CN112853214B - 一种经济型含稀土80ksi钢级抗硫化氢腐蚀兼抗挤毁石油套管 - Google Patents
一种经济型含稀土80ksi钢级抗硫化氢腐蚀兼抗挤毁石油套管 Download PDFInfo
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Abstract
本发明公开了一种经济型含稀土80ksi钢级抗硫化氢腐蚀兼抗挤毁石油套管,其包括如下质量百分比的化学成分:C 0.25%~0.30;Si 0.20%~0.30%;Mn 0.50%~0.60%;P≤0.010%;S≤0.005%;Cr 0.60%~0.70%;Mo 0.10%~0.20%;Al 0.010%~0.030%;稀土元素RE 0.0005%~0.0020%;余量为Fe元素及其不可避免的杂质。还公布了其制备方法。本发明的目的是提供一种生产成本低、夹杂含量少、尺寸精度高、强韧性能匹配好的经济型含稀土80ksi钢级抗硫化氢腐蚀兼抗挤毁石油套管及其制备方法。
Description
技术领域
本发明涉及黑色金属冶炼及金属压力加工领域,尤其涉及一种经济型含稀土80ksi钢级抗硫化氢腐蚀兼抗挤毁石油套管。
背景技术
目前,我国油气田开采工况越来越复杂,高温、高压、屈曲变形的西南部油田、西部油田和海上油田相继投入开发,国内对高抗挤毁套管的需求量也日益增多。选用高抗挤毁套管,一方面满足了在盐岩、盐膏岩、软泥岩等塑性流动地层、高地层压力或存在地应力异常段的油气井对套管挤毁性能的要求,提高了安全性;另一方面,选用较薄壁厚的高抗挤毁套管替代API系列套管,减轻了套管柱的质量,降低了成本。另外,作为油气伴生气体的硫化氢,溶于水后对油井管的腐蚀极为严重。普通碳锰钢套管在开采含硫化氢的油气资源时,套管在使用应力和硫化氢气体的共同作用下,会发生硫化氢应力腐蚀,造成套管柱或整口井的报废,甚至会造成井喷的事故,应对高挤毁、高硫化氢腐蚀的复杂工况,研发一种抗硫化氢腐蚀兼抗挤毁石油套管以满足市场需求。
经过检索,发现有三篇文献专利与本发明技术最为相关,具体内容分述如下:
文献1为一种80ksi钢级抗硫化氢应力腐蚀石油套管及其制造方法(专利申请号:201310150513.6),该文献专利提供的套管产品以钢板为原料,经过卷制焊接而成,钢中含有贵重元素Nb和V,且产品主要针对抗硫化氢腐蚀性能而设计,因此,该文献专利的套管产品不能满足抗挤毁的工况需要,且生产成本相对较高。
文献2为一种80ksi抗硫化氢应力腐蚀的油井管用合金钢及其制造方法(专利申请号:201811032877.3),该文献专利的钢种设计基于C-Mn-Cr-Mo-V-Ti 钢系,且元素Cr和Mo的含量相对较高,产品主要针对抗硫化氢腐蚀性能而设计,因此,该文献专利的油井管产品的生产难度相对较大、生产成本也相对较高,且产品不能满足抗挤毁的工况需要。
文献3为一种含稀土耐硫化氢腐蚀高抗挤毁石油套管及其生产方法(专利申请号:201510089008.4),该文献钢种设计采用低碳+MnCrMo合金+稀土微合金,而本专利采用中碳+CrMo合金+稀土微合金,文献稀土微合金采用LaCe稀土线,而本专利加入稀土铁合金进行微合金,文献制造的套管强度高而韧性差,本专利生产套管有良好的综合力学性能。
发明内容
本发明的目的是提供一种生产成本低、夹杂含量少、尺寸精度高、强韧性能匹配好的经济型含稀土80ksi钢级抗硫化氢腐蚀兼抗挤毁石油套管及其制备方法。
为解决上述技术问题,本发明采用如下技术方案:
