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Emerald Metals LLC

EMERALD METALS LLC Phone: (713) 591-1000 Fax: (281) 895-6618

14340 Torrey Chase Blvd., Suite 370, Houston, TX 77014

REPORT: Investigation of “Small Pipe” with CLAD Alloy 825 Inside

1. Pitting Corrosion Test according to ASTM G48-C a. Attachment 2: Test Report b. Attachment 3: Short report

2. Chemical Composition of the CLAD Alloy 825 inside

a. Attachment 4: Test Report

3. Shear Fracture Test according to ASTM A264 a. Attachment 5: Pictures from test equipment and the test sample b. Attachment 6: Test chart Shear Fracture

4. Side Bend Tests for additional control of bonding

a. Attachment 7: Pictures documenting the bend test specimen Remarks: The comments of the Pitting Corrosion Test according to ASTM G48-C are shown on the short report dated 25.05.2011 (Attachment 3 including Test Reports G48-C with photo doc. of tested specimen as shown in Attachment 2). The result of the CLAD Alloy 825 wet analysis (Attachment 4) shows that for Alloy 825 a chemical composition at a lower limit exists. As well, the Cr – as Mo – content are in the lower tolerance of usually given analysis for Alloy 825. At CPT requirements ≥ 22˚C chromium and molybdenum should be raised above the minimum values of Alloy 825 standard analysis. If tests of intergranular corrosion are required – e.g. ASTM A 262-E – it is reasonable to set the carbon value ≤ 0.025%. Testing of a Shear Test of Clad Plates according to ASMT A 264 is, with customary equipment, not feasible as only a bend specimen can be used with “small pipes”. Special equipment has to be produced to execute such a shear test. Attachment 5 shows the special equipment and also the specimen machined out of the “Small Pipe” for a shear test executed herewith. The test result as in the chart of Attachment 6 shows extraordinary high shear values. Conclusion: an excellent bonding of CLAD Alloy 825 exists to the substrate, almost comparable to a weldment Additionally to the Shear Test nearly according to ASTM A 264, side bend tests on 3 samples were executed. Two (2) specimens with the Alloy 825 usual radius of 4D and one (1) specimen with the extended radius of 3D. All 3 specimens show no disbonding after the test (no defects). See Attachment 7. Also the side bend test confirms an excellent bonding of CLAD Alloy 825 to the substrate.

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ASTM G 48 C Critical Pitting Temperature Test

REPORT Date: Rec. of spec.: Report No. 31156-01 Order-No.:

TEST Material: CLAD Alloy 825 – Small pipe (ID ~ 78mm) Heat: N.A. Specimen: FE 4211.2.1 (Inner side of pipe in delivery condition) Dimensions (mm)

Test – Parameter Test solution: 6% Ferric-III-Chloride Temperature: 20˚C Start: 12.05.2011 Duration: 24 h End: 13.05.2011 Specimen: Pickling (30 min / 40˚C / 40% HNO3 + 6% HF) + Passivating (10 min / RT / 10% HCI)

L W T Area (cm²) Density (g/cm³) 50.9 26.1 1.6 29.03 8.1

Results

All procedures performed in full accordance with ASTM G48 pract. C Results are only belonging to the investigated specimens. *Calculation of corr. rate as per ASTM G1 for information purposes, not applicable acc to ASTM G48 resp. to ASTM G45 Specimens will be disposed after 6 months from completion of test, unless contrary instructions notified by the client.

Test temperature (˚C) 20 Duration (h) 24

Weight loss (mg) 10 Pitting location N.A.

Pitting Density (N/cm²) N.A. Maximum Pit Depth (mm) N.A. Average Pit Depth (mm) N.A.

Corrosion Rate per Area* (mg/cm²)

N.A.

Corrosion Rate* (mm/year)

N.A.

Visual observation at 20X Pitting at both sides

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REPORT Date: Rec. of spec.: Report No. 31156-02 Order-No.: TEST Material: CLAD Alloy 825 – Small pipe (ID ~ 78mm) Heat: N.A. Specimen: FE 4211.2.1 Dimensions (mm)

Test – Parameter Test solution: 6% Ferric-III-Chloride Temperature: 20˚C - 25ºC Start: 19.05.2011 Duration: 24 h End: 24.05.2011 Specimen: surfaces grinded with Grid 120, after that: same pickling + Passivating as Rep. -01

L W T Area (cm²) Density (g/cm³) 50.8 26.0 1.3 28.41 8.1

Results All procedures performed in full accordance with ASTM G48 pract. C Results are only belonging to the investigated specimens. *Calculation of corr. rate as per ASTM G1 for information purposes, not applicable acc to ASTM G48 resp. to ASTM G45 Specimens will be disposed after 6 months from completion of test, unless contrary instructions notified by the client.

Test temperature (˚C) 20 22.5 25 Duration (h) 24 24 24

Weight loss (mg) 0 0 268 Pitting location N.A. N.A. N.A.

