International Conference on Subsea Technologies SubSeaTech2007, June 2007, St.

Petersburg,Russia

RUSSIAN ALUMINUIM ALLOYS FOR ULTRA DEEP WATER PRODUCTION RISERS

Rudolf Alikin1, Vladimir Basovich1, Mikhail Gelfgat1, Vadim Tikhonov1, and Valery Chizhikov2
2 1

Aquatic Co, 90 Dubuninskaya st., 115093 Moscow, Russia Scientific and Technical Center for Aluminum Processing Technologies St. Petersburg, Russia

ABSTRACT An analysis is conducted as to the basic properties of the Russian aluminum alloys to serve as a material for oil production risers designed for operation at a water depth of 2,000 m and deeper. The alloys of different alloying systems are analyzed in terms of manufacturability, strength, ductility and corrosion resistance. The potential applicability of the alloys is assessed with respect to two main types of riser joint connections including a welded and threaded connections. The values of dimensional and weight characteristics of the catenary riser is designed for operation at water depths from 3,500 to 4,000m are given.

INTRODUCTION The exploration and development of subsea oil deposits at water depths ranging from 2,000 to 4,000 m with the use of riser require new light-weight materials and design solutions to be searched and developed. One of the most common deepwater oil production systems is a steel catenary riser (Figure 1) but its operation is limited to water depths from 1,500 to 2,000 m. Greater depths increase the riser tension and pressure as well as the compression force and bending moment at touch down zone. In order to tolerate the increasing loads, it is necessary to use new materials and develop optimum profiles of the riser sag, new technologies and facilities to deploy and keep the riser. Among promising light-weight materials including composites, titanium alloys and aluminum alloys, the best combination of strength, weight and cost can be found in aluminum alloys. As seen from Table 1 [1], aluminum alloys as well as steel are the best with the Strength/(WeightCost) criterion among other materials and are absolutely the best with consideration for corrosion resistance among all materials. The experience in development and operation of the first aluminum deepwater drilling riser developed by Noble Drilling Services in association with Russian companies in 1998-2003 [1-3] has shown an impressive efficiency of the riser and potential of high-strength aluminum alloys for the manufacture of deepwater and ultra deepwater risers of various applications. This study presents the analysis of the basic properties of aluminum alloys developed in Russia 1

Figure. 1. Catenary production riser. for marine applications. The alloying system is the primary factor responsible for the classification of alloys with regard to the complex of their operational properties. The analysis involved such characteristics as strength, ductility and corrosion resistance. In addition to operational properties, manufacturability of extrusions from various alloys and strengthening of extrusions during manufacturing process were of considerable concern. These issues are very important since they greatly affect the weldability of material and, as a consequence, the selection of the type of riser connection between the welded and threaded connections.

Characteristic Yield strength (P) Wet weight (t/m3) Cost ($/t) Strength/(WeightCost)103