一种经济型含稀土80ksi钢级抗H2S腐蚀兼抗挤毁石油套管制品化学成分 (重量百分比%):C 0.25~0.30;Si 0.20~0.30;Mn 0.50~0.60;P≤0.010; S≤0.005;Cr 0.60~0.70;Mo 0.10~0.20;Al 0.010~0.030;稀土元素RE 0.0005~0.0020;余量为Fe元素。
一种经济型含稀土80ksi钢级抗H2S腐蚀兼抗挤毁石油套管制备过程为:首先对来料高炉铁水进行预处理,将重量百分比90%的高炉铁水与10%的优质废钢作为原料一同加入顶底复吹转炉进行冶炼,转炉冶炼过程加入CrMo合金,冶炼完成的钢水装入钢水包进入LF炉工位进行精炼,调整钢液及钢水成分。精炼完成之后进入VD炉工位进行真空脱气处理,脱气结束加入稀土稀土铁合金,静置5分钟后进行圆坯连铸,热切后堆垛缓冷,质量及成分合格的圆管坯运送到环形炉加热,采用菌式穿孔机及MPM连轧机进行穿孔和连续轧制使其成为荒管,荒管先后经过张力减径冷床冷却和定尺锯切后,然进行水淬调质处理及带温矫直,最后对钢管先后进行无损探伤、水压试验和通径检测,合格者在两端进行螺纹加工,这样即为套管成品。
工艺流程简述为:铁水预处理→顶底复吹转炉冶炼→LF炉精炼→VD炉真空处理→圆坯连铸→定尺切割→堆垛缓冷→管坯加热→菌式穿孔→连续轧管→张力减径→冷床冷却→定尺锯切→调质处理→带温矫直→无损探伤→水压试验→通径检测→螺纹加工。
制品化学成分的设计依据如下:
C元素是提高强度和淬透性最有效的元素之一,但为防止淬火变形及开裂,考虑套管耐硫化氢腐蚀性能和冲击性能的要求,尽量提高Mn/C之比,因此,C 元素的含量控制在0.25%~0.30%之间;Si元素有提高强度和镇静脱氧的作用,但不利于塑韧性能,含量超过0.30%时会降低抗硫化氢腐蚀性能,因此,Si元素的含量控制在0.20%~0.30%之间;Mn元素有固溶强化的作用,可扩大奥氏体区、降低奥氏体向铁素体的转变温度,进而细化铁素体晶粒、提高钢的强韧性能,并可补偿降低C元素所造成的强度损失,但Mn元素的含量过高会产生偏析,容易产生对HIC裂纹敏感的MnS夹杂物,因此,Mn元素的含量控制在0.50%~0.60%之间;P元素会造成微观偏析,容易导致淬火马氏体形成显微裂纹,成为氢的聚集源,因此,P元素的含量控制在0.010%以下;S元素能与Mn元素形成对HIC裂纹敏感的MnS夹杂物,为了达到理想的抗硫化氢腐蚀效果,因此,S元素的含量控制在0.003%以下;Cr元素有固溶强化的作用,能提高钢的强度和淬透性,并能在钢表面形成致密的钝化膜,具有抗硫化氢腐蚀和抗氧化能力,同时Cr能抑制S元素的吸附,但需要考虑成本,Cr元素的含量控制在0.60%~ 0.70%之间;Mo元素有固溶强化的作用,能提高钢的强度和淬透性,并能提高回火稳定性,同时还能在钢表面形成致密的钝化膜,具有抗硫化氢腐蚀的能力, Mo合金价格昂贵,因此,Mo元素的含量控制在0.10%~0.20%;Al元素具有良好的脱氧能力,并可细化奥氏体晶粒,提高钢的耐腐蚀能力,因此,Al元素的含量控制在0.010%~0.030%之间;稀土元素有微合金固溶强化的作用,能够净化钢液、改善非金属夹杂物的形态、减少点腐蚀和强化晶界等作用,从而提高钢材的冲击韧性和抗硫化氢腐蚀性能,但含量过高会形成大的夹杂物团絮,因此,稀土元素的含量控制在0.0005%~0.0020%之间。
制品的制造工艺过程叙述如下:
S1、将高炉铁水进行预处理,使得铁水中的S元素的含量(重量百分比) 降低到0.010%以下;
S2、将预处理之后的铁水兑入顶底复吹转炉,加入(重量百分比)10%的优质废钢,采用单渣工艺冶炼,控制终渣碱度≤3.0,出钢过程加入CrMo合金进行合金化,终脱氧采用有铝脱氧,出钢过程必须挡渣;
