Premium Anti-Rotation Casing Connector with Metal-to-Metal Seal Optimized for High Fatigue Performance to Meet Market Needs by Reducing OPEX and Risk Exposure

2021 ◽  
Author(s):  
Scott Patrick Ellisor ◽  
Andrew John Grohmann ◽  
Justin Lee Rye ◽  
Jim T. Kaculi
Keyword(s):  
Oil And Gas ◽  
Performance Testing ◽  
Oil And Gas Industry ◽  
Fatigue Performance ◽  
Risk Exposure ◽  
Test Results ◽  
Element Analysis ◽  
Metal Seal ◽  
High Fatigue ◽  
Verification Techniques

Abstract The oil and gas industry continues to face the need to reduce risk exposure and OPEX as a means to compensate for market volatility and lower oil prices. Typical casing connector designs and methods of running casing are becoming less viable as the industry struggles to lower installation costs and reduce HSE concerns. This dilemma leads manufactures to provide practical solutions to reduce the risk exposure while driving costs down by reducing installation time and required rig personnel. This paper outlines how this innovative and fully qualified technology lowers overall risk exposure while reducing OPEX during the installation of casing connectors. A new premium threaded connector named BADGeR™ has been designed and fully qualified and its features have been patented. State of the art verification techniques utilizing finite element analysis were used to fully simulate the combined load conditions during the qualification program that mimic field conditions and meet and exceed industry standard requirements. Special consideration was given to connector make-up and metal-to-metal sealing technology, superior fatigue performance, welding, coating, galling, surface finish, and lubrication. After a lengthy iterative design process, the final design was fully qualified following ISO 13679 / API 5C5 with additional fatigue performance testing. Details of the design features, analysis methodology and results, structural and sealability test results, and fatigue test results are presented. Advantages of this casing connector design relative to traditional industry casing connectors are highlighted. BADGeR includes an innovative hands-free anti-rotation mechanism that significantly reduces rig time and HSE risk exposure. The connector has automatic make-up with gas tight metal-to-metal seal performance that is not impacted by increased tension to the string. The fatigue performance of this connector exceeds the current market offerings. This combination of features incorporated into the connector has gained the attention of the industry and the opportunity to use this technology for critical service wells applications.

Finite Element Analysis of Casing Material Behavior in Steam Injection Well Operations

2015 ◽  
Vol 799-800 ◽  
pp. 196-200
Author(s):  
Abhilash M. Bharadwaj ◽  
Sonny Irawan ◽  
Saravanan Karuppanan ◽  
Mohamad Zaki bin Abdullah ◽  
Ismail bin Mohd Saaid
Keyword(s):  
Finite Element ◽  
Oil Recovery ◽  
Thermal Stresses ◽  
Oil And Gas ◽  
Extreme Temperature ◽  
Injection Pressure ◽  
Oil And Gas Industry ◽  
Steam Injection ◽  
Material Behavior ◽  
Element Analysis

Casing design is one of the most important parts of the well planning in the oil and gas industry. Various factors affecting the casing material needs to be considered by the drilling engineers. Wells partaking in thermal oil recovery processes undergo extreme temperature variation and this induces high thermal stresses in the casings. Therefore, forecasting the material behavior and checking for failure mechanisms becomes highly important. This paper uses Finite Element Methods to analyze the behavior two of the frequently used materials for casing - J55 and L80 steels. Modeling the casing and application of boundary conditions are performed through Ansys Workbench. Effect of steam injection pressure and temperature on the materials is presented in this work, indicating the possibilities of failure during heating cycle. The change in diameter of the casing body due to axial restriction is also presented. This paper aims to draw special attention towards the casing design in high temperature conditions of the well.

Study of the effect of test parameters on the assessment of steel resistance to carbon dioxide corrosion

2021 ◽  
Vol 87 (12) ◽  
pp. 36-41
Author(s):  
A. S. Fedorov ◽  
E. L. Alekseeva ◽  
A. A. Alkhimenko ◽  
N. O. Shaposhnikov ◽  
M. A. Kovalev
Keyword(s):  
Carbon Dioxide ◽  
Laboratory Tests ◽  
Oil And Gas ◽  
Oil And Gas Industry ◽  
Sample Surface ◽  
Test Results ◽  
Carbon Dioxide Corrosion ◽  
Gas Industry ◽  
Test Parameters ◽  
Repeatability And Reproducibility