Steel 500 6.8 3,300 22.3

Titanium 760 3.5 7,800 2.8

Aluminum 320-350 1.7 8,900 21.2-23.2

Composite 1,050 0.7 111,000 13.6

Table 1. Comparison of characteristics of materials for riser manufacture. Based on the results of the analysis of properties of aluminum alloys and the dimensional and weight characteristics of production riser, the specific alloy grades are suggested for risers with welded and threaded connections. to 430 P and greater, however, the ductility of products substantially reduces. The best strength properties are offered by g5, g6 and g61 series alloys which, in addition to a high Mg content (4.5 to 6.8%), contain a number of transition metals. The alloys of up to 4.5% Mg content continue to be high corrosion resistant after being heated to any temperature. If the alloy contains more than 5%Mg, its stress corrosion resistance may be reduced as a result of unfavorable heat treatment conditions. The grain boundaries show continuous -phase lines indicative of potential de-lamination of the products in the corrosive environment. In this case, annealing improves corrosion resistance and, as a result, the phase partially dissolves with its further redistribution in the form of individual chains which eliminate the de-lamination process along the grain boundaries. The annealed products manufactured from alloys with 5 to 7% Mg content are not susceptible to low-temperature heating up to 70 and stay highly corrosion resistant. The alloys bearing 7% Mg and greater maintain good corrosion resistance only in quenched condition. The Mg content of the alloy also influences weldability of products in such a way that welding of alloys of increased Mg content may provoke hot crystallization cracking. Because of this, it is necessary to use special filler materials (filler wire) when welding alloys of increased Mg content. The influence of the rest alloying elements and additives on processing and operational properties of alloys and their products is as follows: manganese and zirconium additives improve hot cracking resistance of the material during casting and welding and increase the strength of weldments; chromium additives improve stress corrosion resistance of wrought products; small zinc additives improve the strength of products, while joint zinc and chromium

1. ALUMINUM ALLOYING SYSTEMS The most promising alloys for aluminum pipe structures designed for marine service belong to the following four alloying systems [1, 4]: Al-Mg, Al-Mg-Si, Al-Mg-Zn, Al-Mg-Zn-Cu. The processing characteristics of these alloys make it possible to produce rather long extrusions from ingots. 1. 1. Al-Mg alloys Al-Mg alloys belong to the nonheat-treatable alloys. In addition to the basic alloying component (Mg), the alloys of this system are additionally alloyed in various combinations and amounts with transition elements including manganese, chromium, zirconium, titanium and other elements. These additives make up for the required level of the product special properties including fatigue life, corrosion resistance, weldability and other properties. Strength properties of products depend on the basic additive content (1 to 7% Mg) in the alloy as well as the extent of plastic deformation, which the product undergoes from cast to finished condition. Strength properties of these alloys are somewhat lower than those of heat-treatable alloys, however, the alloys show rather high corrosion resistance, especially in sour service, and good behavior during fusion welding. The products can be further strengthened by cold working. Strength of wrought products improves with increasing the Mg content, for instance, with the ultimate strength ult = 80 to 340 P and yield strength 0.2 = 25 to 180 P. Cold working of Al6%Mg alloy increases the ultimate tensile strength up 2

additives improve both the strength and corrosion resistance of products; copper and iron additives have a detrimental effect on weldability and corrosion resistance of products processed from alloys of this group.

The wrought products manufactured from these alloys are easy at argon-arc welding with the strength of weldments reaching 80 to 90% of the strength of the base metal. g61 series alloy is the basic material of the Russian metallurgy for manufacture of hulls. In recent decades the Russian mining and smelting factories have brought the production of scandium compounds and binary aluminum-scandium alloy to a commercial level [5]. Based on this alloying composition, the unique Al-Mg alloys have been developed to manufacture wrought weldable highstrength corrosion-resistant products. For instance, nonheat-treatable corrosion-resistant 1575 series aluminum alloy has been developed for the manufacture of heavy-duty welded structures. In compliance with the manufacturers technical documentation, the yield strength and the ultimate strength of rolled and extruded products manufactured from this alloy are 300 P and 410 P, respectively. Nowadays, the indicated strength is the maximum attainable level with the welded structural aluminum alloys, which do not require heat treatment of products and their weldments. 1. 2 Al-Mg-Si alloys Wrought products processed from these alloys are strengthened using heat treatment (quenching and ageing) and possess far greater processing and operational ductility than those of Al-Mg alloy products. These alloys find their applications where a combination of moderate strength, good manufacturability and corrosion resistance is required. Strength properties of alloys greatly depend on a set of alloying elements and their content as well as the heat treatment process used. The ultimate strength and yield strength of products manufactured from the known alloys of this system may be within 120 to 400 P and 80 to 350 P, respectively. Mg2Si phase is the principal strengthening phase of these alloys. The increased Si content improves weldability of wrought products. The alloys of this system possess reasonably good general corrosion resistance and practically are not affected by corrosion cracking.