S3、转炉冶炼完成的钢水在LF炉进行精练,精炼全过程按要求正常吹氩气,采用从低级数到高级数逐渐提高升温速度的方式加热提温到1565℃±10℃;根据转炉钢水成分进行造渣脱硫、及化学成分调整,精炼结束之后喂入200米硅钙线,喂线后进行10~15分钟吹氩气;
S4、将钢水送入VD炉进行真空处理,真空度≤0.10kPa,深真空时间≥15 分钟,抽真空后采用压入法加入稀土铁合金(稀土元素的重量百分比为10%);
S5、将经过VD炉真空处理之后的钢水静置5分钟,之后送入钢包回转台进行圆坯连铸,采用低拉速(1.2米/min)、结晶器电磁搅拌和全程保护浇注工艺,控制钢水过热度ΔT≤30℃,火焰切割后堆垛缓冷;
S6、圆管坯运送到环形加热炉进行加热,加热炉各段温度的控制范围见下表;
S7、将加热好的管坯进行热定心,然后进行菌式穿孔、MPM轧管机组进行连续轧制成荒管,经过张力减径、冷床冷却和定尺锯切成轧管;
S8、轧管进行水淬调质热处理,具体工艺为:890℃±10℃保温30min~ 50min、钢管出炉进行水淬(淬火之后的水温<30℃),660℃±20℃保温60min~ 80min回火后空冷;回火之后执行带温矫直,钢管矫直时的温度≥500℃。然后对钢管逐支进行无损探伤、水压试验和通径检测,合格者在两端进行螺纹加工。
经过上述工艺过程,可以生产出本发明所述的经济型含稀土80ksi钢级抗 H2S腐蚀兼抗挤毁石油套管。
本发明的有益效果:
①由于制品不含有贵重元素Ni、W、Zr、Nb、V、Ti等贵金属,CrMo含量较低,生产工艺合理,因此实现了低成本制造的目的;
②由于采用低过热度控制技术+电磁搅拌技术+圆管坯保护气氛冷却技术+ 堆垛缓冷技术+环形加热炉缓慢升温技术+120°三辊连轧及减径技术生产的套管内外表面良好,钢管的尺寸精度相对较高,残余应力较低,壁厚不均度≤12%、椭圆度≤0.5%,残余应力≤35MPa(采用环切法);
③由于采用含稀土元素的独特成分设计+纯净的冶炼技术+夹杂物变形变性技术+水淬调质处理技术+残余应力控制技术,使得制品非金属夹杂均≤0.5级,组织均为单一均匀的回火索氏体,原始奥氏体晶粒度均达到10级,钢管的各项指标优异,具体如下:
屈服强度:580MPa~630MPa;抗拉强度:670MPa~730MPa;屈强比:≤0.89;延伸率:≥22%;0℃时的横向冲击值:≥150J/cm2;晶粒度:≥9.0级,抗挤毁性能≥标准指标的30%;按照NACE Standard TM 0177标准A方法,采用光滑拉伸试样法试验恒定应力为440MPa,经过H2S饱和的A溶液连续720小时浸泡,试样保持完好,未出现破坏性裂纹。
本发明针对背景技术中存在的问题,通过“独特的化学成分设计、以高炉铁水+10%优质废钢为原料以及独特生产工艺”,实现了生产成本低、残余应力低、夹杂含量少、尺寸精度高和强韧性能匹配好的经济型含稀土80ksi钢级抗硫化氢腐蚀兼抗挤毁石油套管制备
附图说明
下面结合附图说明对本发明作进一步说明。
图1为试样经720小时硫化氢应力腐蚀后的宏观照片。
具体实施方式
下面结合实施例1~实施例3对本发明专利作进一步详细说明,实施例1~实施例3在原料配比、生产工艺、水淬调质处理工艺和产品规格等工艺指标均完全相同,所不同的只是其管坯的化学成分。
按重量百分比原料为:高炉铁水占比为90%,优质废钢占比为10%。
生产工艺流程顺序为:铁水预处理→顶底复吹转炉冶炼→LF炉精炼→VD炉真空处理→圆坯连铸→定尺切割→堆垛缓冷→圆坯化学成分及质量检查→管坯加热→菌式穿孔→连续轧管→张力减径→带温矫直→冷床冷却→定尺锯切→钢管几何尺寸及表面质量检查→调质处理→带温矫直→无损探伤→水压试验→通径检测→螺纹加工。
