[PPT] - Testing in a safe manner Arild Aarrestad, Senior Project manager PowerPoint Presentation

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Feb. 3 - 7, 2014

2014 Gas-Lift Workshop 1

Testing in a safe manner

Arild Aarrestad, Senior Project manager
International Research Institute of Stavanger
Ullrigg Drilling and Well Center

37th Gas-Lift Workshop Houston, Texas, USA February 3 – 7, 2014

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Feb. 3 – 7, 2014

2014 Gas-Lift Workshop 2

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Short presentation of IRIS Energy The dangerous part of testing How can you assure quality before starting a test Summary Development of new barrier system at IRIS

Agenda

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Feb. 3 – 7, 2014

2014 Gas-Lift Workshop 3

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Control of down hole conditions

Ullrigg Drilling and Well Centre

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Feb. 3 – 7, 2014

2014 Gas-Lift Workshop 4

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Ullrigg Drilling and Well Centre has a

vital place in our petroleum research.

Was built in 1984 and is continuously

being modified to support research programs, technology development and testing requirements.

It includes a full-scale offshore type

drilling rig, with access to seven wells.

A vital partner in research projects

both nationally and internationally.

Second to research, Ullrigg is vital in

supporting the industry's need for testing and verification of new technology.

Ullrigg Drilling and Well Centre

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Feb. 3 – 7, 2014

2014 Gas-Lift Workshop 5

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HPHT Test area Ullrigg Workshop

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Feb. 3 – 7, 2014

2014 Gas-Lift Workshop 6

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Testing and QA/QC

How can you assure quality before starting a test ? Quality will always include safety during testing Risk evaluation of all test facilities Updated minimum once each year SJA- Safe Job Analyse Specific for each test that is performed Barrier plan to be established in the SJA If possible, review of the equipment on test prior to test to identify that all parts are within needed capacity

Ullrigg Drilling and Well Centre

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Feb. 3 – 7, 2014

2014 Gas-Lift Workshop 7

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Ullrigg Drilling and Well Centre

Testing and QA/QC

The equipment on test The challenge is that safety margins down hole compared with surface

ften are different

Ensuring your equipment is “fit for purpose” The easiest part of this is the test facility This is built to a certain spec by “on the shelf parts”, minimum to 1,43 x working pressure Controlled and maintained in regular intervals.

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Feb. 3 – 7, 2014

2014 Gas-Lift Workshop 8

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Ullrigg Drilling and Well Centre Test procedure related to ISO 14310

Related to packers and bridge plugs (or other ISO standards)

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Feb. 3 – 7, 2014

2014 Gas-Lift Workshop 9

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Testing, do that pay off ?

YES

Sorts out any possible failures Confirms capacity against customer test programs

r international standards

Cost effective Time reduction in the total project Product with confirmed functionality to the market

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Feb. 3 – 7, 2014

2014 Gas-Lift Workshop 10

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Ullrigg Drilling and Well Centre

THE DANGORUS PART OF TESTING

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2014 Gas-Lift Workshop 11

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During testing, unforeseen situations will occur. Testing is mostly on prototype equipment New technologies Possible first time on test You just need to be prepared for this The barrier system must handle the energy Pressure testing means a lot of stored energy Video coming up 770 bar nitrogen pressure ~150 litre volume (115 m3 of gas) Burst of sealing in end-cap

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Feb. 3 – 7, 2014

2014 Gas-Lift Workshop 12

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Test area Concrete shield Test pipe 20 cm Concrete wall 20 mm steel plate

0,5 m 4,4 m 2,9 m

Pressure relief area

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Feb. 3 – 7, 2014

2014 Gas-Lift Workshop 13

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Atm pressure

Total length plug, 2460 mm, estimated weight 180 kg

70 mm 370 mm

Gas filled volume 11 litre @550 bar Test pipe 7” P110 #29 OD 179 mm ID 156 mm Length 2900 mm Weight 134 kg

Slips/Anchor Seal element

End cap OD 200 mm Length 125 mm Weight 13 kg

Test set-up

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2014 Gas-Lift Workshop 14

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Estimated values: Speed of plug when hitting the wall = 64.8 [m/s] (234km/h). Force against the wall from the object = 5420 [kN]. (552 tonne) Kinetic energy from object at impact = 377 [kJ]. Time 0 Time ~1 ms Travel distance = 70 mm Time ~2 ms Time ~37 ms Time ~68 ms Time ~8 ms

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2014 Gas-Lift Workshop 15

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New IRIS barrier system

Utilize the experience from the several companies with the most

ptimal competence

A specific company within the Norwegian Defence together with NTNU looking into crash box technology TASK Impact-absorbing taking care of 5600 kJ kinetic energy Take care of 3000 kN static load

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Building construction New building needed to withstand the forces induced by a accident during testing, “Design loading” 5600 kJ Early decision Underground testing to be able to build in needed capacities Test-pit main dimension 20 meter long, 2 meter wide and 3 meter deep CRASH-BOX Similar technology to what you find in a modern car, absorbing energy during a crash and then slowing down the retardation We use the same principal

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2014 Gas-Lift Workshop 17

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Absolute pressure [bar] log-scale Pressurized N2-gas volume [liter] log- scale

Chart guide to choose test hall based upon pressurized N2 gas volume

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2014 Gas-Lift Workshop 18

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Test pit separated from the building Test pit weigh close to 400 ton 20 meter long 3 meter deep 2 meter wide

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2014 Gas-Lift Workshop 20

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9. februar 2014

20

Schematic of CrashBox-system. Height 1.63 m, width 1.24 m, depth 1.01 m, weight 3 800 kg Support frame Crash box support Deformation zone Energy absorption (heat) and transfer zone (mass of Steel plates

& Hardox plates)

Hit zone

Energy from projectile: Ek(p) = 5 600 kJ. Impact peak-force: Fi = 25 x 106 N for 2 ms. (equal to 2 500 ton in earth gravity field) Energy absorbed as heat and plastic deformation in steel plates: Eh = 4968 kJ. Ideal temperature increase by 4 K. Residual energy absorbed as deformation

f crash-boxes: Ed = 632 kJ.

Average crush force: Fcrush = 1 732 kN , deformation length = 365 mm (equal to 176.5 ton in earth gravity field)

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Object speed is 193 m/sec

Crash-box simulation

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IRIS CRASH BOX SYSTEM , maximum capacity 5600 kJ

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Wall force with and without crash-box

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Summary HPHT Testing is equivalent to extreme sport, errors could lead to fatal outcome! Many years with extreme testing has provided valuable experience in HSE Please consider the surrounding working environment before testing. A pressure release can result in substantial damage to your health. Do not consider any short cuts !!!!

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Ullrigg Drilling and Well Centre Thank you for your attention Welcome to Ullrigg Drilling and Well Centre

Arild Aarrestad Senior Project Manager International Research Institute of Stavanger AS Arild.Aarrestad@iris.no www.ullrigg.no