solidification, binding elements tend to remain diluted in the liquid due to their greater solubility compared to the solid (δ or austenite ferrite). Solute-rich areas form two types of non-uniform chemical composition patterns under solidification: microsegregation and macrosegregation.
[0096] Microsegregation results from the freezing of solute-enriched liquid in interdendritic spaces, but it is not a major problem, since the effects of microsegregation can be removed during subsequent hot work. On the other hand, macrosegregation is a non-uniformity of the chemical composition in the mold section on a larger scale. It cannot be completely eliminated by high temperature disposal and / or hot work. In the case of interest for this description, which is the continuous sheet mold, it produces the centerline segregation strip.
[0097] A central segregation strip should be avoided because: - Brittle constituents, such as non-tempered martensite, may appear in this region as a result of welding operations (bias and SRE welding; see, for example, Figures 5A-B). These unwanted constituents are removed during the subsequent whole body heat treatment. However, the tube can be plastically deformed by flexing between welding and heat treatment operations, producing a failure during industrial production. -After the TTCC, the rest of the central segregation strip is a region enriched with substitute solutes (such as Mn, Si, Mo) with a higher density of coarse carbides than the rest of the material. This region is susceptible to nucleated fractures during low cycle fatigue, as can be seen in Figures 6-7. In addition, prominent segregation strips are associated with low sulfide stress fracture resistance.
[0098] Although it is not possible to remove macrosegregation, its negative effects on toughness, fatigue life and resistance to fracture by sulfide stress can be reduced by an appropriate selection of steel chemistry.
[0099] Based on EDX measurements in samples corresponding to a wide range of steel chemicals, enrichment factors in the central segregation strip were estimated for different alloy elements. The results are shown in Table Cl. The enrichment factors (EF) are ratios between each concentration of element in the central strip and that corresponding to the average in the matrix. These factors are mainly dependent on the thermodynamic partition coefficient between liquid and solid; and diffusivities during solidification.
Table Cl: Enrichment factors (FE) in the central segregation strip corresponding to different substituting alloy elements.
[0100] Table Cl clearly shows that there are some elements that have a strong tendency to segregate during solidification, such as Si and Cu. On the other hand, Cr and Ni have low enrichment factors. Ni is a costly addition, but Cr can be used when an increase in hardening and / or tempering strength is desired without producing strong segregation patterns.
[0101] The enrichment factors provide information about the increase in concentration that can be expected for each element in the central segregation strip. However, not all of these elements have the same effect in relation to the material's tendency to form brittle constituents during welding or heat treatment. It is observed that the greater the increase in hardening, the greater the tendency for brittle constituents during processing. It is important to mention that elements with high diffusion coefficients, such as carbon and boron, can segregate during solidification, but are homogenized during hot rolling. Therefore, they do not contribute to forming brittle constituents located on the segregation strip.
[0102] From the analysis of the TRC diagrams (Example A), it can be concluded that manganese produces the greatest increase in hardening. This is in addition to carbon and boron, which do not show great segregation patterns after hot rolling. On the other hand, Si and Cu, which have a strong tendency to segregate, do not play an important role in hardening. Due to its high enrichment factor and great effect on hardening, the addition of Mn should be reduced as much as possible when trying to reduce the negative effects of macrosegregation, such as reducing the low cycle fatigue life.
[0103] Large Mn contents are commonly added to the steel composition because of its effect on hardening. In this description, hardening is mainly achieved through greater carbon addition, so the Mn concentration can generally be reduced. Additional manganese reductions can be achieved using boron and / or chromium additions. Examples can be seen in Table 02, which shows the critical cooling rate (CR90) for different steel compositions obtained from the TRC diagrams (data taken from Example A above). In order to achieve hardening in a steel with about 0.25% carbon, Mn can be reduced from 1.6% to 1.3% with the addition of Boron, and additionally reduced to 0.4% if Cr- Mo is additionally used.
Table C2: Critical cooling rates to have more than 90% martensite (CR90) measured for the analyzed steels. Values determined from Gleeble® dilatometric tests and metallographic analysis.
