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BENEFITS from NEW and ADVANCED COILED TUBING MANUFACTURING TECHNOLOGIES Dr. H.B. “Bernie” Luft PhD, P.Eng. Vice President – Technology Global Tubing LLC.

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Presentation on theme: "BENEFITS from NEW and ADVANCED COILED TUBING MANUFACTURING TECHNOLOGIES Dr. H.B. “Bernie” Luft PhD, P.Eng. Vice President – Technology Global Tubing LLC."— Presentation transcript:

1 BENEFITS from NEW and ADVANCED COILED TUBING MANUFACTURING TECHNOLOGIES Dr. H.B. “Bernie” Luft PhD, P.Eng. Vice President – Technology Global Tubing LLC

2 INTRODUCTION & AGENDA IMPROVED COILED TUBING FATIGUE PERFORMANCE AND RELIABILITY CAN BE ACHIEVED WITH THE USE OF INNOVATIVE AND ADVANCED COILED TUBING MANUFACTURING TECHNOLOGIES - FATIGUE TEST RESULTS CAN IMPROVED FATIGUE PERFORMANCE BENEFITS EXTEND TO COILED TUBING WITH MECHANICAL DAMAGE? WHY THE INCREASE IN COILED TUBING FATIGUE PERFORMANCE?

3 DIFFERENTIATING FEATURES OF NEW COILED TUBING MILLING TECHNOLOGY ADVANCED MILLING SYSTEMS WITH DIGITAL MILL CONTROLS Mill operations permissives Fault and alarm enunciators Advanced variable frequency ERW system Strategic control of ERW welding heat input and temperature monitoring Automatic real-time control of ERW welding power and electrical characteristics Digital IR capture of each ERW seam weld Digital archive of coiled tubing milling parameters for all strings produced Superior data traceability and accessibility tube manufacturing repeatability Dedicated electric power supply ADVANCED HEAT TREATING TECHNOLOGY Enhanced full body stress relief induction heating and temperature control Improved control of ERW seam annealing post weld heat treatment (PWHT) NEW AND HIGH TECHNOLOGY CT STRIP BIAS JOINT WELDING Friction stir welding (FSW) of bias weld joints – elimination of filler metal STEEL SUPPLY Proprietary micro-alloys Advance and proprietary steel production practices

4 FRICTION STIR WELDING (FSW) TECHNOLOGY USED IN ADVANCED TECHNOLOGY STRIP/SKELP “BIAS WELD” CONNECTIONS (patent pending) Solid-state joining process – Parent metals are “stirred” together with a rotating tool Base metals are softened by frictional and deformation heat, stirred & metallurgically bonded together Figures courtesy of Smith International, Inc. Key Advantages  Autogenous weld - no filler metal  Low heat input, base metal not molten, smaller Heat Affected Zone (HAZ)  Reduces problems due to “hot spot” fatigue crack initiation  (e.g. out of 30 tests to date, not one case fatigue initiated at bias/ERW intersection)  Better joint reliability, quality and hardness control  Expect reduced susceptibility to preferential corrosion (e.g. sulphide stress cracking, galvanic corrosion, etc.)  Reduced environmental impact  Safer to manufacture

5 Consistently Fine-Grained Microstructure TYPICAL MICROSTRUCTURES of FRICTION STIR BIAS WELDS (Polygonal Ferrite Microstructures : 3% Nital 1000X) HARDNESS SURVEY (HRB) : BM = 88.9 TMAZ/HAZ = 85.3 FSZ = 92.1 TMAZ/HAZ = 86.5 BM = 88.4 BM = Base Metal HAZ = Heat Affected Zone FSZ = Friction Stir Zone TMAZ = Thermo-Mechanical Affected Zone 0.125” (3.2 mm) Steel Strip

6 TYPICAL IMPROVEMENTS IN LOW CYCLE FATIGUE (N B ) OF ADVANCED TECHNOLOGY COILED TUBING PRODUCTS (1-1/2 X on 48” radius bend form)

7 INCREASED COILED TUBING FATIGUE PERFORMANCE AND RELIABILITY ACHIEVED WITH INNOVATIVE AND ADVANCED COILED TUBING MANUFACTURING TECHNOLOGIES – TYPICAL RESULTS DOES FATIGUE PERFORMANCE BENEFITS EXTEND TO COILED TUBING WITH - MECHANICAL DAMAGE? WHY THE INCREASE IN COILED TUBING FATIGUE PERFORMANCE?