具体生产工艺流程如下所述:
首先将90吨的高炉铁水用“金属镁粉”作脱硫脱氧预处理,使铁水中的S 元素的含量降低到(重量百分比)0.010%以下;
然后将所述的90吨预处理铁水兑入100吨级的顶底复吹转炉之内,加入10 吨的优质废钢,采用恒压变枪位、单渣工艺进行冶炼,终渣碱度控制3.0左右;利用吹炼前期炉温低、渣中FeO较高的有利时机去除P元素,提高脱P效率;采用硅锰、锰铁和铬铁合金进行脱氧合金化,终脱氧采用铝锰铁合金;出钢过程使用挡渣球挡渣,并且加入200公斤的白灰块。
将冶炼好的钢水装入钢水包送入LF炉工位进行精炼,精炼全过程按要求正常吹氩气,采用从低级数到高级数逐渐提高升温速度的方式加热升温。根据转炉钢水成分及温度变化进行造渣脱硫、成分及温度调整操作,LF炉精炼结束之后喂入定长硅钙丝,喂丝之后进行10~15分钟吹氩气。
将精炼好的钢水送入VD炉工位进行真空处理,抽真空后采用压入法加入稀土铁合金(稀土元素的重量百分比为10%),真空度≤0.10kPa,深真空时间≥ 15分钟。
将经过VD炉真空处理之后的钢水静置5分钟,将钢水大包吊上钢包回转台进行5机5流的圆坯连铸,连铸时采用低拉速的恒速控制、电磁搅拌和全程保护浇注工艺;钢水过热度控制在23℃~25℃之间;铸坯出二次冷却区域之后进行矫直,用火焰将管坯进行定尺切割后堆垛缓冷,管坯的规格为
表2管坯的化学成分检测结果(重量百分比%)
所述稀土铁合金为:稀土元素的重量百分比为10%,其化学成分及其含量合格。
硫印:均不超过1.0级,低倍检验合格。
表3环形加热炉各段温度控制(℃)
预热一段 | 预热二段 | 加热一段 | 加热二段 | 均热一段 | 均热二段 |
1060~1100 | 1160~1220 | 1200~1250 | 1230~1300 | 1250~1300 | 1260~1290 |
将加热好的规格为的管坯进行热定心,热定心之后的管坯送入菌式穿孔机进行菌式穿孔,通过运输辊道将穿孔之后的毛管送入轧管机组进行连续轧制,将连轧之后的荒管送入24机架张力减径机组进行张力减径,最终制成规格为的无缝钢管,每批进行一次热取样,检查几何尺寸及内外表面质量。
几何尺寸及表面质量检查均合格的钢管再进行热处理:具体工艺参数控制见表4。
表4无缝钢管的水淬调质工艺参数控制
注:淬火之后的水温控制在23℃~25℃之间。
钢管出回火炉之后进行带温矫直,矫直温度控制在520℃~530℃之间。对矫直之后的钢管逐支进行无损探伤检测、水压试验和通径检测,合格者在两端进行螺纹加工。
经过上述的工艺生产及检验过程,合格者即成为本发明所述的“一种经济型含稀土80ksi钢级抗H2S腐蚀兼抗挤毁石油套管”的成品,用其制取试样进行力学性能检验。
表5无缝钢管的力学性能检测结果
R<sub>t0.5</sub>(MPa) | R<sub>m</sub>(MPa) | R<sub>t0.5</sub>/R<sub>m</sub> | A(%) | a<sub>KV</sub>(J/cm<sup>2</sup>) | 压溃值(MPa) | 残余应力 | |
实施例1 | 592 | 681 | 0.87 | 27 | 186 | 57.8 | 29MPa |
实施例2 | 604 | 695 | 0.87 | 26 | 173 | 59.7 | 30MPa |
实施例3 | 621 | 715 | 0.87 | 25 | 162 | 62.3 | 32MPa |
注:冲击试样均为横向、试验温度为0℃。
表6无缝钢管的金相性能检测结果(级)