The maximum strength of products is attained after heat treatment. However, after artificial ageing process they may appear to be prone to intercrystalline corrosion to some extent. The increased content of Mg2Si phase and copper and iron impurities with the Si excess reduce corrosion resistance of Al-Mg-Si alloys. The increased Mg content does not reduce corrosion resistance. With maintaining the content of principal strengthening Mg2Si phase, the alloys exhibit marked deterioration in corrosion resistance in going from alloys with the Mg excess to alloys with the Si excess. Because of this, alloys with the Mg excess are preferable in those applications, where improved corrosion resistance is required. Further copper, manganese and chromium alloying improves the strength properties. Manganese and chromium improve corrosion resistance, while copper makes it significantly worse. The greater is the copper content in alloys, the greater is their susceptibility to intercrystalline corrosion after artificial ageing process. Naturally aged alloys possess high corrosion resistance regardless of the copper content. Under certain conditions, Al-Mg-Si alloys may be prone to develop crystallization cracking during welding. However, this effect can be reduced using a special filler wire. The wrought products processed from the most alloys of this system show satisfactory results at argon-arc welding; however, the strength of their weldments is 40-60% of that of the base metal. Al-Mg-Si alloys are not prone to stress corrosion regardless of their condition. The general corrosion resistance of naturally aged alloys is as high as that of the Al-Mg alloys. D31, D33 and D series alloys of this alloying system have been developed and commercialized for the Russian industry. 1. 3. Al-Zn-Mg alloys Al-Zn-Mg alloys belong to the weldable heattreatable alloys. These alloys are remarkable by their self-hardening, that is why the properties of heattreated (artificially aged) weldments are similar to those of the base metal (75 to 85% of its ultimate strength). These alloys show high strength (the ultimate strength of up to 500 MPa) and good general corrosion resistance. One of the main limitations of alloys is their high readiness to stress corrosion and layer corrosion. Al-Zn-Mg alloys differ from other aluminum alloys in that their stress corrosion resistance depends to a greater extent on the grain boundary condition, nature of solid solution 3

decomposition, precipitation particles (their shape, composition and size), alloy composition, manufacturing technology, and heat treatment and storage conditions. One of the key parameters of alloys is the Zn/Mg ratio. The optimum set of corrosion and strength properties may be found in alloys with Zn/Mg = 1.5 to 2.5. Stress corrosion resistance of alloys can be considerably improved with 0.1-0.2% copper additives. Further chromium alloying has a beneficial effect on the layer corrosion because of intermetallic compounds (Al18Cr2Mg3), which inhibit the boundary and sub-boundary movement and become the nuclei of forming MgZn2 particles. This promotes a more uniform deformation and reduced grain boundary stress concentration, and, as a consequence, reduced probability of crack initiation. Furthermore, the development of molecular hydrogen, which occurs at chromium-bearing intermetallic compounds, improves the hydrogen embrittlement resistance. The same but somewhat less effect is found with introducing such additives as copper, zirconium and manganese. However, it should be appreciated that copper, on the one hand, being part of oxide films, deteriorates their protective properties, and, on the other hand, encouraging the development of molecular hydrogen, reduces the hydrogen concentration at the top of developing crack. Copper additives considerably worsen weldability of alloys to the point that fusion welding is no longer applicable. Zirconium additives prove to be more effective with the welded structures. Here, heat treatment is one of the primary factors responsible for the combination of strength and anticorrosive properties of wrought products. Hightemperature ageing somewhat improves stress corrosion resistance but, at the same time, worsens the alloy strength. The optimum combination of mechanical properties and stress corrosion resistance can be attained using a two-stage ageing process. Artificial ageing process with the 5 to 15% overageing provides a reliable performance of products with the residual stresses being reduced considerably. These alloys are known as 1980 and V92 series alloys in the Russian industry. 1. 4. Al-Zn-Mg-Cu alloys These alloys belong to the best high-strength aluminum alloys. They are used only after the alloys have undergone artificial ageing process under specially developed conditions. Their ultimate strength is 750 to 800 P.

