1SelectionofMaterialsforHighReliabilitySubseaApplications&HighPower

Dr.SergioL.dosSantoseLucatoSeniorScientist Materials&Structures

2Increasing Demands on MaterialsIncreasing Demands on MaterialsNewHPsubseasystemsdeployedindeeperwater,requiringmorepowerandoperatingathighertemperaturesIndepthknowledgeofphysicalmaterialbehaviorisneededtopredictEndofLifePerformanceDevelopaproprietarymaterialsdatabaseandselectiontoolstominimizeproductriskanddevelopmentrisk

Developsuperiorproductsinshortertime

3MultiStressUniverseMultiStressUniverse

DetailedknowledgeofuseenvironmentiscriticaltomaterialsselectionMultiple stressorsactingsimultaneouslySynergisticdegradationmechanismsSequentialtestingis notsufficienttodeterminematerialproperties

4Notional ProjectsNotional Projects

ExamplesofenvironmentsonseveraltypicalconnectorapplicationsDrymatelowvoltagesignalconnector Wellcontrolledchemical

environment LowstressonmaterialsoverallWetmatemediumvoltageconnector/penetratorthroughtubinghangerforESPs Chemicalstressdueto

completionfluids Elevatedtemperaturesand

pressure Highelectricalpower

requirements

5Notional ProjectsNotional Projects

Otherchallengingapplicationsclockwisefromtopleft CaissonESPfeedthroughdueto

chemicalenvironment Subseaelectricalsubstationconnector

duetohighvoltage Hotrockdownhole geothermal

penetratorduetothermomechanicalenvironment

Nosinglematerialcansatisfyallenvironments

6Materials Selection & Reliability AssuranceMaterials Selection & Reliability AssuranceEstablishafullysearchableproprietarymaterialsdatabaseandmaterialsselection&reliabilitytoolsDeveloptechnicalstandards&testmethodsformaterialssubjectedtomultiplestressconditionsDeterminecriticallifelimitingdegradationmechanismstoreduceriskinnewproductsIdentifyrobustmaterials forlongtermreliability(>25year)underseveresubseaconditions

7Materials SelectionMaterials Selection

Identifykeyperformancerequirements&propertiesthatgovernperformanceDefinedesignspace(satisfyableoperatingconditionsforbestsuitedmaterials)Rankmaterialsclasses&individualmaterialsbasedonkeyproperties

NeedtobebasedonpredictedEndofLifePerformance

8Understand Environmental EffectsUnderstand Environmental Effects

Use material property data and environment data to screen materials

Use material property data and environment data to generate aging prediction lawsDetermine the degradation mechanisms

based on materialproperty data and post-mortem specimenanalysis

Measure the materials properties as function of the environment (time, temp., pressure)

Study degradation

Generate prediction laws

Collect material data Screen Materials

9As received

Water / 23C / 15 kpsig

EffectsofAgingEffectsofAging

As received

Water / 23C / 15 kpsig

Drop in tensile strength on thermoplastic material

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EffectofCombinedStressEffectofCombinedStress

As received

Air / 150C / 0 kpsig

Water / 23C / 0 kpsig

Water / 23C / 15 kpsig

Water / 150C / 15 kpsig

TG ~ 240C

DMA

Tensile Test

HP/HT Water

Catastrophic failure of thermoplastdue to combined stresses. Same material passes all single stress tests typically required during product qualification testing.

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EffectofCombinedStressEffectofCombinedStress

As received

Water / 120C / 15 kpsig

Water / 150C / 15 kpsig

Water / 23C / 15 kpsig

As receivedTG ~ 145C

1 week at 150C / 20 kpsigTG ~ 130C

CaCl2 / 124C / 1 kpsig

MEG / 124C / 1 kpsig

Water / 150C / 20 kpsig

Chemical environment can cause more severe

degradation when compared to testing in water at otherwise

identical temperature and pressure

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Post-Exposure AnalysisPost-Exposure Analysis

ElectricalPropertiesDCVolumeResistivity(ASTMD257)ACPermittivityandDissipationFactor(ASTMD150):50Hz 2GHzDielectricStrength(ASTMD149):60Hz

