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Low Temperature Effects on Drilling Equipment (Seals, Lubricants, Embrittlement)

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Low Temperature Effects on Drilling Equipment (Seals, Lubricants, Embrittlement) Low Temperature Effects on Drilling Equipment (Seals, Lubricants, Embrittlement) Prepared for: BSEE Doc Ref: WGK-240030-01-K-RP-03 Rev: 0 Date: March 2016 Final Report Low Temperature Effects on Drilling Equipment (Seals, Lubricants, Embrittlement) Final Report Client BSEE Document Title Low Temperature Effects on Drilling Equipment (Seals, Lubricants, Embrittlement) WG Reference Number Client Reference Number (if applicable) WGK-240030-01-K-RP-03 BSEE Contract E14PC00012 Contact Luis F. Garfias, Ph.D. Materials and Testing Consultant +1 (832) 499-1043 (Cell) [email protected] Wood Group Kenny 15115 Park Row, 2nd Floor Houston, TX 77084 http://www.woodgroupkenny.com Revision Date Reason for Issue Prepared Checked Approved VM, TA, TL, A4 17/Feb/2016 Issued for Third Party Reviewer (SHEA) AC, JA LFG TC, CG, BT, Issued with Comments from Third Party VM, TA, TL, AC, JA, RC A5 24/Feb/2016 LFG Reviewer (SHEA) TC, CG, BT (SHEA) VM, TA, TL, AC, JG, JA, BL A6 25/Feb/2016 Issued for Final Review LFG TC, CG, BT RC (SHEA) VM, TA, TL, AC, JG, JA, BL B1 26/Feb/2016 Issued for Client Review LFG TC, CG, BT RC (SHEA) VM, TA, TL, AC, JG, JA, BL 0 8/March/2016 Final Report to Client LFG TC, CG, BT RC (SHEA) INTELLECTUAL PROPERTY RIGHTS NOTICE AND DISCLAIMER Wood Group Kenny, Inc, is the owner or the licensee of all intellectual property rights in this document (unless, and to the extent, we have agreed otherwise in a written contract with our client). The content of the document is protected by confidentiality and copyright laws. All such rights are reserved. You may not modify or copy the document or any part of it unless we (or our client, as the case may be) have given you express written consent to do so. If we have given such consent, our status (and that of any identified contributors) as the author(s) of the material in the document must always be acknowledged. You must not use any part of the content of this document for commercial purposes unless we (or our client, in the event that they own intellectual property rights in this document) have given you express written consent for such purposes. This document has been prepared for our client and not for any other person. Only our client may rely upon the contents of this document and then only for such purposes as are specified in the contract between us, pursuant to which this document was prepared. Save as set out in our written contract with our client, neither we nor our subsidiaries or affiliates provide any warranties, guarantees or representations in respect of this document and all liability is expressly disclaimed to the maximum extent permitted by law. WGK-240030-01-K-RP-03 | Rev 0 | March 2016 Page 2 of 208 Low Temperature Effects on Drilling Equipment (Seals, Lubricants, Embrittlement) Final Report Limitations of the Report The scope of this report is limited to the matters explicitly covered and is prepared for the sole benefit of the Bureau of Safety and Environmental Enforcement (BSEE). In preparing the report, Wood Group Kenny (WGK) relied on information provided by BSEE and third parties. WGK made no independent investigation as to the accuracy or completeness of such information and assumed that such information was accurate and complete. All recommendations, findings, and conclusions stated in this report are based on facts and circumstances as they existed at the time this report was prepared. A change in any fact or circumstance on which this report is based may adversely affect the recommendations, findings, and conclusions expressed in this report. WGK-240030-01-K-RP-03 | Rev 0 | March 2016 Page 3 of 208 Low Temperature Effects on Drilling Equipment (Seals, Lubricants, Embrittlement) Final Report Executive Summary Wood Group Kenny (WGK) is under contract with the Bureau of Safety and Environmental Enforcement (BSEE) to execute a technology and research project to assess Low Temperature Effects on Drilling Equipment and Materials. This study was performed in accordance with Section C (BSEE’s Contract No. E14PC00012). A summary of the main findings follows. The qualification of drilling structures and equipment for Arctic drilling and production of oil and gas involves different steps. The first step requires determining the Lowest Anticipated Service Temperature (LAST) of the materials that will be exposed to the Arctic environment. The second step requires an understanding of the effects of the Arctic environment in the degradation mechanism (or mechanisms) of the materials. In some cases, the qualification can follow existing regulations or international standards. In other cases (particularly at lower LAST), the existing regulation or