The as-quenched and naturally aged alloys exhibit low resistance to corrosion cracking and layer corrosion. All alloys of this system are anisotropic in terms of mechanical and corrosive properties (generally, the longitudinal fiber shows better characteristics). As compared to the moderatestrength alloys, the high-strength alloys suggest lower ductility and higher susceptibility to stress concentrators. Because of this, the components produced from these alloys should be fabricated with maintaining very smooth transitions and minimum stress concentrators. The alloys of this system possess not only high static strength but also good ductility and good resistance to low-cycle fatigue. At the same time, the alloys are prone to stress corrosion and layer corrosion. The 0.1 to 0.3% copper additives significantly increase stress corrosion resistance. The problem of improving their corrosion resistance may be solved using such two-stage ageing process that would result in the coagulation of solid solution decomposition products. However, such heat treatment causes 10-15% loss of strength of the material. After the described heat treatment the products show higher values of fracture toughness and fatigue cracking resistance. V93, V95 and V96 series alloys of this system have been developed and commercialized for the Russian industry.

2. SELECTION OF ALUMINUM ALLOY The selection of aluminum alloy as a material for catenary production riser is mainly governed by the riser joint connection design. The connection design in turn depends on the method of deployment the riser from the floating unit at installation at the location. The three most common methods of deployment the riser are as follows [6]: 1) Reel-lay method; 2) Subsurface catenary tow method; 3) J-lay method. The first method consists in welding of rather long riser joints onshore and reeling a reel on board an installation vessel which transports the reeled pipe to the location (Fig. 2). Once on location, the riser is being unreeled and connected to the production unit. The benefits of this method are low cost installation, reliability and quick deployment. The main limitations are a need for 30-50 m dia reels and plastic deformation, which occurs at the pipe reeling and inevitably leads to the reduced fatigue life of pipes. Obviously, this deployment method implies that the lengths of pipes should be connected by welding. At the same time, the lengths of riser pipes can be connected using thread.

Figure 2. The Reel-lay method. In the Subsurface catenary tow method, the entire length of riser pipes is assembled onshore, and then it towed to the location (Fig. 3) with further deployment and connecting to the production unit. The main concerns of this deployment method are monitoring and control of the riser stress during towing. The length of riser pipes can be assembled using both welded and threaded connections. The J-lay method is one of the most traditional methods of pipe laying in deep water. In this case the deployment procedure involves welding the riser joint

Figure. 4. J-lay method. Strength of connection being as much similar to that of the base metal as possible

The most appropriate alloys for the welded connection are Al-Mg alloys because they meet the requirements to the maximum extent. Scandiumbearing 1575 series aluminum alloy is the most promising alloy among those alloys in terms of high operational properties including strength, ductility and corrosion resistance. A great advantage of this alloy lies in the fact that its weldments do not require any heat treatment.

Figure. 3. Subsurface catenary tow method. to the available riser string hanging into the sea (Fig.4). The J-lay method is rather cost-prohibitive and time-consuming. The main concerns of this method are vertical welding of pipes and quality control during welding in the marine environment. 2. 1. Selection of alloy for the welded connection The main processing requirements for butt-welded connection are as follows: Excellent material weldability including improved hot cracking resistance; When welding the products processed from 1575 alloy, it is necessary to select the filler wire of special chemical composition in order to provide high operational properties of the weld metal and weldments without compromising the requirements for weldability. The filler wire selected must provide higher strength of the weld metal in as-cast condition maintaining the adequate level of operational properties. The indicated properties for welding 1575 alloy are specific to the filler wire processed from Sv. 1597 series alloy with increased scandium content and reduced level of Fe+Si impurities. The strength

