Transcript No Slide Title

BENEFITS from NEW and ADVANCED COILED
TUBING MANUFACTURING TECHNOLOGIES
Dr. H.B. “Bernie” Luft PhD, P.Eng.
Vice President – Technology
Global Tubing LLC
INTRODUCTION & AGENDA
IMPROVED COILED TUBING FATIGUE PERFORMANCE AND RELIABILITY
CAN BE ACHIEVED WITH THE USE OF INNOVATIVE AND ADVANCED COILED
TUBING MANUFACTURING TECHNOLOGIES - FATIGUE TEST RESULTS
CAN IMPROVED FATIGUE PERFORMANCE BENEFITS EXTEND TO COILED
TUBING WITH MECHANICAL DAMAGE?
WHY THE INCREASE IN COILED TUBING FATIGUE PERFORMANCE?
DIFFERENTIATING FEATURES OF NEW COILED TUBING MILLING TECHNOLOGY
ADVANCED MILLING SYSTEMS WITH DIGITAL MILL CONTROLS
Mill operations permissives
Fault and alarm enunciators
Advanced variable frequency ERW system
Strategic control of ERW welding heat input and temperature monitoring
Automatic real-time control of ERW welding power and electrical characteristics
Digital IR capture of each ERW seam weld
Digital archive of coiled tubing milling parameters for all strings produced
Superior data traceability and accessibility
tube manufacturing repeatability
Dedicated electric power supply
ADVANCED HEAT TREATING TECHNOLOGY
Enhanced full body stress relief induction heating and temperature control
Improved control of ERW seam annealing post weld heat treatment (PWHT)
NEW AND HIGH TECHNOLOGY CT STRIP BIAS JOINT WELDING
Friction stir welding (FSW) of bias weld joints – elimination of filler metal
STEEL SUPPLY
Proprietary micro-alloys
Advance and proprietary steel production practices
FRICTION STIR WELDING (FSW) TECHNOLOGY
USED IN ADVANCED TECHNOLOGY STRIP/SKELP “BIAS WELD” CONNECTIONS
(patent pending)
Figures courtesy of Smith International, Inc.
•
•
Solid-state joining process – Parent metals are “stirred” together with a rotating tool
Base metals are softened by frictional and deformation heat, stirred & metallurgically bonded together
Key Advantages
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Autogenous weld - no filler metal
Low heat input, base metal not molten, smaller Heat Affected Zone (HAZ)
Reduces problems due to “hot spot” fatigue crack initiation
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(e.g. out of 30 tests to date, not one case fatigue initiated at bias/ERW intersection)
Better joint reliability, quality and hardness control
Expect reduced susceptibility to preferential corrosion (e.g. sulphide stress cracking, galvanic corrosion, etc.)
Reduced environmental impact
Safer to manufacture
TYPICAL MICROSTRUCTURES of FRICTION STIR BIAS WELDS
HARDNESS SURVEY (HRB) : BM = 88.9 TMAZ/HAZ = 85.3
FSZ = 92.1 TMAZ/HAZ = 86.5 BM = 88.4
BM = Base Metal
HAZ = Heat Affected Zone
FSZ = Friction Stir Zone
TMAZ = Thermo-Mechanical
Affected Zone
0.125” (3.2 mm)
Steel Strip
Consistently Fine-Grained Microstructure
(Polygonal Ferrite Microstructures : 3% Nital Etch @ 1000X)
TYPICAL IMPROVEMENTS IN LOW CYCLE FATIGUE (NB) OF ADVANCED TECHNOLOGY
COILED TUBING PRODUCTS (1-1/2 X 0.134 on 48” radius bend form)
1000
900
60%
885
859
52%
812
814
GT-80 TU Flexor
CYCLES TO FRACTURE
800
50%
CT-80 TU Flexor
45%
42%
700
600
685
GT-80X Test
40%
600
571
% Greater Life GT-80X
533
500
30%
413
25%
400
300
19%
255
182
200
20%
204
10%
73 87
100
29
0
0%
500
1500
3000
5000
7500
PRESSURE (psi)
INCREASED COILED TUBING FATIGUE PERFORMANCE AND RELIABILITY
ACHIEVED WITH INNOVATIVE AND ADVANCED COILED TUBING
MANUFACTURING TECHNOLOGIES – TYPICAL RESULTS
DOES FATIGUE PERFORMANCE BENEFITS EXTEND TO COILED TUBING WITH MECHANICAL DAMAGE?
WHY THE INCREASE IN COILED TUBING FATIGUE PERFORMANCE?
IF COILED TUBING FAILS PREMATURELY, WHAT ARE THE MAJOR CAUSES?