Carbon dioxide (CO2) corrosion is one of the most dangerous types of destruction of metal products in the oil and gas industry. The field steel pipelines and tubing run the highest risk. Laboratory tests are carried out to assess the resistance of steels to carbon dioxide corrosion. However, unified requirements for certain test parameters are currently absent in the regulatory documentation. We present the results of studying the effect of the parameters of laboratory tests on the assessment of the resistance of steels to CO2 corrosion. It is shown that change in the parameters of CO2 concentration, chemical composition of the water/brine system, the buffer properties and pH, the roughness of the sample surface, etc., even in the framework of the same laboratory technique, can lead in different test results. The main contribution to the repeatability and reproducibility of test results is made by the concentration of CO2, pH of the water/brine system, and surface roughness of the samples. The results obtained can be used in developing recommendations for the choice of test parameters to ensure a satisfactory convergence of the results gained in different laboratories, as well as in elaborating of a unified method for assessing the resistance of steels to carbon dioxide corrosion.

Structural Impact in FPSO Life Extension: A Class Perspective

2013 ◽  
Author(s):  
Christiane L. Machado ◽  
Sudheer Chand
Keyword(s):  
Service Life ◽  
Oil And Gas ◽  
Structural Response ◽  
Oil And Gas Industry ◽  
Environmental Data ◽  
Life Extension ◽  
Element Analysis ◽  
Actual Performance ◽  
Remaining Service Life ◽  
The Impact

The Offshore Oil and Gas Industry has converted a large number of units from trading tankers and carriers into Floating Production, Storage and Offloading units (FPSOs). Several of these have been moored offshore Brazil during the last 15 years. Following the discovery of offshore pre-salt fields some years ago, demand for FPSOs has increased, and the forecasts for productive field lives have grown. The result of these developments is the need to extend the service lives of existing FPSOs. The main aim of this study is to investigate FPSO structural response to environmental conditions and functional loads, considering the actual available tools for numerical simulations and Rule requirements, which currently are basic requirements for design review for Classification. The procedure was developed from one selected FPSO converted from a trading Very Large Crude Carrier (VLCC) tanker approximately 15 years ago and includes investigation of the impact on hull behavior comparing the motion analyses of the production unit under environmental data and software capabilities available at the period of conversion and actual performance: variances in the environmental (sea scatter diagrams) datasets; updates to Classification requirements for defining offloading conditions, environmental loads, acceptance criteria and remaining fatigue life (RFL); and incorporating the most recent gauged thickness for primary structure. The selected FPSO was evaluated according to prescriptive Rule requirements and also using finite element analysis, taking into account the previous conditions of Classification approval as well as the actual requirements and available data. Structural analysis included one global model and some local refined models to address strength, buckling and fatigue capacity of the typical portions/connections of the hull. The comparisons performed from the results of these analyses are a crucial step toward understanding the structural capacity of the FPSO at the conversion stage, its performance during the last 15 years, and its remaining service life. Differences were tabulated and evaluated so that a more precise level of uncertainty could be achieved for predicting the estimated remaining service life, and consequently, a new and dedicated approach to investigate the existing FPSO fleet is being generated.

Effects of Thickness and Winding Angle of the Laminate on Internal Pressure Capacity of Thermoplastic Composite Pipes

2020 ◽  
Author(s):  
H. Xia ◽  
C. Shi ◽  
J. Wang ◽  
X. Bao ◽  
H. Li ◽  
...  
Keyword(s):  
Internal Pressure ◽  
Oil And Gas ◽  
Solid Wall ◽  
Three Dimensional ◽  
Oil And Gas Industry ◽  
Thermoplastic Composite ◽  
Critical Parameters ◽  
Element Analysis ◽  
Composite Pipes ◽  
Winding Angle