Example D: Microstructure homogenization [0104] As previously mentioned, the fatigue life of the spiral pipe is strongly dependent on microscopic characteristics such as microstructural heterogeneities. The combination of soft and hard microconstituents tends to produce localization of plastic tension, which is the driving force for nucleation and fracture propagation. In this section, the spiral pipe microstructures obtained with the standard production method applied to chemicals in API 5ST are compared, and those corresponding to a chemistry and processing conditions in the ranges described in this description.
[0105] As a reference material, a standard Grade 110 spiral pipe (yield strength of 758.4 MPa to 827.4 MPa (110-120 Ksi)) with chemistry entitled STD2 in Table Al, which is in API 5ST specification. This standard material was compared to a spiral tube of the same grade produced with BTi2 chemistry and applying the TTCC.
[0106] In this comparison, different pipe locations will be considered: - Base Metal (MB): microstructure of the spiral pipe separated from the SRE line and bias welds, where "separated" means that the thermally affected zones are not included in this region ( ZAT) produced during any welding operation and its possible Post Welding Heat Treatments (TTPS). -Bias weld (SV): microstructural region corresponding to the strip-to-strip joint that can be performed by Plasma Arc Welding (SAP), Friction Welding and Mechanical Stirring (FSW) or any other welding techniques. Also included in this region is the corresponding thermally affected zone during welding and TTPS., -SRE line: microstructure resulting from longitudinal SRE welding during the formation of the tube and its localized TTPS, which is usually a seam annealing. As in previous cases, this region also includes the corresponding thermally affected zone.
[0107] In Figures 8A-B, the basic metal microstructures corresponding to the standard spiral tube (A) and to this description (B) are shown. In the first case, a ferrite matrix with a fine carbide distribution is observed. This matrix and fine structure results from the controlled hot rolling process. This microstructure of the description (Figure 8B) is mainly composed of tempered martensite. The volumetric fraction of bainite is less than 5% in this case. The tempered martensite structure is also a fine distribution of iron carbides in the ferrite matrix. The main difference between conventional and new structures is related to the morphology of the ferrite grains and sub-grains and the displacement density. However, in relation to refinement and homogeneity, both structures are very similar.
[0108] Figures 9A-B show electronically scanned micrographs corresponding to the SRE line. Of course, in the conventional structure, two microconstituents appear: there are grains of soft ferrite and rigid blocks composed of a mixture of fine perlite, martensite and some retained austenite. In this type of structure, plastic tension is located in the ferrite and fractures can nuclear and propagate in the surrounding brittle constituents (non-tempered martensite and austenite with a lot of carbon retained). On the other hand, the microstructure of the SRE line obtained with chemistry and processing conditions within the ranges of this description is homogeneous and very similar to the structure of the corresponding base metal.
[0109] Microstructures corresponding to SRE's ZAT are shown in Figures 10A-B. In the standard material, the appearance of the remainder of the central segregation strip is clear, which after annealing the seam is partially transformed into non-tempered martensite. Again, these are brittle constituents that are located along the SRE line and can nuclear and propagate fractures during service. The risk of failure is greater in the previous case due to the larger size of the constituents already mentioned. On the other hand, in the tempered and tempered spiral pipe, the structure close to the SRE line is homogeneous and the remainder of the central segregation strip is not observed.
[0110] In Figures 11A-B, some electronically scanned micrographs are presented corresponding to the ZAT of the weld in bias of both the conventional spiral tube and this description. For conventional material, the microstructure is very different from that of the base metal (MB). It is composed mainly of upper bainite and the grain size is large (50 microns, compared to less than 15 microns for MB). This type of coarse structure is not suitable for low cycle fatigue because fractures can easily spread along bainitic strips. An example of a fatigue fracture running through the coarse bainite in the bias weld is shown in Figure 12. This is a secondary fracture located close to the main failure that occurred during the service of a standard Grade 110 spiral pipe.
