Casing Connection Selection for Geothermal Applications ... · PDF fileCasing Connection...
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Casing Connection Selection for Geothermal
Applications Using Input From HPHT and
Thermal Wells Testing Protocols
Mustaffa Merliahmad, Tenaris
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Agenda
• Geothermal Operation
• Connection Testing
• Connection Selection
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Agenda
• Geothermal Operation
• Connection Testing
• Connection Selection
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Geothermal Operation
» AXIAL LOAD CYCLING – TENSION COMPRESSION
CYCLES
» Caused by temperatures cycle during injection – shut-in –
production cycles, involving huge temperature span (RT to
more than 200°C – reaching up to 350°C).
» Thermal cycles lead to expansion and contraction of
pipes, imposing compression and tension loads on the
joints.
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Geothermal Operation
1. During initial heating, the material is
compressed elastically until the elastic limit
is reached near 200°C
2. Further heating leads to plastic deformation
from constrained thermal expansion
3. As the temperature is held constant at
275°C, stress relaxation occurs from creep
strain
4. As the confined string cools, the axial load
gradually becomes tensile.
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Agenda
• Geothermal Operation
• Connection Testing
• Connection Selection
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Objective
To perform a minimum design verifications on connections simulating the worst geometries in accordance with the specified range of tolerances.
Connection Qualification & Testing
Types of Qualification Programs
Full Scale Tests : Actual samples manufactured on steel pipes. Advantage: Real data / Disadvantage: Cost and Time
Finite Element Analysis : Numerical simulations. Advantage: Lots of data at low cost / Disadvantage: Some variables cannot be modeled.
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• Full Scale Tests (FST) – Different Types
1) ISO 13679 / API RP 5C5
2) ExxonMobil Connection Evaluation Program
3) TWCCEP (Thermal Wells Casing Connection Evaluation Protocol) / ISO PAS 12835
3) Customer specifications: Fatigue
Extra torque
Connection Qualification & Testing
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ISO 13679:2002 testing protocol
Failure test
pil+T to F
7.5.8
P8
7.3.2
T/C pi w B
7.3.4
FMU (B)
7.2.5
H/L
Bake
MBG (B)
7.2.3
L/H
MU (A)
7.2.2
H/L
T/C pi w B T/C pi w B
7.3.2
T/C pi/po
7.3.3
Specimen 8
L-H
PFBSThread taper
Specimen preparation Specimen 7
L-H
PFBS
Specimen 6
H-L
Failure test
po to F
7.5.7
P7
FMU (B)
7.2.5
H/L
Bake
MBG (B)
7.2.3
L/H
MU (A)
7.2.2
H/L
7.3.4 7.3.4
RRG (B)
7.3.2
FMU (B)
7.2.5
H/H
Failure test
pi+C to F
7.5.6
P6
Bake
7.2.4
L/H
MU (A)
7.2.2
H/H
RRG (B)
PSBF
7.2.4
Failure test
T to F
MBG (B)
7.2.3
L/H
FMU (B)
MU (A)
7.2.2
Specimen 3
H-H
NOM-NOM
7.5.3
Bake
7.3.2
Thermal Cycle
7.3.5
po+C to F
7.5.4
H/H
L/H
T/C pi/po
7.3.3
7.2.2
Series CThermal Cycle
7.3.5
Thermal Cycle
7.3.5
Thermal Cycle
7.3.5
7.5.5
P2 P4 P5P3
Failure test Failure test
T+pi to F
IV & III
Failure test
pih+T to F
7.5.1
Path No. P1
Structural tests
CAL
Failure test
C+po to F
7.5.2
Series BT/C pi w B
7.3.4
T/C pi/po
7.3.3
T/C pi/po
7.3.3Series A
Bake
7.3.2CAL II, III, IV
Bake
7.3.2
Bake
7.3.2
Bake Bake
7.3.2
FMU (B)
7.2.5
H/LH/H
FMU (B)
7.2.5
H/H
7.2.5
H/H
FMU (B)
7.2.5
H/L
FMU (B)
7.2.5
7.2.3
L/H
MBG (B)
RRG (B)
7.2.4
L/H
RRG (B)
7.2.4
L/H
H/H
MU (A)
7.2.2
H/L
MU (A)MU (A)
7.2.2
H/L
MU (A)
7.2.2
H/H
Specimen 5
H-L
PSBF
Specimen 4
L-H
PFBS
Specimen 2
L-L
PSBF
Thread-seal interference
Amount thread
compound/torque shown in
each block
Specimen 1
H-L
PSBF
Make and
break properties
GALLING RESISTANCE EVALUATION
MAKE AND BREAK TESTS
SEALABILITY EVALUATION
COMBINED LOAD TESTS
3 MONTHS TESTING AT FULL LAB
CAPACITY
8 SPECIMENS
FAILURE TESTS
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Full scale test execution
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ISO 13679:2002 testing protocol
Severity defined as CONNECTION APPLICATION LEVELS (CAL)
CAL I: 3 samples - 2 Quadrants (Liquid) only Internal pressure – Bending optional – No thermal cycles
CAL II: 4 samples - 2 Quadrants (Gas) only Internal pressure – Bending optional – 5 thermal cycles for tubing – Temperature 135°C (275°F)
CAL III: 6 Samples - 4 Quadrants (Gas) – Bending optional – 10 thermal cycles for tubing –Temperature 135°C (275°F)
CAL IV: 8 Samples – 4 Quadrants (Gas) – Bending required – 100 thermal cycles for tubing –Temperature 180°C (356°F)
Loads based on actual Minimum Yield Strength and actual minimum wall thickness.