standard is not applicable to the given environment. Some of the challenges to drilling onshore and offshore wells in Arctic environments include the extremely cold temperature, frozen ground covered with ice, frozen seas during the long winter season, and a short drilling season. A rig that is capable of drilling in Arctic conditions can begin work earlier in the drilling season because the rig can move in when the sea ice starts to recede (thereby reducing total drilling costs). Well design should take into consideration materials selection for casing, cementing, drilling hydraulics, and drilling fluids and should account for potential thermal cycling of the formation. WGK has found that current industry initiatives have focused either on improving the safety and containment during drilling or on the selection of the appropriate vessels and offshore structures. In the case of metallic materials, understanding the brittle fracture and fatigue life acceptance criteria of materials at the LAST in Arctic conditions is crucial. The current materials specifications are not specifically intended for Exploration and Production (E&P) in Arctic environments. The industry has been focusing on the improvement of a wide range of materials properties such as strength, fracture toughness, fatigue performance, weldability, and corrosion resistance. Additionally, the industry is now focusing on the improvement of fabrication, welding techniques, methods for analysis, and experimental measurements of fracture toughness. New guidelines for the selection and qualification of materials for Arctic applications and the standardization of techniques such as probabilistic fracture mechanics and reliability-based design for Arctic offshore applications are still under development. Therefore, additional guidance regarding codes and standards that are specifically targeted to increase safety during E&P in Arctic environments is needed. Many non-metallic materials have been developed, tested and qualified for low temperature applications to their metallic counterparts. The mechanical properties of many non-metallic materials are very similar to their metallic counterparts. Some of them are lighter or ‘immune’ to WGK-240030-01-K-RP-03 | Rev 0 | March 2016 Page 4 of 208 Low Temperature Effects on Drilling Equipment (Seals, Lubricants, Embrittlement) Final Report corrosion, or both. Although some non-metallic materials may undergo other types of aging or degradation, their chemical interactions with the environment appear to be minimal. Data regarding the performance of polymers and composites in Arctic conditions is limited. The industry is focusing on researching and developing new polymeric materials and composites (including fiber-reinforced polymers) as replacements for metallic components used in aggressive environments where the use of metallic components is prohibited. Constant improvement of the properties of polymers and composites and the development of new non- metallic materials to satisfy the need for longer life expectancy in harsh applications is underway; WGK has found that several companies at the forefront of this effort are not willing to share their findings. WGK developed a survey questionnaire and sent it to material producers, equipment manufacturers, operators, testing laboratories, and consultants. The survey focused on the materials used in Arctic conditions and included some of the common practices for transportation, storage, drilling, and production. The survey identified gaps in the industry with respect to the storage, safe handling, and de-rating of the materials when they are used in Arctic environments. Currently, there are no guidelines that prescribe requirements for packing, shipping, safe handling, testing, qualification, and de-rating of materials that are conventionally used in the contiguous U.S. which may be applied to Arctic environments. Materials producers, equipment manufacturers, and operators need this information to de-rate and prescribe proper procedures for handling and deploying materials in Arctic conditions. Recommendations The use of drilling rigs that are capable of drilling in Arctic conditions could open up the drilling season beyond the conventional open water season, but it could increase the risk for failure of some materials due to their exposure to Arctic conditions for longer periods of time. To avoid premature failure of materials used in the manufacturing of such drilling rigs and the equipment used during oil and gas operations, WGK recommends that the industry: 1. Seek a better understanding of the properties of critical materials used in the Arctic. 2. Use high capacity mud cooling systems for Arctic drilling, as they prevent the thawing of permafrost and help to prevent materials failure. 3. During Arctic drilling, use a high viscosity fluid with minimal shear to reduce
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