(Recently published COILED TUBING FAILURE STATISTICS, 2004-2007, SPE 113149-PP, T. Padron, BJ Services)
Operator Error, 10%
Manufacturing defect, 9%
(ERW Lack of fusion “cold weld”)
Other Causes
Plow marks
(Erosion, Wear , etc)
Corrosion-Fatigue
13%
Corrosion
20%
Mechanical Damage
35%
Dents
Scrapes
Pitting
FATIGUE DE-RATING FACTOR FOR COILED TUBING WITH MECHANICAL DAMAGE
1.4
The University of Tulsa Consortium Data
a
1.2
dd-TU
dd-BA
mc-ball-TU-48
mc-cyl-TU-48
mc-co-TU-48
wx-TU
stat-BA
wx-BA
imp-TU
LM
mc-ball-TU-72
mc-cyl-TU-72
mc-co-TU-72
edm-ball-TU-72
edm-cyl-TU-72
edm-co-TU-72
sdjip-fit
Different damage details
1
N/NB
0.8
0.6
0.4
0.2
0
0
0.1
0.2
0.226
0.3
0.335
0.350
0.4
0.469
0.5
0.474 0.493
N = CT fatigue cycles with surface damage
Q = Damage parameter
0.6
0.7
0.750
0.8
0.9
1
1.5
Q
NB = Baseline CT fatigue cycles without damage
N/NB = Fatigue de-rating factor
2
INCREASED CT STRING LIFE of ADVANCED COILED TUBING with MECHANICAL DAMAGE
(1-1/2 X 0.134 ( 38.1 X 3.4 mm) LOW and HIGH PRESSURE)
x
300
261
Milled (cut) defect
%WT = Depth of damage, %wall thickness
W/X = Aspect ratio
x
w
250
TRIPS to Failure
200
CT-80, 15%WT, W/X=4
164
GT-80, 15%WT, W/X=4
150
CT-80, 22%WT, W/X=1
111
96
100
96
71
70
60
56
52
50
42
38
13
0
GT-80, 22%WT, W/X=1
21
16 21
1500 (10.35)
Pressure, psi (MPa)
5000 (34.5)
CT-80, 33%WT, W/X=3.8
GT-80, 33%WT, W/X=3.8
CT-80, 46%WT, W/X=1
GT-80, 46%WT, W/X=1
INCREASED COILED TUBING FATIGUE PERFORMANCE AND RELIABILITY
ACHIEVED WITH INNOVATIVE AND ADVANCED COILED TUBING
MANUFACTURING TECHNOLOGIES – TYPICAL RESULTS
FATIGUE PERFORMANCE BENEFITS EXTEND TO COILED TUBING WITH
MECHANICAL DAMAGE?
WHY THE INCREASE IN COILED TUBING FATIGUE PERFORMANCE?
Baseline Failure
Distribution
(BA Machine)
21
Number of
occurrences
(tension side)
Baseline Failure
Distribution
(TU Machine)
62 total on
failures on
tension side
-6.5
Position (in)
ASSESSMENT OF LONGITUDINAL (ERW) SEAM WELD ON FATIGUE CRACK INITIATION
8
10 total on
failures on
tension side
+5.5
16 total on
failures on
compression
side
Position (in)
Number of
Occurrences
(compression side)
17
Number of
occurrences
(tension side)
Number of
Occurrences
(compression side)
96 total on
failures on
compression
side
4
17
3
Frequency Distribution of CT Pin Hole Initiation in Conventional ERW Weld Seams – High & Low Pressure Data Lumped
(Source: University of Tulsa CT Materials Research Consortium, TUCTMRC)
0 Position
40
Number of Samples
50
180 Position
(ERW Seam) (Base Metal)
30
20
10
0
200
500
1500
2500
3000
Pressure (psi)
5000
7500
•Consistent & Uniform ERW Flash Possible with HCT Technology
(favourable flash profile reduces notch acuity - lower stress raiser)
•Reduced susceptibility to lack of ERW fusion – “cold weld” defects
Frequency Distribution of GT Pin Hole Initiation in ERW Weld Seams – High & Low Pressure
(Source: Global Tubing (GT) Fatigue Testing Data Base)
SELECTION OF COILED TUBING STRIP
CT90
Crack
CT80
1 mm
25.0 26.6 26.0 24.4 HRC
38.3 39.7 45.3 39.7 HRC
20 μm
50 μm
20 μm
HIC Cracking in Banded Microstructures (Ref. K.E. Szklarz et al, NACE Paper No. 07102, (2007))
Longitudinal
Transverse
Global Tubing (GT) strip supplied
by Unites States Steel (USS)
• Fine grained, equiaxed pearlite/ferrite
50 μm
20 μm
• Only Slight banding/segregation,
20 μm
islands of pearlite
• Clean micro-structure,
(e.g. negligible inclusions)
•Special micro-alloy designs
Example of GT-80 Microstructures – Minimal Segregation or “Banding” (Mag. 500X)
EVALUATION OF “GT” COILED TUBING GRADES FOR SOUR ENVIRONMENTS
GT BASE METAL TESTING
NACE Standard TM0177-05 Method B
Tests performed by United States Steel (USS)
(Solution A, 0.5 wt% glacial acetic acid in de-ionized water, 24C, 99.5% H2S @44cc/min, pH=2.8 start-3.75 finish)
Strip/Skelp size: 0.109” (2.77 mm) wall thickness
36 samples tested (3 @ 12 specimens)
Hardness range: 79.6 – 86.3 HRB
Applied stress: 80, 90, 100% of yield
(4.8 – 6 X104 psi (33.1 – 41.4 MPa))
Duration of applied stress: 30 days (720 hrs)
Specimens examined at 10X and 50X magnification
RESULTS: All 36 tests PASSED (no cracking)
ONGOING SOUR SERVICE TESTING:
NACE Standard TM0177-05 Method A on FSW Welds
Full body bend fatigue machine (BFM) testing of
pre-immersed fatigue specimens
National Association of Corrosion Engineers
(NACE) Standard Proof Ring Test Cell for SSC
SUMMARY
TEST RESULTS INDICATE THAT NEW AND ADVANCED TECHNOLOGY
CT MANUFACTURING CAN DELIVER BENEFITS FOR CT OPERATIONS
IN THE WESTERN CANADA BASIN:
EXPECT tubing with Improved baseline fatigue life
Improved CT string operational life (damaged strings)
Improved performance in sour conditions
Thank you for your time.
QUESTIONS?
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