[0111] On the other hand, the bias weld microstructure in this description is again very similar to that corresponding to that of the base metal. No grain of superior bainite was observed. It is important to mention that some bainite may appear after the heat treatment of the complete body, but, due to the selection of chemistry and suitable processing conditions, the corresponding volumetric fraction of this constituent is less than 10%. This is the main reason for the good hardening of the chemicals described in this description. Additionally, due to the upper limit on the austenitizing temperature, the final grain size is small (less than 20 microns), so large slats of bainite that can propagate fractures are completely avoided.
[0112] Further examples of the microstructural homogeneity achieved by combining the steel chemistry and processing conditions described in this description are presented in Figures 13-14. In Figure 13, the typical variation of hardness is shown through bias welding for conventionally produced spiral tubes compared to that obtained using the new chemistry and processing route. Of course, when using this description, the variation in hardness is highly reduced. As a consequence, the tendency of the material to accumulate stress in localized regions (in this case, the ZAT of the bias weld) is also reduced and the fatigue life is improved.
[0113] In Figures 14A-B, some microstructures corresponding to the intersection between the bias weld and the SRE line are shown. It is clear that large microstructural heterogeneities are obtained following the conventional route. These heterogeneities are successfully eliminated using the chemistry and processing conditions described in this description.
Example E: Fatigue test for spiral pipe [0114] In order to compare the performance of the spiral pipe produced according to this description with that corresponding to standard products, a series of tests were carried out in the laboratory. Spiral tube samples were tested on a fatigue machine shown schematically in Figure 15. This machine is capable of simulating bending deformations during winding and unwinding operations, while applying internal pressures. Therefore, the tests are useful for listing materials under low cycle fatigue conditions that are close to those experienced during actual field operation.
[0115] During the test, fatigue specimens (pieces of pipe 1.5 or 1.8 meters [5 or 6 feet] long) are attached at one end while an alternative force is applied by a hydraulic actuator at the end opposite. Deformation cycles are applied to the specimens by flexing the samples along a curved mandrel with a fixed radius, and then straightening them against a straight reinforcement. Steel capsules are welded at the ends of the specimen and connected to a hydraulic pump, so that the cycle is conducted with the specimen filled with water at constant pressure until it fails. The test ends when a loss of internal pressure occurs, due to the development of a fracture through the wall thickness.
[0116] The test was performed on spiral pipes with different chemicals and Degrees, as shown in Table El. The pipe geometry was the same in all cases (DO 5.08 cm (2 "), EP 0.48 cm (0.19 ")). STD1, STD2 and STD3 are steels within the limits described in API 5ST, processed following the standard route. BTii, BTi2 and CrMoBTi4 are chemicals selected and processed according to this description. It is important to mention that CrMoBTi4 steel was used to produce two non-standard grades with 861.8 MPa and 965.3 MPa (125 Ksi and 140 Ksi) of minimum yield strength (the highest Grade described in API 5ST is 758.4 MPa (110 Ksi) of LEM). Tests were carried out on pipe pieces with and without bias welding (in all cases, the longitudinal SRE line is included in the samples). The severity of the test depends mainly on two parameters: bending radius and internal pressure. In this study, the bending radius was 1.2 meters (48 inches), which corresponds to a plastic tension of about 2%. Internal pressures between 11.0 MPa and 93.1 MPa (1600-13500 psi) were considered, producing arc stresses that varied from about 10% to 60% of the minimum degrees of elasticity.
Table El: Steel chemicals and spiral tube grades analyzed.
[0117] In Figure 16, some results are presented in comparison between the fatigue life measured in samples with and without bias welding (SV). The values shown in the figure correspond to the averages obtained in the Degree test of conventional and unconventional spiral tubes. In the case of conventional material, there is clearly a reduction in fatigue life when testing samples containing the bias weld. On the other hand, the spiral tubes produced according to this description do not show an important change in the fatigue life when the tests are performed on SV samples. This is a consequence of the homogeneous structure of the tube, with virtually no difference in the mechanical properties between base metal, SRE line and bias welding.
[0118] Figure 17 shows the improvements in the fatigue life of the spiral tube obtained with chemicals and processing conditions as described by this description. For grades 80, 90 and 110, the comparison was made against the equivalent grade produced by the conventional route. In the case of Grades 125 and 140, which are not standard, the fatigue life comparison was made against a Grade 110 STD3 steel tested under similar conditions (tubular geometry, bending radius and internal pressure). The results presented in the figure correspond to average values for each Degree, in which the error bars represent the dispersion obtained when using different internal pressures.
