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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.