of pipe weldments using this type of wire is no less than 90% of that of the base metal. Table 2 [1] shows the main mechanical properties of weldable 1575 and 1980T1 alloys, the latter being Alloy grade Alloying elements, total Fusion weldability Ultimate tensile strength (MPa) Yield strength (P) Elongation (%) KIC (kg/m3) Crack critical length (mm) Fatigue strength (P) General corrosion (mm/yr) 1575 6.95 Yes 410 300 11 100 0.02

used in the manufacturing of the main pipe of the first aluminum alloy drilling riser. Table 2 [1] shows the main mechanical properties of non-weldable 48-2hp1 alloy and 19531 alloy which was used as a material for service line pipes of 19801 7.39 Yes 410 350 9 36 8.9 120 0.05 48-2hp1 8.64 No 470 400 8-10 19531 9.65 No 520 470 6.5 62 11.2 170

Table 2. Mechanical properties of aluminum alloys of various alloying systems. 2. 2. Selection of alloy for the threaded connection Since no weldability requirements are implied for the riser with threaded connections, it is appropriate to select an aluminum alloy among Al-Zn-Mg-Cu system, which involves the best high-strength alloys. A specific alloy grade (a certain combination of basic and supplementary alloying elements) should be chosen based on a trade-off between the strength of material and its other important properties including ductility, fracture toughness and corrosion resistance. The total content of basic and supplementary elements in these alloys provides a good potential for developing the strength properties of products. The greater is the percentage of elements, the higher strength may be attained. The optimum combination of required operational properties is offered by 48-2hp1 series alloy when used as the material for riser pipes. This can be achieved through: limiting (in relation to the maximum level of solid solution saturation of the alloy matrix) the alloying with basic elements such as Mg, Zn and Cu; reducing the total content of Fe+Si impurities to 0.25%; introducing a second stage (at elevated temperature of heating) of artificial ageing process for products. 48-2hp1 alloy was developed in Russia to manufacture heavy-duty combined loading structures designed for extended operation in marine environments. The successful experience in long operation of marine service structures such as hulls, superstructures, etc. also indicates a reasonable selection of aluminum alloy as the material for the riser manufacturing. of aluminum alloy drilling riser. The available threaded connections can provide the strength of tubular structures [7], which is no less than that provided with the plain-end pipes. Figure 5 shows the tapered thread connection which can serve as an aluminum alloy production riser prototype. Similar connections are widely used in casings at drilling. The thread profile is an unequal-sided trapezoid with its supporting surface, which carries the axial load, made at an angle of 3-5. This profile allows for reducing the radial constituent of the connection at the riser tension and bending. The inner bearing face provides the connection tightness at making-up, while anticorrosive grease and seals prevent sea water from penetrating into threaded connection. All this makes the connection highly reliable at variable loads with the riser inner pressure of up to 100 P. 3. BASIC CHARACTERISTICS ALUMINUM ALLOY CATENARY RISER OF

The wall thickness of the pipe is the main design parameter of all tubular structures. It is assumed that the wall thickness of production risers should be designed based on the specified internal diameter of the riser. The initial static analysis of the riser is conducted with regard to the action of: internal pressure, tension, bending moment. The design criterion is the maximum equivalent stress (the von Mises criterion) of the riser leaving shear and torsional stresses out of account. The analysis only recognizes the primary membrane stress of each of three principal stresses, i.e. the stress which is

Figure. 5. Threaded connection of production riser. averaged across the entire cross section. The bending stress is added to the axial principal membrane stress. In accordance with the code [6], the condition of the strength of the production riser pipe can be written as: in the value of effective tension Teff and this effect is not as pronounced. The plot shows that the catenary oil production riser designed at water depths of 2,000-4,000 m can be assembled using pipes of 25-35 mm wall thickness. The wall thickness of riser pipe (48-2hp1 alloy) with the threaded connection is 8-10 mm smaller than that of riser pipe (1575 alloy) with the welded connection. The dry weight of one meter of 6.5-in. riser with 2535 mm wall thickness is 440-820 N, while the top tension does not exceed 1.7-2.0 MN.