[0119] In Figure 17, it is clear that a noticeable improvement in fatigue life is seen when using chemicals and processing conditions according to this description. For example, at Grade 110, there was an improvement of about 100% in the fatigue life. This is a consequence of the fact that, in conventional spiral tubing, fatigue performance is limited to that of bias welding (which is generally the weak point in relation to low cycle fatigue, due to its microstructural and constituent heterogeneities brittle). In spiral tubes produced according to this description, there is no significant reduction in fatigue life in bias welds, which greatly increases the overall performance of the tube. In relation to non-standard Degrees, the major improvement in fatigue life is due to the fact that the comparison is made against a conventional Grade 110 tested under similar processing conditions. However, for the same internal pressures, the arc stresses are closer to the lower elastic limit of the lower Grade, and the test severity increases to Grade 110 compared to Grade 125 and 140. These results show that, using Higher degrees, (not achievable with the conventional method), the fatigue life is strongly increased for the same conditions.
Example F: Sulfide stress fracture resistance [0120] The performance of material in relation to hydrogen embrittlement in environments containing H2S is related to the combined effects of corrosive environments, the presence of blockages (for example, precipitates and displacements) that could increase locally the concentration of hydrogen, as well as the presence of brittle areas, where fractures could easily spread. A possible source of critical brittle regions in conventional spiral pipe materials is the pattern of segregation of replacement elements, such as Mn, in the raw material. Differential concentration regions tend to respond differently to thermal cycles imposed during bias welding, TTPS, SRE and seam annealing, and could lead to the local formation of brittle constituents. In particular, when the material is annealed at the seams after the SRE process, the tubular body quickly extracts heat from the weld area. If segregation is high enough, areas of high hardness elongated with the possible presence of martensite can be formed as a consequence of the cooling conditions. These areas will remain in the tube to become easy paths for fracture propagation. The fact that the new process is applied as the last stage of production allows the minimization of excessively hardened areas. Other relevant differences are: a) the displacements introduced during the cold forming of the tube are not present in the new product, b) the carbides in the new product are smaller and isolated compared to the typical brittle perlite / bainite carbides. As a consequence, the spiral tube produced with chemicals and processing conditions in accordance with this description presents an improved fracture performance in an environment containing H2S.
Table F1: Steel chemicals and grades of spiral tubes analyzed in this study.
[0121] In order to perform a first analysis of the sulfide stress fracture resistance, Grade 80 spiral tube samples produced by i) the standard process and ii) the new chemical process were evaluated using method C (ring in form C) of NACE TM0177. Steel chemicals are shown in Table F1. Both materials (3 specimens in each case) were tested with the SRE seam in the center of the sample in C-ring, using the following conditions: [0122] Load: 90% of 551.6 MPa (80Ksi), Solution A, 1 bar H2S, Test time: 720 h [0123] In the case of the standard spiral tube all 3 specimens failed. On the other hand, the 3 samples corresponding to the new chemical-process passed the test (Figures 5A-B with ring and C figures). Although more tests are underway to analyze the embrittlement resistance of different degrees, as well as the effects of bias welding, this first result shows a clear improvement compared to the standard condition, attributed to a more homogeneous base metal microstructure and SRE line in the case of the new new process route.
[0124] As shown in Figures 18A-B, the C-ring formed by the conventional process has a large fracture below the middle, while the C-ring formed by the modalities of the described process has not fractured.
[0125] In some embodiments, additions of B-Ti and Cr-Mo can reduce the maximum amount of Mn. In some modalities, Degrees can be greater than 110, which can be difficult to achieve using the standard method.
