Modumetal introduced its zinc-based alloy, NanoGalv, part of its new class of nanolaminated materials with broad application in structural parts, coatings and claddings, thermal barriers, and armor. To create nanolaminated coatings, zinc-based metallic alloys are applied electrochemically, at room temperature, to steel substrates to enhance corrosion resistance and base-material-mechanical properties. By balancing the tradeoffs in conventional material performance, nanolaminated materials have the potential for broad application as surface coatings, claddings, bulk materials, or as near-net-shape parts. The deposition process can be controlled to produce nanoscale layers with unique interfacial properties resulting in enhanced corrosion-resistance, elastic-modulus, strength, hardness, and fracture-toughness combinations uniquely different from conventional material processing.
AbstractDuring subsea mining operations, minerals are extracted from the seabed, typically at about 2000m depth, and pumped with water through a riser pipe to a surface processing vessel. TechnipFMC, through its subsidiary Technip France, is the lead of a consortium comprising COMEX and DCNS which has been awarded a contract by BPIFrance to develop a pilot subsea mining system. The scope includes the development of a flexible riser. This flexible riser comprises an inner wear protection layer to resist the wear from the slurry, covered by a structure to withstand mechanical loads applied to the flexible during its lifetime.In order to select the most appropriate anti-abrasion material, a large scale bench test has been built to reproduce realistic flow in a piping system and compare wear on different materials; rubber, polyethylene and stainless steels. Complete analysis of the wear patterns has been conducted with the expertise of a laboratory. A statistical comparison between materials is presented. The response to wear, depending on material, geometry and position, is better known. One of the materials shows much better wear resistance than the others and is selected for further development.The next step is the development and qualification of the manufacturing process for the wear protection layer. This process has to be as much as possible compatible with current flexible pipe manufacturing plant. Parameters such as thickness, diameter or length of the layer should be adaptable according to needs. The compatibility with the pipe mechanical structure has to be tested as well. To meet these requirements, existing manufacturing processes are limited. At the time of writing this paper, different manufacturing methods to incorporate this wear protection layer within a continuous industrial flexible production are currently under investigation. Several prototypes will be realized for each manufacturing step. Prototyping is under test and will be presented in a forthcoming presentation.
AbstractMaintaining a safe offshore operating environment is becoming increasingly difficult, as producers are pushing their equipment harder to achieve their productivity goals. In this context, maintaining the required safety environment requires a robust lubrication program that can protect equipment from extreme operating conditions and maximize that equipment's availability, thus reducing the need for human-machine interaction (HMI) and enhancing the safety of maintenance personnel.This paper will provide guidance on how operators can maintain a high standard of operational safety in the face of the ever-increasing complexity and challenging conditions of offshore operating environments. The paper will outline how producers can design a robust lubrication approach - incorporating key lubricant technology considerations and expert technical services to help enhance the reliability and availability of their equipment.First, the paper will highlight what producers should look for in lubricant formulation. While synthetic lubricants are well understood to be the best performing lubricants, performance among synthetics can vary depending on formulation. And, while some operators may be hesitant to adopt synthetic lubricants due to traditional preferences or cost considerations, this paper will provide a data- based argument for why synthetic lubricants are a must for any best-in-class safety program.In addition to lubricant technologies, producers must also have the right equipment maintenance processes in place to identify and respond to equipment performance issues before they become a problem. The most important of these services is used oil analysis. This paper will briefly highlight the value of this service and outline specific considerations to help operators optimize their oil analysis programs.Backed by insights and data from laboratory testing and real-world performance, offshore professionals will be provided with the latest information and best practices they need to further optimize their maintenance program as they work to deliver a best-in-class safety environment for their workers.
Neale, Peter (Continental ContiTech Industrial Fluid Solutions) | Nagy, Tibor (ContiTech Rubber Industrial Ltd) | Grepaly, Istvan (ContiTech Rubber Industrial Ltd) | Tóth, Péter (CFD.HU Ltd.) | Kristóf, Gergely (Department of Fluid Mechanics, Faculty of Mechanical Engineering, Budapest University of Technology and Economics) | Csobán, Attila (Department of Machine and Product Design, Faculty of Mechanical Engineering, Budapest University of Technology and Economics)
AbstractThe results of a long term abrasion test on 10" hoses were compared to flow simulation based abrasion calculations. An impact angle dependent small scale abrasion test was carried out on the rubber liner material to establish input data for abrasion simulation. The simulation proved to be very sensitive to the dependence of the impact angle on the abrasion rate, particularly at low impact angles. Three different lining materials were applied in the full scale test: rubber, a proprietary plastic liner and rubber with built in hard steel rings using a purpose built machine. The abrasion rate increased in the following order: armored liner, rubber and plastic, although the plastic had better Schopper abrasion than rubber.
