37 th Gas-Lift Workshop Houston, Texas, USA February 3 – 7, 2014 Testing in a safe manner • Arild Aarrestad, Senior Project manager • International Research Institute of Stavanger • Ullrigg Drilling and Well Center 2014 Gas-Lift Workshop 1 Feb. 3 - 7, 2014
Agenda Heading • Point 1 Short presentation of IRIS Energy • Point 2 How can you assure quality before starting a test • Point 3 • Point 3 The dangerous part of testing Development of new barrier system at IRIS Summary 2014 Gas-Lift Workshop 2 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading • Point 1 • Point 2 Control of down hole conditions • Point 3 • Point 3 2014 Gas-Lift Workshop 3 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading • Ullrigg Drilling and Well Centre has a vital place in our petroleum research. • Point 1 • Was built in 1984 and is continuously • Point 2 being modified to support research • Point 3 programs, technology development and testing requirements. • Point 3 • 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. 2014 Gas-Lift Workshop 4 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading Ullrigg • Point 1 • Point 2 Workshop • Point 3 HPHT Test area • Point 3 2014 Gas-Lift Workshop 5 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading Testing and QA/QC • Point 1 How can you assure quality before starting a test ? • Point 2 Quality will always include safety during testing • Point 3 Risk evaluation of all test facilities Updated minimum once each year • Point 3 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 2014 Gas-Lift Workshop 6 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading Testing and QA/QC • Point 1 Ensuring your equipment is “fit for purpose” • Point 2 The easiest part of this is the test facility This is built to a certain spec by “on the shelf parts”, • Point 3 minimum to 1,43 x working pressure • Point 3 Controlled and maintained in regular intervals. The equipment on test The challenge is that safety margins down hole compared with surface often are different 2014 Gas-Lift Workshop 7 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading Test procedure related to ISO 14310 • Point 1 Related to packers and bridge plugs (or other ISO standards) • Point 2 • Point 3 • Point 3 2014 Gas-Lift Workshop 8 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading Testing, do that pay off ? • Point 1 • Point 2 YES • Point 3 Sorts out any possible failures • Point 3 Confirms capacity against customer test programs or international standards Cost effective Time reduction in the total project Product with confirmed functionality to the market 2014 Gas-Lift Workshop 9 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading • Point 1 • Point 2 • Point 3 • Point 3 THE DANGORUS PART OF TESTING 2014 Gas-Lift Workshop 10 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading During testing, unforeseen situations will occur. • Point 1 Testing is mostly on prototype equipment New technologies • Point 2 Possible first time on test • Point 3 You just need to be prepared for this The barrier system must handle the energy • Point 3 Pressure testing means a lot of stored energy Video coming up 770 bar nitrogen pressure ~150 litre volume (115 m 3 of gas) Burst of sealing in end-cap 2014 Gas-Lift Workshop 11 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading 20 mm steel plate • Point 1 • Point 2 20 cm Concrete wall Test pipe • Point 3 Concrete shield 0,5 m 2,9 m 4,4 m • Point 3 Test area Pressure relief area 2014 Gas-Lift Workshop 12 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Test set-up Heading 7” P110 # 29 Test pipe OD 179 mm • Point 1 ID 156 mm Gas filled volume End cap Length 2900 mm 11 litre @550 bar • Point 2 OD 200 mm Weight 134 kg Length 125 mm • Point 3 Weight 13 kg Slips/Anchor Atm pressure • Point 3 70 mm 370 mm Seal element Total length plug, 2460 mm, estimated weight 180 kg 2014 Gas-Lift Workshop 13 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading Time 0 • Point 1 Time ~1 ms • Point 2 Travel distance = 70 mm • Point 3 Time ~2 ms • Point 3 Time ~37 ms Time ~8 ms Time ~68 ms 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]. 2014 Gas-Lift Workshop 14 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading New IRIS barrier system • Point 1 Utilize the experience from the several companies with the most optimal competence • Point 2 A specific company within the Norwegian Defence together with • Point 3 NTNU looking into crash box technology TASK • Point 3 Impact-absorbing taking care of 5600 kJ kinetic energy Take care of 3000 kN static load 2014 Gas-Lift Workshop 15 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading Building construction • Point 1 New building needed to withstand the forces induced by a accident during testing, “Design loading” 5600 k J • Point 2 • Point 3 Early decision Underground testing to be able to build in needed capacities • Point 3 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 2014 Gas-Lift Workshop 16 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading Chart guide to choose test hall based upon pressurized N2 gas volume • Point 1 Absolute pressure [bar] log-scale • Point 2 • Point 3 • Point 3 Pressurized N2-gas volume [liter] log- scale 2014 Gas-Lift Workshop 17 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading • Point 1 Test pit separated from the building • Point 2 Test pit weigh close to 400 ton • Point 3 20 meter long • Point 3 3 meter deep 2 meter wide 2014 Gas-Lift Workshop 18 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading • Point 1 • Point 2 • Point 3 • Point 3 2014 Gas-Lift Workshop 19 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading Schematic of CrashBox-system. Energy from projectile: E k(p) = 5 600 kJ. • Point 1 Impact peak-force: Support frame F i = 25 x 10 6 N for 2 ms. (equal to • Point 2 2 500 ton in earth gravity field) Crash box support • Point 3 Energy absorbed as heat and plastic Deformation zone deformation in steel plates: E h = 4968 kJ. • Point 3 Ideal temperature increase by 4 K. Energy absorption (heat) Residual energy absorbed as deformation and transfer zone of crash-boxes: E d = 632 kJ. ( mass of Steel plates Average crush force: F crush = 1 732 kN , deformation length = 365 mm & Hardox plates) (equal to 176.5 ton in earth gravity field) Hit zone Height 1.63 m, width 1.24 m, depth 1.01 m, weight 3 800 kg 9. februar 2014 20 2014 Gas-Lift Workshop 20 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading • Point 1 Object speed is 193 m/sec • Point 2 • Point 3 • Point 3 Crash-box simulation 2014 Gas-Lift Workshop 21 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading • Point 1 • Point 2 • Point 3 • Point 3 IRIS CRASH BOX SYSTEM , maximum capacity 5600 k J 2014 Gas-Lift Workshop 22 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading Wall force with and without crash-box • Point 1 • Point 2 • Point 3 • Point 3 2014 Gas-Lift Workshop 23 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading Summary • Point 1 • Point 2 HPHT Testing is equivalent to extreme sport, errors could lead to fatal outcome! • Point 3 • Point 3 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 !!!! 2014 Gas-Lift Workshop 24 Feb. 3 – 7, 2014
Ullrigg Drilling and Well Centre Heading Thank you for your attention • Point 1 • Point 2 Welcome to Ullrigg Drilling and Well Centre • Point 3 • Point 3 Arild Aarrestad Senior Project Manager International Research Institute of Stavanger AS Arild.Aarrestad@iris.no www.ullrigg.no 2014 Gas-Lift Workshop 25 Feb. 3 – 7, 2014
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