Pitting Density (N/cm²) N.A. N.A. N.A. Maximum Pit Depth (mm) N.A. N.A. N.A. Average Pit Depth (mm) N.A. N.A. N.A.

Corrosion Rate per Area* (mg/cm²)

N.A. N.A. N.A.

Corrosion Rate* (mm/year)

N.A. N.A. N.A.

Visual observation at 20X No pitting

No pitting

Pitting only at bonding site

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Photo 1: Clad 825 Pickling + Passivating, inner side of pipe

Photo 2: Clad 825, Pickling + Passivating, bonding side of pipe

Photo doc. – Report 31156-01.doc. Page 1 of 2

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Photo 3: Clad 825, G 48 C - 20˚C / 24h, inner side of pipe, pitting

Photo 4: Clad 825, G 48 C - 20˚C / 24h, bonding side of pipe, pitting


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Photo 1: Clad 825, Pickling + Passivating, inner side of pipe

Photo 2: Clad 825, Pickling + Passivating, bonding side of pipe


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Photo 3: Clad 825, G 48 C - 25˚C / 24h, inner side of pipe, no pitting

Photo 4: Clad 825, G 48 C - 25˚C / 24h, bonding side of pipe, pitting


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Attachment 3

FE 4211.2 – COMMENT ref. ASTM G48-C – CLAD Alloy 825 “Small Pipe”

Ref.: Investigation of CLAD Alloy 825 applicated inside of “Small Pipe” Corrosion test acc. To ASTM G 48, practice C

1. 1st Preparation of the test specimen.

From a segment of delivered “Small Pipe” one test specimen was machined to separate the CLAD Alloy 825 from the ferritic pipe substrate. The surface of inner side of the pipe was left in the delivery condition. To make sure that the rest of ferritic substrate was removed from the bonding side surface of the test specimen this surface was not only grinded with Grid 80 but also chemically cleaned with HNO3-solution at 60˚C. Dimension of the test specimen for the 1st run: 50.9 x 26.1 x 1.6 mm thick.

2. The start temperature of the 1st test run according to ASTM G 48-C was 20˚C with a test

duration of 24 hours in the test solution 6% Ferric-III-Chloride. Result after the 1st test run: Pitting at both sides of the test specimen at 20˚C so well on the inner side as on the bonding side of the “Small Pipe”. See REPORT no.: 31156-01 with photo doc. ref. the surfaces of specimen FE 4211.2.1 after Pickling and Passivating and after the 1st test run 20˚C / 24 h.

3. 2nd Preparation of the test specimen.

Thinking that the Critical Pitting Temperature of an Alloy 825 cannot be lower than 20˚C we repeated the Pitting Test acc. To ASTM G 48-C with the same specimen but grinded with Grid 120 the rough surfaces of both the inner side and bonding side of the “Small Pipe”. Dimension of the “new” test specimen for the 2nd run: 50.8 x 26.0 x 1.3 mm thick. Also this test specimen was pickled and passivated in the same way as for the 1st run. Start temperature for the 2nd run also was 20˚C with test duration 24h and with further increasing 2.5˚C each test run. Result after the 2nd test run: Pitting only on bonding side at 25˚C – means Critical Pitting Temperature = 25˚C. See REPORT No.: 31156.02 with photo doc. ref. the surfaces of the “new” specimen FE 4211.2.1 after Pickling and Passivating and after the 2nd test run with beginning at 20˚C.

4. Conclusions

The Pitting Corrosion Test according to ASTM G-48, practice C at CLAD Alloy 825 (Specimen No.: FE 4211.2.1 – 2nd run) shows a Critical Pitting Test Temperature of 25˚C. Before using the investigated “Small Pipe” with inner CLAD Alloy 825 in corrosive environments, the inner surface should be cleaned accurately – possibly grinded – and strongly pickled and passivated. Under described circumstances you may accept the use of CLAD Alloy 825 in corrosive media with Chlorides at max. 22˚C.

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Chemical Analysis

C (IR) 0.064 [%] Si (grav) 0.71 [%] Mn (ICP) 0.71 [%] Cr (maßanalytisch) 21.5 [%] Ni (grav) 38.1 [%] Mo (ICP) 2.69 [%] Cu (ICP) 1.36 [%]

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FE 4211.2 – CLAD 825 in “Small Pipe” Attachment 5

1. Shear Test according to ASTM A264

Inspection equipment with specimen

Specimen with separated piece of CLAD 825 (2.45 mm) Specimen after shear test

Details of Shear Results

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2. Shear Fracture Strength Attachment 6

Attachment 6

FE 4211.2 – CLAD 825 in “Small Pipe”

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Attachment 7

FE 4211.2 – CLAD Alloy 825 in “Small Pipe”

3. Side Bend Test

Equipment for bending Tested specimen – 2x 4D / 1 x 3D

Tested specimen without disbanding / no defects Different bending angles of tested specimen

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