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SelectionofMaterialsfor HighReliabilitySubsea Applications&HighPower

Dr.SergioL.dosSantoseLucato SeniorScientist Materials&Structures

Increasing Demands on Materials


NewHPsubseasystems deployedindeeperwater, requiringmorepowerand operatingathigher temperatures Indepthknowledgeof physicalmaterialbehavior isneededtopredictEndof LifePerformance Developaproprietary materialsdatabaseand selectiontoolstominimize productriskand developmentrisk Developsuperiorproducts inshortertime
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MultiStressUniverse
Detailedknowledgeof useenvironmentis criticaltomaterials selection Multiple stressorsacting simultaneously Synergisticdegradation mechanisms Sequentialtesting is notsufficient todeterminematerial properties

Notional Projects
Examplesofenvironmentson severaltypicalconnector applications Drymatelowvoltagesignal connector
Wellcontrolledchemical environment Lowstressonmaterialsoverall

Wetmatemediumvoltage connector/penetrator throughtubinghangerfor ESPs


Chemicalstressdueto completionfluids Elevatedtemperaturesand pressure Highelectricalpower requirements
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Notional Projects

Otherchallengingapplications clockwisefromtopleft
CaissonESPfeedthroughdueto chemicalenvironment Subseaelectricalsubstationconnector duetohighvoltage Hotrockdownhole geothermal penetratorduetothermomechanical environment

Nosinglematerialcansatisfyall environments
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Materials Selection & Reliability Assurance


Establishafullysearchable proprietarymaterialsdatabase andmaterialsselection& reliabilitytools Developtechnicalstandards& testmethodsformaterials subjectedtomultiplestress conditions Determinecriticallifelimiting degradationmechanismsto reduceriskinnewproducts Identifyrobustmaterials for longtermreliability(>25year) underseveresubseaconditions

Materials Selection
Identifykeyperformance requirements&properties thatgovernperformance Definedesignspace (satisfyableoperating conditionsforbestsuited materials) Rankmaterialsclasses& individualmaterialsbased onkeyproperties Needtobebasedon predictedEndofLife Performance

Understand Environmental Effects


Collect material data Measure the materials properties as function of the environment (time, temp., pressure) Screen Materials Use material property data and environment data to screen materials

Generate prediction laws Study degradation Determine the degradation mechanisms based on material property data and postmortem specimen analysis Use material property data and environment data to generate aging prediction laws

EffectsofAging
As received

Drop in tensile strength on thermoplastic material

Water / 23C / 15 kpsig

As received Water / 23C / 15 kpsig

EffectofCombinedStress
As received Air / 150C / 0 kpsig Water / 23C / 0 kpsig Water / 23C / 15 kpsig Water / 150C / 15 kpsig DMA Tensile Test

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

TG ~ 240C

HP/HT Water
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EffectofCombinedStress
As received TG ~ 145C

Chemical environment can cause more severe As received degradation when compared to Water / 120C / 15 kpsig testing in water at otherwise Water / 150C / 15 kpsig identical temperature and pressure Water / 23C / 15 kpsig
CaCl2 / 124C / 1 kpsig MEG / 124C / 1 kpsig Water / 150C / 20 kpsig 1 week at 150C / 20 kpsig TG ~ 130C

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Post-Exposure Analysis
ElectricalProperties DCVolumeResistivity(ASTMD257) ACPermittivityandDissipationFactor (ASTMD150):50Hz 2GHz DielectricStrength(ASTMD149):60Hz PhysicalProperties(25C 300C) SpecificHeat(cp) CoefficientofThermalExpansion WaterAbsorption Polymerconfigurationchanges(FTIR) GlassTransitionTemperature(Tg) ThermalConductivity Density Swelling RapidGasDecompression MechanicalProperties Youngsmodulus,TensileStrength,Yield Strength Dynamicshearmodulus(25C 300C) Hardness,Toughness
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Allpropertiesaremeasuredin houseondedicatedequipment Fullcontroloverallprocess parametersandspecimenhistory Reduceturnaroundtimeand minimizerecoveryeffects

Deep-Sea Environment Simulation


CustomPressureVessel 2Largesaltwatervessels
Pressureto40kpsi (2750bar) Temperature0Cto250C Saltwatercompatible

TestEnvironments Saltwater Downhole completionfluids Hydrateformationinhibitors MaterialGroups


Thermoplastics Ceramics Elastomers Silicones Rubbers Epoxies

5Smallvesselsforexposure tootherenvironments
Pressureupto5ksi (345bar) Temperatureupto300C ProcessandPumpfluids Corrosivesystems Hydraulicfluids Rapidgasdecompression

CurrentStatus

SourgasagingandRGD facilityin2012

>100materialsand >5000specimens Newandestablishedmaterials fromcommercialvendors

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DataRetrievalasEngineering Tool

Engineering tool from design to failure analysis


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MaterialsSelectionandReliability

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Case Study Downhole ESP


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

Highmechanicalstrength requiredatelevated temperatures Materialthatiscompatible withcompletionfluidandany additives

4.6 kV Ceramic Penetrator

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DielectricStrengthvs. CompressiveStrength
BN Al2O3 Si3N4 AlN PEEK Best material is Al2O3 for high strength at elevated temperature

Dielectric Strength [MV/m]

Alumina (Thin-film) PEEK at 23C

PEEK at 80C Alumina (Bulk) Dielectric Strength 11 MV/m (250 V/mil) 15 ksi @ 80C Compressive Strength 22.5 ksi @ 23C

Compressive Strength [MPa]


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Case Study Distribution


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

Materialwithaveryhigh dielectricstrengthand electricalresistanceisrequired Verylargecomponent

G2 Distribution Hub

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DielectricStrengthvs.Electrical Resistivity
BN Al2O3 Si3N4 AlN PEEK Best material is PEEK for its high dielectric strength and electrical resistance

Dielectric Strength [MV/m]

PEEK at 23C

Dielectric Strength 15 MV/m (400 V/mil) Alumina (Bulk) Resistivity 1014 cm Electrical Resistivity [ cm]

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History of Successful Partnerships


New product development: High Temperature, High Pressure Ceramic Pin -materials selection -fabrication process recommendations -vendor/ customer interface New product development: High Temperature, High Pressure Ceramic Wet-mate -materials selection -fabrication process recommendations -numerical analysis

2009

2010
New product development: High Temperature, High Pressure Ceramic Pin

2011

Strategic Reinvestment Project: Materials Reliability for Deepsea Use


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

Summary
Theproprietarymaterial propertiesdatabasebyTeledyne Oil&Gasincorporates degradationmechanism identification foraccelerated agingtestingandanalysis. Theresultingmaterialsselection andlifepredictiontoolsreduces theproductrisk offuturesubsea powerproducts andsimultaneouslyreduces theirdevelopmenttime and expense. Providinguniquebenefittothe endcustomer.

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