1. 1 Fatigue Performance of High Strength Riser Materials RPSEA Project No. DW 1403 TAC Quarterly Meeting September 8, 2009 Houston, Texas Presented by Stephen J. Hudak, Jr. Materials Engineering Department Southwest Research Institute Research Partnership to Secure Energy for America

2. 2 Project Objective Assess the fatigue resistance of new high strength HPHT riser materials in representative environments Assess the fatigue resistance of new high strength HPHT riser materials in representative environments Fatigue Crack Growth Rates (FCGR) Classical S-N fatigue life Environments Air (baseline) Sour brine Seawater

3. 3 Materials Material YS Sour Status 1 114 ksi yes Specimens machined; frequency-scan tests complete; 1 114 ksi yes Specimens machined; frequency-scan tests complete; Fatigue testing underway 2 131 ksi yes Specimens machined; frequency-scan tests complete 2 131 ksi yes Specimens machined; frequency-scan tests complete Fatigue testing underway 3 ~125 ksi yes Received material this quarter; 3 ~125 ksi yes Received material this quarter; Specimen machining complete 4 132 ksi no Specimens machined; frequency-scan tests complete; 4 132 ksi no Specimens machined; frequency-scan tests complete; Fatigue testing underway. 5 156 ksi no Specimens machined; 5 156 ksi no Specimens machined; Frequency-scan tests complete; Fatigue testing underway 6 ~120 ksi yes Received material this quarter: 6 ~120 ksi yes Received material this quarter: S-N specs. machined

4. FCGR in Lab Air FCGR testing in air complete for four steels initially acquired FCGR increases slightly with increase material YS FCGRs may also be influenced by material microstructure Air data provide baseline for comparison with FCGRs in seawater and sour brine

5. Frequency Response vs. YS 5 Sour Brine Air Baseline Seawater Air Baseline

6. FCGRs in SW+CP vs. Lab Air

8. 8 Background: Freq. Dependence Complex at Low  K Region II Classical Freq. Effect Region I Inverse Freq Effect Mod 4130 Steel: YS=98ksi Sour Environment

9. 9 Inverse Freq. Effect at Low  K Due to Corrosion-Product Wedging =1/ (K max /E  ys ) 2

10. FCGR Testing Summary 10

11. S-N Testing Summary 11 Material # YS Air TestsSeawater + CP TestsSour Tests 1114 ksi 2131 ksi 3~125 ksi Not required 4132 ksi Not required 5156 ksi Not required 6~120 ksi Not required Percent running and complete of each task 13%8%17% Complete Total Tests104 In progress Comp + Prog12 Untested % complete11 Not required

12. Initial S-N Results: 114 ksi YS Material in Sour Brine 12 X65 Weldment in sour brine trend line

13. 13 Last-Quarter Progress Procured remaining two test materials Procured remaining two test materials Completed all S-N specimen machining Completed all S-N specimen machining Completed frequency-scan tests on four steels initially acquired Completed frequency-scan tests on four steels initially acquired Met with PWC to select optimum test frequencies Met with PWC to select optimum test frequencies Completed air S-N testing at SwRI to assess inter- laboratory reproducibility with NETL Completed air S-N testing at SwRI to assess inter- laboratory reproducibility with NETL Initiated air S-N testing at NETL Initiated air S-N testing at NETL Initiated seawater S-N testing Initiated seawater S-N testing Initiated sour brine S-N testing Initiated sour brine S-N testing Initiated seawater FCGR testing Initiated seawater FCGR testing Initiated sour brine FCGR testing Initiated sour brine FCGR testing

14. Machine several Ti-alloy FCGR specimens (CT geometry) and assess their viability in view of propensity for out-of-plane cracking in Ti alloys. Machine several Ti-alloy FCGR specimens (CT geometry) and assess their viability in view of propensity for out-of-plane cracking in Ti alloys. Perform frequency-scan tests on Ti-alloy in sour brine environment. Perform frequency-scan tests on Ti-alloy in sour brine environment. Assess effectiveness of variable-frequency S-N and FCGR testing strategy in terms of technical objectives and project schedule. Assess effectiveness of variable-frequency S-N and FCGR testing strategy in terms of technical objectives and project schedule. Assess inter-laboratory reproducibility of S-N air data generated at SwRI vs. NETL-Albany, Oregon. Assess inter-laboratory reproducibility of S-N air data generated at SwRI vs. NETL-Albany, Oregon. 14 Next-Quarter Plans

15. 15 Schedule

16. 16 Costs RPSEA Contract Amt$800K BP Cost Share$200K Total Contracted Amt $1,000K Costs to Date$430K Balance$570K

17. Question & Comments Are Always Welcome SwRI’s RPSEA DW 1403 Project Manager SwRI’s RPSEA DW 1403 Project Manager Steve Hudak (210) 522-2330 shudak@swri.org RPSEA’s DW 1403 Project Manager RPSEA’s DW 1403 Project Manager Jim Chitwood (713) 754-4513 JimChitwood@chevron.com PWC Co-Chairmen PWC Co-Chairmen Himanshu GuptaSteven Shademan (281) 366-3235(281) 366-6171 Himanshu.gupta@bp.comSteven.Shademan@bp.com Himanshu.gupta@bp.comSteven.Shademan@bp.com 17

18. Backup Slides 18

19. 19 Environments Lab air (baseline): 70-75°F, 40-60% RH Lab air (baseline): 70-75°F, 40-60% RH Seawater: ASTM D1141 substitute ocean water open to the air with cathodic protection: - 1050mv vs. Saturated Calomel Electrode Seawater: ASTM D1141 substitute ocean water open to the air with cathodic protection: - 1050mv vs. Saturated Calomel Electrode Sour Brine: Production brine with oxygen below 10 ppb and 35% H 2 S + 65% CO 2 Sour Brine: Production brine with oxygen below 10 ppb and 35% H 2 S + 65% CO 2

20. 20 FCGR Specimen

21. 21 Frequency Scan Testing Corrosion fatigue performance sensitive to loading frequency Corrosion fatigue performance sensitive to loading frequency Fatigue crack growth rates at constant-K used to characterize frequency effect in frequency scan (FS) tests Fatigue crack growth rates at constant-K used to characterize frequency effect in frequency scan (FS) tests 13x Seawater

22. Seawater vs. Sour Brine 22 6X Seawater 24X Sour Brine YS = 114 ksi

23. Seawater vs. Sour Brine 23 YS = 131 ksi Seawater 15X 250X Sour Brine

24. Yield Strength, ksi 114 131 132 Material-Environment Interactions 24 Environment: Sour Brine Seawater 24X 250X --- 6X 15X 15X Corrosion-Fatigue Acceleration* vs. Air Baseline * At K= 20 ksi√in. R=0.5 and Frequency = 0.01 Hz