[0126] Functionalities, materials, characteristics, or groups described together with a specific aspect or modality, or for example must be understood to be applicable to any other aspect, modality or example described here, unless it is incompatible with them. All features described in this specification (including any claims, summary and accompanying figures), and / or any and all steps of any method or process then described, may be combined in any combination, except combinations in which at least some of said features and / or steps are mutually exclusive. Protection is not restricted to the details of any of the previous modalities. The protection extends to any new, or any new combination, of the characteristics described in this report (including any claims, summary and accompanying figures), or to any new, or any new combination, of the steps of any method or process then described.
[0127] While certain modalities have been described, these modalities have been presented by way of example only, and are not intended to limit the scope of protection. In fact, the new methods and apparatus described here can be incorporated in a variety of other ways. In addition, various omissions, substitutions and changes in the form of the methods, compositions and apparatus described here can be made. Those skilled in the art will appreciate that, in some modalities, the steps actually taken in the illustrated and / or described processes may be different from those shown in the figures. Depending on the modality, certain of the steps described above can be removed, others can be added. In addition, the characteristics and attributes of the specific modalities described above can be combined in different ways to form additional modalities, all of which are within the scope of the present description.
[0128] Although the present description includes certain modalities, examples and applications, it will be understood by those skilled in the art that the present description extends beyond the modalities described specifically for other "alternative modalities and / or uses and obvious and equivalent modifications. of them, including modalities that do not provide all the features and advantages set forth here. Therefore, the scope of this description is not intended to be limited by the specific descriptions of the preferred modalities here, and can be defined by the claims as presented here or as presented in the future.

权利要求:
Claims (24)
[1]
1. Spiral steel tube formed by a plurality of welded strips characterized in that the tube includes regions of base metal, weld joints, and their heat affected zones, comprising: an elastic limit greater than about 551.58 MPa ( 80ksi); a composition comprising: 0.17-0.35% w / carbon; 0.30-2.00% p manganese; 0.10-0.30% p silicon; 0.010-0.040% p aluminum; up to 0.010% p sulfur; up to 0.015% p phosphorus; up to 1.0% chromium; up to 0.5% p molybdenum; up to 0.0030% p boron; up to 0.030% p titanium; up to 0.50% p copper; up to 0.50% p nickel; up to 0.1% p niobium; up to 0.15% w vanadium; up to 0.0050% p oxygen; up to 0.05% p calcium; and the iron balance and impurities being inevitable; and a final microstructure comprising a mixture of tempered martensite and bainite; where the final microstructure of the spiral tube comprises more than 90% volume of tempered martensite in the base metal regions, in the weld joints and in the areas affected by heat; where the final microstructure across all base metal regions, weld joints and heat-affected zones is homogeneous; and in which the final microstructure comprises a uniform distribution of fine carbides throughout the base metal regions, weld joints and areas affected by heat.
[2]
Spiral steel tube according to claim 1, characterized in that the composition comprises: 0.17 to 0.30% p carbon; 0.30 to 1.60% p manganese; 0.10 to 0.20% p silicon; up to 0.7% p chromium; up to 0.5% p molybdenum; up to 0.04% p niobium; up to 0.10% p vanadium; up to 0.0015% p oxygen; up to 0.03% p calcium; up to 0.003% p sulfur; and up to 0.010% p phosphorus.
[3]
Spiral steel tube according to claim 1, characterized in that the composition comprises: 0.0005 to 0.0025% p boron; and 0.010 to 0.025% p titanium.
[4]
Spiral steel tube according to claim 1, characterized in that the composition comprises: 0.25 to 0.35% w copper; and 0.20 to 0.35% p nickel.
[5]
Spiral steel tube according to claim 1, characterized in that the tube has a minimum elastic limit of 861.84 MPa (125 ksi).
[6]
6. Spiral steel tube according to claim 1, characterized in that the tube has a minimum elastic limit of 965.27 MPa (140 ksi).
[7]
Spiral steel tube according to claim 1, characterized in that the tube has a minimum elastic limit between 861.84 MPa (125 ksi) and 965.27 MPa (140 ksi).
[8]
Spiral steel tube according to claim 1, characterized in that the final microstructure comprises at least 95% volume of tempered martensite in the regions of base metal, weld joints and areas affected by heat.
[9]
Spiral steel pipe according to claim 1, characterized in that the pipe has a final grain size below 20 pm in the base metal regions, weld joints and areas affected by heat.