Abstract Thermoplastic composite pipes (TCPs) are increasingly used to transport hydrocarbons and water in the oil and gas industry due to their superior properties including corrosion resistance, thermal insulation, light weight, etc. The cross-section of TCPs generally consists of three layers: inner liner, composite laminate, and outer jacket. Three layers are bonded together and form a solid-wall construction. Inner liner and outer jacket made of thermoplastic polymer provide protective barriers for the laminate to against the inner fluid and outer environment. The laminate is constructed by an even number of helically wounded continuous fiber reinforced thermoplastic composite tapes. In this study, mechanical behaviors of a TCP under an internal pressure were investigated by using analytical and finite element analysis (FEA) methods. The analytical method which is based on the three-dimensional (3D) anisotropy elastic theory can take account of non-uniformly distributed stress and strain through the thickness of the pipe wall. FEA models were setup by using the software ABAQUS to predict the stress distribution of the pipe. 3D Tsai-Wu failure criterion was used to predict the maximum internal pressure of the pipe. Effects of some critical parameters, such as the winding angle of composite tapes and the number of reinforced plies, on the internal pressure capacity of TCPs were studied. Results obtained from the analytical and FEA methods were fairly agreed with each other, which showed that with the increasing of the number of reinforced plies the internal pressure capacity of a TCP gradually increases and approaches to an extreme value. In addition, the optimal winding angle which results the maximum internal pressure is not a constant value, instead, it varies with the increasing thickness of the laminate layer. This study provides useful tools and guidance for the design and analysis of TCPs, and is currently under validation through experiments.

Root Cause Analysis of 8-Inch FRP Pipeline Failure That Resulted in a Spill and Fire

2016 ◽  
Author(s):  
Frank Gareau ◽  
Alex Tatarov
Keyword(s):  
Oil And Gas ◽  
Oil And Gas Industry ◽  
Failure Rates ◽  
Material Degradation ◽  
Element Analysis ◽  
Dynamic Stresses ◽  
Gas Industry ◽  
Root Cause ◽  
Reinforced Plastic ◽  
Fire Initiation

Fibreglass reinforced plastic pipe (FRP) is the second most common type of pipe in the Canadian oil and gas industry, based on installed length. Industry methods to define risks and prevent failures are difficult because industry is still learning how these types of materials fail. Current industry failure records indicate that the failure rates for some of these materials are higher than steel failure rates. Unique details related to a specific FRP failure will be discussed in this paper. This failure occurred on an 8-inch OD FRP pipeline at the bottom of a riser. The failure resulted in a spill and a fire. The reasons for failure and fire initiation were analysed separately. The failure was a result of a combination of several types of stresses and material degradation. Both static and dynamic stresses contributed to the failure. • Ground settling resulted in high static bending stress of the last section of the pipeline connected to the riser elbow supported by the anchor. • The failure was in the last connection of the pipeline. Static tie-in stresses could have contributed to the failure. • Static stresses were evaluated using Finite Element Analysis (FEA) approach and found to be insufficient for the failure. • Dynamic stresses contributed to the failure. The failure happened soon after a power outage, when numerous wells were restarted, and several fluid surges may have occurred. • Material degradation associated with a specific orientation of glass fibres at the connection pup contributed to the failure. The failure sequence was established and different modes of fire initiation were analysed.

Development of Test Stand for Measuring Aerodynamic, Erosion, and Rotordynamic Performance of a Centrifugal Compressor Under Wet Gas Conditions

2014 ◽  
Author(s):  
Matteo Bertoneri ◽  
Melissa Wilcox ◽  
Lorenzo Toni ◽  
Griffin Beck
Keyword(s):  
Oil And Gas ◽  
Performance Testing ◽  
Oil And Gas Industry ◽  
Test Stand ◽  
Liquid Volume ◽  
Wet Gas ◽  
Liquid Load ◽  
Test Loop ◽  
Gas Environment ◽  
Set Up

As the oil and gas industry addresses technology challenges for accessing gas reserves and enhancing the production of existing installations, wet gas compression becomes an important technology focus. When liquid is introduced into a compressor flow stream, the performance of the compressor is significantly influenced. Therefore, a concentrated effort is required to develop the tools to adequately predict the performance of the compressor when subjected to wet gas conditions. A series of tests were performed on a single stage compressor in a wet gas environment in order to provide empirical data for understanding how to predict wet gas performance. The compressor underwent aerodynamic, erosion, and rotordynamic performance testing. The tests were completed with a mixture of air and water at suction pressures of 10, 15, and 18.5 bar. The compressor was subjected to a multiphase flow with liquid volume fractions ranging from 0 to 3% (corresponding to a mass fraction of 73%) at three Mach numbers. Transient tests with liquid load variation were also done. This paper describes the test stand that was developed and operated for testing of the compressor in a wet gas environment. This includes a review of the overall test set-up, description of key test components and of the instrumentation installed on the compressor and the test loop. An overview of main test results is eventually shown.