表7无缝钢管的电解夹杂检验结果(ppm)
总夹杂 | FeO | SiO<sub>2</sub> | CaO | MgO | TiO<sub>2</sub> | Al<sub>2</sub>O<sub>3</sub> | MnO | |
实施例1 | 19.95 | 0.43 | 0.43 | 0.51 | 2.57 | 0.08 | 14.36 | 0.09 |
实施例2 | 20.17 | 0.46 | 0.51 | 0.52 | 2.46 | 0.09 | 14.57 | 0.07 |
实施例3 | 20.58 | 0.51 | 0.52 | 0.46 | 2.63 | 0.09 | 14.72 | 0.07 |
表8硫化氢应力腐蚀性能检验结果
以上所述的实施例仅是对本发明的优选方式进行描述,并非对本发明的范围进行限定,在不脱离本发明设计精神的前提下,本领域普通技术人员对本发明的技术方案做出的各种变形和改进,均应落入本发明权利要求书确定的保护范围内。
Claims (2)
1.一种经济型含稀土80ksi钢级抗硫化氢腐蚀兼抗挤毁石油套管,其特征在于,其包括如下质量百分比的化学成分:C 0.25%~0.30%;Si 0.20%~0.30%;Mn 0.50%~0.60%;P≤0.010%;S≤0.005%;Cr 0.60%~0.70%;Mo 0.10%~0.20%;Al 0.010%~0.030%;稀土元素RE 0.0005%~0.0020%;余量为Fe元素及其不可避免的杂质;
其制备方法包括:
S1、将高炉铁水进行预处理,使得铁水中的S元素的质量百分比含量降低到0.010%以下;
S2、将预处理之后的铁水兑入顶底复吹转炉,加入质量百分比为10%的优质废钢,采用单渣工艺冶炼,控制终渣碱度≤3.0,出钢过程加入CrMo合金进行合金化,终脱氧采用有铝脱氧,出钢过程必须挡渣;
S3、转炉冶炼完成的钢水在LF炉进行精练,精炼全过程按要求正常吹氩气,采用从低级数到高级数逐渐提高升温速度的方式加热提温到1565℃±10℃;根据转炉钢水成分进行造渣脱硫、合金元素化学成分调整,精炼结束之后喂入200米硅钙线,喂线后进行10~15分钟吹氩气;
S4、将钢水送入VD炉进行真空处理,真空度≤0.10kPa,深真空时间≥15分钟,抽真空后采用压入法加入稀土铁合金;
S5、将经过VD炉真空处理之后的钢水静置5分钟,之后送入钢包回转台进行圆坯连铸,采用低拉速、结晶器电磁搅拌和全程保护浇注工艺,控制钢水过热度ΔT≤30℃,火焰切割后堆垛缓冷;
S6、圆管坯运送到环形加热炉进行加热,加热炉各段温度的控制范围如下:
预热一段1060-1100℃;预热二段1160-1220℃;加热一段1200-1250℃;加热二段1230-1300℃;均热一段1250-1300℃;均热二段1260-1290℃;
S7、将加热好的管坯进行热定心,然后进行菌式穿孔、MPM轧管机组进行连续轧制成荒管,经过张力减径、冷床冷却和定尺锯切成轧管;
S8、轧管进行水淬调质热处理,具体工艺为:890℃±10℃保温30min~50min、钢管出炉进行水淬,660℃±20℃保温60min~80min回火后空冷;回火之后执行带温矫直,钢管矫直时的温度≥500℃,然后对钢管逐支进行无损探伤、水压试验和通径检测,合格者在两端进行螺纹加工;
晶粒度≥9.0级 。
2.根据权利要求1所述的经济型含稀土80ksi钢级抗硫化氢腐蚀兼抗挤毁石油套管,其特征在于,稀土元素的重量百分比为10%。
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