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Dunlap, Dennis
Feasibility Study of Premium Casing Connection with Titanium Alloy for High-Temperature Geothermal Applications
Tao, Gang (C-FER Technologies 1999 Inc) | Abdulhameed, Diana (C-FER Technologies 1999 Inc) | MacDonald, William (Titanium Metals Corporation) | Dunlap, Dennis (PCC Energy Group) | Elder, Russell (Marubeni-Itochu Tubulars America Inc)
Abstract The harsh environment in high-temperature geothermal wells poses significant challenges to casing integrity. As alternatives to Oil Country Tubular Goods (OCTG) materials, titanium alloys have shown great corrosion resistance in geothermal wells. However, little work has been done to investigate the structural performance and sealability of titanium alloy casing and casing connections. Using advanced Finite Element Analysis (FEA), an engineering study was performed to evaluate the sealability of a premium casing connection with a proprietary titanium alloy material. Coupon tests were conducted to characterize the temperature-dependent mechanical response of the titanium alloy as the key inputs for the study. Thermal cycle loading representative of geothermal well conditions was applied to the FEA model to quantitively evaluate the connection sealability performance. The advantage of the sealability performance of the titanium alloy connection was demonstrated by comparing the model response of the titanium alloy connection to the same connection design with L80 material that was previously qualified for this application by full-scale physical testing. The titanium alloy connection showed a much more stable sealability response when compared to the L80 connection throughout the thermal cycles. This superior performance was primarily attributed to the elastic response of the pipe body, relatively low thermal stress, and minimal plastic deformation within the connection. Preliminary physical make-and-break test results were also shown to demonstrate the galling resistance of several connection types made of the titanium alloy. The engineering study established a strong technical basis for further development of casing and premium casing connections with titanium alloys for challenging high-temperature geothermal well applications. The technical information in this paper provides a reference for high-temperature geothermal and thermal well operators who are considering alternative materials to improve casing integrity.
- Europe (1.00)
- North America > Canada > Alberta (0.47)
- North America > United States > California (0.29)
- Materials > Metals & Mining > Titanium (1.00)
- Energy > Renewable > Geothermal (1.00)
- Energy > Oil & Gas > Upstream (1.00)
Abstract A new titanium alloy, TIMETAL® 475 (Ti-475), which was developed for use in aggressive geothermal fields as a casing material, has been tested for use in typical oil and gas environments. The alloy composition, Ti-0.4Ni-3.75Mo-0.75Zr, provides excellent corrosion resistance in geothermal brines which are low pH and high in chlorides. For oil and gas applications, the additional effects of H2S and CO2 on the alloy must be considered. To this end, the alloy was subjected to the NACE TM-0177 Level VII exposure test. For the geothermal application, the alloy is prepared in the Solution Treated and Aged (STA) condition with a typical titanium bimodal microstructure. For use in oil and gas, the alloy is prepared in the Beta Annealed condition. The beta annealed condition is required for large components such as titanium stress joints where superior fatigue properties are required. This paper reviews the mechanical properties and corrosion evaluation of the Ti-475 alloy in the beta annealed condition as compared to the STA condition. Introduction ASTM Grade 29 titanium alloy (UNS R56404) has been traditionally used for oil and gas stress joints (TSJ) [1]. However, given the general difficulty of processing this type of alloy in the beta quenched condition and more recently the exorbitant increase in alloying costs due to the ruthenium, a new solution is required if titanium is to be considered for future applications. This 475 alloy was developed to meet geothermal requirements to replace Grade 29 seamless casing. The essential material properties of Grade 29 in bulk and welded condition as used for titanium stress joints were reported by Shutz et al. [2]. Effects of galvanic corrosion in the TSJ application were reported by Shutz [3]. More specific requirements for corrosion fatigue and fatigue crack growth rate were presented by Rombado et al. [4,5]. Hence the mechanical and corrosion requirements for TSJ's are well known and can be used to qualify the new alloy.
- Materials > Metals & Mining (1.00)
- Energy > Oil & Gas (1.00)
- Energy > Renewable > Geothermal > Geothermal Resource (0.34)
- Well Completion > Well Integrity > Subsurface corrosion (tubing, casing, completion equipment, conductor) (1.00)
- Reservoir Description and Dynamics > Non-Traditional Resources > Geothermal resources (1.00)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (1.00)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Materials and corrosion (1.00)
Coiled Tubing Pipelines The Technology and Cost Effectiveness Challenge
Kenawy, Farouk A. (Gulf of Suez Petroleum Company ) | Ellaithy, Wael F. (Gulf of Suez Petroleum Company ) | Burseaux, Andre (Stolt Comex Seaway ) | Louvety, Franck (Stolt Comex Seaway ) | Dunlap, Dennis (Precision Tube Technology )
Abstract Coiled tubing pipeline is a rapidly growing technology. Gulf of Suez Petroleum Company (Gupco) as a joint venture between Egyptian General Petroleum Corporation and Amoco is a role model of the implementation of coiled tubing pipeline technology. Gupco is utilizing coiled tubing pipeline technology both for the development of economically marginal projects or for the development of financially more robust prospects. This paper presents Gupco case history for the installation of 1. 75", 3.5" & 4.5" of coiled tubing pipelines in the Gulf of Suez both from technical and economical standpoints, over the last 4 years. Technological and economical limitations of different approaches regarding the coiled tubing pipeline installation as witnessed and foreseen by GUPCO and STOLT COMEX SEAWAY are assessed. A parametric/historical approach of costs involved with the full installation and procurement of such lines will be reviewed. Future developments and challenges of the product and related installation technology and means are also reviewed in light of expected customer requirements and new applications. Finally, a prospective approach of future applications (including in deepwater) will be presented. Introduction The Gulf of Suez Petroleum Company has been using coiled pipe technology since 1994. Since that time the technology has grown with larger diameters and improved material grades being offered. These larger pipes and high strength material have enabled the company to examine additional opportunities in the Gulf of Suez. To date the company has installed a total of ¼ million Feet of coiled tubing pipeline. [n 1994 GUPCO embarked on its first two coiled pipeline projects using the 3.5 inch material. By 1995 a new larger diameter coiled pipe was being offered. The 4.5 inch material offered additional application in the Gulfand GUPCO pursued three additional projects. In January of 1996 the company installed the world's first and longest 4.5 inch coiled pipeline. In 1997 Gupco utilized the coiled tubing pipeline to develop a subsea completion (ESMA-2) in the Gulf of Suez. Utilization of the coiled tubing pipeline technology made ESMA-2 development economically viable. Gupco anticipates to lay as high as 100,000 IT of coiled tubing pipelines in 1998. A total of three projects were completed in 1996, two in 1997, and anticipated five in 1998. Projects have been completed successfully and the future application appears promising. Low overall cost and rapid installation continue to be the main attraction of the coiled pipe. As the coiled tubing pipeline diameter gets bigger, the application of the coiled tubing covers wider range of service. Following table shows the various applications of the coiled tubing pipelines utilized in Gupco. Figure 1.0 Summary of coiled pipe projects completed in the Gulf of Suez. (available in full paper) History of coiled pipe in the Gulf of Suez. In the 1990's, the company was faced with maturing fields and limited growth potential. One area of potential growth was in marginal field development. These marginal opportunities had been identified in the past but were passed over for more lucrative field developments. As a result of their smaller size, these marginal fields do not usually require large service pipelines (i.e., the smaller coiled tubing pipe are often adequate for the design rates).
- Asia > Middle East > Saudi Arabia (1.00)
- Africa > Middle East > Egypt (1.00)