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Full scale test execution
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Test Series C:
Mechanical cycles both at ambient and elevated temperature with axial tension loads combinedwith internal pressure
ISO 13679:2002 testing protocol
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New API RP 5C5 (2017?) testing protocol
Complete
Specimen
Make and Break Test
Bake-out
90% Level Sealability Testing
90% Level
95% LevelSealability Testing
95% Level
Limit Load Testing
End of Testing
Thread / SealThread Taper
1
XH-XLPS-BF
Complete
Bake-out
Test Series B
Room Temp. / 95%@180°C / 90%
Room Temp. / 90%
Test Series C
10 Thermal Cycles5 Mechanical Cycles
Test Series A
@180°C / 90%5x Q1-Q3-Q1 CyclesRoom Temp. / 90%
T + IP
To Failure
Complete
A End
FMU
B End
M&B x 2
B End
FMU
Test Series A
Room Temp. / 90%
Complete
2
XH-XLPS-BF
Complete
Bake-out
Test Series B
Room Temp. / 95%@180°C / 90%
Room Temp. / 90%
Test Series C
10 Thermal Cycles5 Mechanical Cycles
Test Series A
@180°C / 90%5x Q1-Q3-Q1 CyclesRoom Temp. / 90%
70% IP + C
To Failure
Complete
A End
FMU
B End
FMU
Test Series A
Room Temp. / 90%
Complete
3
L-HPF-BS
Complete
Bake-out
Test Series B
Room Temp. / 95%@180°C / 90%
Room Temp. / 90%
Test Series C
10 Thermal Cycles5 Mechanical Cycles
Test Series A
@180°C / 90%5x Q1-Q3-Q1 CyclesRoom Temp. / 90%
95 % IP + T
To Failure
Complete
A End
FMU
B End
FMU
Test Series A
Room Temp. / 90%
Complete
4
L-LPS-BF
Complete
Bake-out
Test Series B
Room Temp. / 95%@180°C / 90%
Room Temp. / 90%
Test Series C
10 Thermal Cycles5 Mechanical Cycles
Test Series A
@180°C / 90%5x Q1-Q3-Q1 CyclesRoom Temp. / 90%
50% C + EP
To Failure
Complete
A End
FMU
B End
M&B x 2
B End
FMU
Test Series A
Room Temp. / 90%
Complete
A End
M&B x 2
5
H-HPF-BS
Complete
Bake-out
50% C + EP
To Failure
A End
FMU
B End
M&B x 2
B End
FMU
Complete
A End
M&B x 2
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TWCCEP/ ISO PAS 12835: 2013 Thermal Well Connection Classification Evaluation Program
• multi-client project, sponsored by operators and connection manufacturers involved in thermal-well operations in Canada.
• both analytical and experimental procedures to assess performance of a candidate connection under conditions typical of service in thermally-stimulated wells.
• Connections are subjected to compressive stresses beyond yield at high temperature and to tensile stresses during the cooling phase.
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TWCCEP/ ISO PAS 12835: 2013Test Protocol
Galling Resistance
Thermal Cycles
Limit
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TWCCEP/ ISO PAS 12835: 2013
Application Severity Level
Source: TWCCEP/ISO PAS 12835: 2013
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TWCCEP/ ISO PAS 12835: 2013
First two thermal cycles of ASL 290 test
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Connection Testing Summary
API 5C5 2012
CAL IV
ISO 13679:2002
CAL IVTWCCEP
Application
# of Samples
Max. Temperature
Max.# M&Bs
Csg / Tbg
T, C, IP & EP
T,C, IP & Bending (RT or ET)
Thermal Cycles
Csg / Tbg
Failure Tests
-- THERMAL WELLS
58 6
180°C180°C Up to 350°C
3 / 102 / 9 3 / -
YESYES NO
Max 20°RT & ET
Max 20°Only RT
NO
10 / 10
+ 5 MC AT
10 / 100
+ 10 MC RT & 5 MC ET
10
+ IP and fixed ends
YESYES YES
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Agenda
• Geothermal Operation
• Connection Testing
• Connection Selection
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3° 10°
Advantages• Easy manufacture• Easy running• High Tensile resistance
Disadvantages• Poor sealability• Compression• Non-flush ID
Connection Selection: API Buttress
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Proprietary Connections
• Typical Design Requirements
Functional Runnability (Makes & Breaks) Sealability under combined loads
Structural Efficiencies (tension, compression)
Geometry: Coupled, integral, flush, semi-flush Box OD, Drift
Others: Fatigue Overtorque
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Connection SelectionPremium Connection Features
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Jump-In
Connection SelectionCompression
Premium
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Connection SelectionFlow Characteristic
Premium
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Connection SelectionSealability
Fluid Leak
Premium
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Questions
» When to switch from API BTC to proprietary connection?
» How many thermal cycling?
» Enhancing flow, more steam more power generation larger borehole. Prevent
mass and heat loss by using metal seal connection?
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Thanks!