[10]
10. Spiral steel tube according to claim 9, characterized in that the tube has a final grain size below 15 pm in the base metal regions, weld joints and heat-affected areas.
[11]
11. Spiral steel pipe according to claim 1, characterized in that the weld joints comprise bias welds.
[12]
12. Spiral steel tube according to claim 11, characterized in that the fatigue life of bias welds is at least about 80% of the base metal regions.
[13]
13. Spiral steel tube according to claim 1, characterized in that the percentage hardness of a weld joint, including its zone affected by heat, is 110% or less than the hardness of the base metal.
[14]
14. Method for forming a spiral steel tube characterized by comprising: providing strips having a composition comprising: 0.17-0.35% w carbon; 0.30-2.00% p manganese; 0.10-0.30% p silicon; 0.010-0.040% p aluminum; up to 0.010% p sulfur; up to 0.015% p phosphorus; up to 1.0% chromium; up to 0.5% p molybdenum; up to 0.0030% p boron; up to 0.030% p titanium; up to 0.50% p copper; up to 0.50% p nickel; up to 0.1% p niobium; up to 0.15% w vanadium; up to 0.0050% p oxygen; up to 0.05% p calcium; and the iron balance and impurities being inevitable; and weld the strips together; forming a tube from the welded strips, where the tube comprises regions of base metal, joint welds and their heat affected zones; austenitize the tube between 900-1000 ° C; temper the tube to form a microstructure of martensite and final bainite while tempered, where the microstructure, while tempered, comprises at least 90% martensite in the base metal regions, weld joints and heat-affected areas; and tempering the quenched pipe at 550-720 ° C, where quenching the quenched pipe results in an elastic limit greater than about 551.58 MPa (80 ksi); where the microstructure across all regions of base metal, weld joints and heat-affected zones is homogeneous; and where the microstructure comprises a uniform distribution of fine carbides across the base metal regions, weld joints and heat-affected zones.
[15]
15. Method according to claim 14, characterized in that the strip solder comprises bias solder.
[16]
16. Method according to claim 14, characterized in that the formation of the tube comprises the formation of a joint in line.
[17]
17. Method according to claim 14, characterized in that it further comprises twisting the tempered tube into a coil.
[18]
18. Method according to claim 14, characterized in that the austenitization forms a grain size below 20pm in the base metal regions, weld joints and areas affected by heat.
[19]
19. Method according to claim 14, characterized in that the composition comprises: 0.17 to 0.30% w / w carbon; 0.30 to 1.60% p manganese; 0.10 to 0.20% p silicon; up to 0.7% p chromium; up to 0.5% p molybdenum; up to 0.04% p niobium; up to 0.10% p vanadium; up to 0.00015% p oxygen; up to 0.03% p calcium; up to 0.003% p sulfur; and up to 0.010% p phosphorus.
[20]
20. Method according to claim 14, characterized in that the composition comprises: 0.0005 to 0.0025% p boron; and 0.010 to 0.025% p titanium.
[21]
21. Method according to claim 14, characterized in that the composition comprises: 0.25 to 0.35% w copper; and 0.20 to 0.35% p nickel.
[22]
22. Method according to claim 14, characterized in that the tempered pipe has an elastic limit greater than or equal to 861.84 MPa (125 ksi).
[23]
23. Method according to claim 14, characterized in that the tempered pipe has a minimum elastic limit of 965.27 MPa (140 ksi).
[24]
24. Method according to claim 14, characterized in that the tempered pipe has a minimum elastic limit between 861.84 (125 ksi) and 965.27 MPa (140 ksi).

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法律状态:
2016-01-26| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]|

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2018-11-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-06-04| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|

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2020-01-14| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-03-17| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 14/03/2014, OBSERVADAS AS CONDICOES LEGAIS. |

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2021-12-14| B16C| Correction of notification of the grant [chapter 16.3 patent gazette]|Free format text: REFERENTE A RPI 2567 DE 17/03/2020, QUANTO AO ITEM (30) PRIORIDADE UNIONISTA. |

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