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roy.johnsen@ntnu.no
CATEGORIES OF AGING
AGEING MANAGEMENT
A. Material degradation
- Material properties
- Operation conditions
- Environmental conditions
- Maintenance practices
B. Obsolescence
C. Organisational issues
- Reorganisation
- Ageing of personnel
- Transfer of knowledge
Adopted from: Ageing of Components and Systems. Edited by Lars Pettersson and Kaisa Simola. An ESReDA Working Group Report.
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Modeling
Monitoring
Inspection
Initial
Technical Integrity
START
TODAY
END LIFE
Minimum
History
Future - Prediction
END LIFE
Time in operation
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roy.johnsen@ntnu.no
Probabilistic
Veslefrikk structures
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DEGRADATION MECHANISMS
A. Blockage (III)
B. Corrosion (I)
1.
2.
3.
4.
5.
6.
7.
Bacterial
Crevice
CUI
Galvanic
General
Pitting
SCC
C. Creep (III)
D. Flow induced metal loss (I)
1. Erosion from solids
2. Flow induced corrosion
3. Cavitation
E. Fatigue (I)
1. General
2. Vibration
Ptil "Aging seminar" April 7th 2010
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PREDICTION OF CO2-CORROSION OF CS
through modeling
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pCO2 = 4 bar
T = 500C
Vcorr = 8 mm/y
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STATE-OF-THE-ART
NORSOK
Ptil "Aging seminar" April 7th 2010
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Fluid composition
Bicarbonate
Acid
Ione strength
pH
Condensed or
formation water?
Shear force
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CARBON STEEL
DNV
API -- Model
Model
Ptil "Aging seminar" April 7th 2010
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CORROSION IN WATER
INJECTION SYSTEM WITH CS
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EROSION RATE
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WTMod
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TYPE OF FAILURE
Leakage
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SOUR SERVICE
Hydrogen embrittlement
Solution pH
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Key document:
NACE MR0175 ISO 15156
Ptil "Aging seminar" April 7th 2010
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CRACKS
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Foinaven
HUB
Tune pipeline
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Susceptible microstructure
Microstructure
StressStrain
Hydrogen
Availability of hydrogen
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An Industry Design Guideline that defines the best practice for design
and fabrication of duplex stainless steels for subsea equipment
exposed to Cathodic Protection.
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DNV RP F112
Max. strain to avoid HISC
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NOBLE ALLOYS
e.g. stainless steels and nickel alloys
WILL CORROSION BE INITIATED?
Yes?
No?
SAFE OPERATION WINDOW
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As-built documentation
Information from commissioning
Process parameters
Operation conditions
Monitoring data
Inspection data
Maintenance history
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PROCESS-/OPERATION PARAMETERS
Process parameters
Operation parameters
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SYSTEMS TO BE DISCUSSED
Wells (including
X-mas tree)
Subsea systems
Topside process
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WELL BARRIERES
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Production casing
Sand production causing erosion
Produced water / water injection causing corrosion
Wellhead
Fatigue due to riser load during workover
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NDT
Dimensional check of
selected components/review
of dimensional check reports
Change out of seals, treads
etc.
Reassembly recoating
preservation
Load/pressure testing and
functional testing.
Ptil "Aging seminar" April 7th 2010
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WORKOVER RISER
Schematic
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SUBSEA SYSTEMS
Foundation structure
Separator
Riser
PLEM
Template
Pipeline
Manifold
Ptil "Aging seminar" April 7th 2010
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SUBSEA SYSTEM
Main elements
Pipeline/flowline
Riser
Pipeline End Manifold (PLEM)
Subsea wellhead and X-mas tree
Manifold piping, valves and connection
Control and monitoring systems
Control umbilical
Subsea power and frequency converters
Subsea separation and boosting systems
Template with protection structure
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FLEXIBLE PIPE
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FLEXIBLE PIPES
Failure cases
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DEGRADATION OF SUBSEA
PRODUCTION SYSTEMS
TEMPLATE/MANIFOLD
External corrosion due to poor coating and/or lack of
protection from anodes (lack of electrical contact)
Too high load due to
Operation outside original design criteria
Change in foundation due to seabed erosion
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DEGRADATION OF SUBSEA
PRODUCTION SYSTEMS, cont.
CONTROL SYSTEM
Failures in electronics and electrical connectors, failure in
control valve and internal leakage.
Over time, failure in cables for power and signal
transmission due to migration of water through insulation,
etc., may take place.
Degradation of the control system takes place due to
wear, exposure to sea water and well fluids, high
temperatures, hydraulic fluids, etc.
SUBSEA SEPARATION/BOOSTING
Lack of experience
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SUBSEA
Challenges and lack of knowledge
Subsea production systems
Structural integrity monitoring system
Sand disposal system
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PROPOSAL
Further research and development
8. Initiating an interdisiplinary project on analysis
of degradation mechanisms of critical systems
Modeling of the main degradation mechanisms
Development of systems for data collection
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QUESTIONS?
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