8 IF COILED TUBING FAILS PREMATURELY, WHAT ARE THE MAJOR CAUSES? (Recently published COILED TUBING FAILURE STATISTICS, , SPE PP, T. Padron, BJ Services ) Mechanical Damage 35% Corrosion 20% Corrosion-Fatigue 13% Other Causes (Erosion, Wear, etc) Operator Error, 10% Pitting Manufacturing defect, 9% (ERW Lack of fusion “cold weld”) Dents Scrapes Plow marks

9 FATIGUE DE-RATING FACTOR FOR COILED TUBING WITH MECHANICAL DAMAGE N = CT fatigue cycles with surface damageN B = Baseline CT fatigue cycles without damage Q = Damage parameterN/N B = Fatigue de-rating factor The University of Tulsa Consortium Data Different damage details N/N B a

10 INCREASED CT STRING LIFE of ADVANCED COILED TUBING with MECHANICAL DAMAGE ( 1-1/2 X ( 38.1 X 3.4 mm) LOW and HIGH PRESSURE) Milled (cut) defect %WT = Depth of damage, %wall thickness W/X = Aspect ratio w xx Pressure, psi (MPa) ( 34.5 ) TRIPS to Failure

11 INCREASED COILED TUBING FATIGUE PERFORMANCE AND RELIABILITY ACHIEVED WITH INNOVATIVE AND ADVANCED COILED TUBING MANUFACTURING TECHNOLOGIES – TYPICAL RESULTS FATIGUE PERFORMANCE BENEFITS EXTEND TO COILED TUBING WITH MECHANICAL DAMAGE? WHY THE INCREASE IN COILED TUBING FATIGUE PERFORMANCE?

12 ASSESSMENT OF LONGITUDINAL (ERW) SEAM WELD ON FATIGUE CRACK INITIATION Frequency Distribution of CT Pin Hole Initiation in Conventional ERW Weld Seams – High & Low Pressure Data Lumped (Source: University of Tulsa CT Materials Research Consortium, TUCTMRC) Frequency Distribution of GT Pin Hole Initiation in ERW Weld Seams – High & Low Pressure (Source: Global Tubing (GT) Fatigue Testing Data Base) (ERW Seam) Consistent & Uniform ERW Flash Possible with HCT Technology (favourable flash profile reduces notch acuity - lower stress raiser) Reduced susceptibility to lack of ERW fusion – “cold weld” defects

13 SELECTION OF COILED TUBING STRIP HIC Cracking in Banded Microstructures (Ref. K.E. Szklarz et al, NACE Paper No , (2007)) HRC HRC Crack 20 μm 1 mm 50 μm20 μm CT90 CT80 Example of GT-80 Microstructures – Minimal Segregation or “Banding” (Mag. 500X) Global Tubing (GT) strip supplied by Unites States Steel (USS) Fine grained, equiaxed pearlite/ferrite Only Slight banding/segregation, islands of pearlite Clean micro-structure, (e.g. negligible inclusions) Special micro-alloy designs TransverseLongitudinal 20 μm 50 μm20 μm

14 EVALUATION OF “GT” COILED TUBING GRADES FOR SOUR ENVIRONMENTS GT BASE METAL TESTING NACE Standard TM Method B (Solution A, 0.5 wt% glacial acetic acid in de-ionized water, 24C, 99.5% H 2 pH=2.8 start-3.75 finish) Strip/Skelp size: 0.109” (2.77 mm) wall thickness 36 samples tested 12 specimens) Hardness range: 79.6 – 86.3 HRB Applied stress: 80, 90, 100% of yield (4.8 – 6 X10 4 psi (33.1 – 41.4 MPa)) Duration of applied stress: 30 days (720 hrs) Specimens examined at 10X and 50X magnification RESULTS: All 36 tests PASSED (no cracking) ONGOING SOUR SERVICE TESTING: NACE Standard TM Method A on FSW Welds Full body bend fatigue machine (BFM) testing of pre-immersed fatigue specimens Tests performed by United States Steel (USS) National Association of Corrosion Engineers (NACE) Standard Proof Ring Test Cell for SSC

15 SUMMARY TEST RESULTS INDICATE THAT NEW AND ADVANCED TECHNOLOGY CT MANUFACTURING CAN DELIVER BENEFITS FOR CT OPERATIONS IN THE WESTERN CANADA BASIN: EXPECT tubing with - Improved baseline fatigue life Improved CT string operational life (damaged strings) Improved performance in sour conditions

16 Your New Choice for Coiled Tubing Thank you for your time. QUESTIONS?

17 GT FATIGUE TESTING – BEND FATIGUE MACHINE (BFM) “Broken Arrow” (BA) Bend Fatigue Machine originally used by Tulsa University to develop “Cerberus” CT Fatigue Prediction model Same “BA” Bend Fatigue Machine now located at Global Tubing (GT) laboratory to develop GT manufactured coiled tubing fatigue data

18 BENEFITS from NEW and ADVANCED COILED TUBING MANUFACTURING TECHNOLOGIES Friction Stir Welding (FSW) Technology Advanced ERW Control Technology Mill Building Electrical Substation Service Building Hwy 90 Office Building Rail Access Winder Building Advanced ERW Seam Welding Technology Weld Scan Isotherm Technology

19 ADVANCED MANUFACTURING TECHNOLOGY USES FRICTION STIR WELDING (FSW) FOR MANUFACTURING CT BIAS WELDS (patent pending) CT Strip “BIAS WELD” Joint in Flat CT Strip Run-on/off tabs Computer Control, Monitored & Archived Welding Parameters


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