PhysicalProperties(25C 300C)SpecificHeat(cp)CoefficientofThermalExpansionWaterAbsorptionPolymerconfigurationchanges(FTIR)GlassTransitionTemperature(Tg)ThermalConductivityDensitySwellingRapidGasDecompression

MechanicalPropertiesYoungsmodulus,TensileStrength,YieldStrengthDynamicshearmodulus(25C 300C)Hardness,Toughness

AllpropertiesaremeasuredinhouseondedicatedequipmentFullcontroloverallprocessparametersandspecimenhistoryReduceturnaroundtimeandminimizerecoveryeffects

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CustomPressureVessel2Largesaltwatervessels Pressureto40kpsi (2750bar) Temperature0Cto250C Saltwatercompatible5Smallvesselsforexposuretootherenvironments Pressureupto5ksi (345bar) Temperatureupto300C ProcessandPumpfluids

CorrosivesystemsHydraulicfluids

RapidgasdecompressionSourgasagingandRGDfacilityin2012

TestEnvironmentsSaltwaterDownhole completionfluidsHydrateformationinhibitors

MaterialGroupsThermoplasticsCeramicsElastomersSiliconesRubbersEpoxies

CurrentStatus>100materialsand>5000specimensNewandestablishedmaterialsfromcommercialvendors

Deep-Sea Environment Simulation Deep-Sea Environment Simulation

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DataRetrievalasEngineeringToolDataRetrievalasEngineeringTool

Engineering tool from design to failure analysis

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MaterialsSelectionandReliabilityMaterialsSelectionandReliability

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Case Study Downhole ESPCase Study Downhole ESP

Keyperformancereqs: Completionfluid 4.6kVU0/200A 80C/15kpsig

HighmechanicalstrengthrequiredatelevatedtemperaturesMaterialthatiscompatiblewithcompletionfluidandanyadditives

4.6 kV Ceramic Penetrator

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DielectricStrengthvs.CompressiveStrengthDielectricStrengthvs.CompressiveStrength

Compressive Strength [MPa]

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PEEK at 80C

Alumina (Thin-film)

BN Al2O3 Si3N4 AlN PEEK

PEEK at 23C

Compressive Strength 22.5 ksi @ 23C

Dielectric Strength 11 MV/m (250 V/mil)

15 ksi @ 80C

Alumina (Bulk)

Best material is Al2O3for high strength at

elevated temperature

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Case Study DistributionCase Study Distribution

Keyperformancereqs Saltwater 36kV/1000A 5C/2kpsig

MaterialwithaveryhighdielectricstrengthandelectricalresistanceisrequiredVerylargecomponent

G2 Distribution Hub

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DielectricStrengthvs.ElectricalResistivityDielectricStrengthvs.ElectricalResistivity

Resistivity 1014 cm

Dielectric Strength 15 MV/m (400 V/mil)

BN Al2O3 Si3N4 AlN PEEK

PEEK at 23C

Electrical Resistivity [ cm]

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Alumina (Bulk)

Best material is PEEK for its high dielectric strength and electrical resistance

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2009 2010

Strategic Reinvestment Project:

Materials Reliability for Deepsea Use

New product development:High Temperature, High PressureCeramic Pin-materials selection-fabrication process recommendations-vendor/ customer interface

History of Successful PartnershipsHistory of Successful Partnerships

2011

New product development:High Temperature, High Pressure Ceramic Wet-mate-materials selection-fabrication process recommendations-numerical analysis

New product development:High Temperature, High Pressure Ceramic Wet-mate

New product development:High Temperature, High Pressure Ceramic Pin

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SummarySummary

TheproprietarymaterialpropertiesdatabasebyTeledyneOil&Gasincorporatesdegradationmechanismidentification foracceleratedagingtestingandanalysis.Theresultingmaterialsselectionandlifepredictiontoolsreducestheproductrisk offuturesubseapowerproductsandsimultaneouslyreducestheirdevelopmenttime andexpense.

Providinguniquebenefittotheendcustomer.