3( Pi Po ) Do Di Teff M ( Do t ) + a , 2I 2( Do + Di )t A
where Pi and Po are internal and outside pressure, respectively; Do and Di are outside and inside diameter of the pipe, respectively; A = cross sectional area; t = wall thickness; Teff = effective tension of the riser; M = bending moment; I = cross sectional moment of inertia of the pipe; a = allowable stress, which is taken equal to 2/3 of the yield strength with the ductile materials. Figure 6 shows the wall thickness of 6.5-in I.D. production riser vs water depth at various values of internal pressure. The analysis was conducted for two most promising aluminum alloys including 1575 alloy (with welded connection) and 48-2hp1 alloy (with threaded connection).

CONCLUSIONS 1) Aluminum alloys as well as steel are the best with the Strength/(WeightCost) criterion among other materials, while their corrosion resistance being better than that of steel. At the same time, they are absolutely the best among light-weight materials. 2) The most promising aluminum alloys for catenary production riser in terms of strength, ductility, corrosion resistance and manufacturability are the weldable 1575 aluminum alloy and non-weldable 48-2hp1 aluminum alloy developed in Russia for marine applications. 3) The pipes processed from the mentioned alloys can be used for the manufacture of production riser designed for operation at depths of up to 4,000 m. The maximum design internal pressure of the1575 aluminum alloy and 48-2hp1 aluminum alloy riser is 35 MPa and 45 MPa, respectively. 4) Application of aluminum alloys for the manufacture of production riser reduces the riser tension and, as a consequence, the capacity of tensioners. 5) The successful operation of the first aluminum alloy drilling riser has shown the efficient application of high-strength aluminum alloys. Their application may prove to be promising not only in manufacturing 7

1 - Pi = 35 P, 1575 alloy 2 - Pi = 35 P, 48-2hp1 alloy 3 - Pi = 45 P, 48-2hp1 alloy As seen from Fig. 6, the selected wall thickness of production riser mostly depends on the internal pressure Pi. The effect of the water depth is reflected

of the production riser but high pressure risers, completion risers and other deep water facilities for exploration and development of subsea oil deposits.

REFERENCES 1. Gelfgat M., Tikhonov V., Vygodsky B., Chizhikov V., Adelman A., 2006, New Prospects in Development of Aluminum Ultra Deepwater Riser, Proceedings of the 18th Annual Deep Offshore Technology Conference & Exhibition, Houston. 2. Deul H., 2005, Aluminum Alloy Riser Allows for Deeper Drilling on Existing Rigs, Proceedings of the SPE/IADC Drilling Conference, Paper SPE/IADC 92559, Amsterdam, The Netherlands, 2005. 3. Gelfgat M., Grebtsov N., Podrazhansky A., Vygodsky B., Tikhonov V., Shaposhnikov V.,

Chizhikov V., High-Strength Aluminum Alloys for Deepwater Riser Applications, Proceedings of the Offshore Technology Conference, Paper OTC 16185, Houston, Texas, 2004. 4. Metals and Alloys. Handbook, 2003, Edited by Yu.P. Solntsev, St. Petersburg, ANO NPO Mir i Semya, 1090 pp. (in Rusian). 5. Gorynin, I., Zolotarevsky Yu., Rybin V. and Chizhikov V.: Metallurgical Concepts of Development of Wrought Aluminum Alloys for HighSpeed Sea Ships, 1999, Issues of Metal Science, No. 3 (20), St. Petersburg (in Russian). 6. Design of Risers for Floating Production Systems (FPSs) and Tension-Leg Platforms (TLPs), 2006, Recommended Practice 2RD, API. 7. Pipes for Oil Industry: Handbook, 1987, Edited by Fain., G.M., Moscow, Nedra Publishing, 488 pp. (in Russian).