scholarly journals Project-Based Learning for the Design of Progressive Dies Supporting Tools

2021 ◽  
Vol 12 (1) ◽  
pp. 117
Author(s):  
Rahman Hakim ◽  
Hanifah Widiastuti ◽  
Ita Wijayanti ◽  
Mufti Fathonah Muvariz ◽  
Andre Kevil Silaban
Keyword(s):  
Oil And Gas ◽  
Oil And Gas Industry ◽  
Project Based Learning ◽  
Standard Size ◽  
Gas Industry ◽  
Alternative Design ◽  
High Fatigue ◽  
Pipe Fittings ◽  
Resistance Rates ◽  
Alternative Designs

<p class="Abstract">In the oil and gas industry, manufacturing processes covered a variety of fields including pipe fittings production. Generally, this process involves a press machine utilized as a shape forming using punch-dies sets as mold profiles. The common problem found with the dies is the dimension of dies is not ergonomics to be handled manually by operators. Additionally, the support of dies tends to experience buckling upon receiving a pressure load of 15 MPa. Hence, alternative and practical designs are required, which have low deflection values and high fatigue resistance rates. Additionally, the designs are expected to be safe and economical. In this study, two alternative designs of punch-dies support are proposed. Subsequently, the FEA simulation was carried out for pipe fittings of 8 inches with ASME B16.9 standard size for WF Beam A36 Steel to compare the two proposed designs. The results show that alternative design 2 has a lower deflection value of 0.181 mm, a higher Factor of Safety of 3.21, and a higher cycle time of 358569 cycles than alternative design 1. Nevertheless, alternative design 2 has a higher production cost of 220 USD compared to alternative design 2. Therefore, this study shows that alternative design 2 has better performance while alternative design 1 is more economical.</p>

ANALYSIS OF A STRAIN GAUGE FOR THE OIL AND GAS INDUSTRY

2020 ◽  
pp. 10-15
Author(s):  
G.A. Ermolaev ◽  
N.V. Gorbunov
Keyword(s):  
Oil And Gas ◽  
New Technologies ◽  
Raw Materials ◽  
Oil And Gas Industry ◽  
Element Analysis ◽  
Gas Industry ◽  
Analysis And Design ◽  
Sensor Model ◽  
Specialized Equipment ◽  
Tension Sensor

Hydrocarbon raw materials are the cornerstone of modern civilization. Evaluating the resources of existing fields is the most important condition for making a decision on the feasibility of production using new technologies. We discuss the results of analysis and design of a rope tension sensor model for delivering specialized equipment to wells to determine the prospects of a well. The calculations were performed using the universal finite element analysis software package ANSYS.

Use of Finite Element Analysis for Stud Pre-Tension Determination of Large Diameter Integral Flanges With Ring Joint Gaskets

2010 ◽  
Author(s):  
Upali Panapitiya ◽  
Haoyu Wang ◽  
Syed Jafri ◽  
Paul Jukes
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Oil And Gas ◽  
Large Diameter ◽  
Three Dimensional ◽  
Oil And Gas Industry ◽  
Element Analysis ◽  
Axial Forces ◽  
Three Dimensional Finite Element

Large diameter integral steel flanges are widely used in many applications in the oil and gas industry. The flanges of nominal pipe sizes, 26-inch and above with ring-joint gaskets as specified in ASME B 16.47 Standard, are used in the offshore applications for the transportation of oil and gas from production facilities. These pipelines require flanged connections at end terminations, mid-line tie-ins and expansion loops. The conventional design of large diameter steel flanges is based on one-dimensional analytical methods similar to the procedure in ASME VIII Boiler and Pressure Vessel Code, Division 1 Appendix 2. The effects of axial forces and bending moments are approximated by calculating an equivalent pressure. This usually results in conservative designs for the large flanges because it estimates the required stud pre-tension based on the assumption that the gasket will be unloaded entirely to a minimum stress, whereas only a small section of the gasket is subjected to low stress. This technical paper presents the quasi-static, nonlinear, and three-dimensional finite element models of large diameter steel flanged joint for the determination of stud pre-tension and change of stud tension under various loading conditions. The finite element analysis results are compared with the results obtained by using the equivalent pressure method and flange “Joint Diagram”.

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