Quite often, the main issues occurred on unmanned platforms are due to erosion on XTree. The frozen well intervention system is a typical remedial job to resolve this kind of problems, generating extremely high costs, between 3,5 MMUSD and 12 MMUSD per intervention. Eni conducts pipe erosion studies using a JIP with the Tulsa University; however, no dedicated analyses were demanded on XTree valves geometries.
An R&D project was created to cover this gap, in order to replace the current corrective maintenance approach with a preventive one. A new erosion Prediction Model for XTree valves, both subsea and surface in brown fields, was developed to increase wells life expectancy and maximize assets integrity. In order to do this jointly with the Politecnico di Milano University, the project was developed in steps:
The prediction model was integrated in a tool that adds erosion alerts to the Eni Wells Integrity Dashboard, and constitutes an upgrade to the internal wells control tool. The delivered software helps to plan equipment maintenance activities, especially in brown fields, intensely reducing remedial jobs performed in emergency conditions.
Moreover, the project achievements can also be extended to additional applications, such as: studies on new non-metallic materials characterization in harsh conditions, usage validation for valves/pipe coatings and supply of additional information to support well completion design. Furthermore, the experimental set-ups are now available for erosion tests as Eni asset.
To safeguard well integrity and avoid production downtime caused by equipment failure, a key aspect for proper management of oil & gas assets is represented by the efficient maintenance of XTrees, mainly to prevent erosion issues. This is particularly true for brown fields, where erosion rates of the relevant components, especially valves, accelerate due to the lower quality of the produced hydrocarbons (i.e., increased amount of basic sediment and water) or to the higher production of sand/fines. In this case, the particles being produced, travelling at high velocity and impinging on the internal walls of XTrees, can erode material thus reducing the service life of critical elements.
Moyno's gear joint used on its new Moyno 2000, 2000 WA, and 2000 WB pumps is designed for decreased wear, reduced friction, and increased loading capabilities. The gear joint is also available as a drop-in replacement for the existing models of the pumps listed above and requires no modification. Advanced material selection and improved manufacturing methods for the gear joint help to reduce wear characteristics and improve performance by increasing the pressure limits for existing pumps and allowing the use of larger element options for drive ends. The pumps fitted with the gear joint improve performance in sludge and mineral slurry transfer and feeding of dewatering equipment.
Precise casing-wear prediction is important for improving well integrity and longevity, while simultaneously making casing designs more cost-effective. Currently, there are no known and commonly accepted guidelines available in the industry. Several studies have been presented in literature over the past couple of decades that proposed various methods for estimating the downhole wear in casings. However, the results of all such efforts have been mixed. Predicted values of casing wear using wear models failed to accurately match the wear logs from the wells when scaled up to the field level. This has led to a perception in the industry that existing casing-wear prediction methods lack the desired accuracy.
Modumetal introduced its zinc-based alloy, NanoGalv, part of its new class of nanolaminated materials with broad application in structural parts, coatings and claddings, thermal barriers, and armor. To create nanolaminated coatings, zinc-based metallic alloys are applied electrochemically, at room temperature, to steel substrates to enhance corrosion resistance and base-material-mechanical properties. By balancing the tradeoffs in conventional material performance, nanolaminated materials have the potential for broad application as surface coatings, claddings, bulk materials, or as near-net-shape parts. The deposition process can be controlled to produce nanoscale layers with unique interfacial properties resulting in enhanced corrosion-resistance, elastic-modulus, strength, hardness, and fracture- toughness combinations uniquely different from conventional material processing.
Cutting & Wear's SupaCutt range of hardfacing rods are used to hardface mills for cutting steel and other materials downhole. They are made up of crushed tungsten carbide in a brazing alloy. When deposited on a mill, the brazing alloy is melted, bonding the tungsten carbide fragments to the tool. However, Cutting & Wear's latest addition to the product line, SupaCutt Xtreme, uses a new fragmentation process that breaks steel-cutting grades of tungsten carbide into uniform fragments; these fragments present an excellent shape for cutting applications downhole.