DEA-137 – Deepwater Riser Wear Technology

Deepwater Riser Wear Technology John Cohen at 713-683-8227 x 215 jhc@maurertechnology.com

DEA Project Summary DEA-137 “Minimizing Wear in Deepwater Risers, Flex Joints, and BOPs”

This project was conducted to develop a wear model that accurately predicts wear in deepwater risers, flex joints, and BOPs; perform riser-wear laboratory tests; stimulate the development of wear-resistant components, linings, coatings, and improved tool-joint hardmetals; observe wear in titanium, composite and aluminum risers; and develop strategies for reducing wear problems in the offshore environment. The project began in February 2001 and was completed in October 2002. A description can be found at www.maurertechnology.com and go to the JIP page.

Point of contact is John Cohen at 713-683-8227 x 215 jhc@maurertechnology.com
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Update: 8/12/02
DEA Project Number: 137
Project Title: Minimizing Wear in Deepwater Risers, Flex Joints, and BOPs
Contractor: Tom Prosser MAURER TECHNOLOGY INC. 2916 West T.C. Jester Houston, TX 77018-7098 (713) 683-8227 ext. 260
Email: prosser@maurertechnology.com
World Wide Web Site: www.maurertechnology.com
Startup Date: January 2001
Scope of Work: Evaluate wear properties of risers. Analyze factors that affect riser system wear. Investigate riser lining and coating wear resistance. Document riser, BOP, and flex-joint field wear problems. Evaluate improved BOP and flex-joint wear properties and alternatives. Develop and test DRILLRISER riser wear model. Determine drillstring lateral loads in BOPs and flex-joints. Stimulate development of riser wear inspection tools. Investigate improved tool-joint hardmetals. Write reports.
Current Status: Held 6 quarterly meetings, the latest being July 18. The content of this meeting involved the following: SALTECH, a Canadian company, reviewed recent test results of their urethane material which showed excellent wear and related characteristics as a lining and coating product with the group. Additional tests are planned due to the great interest. West Engineering Services was engaged by DEA-137 Participants to study wear related problems observed during inspections in the Gulf of Mexico since the year 2000. This report covered over 90 inspections that yielded 7 wear events and recommended actions to avoid future wear problems. This verified the observations and recommendations generated by the DEA-137 project. Dr. Russell Hall, Consultant, discussed the direct causes of wear in the offshore riser system, where it will occur, how to recognize it, and what action is necessary to minimize or eliminate it in risers, flex-joints and associated components. Lee Chu, Programming Manager of MTI, gave an update on the completion of the DRILLRISER program. Due to lack of funds, our final meeting is scheduled to take place on October 17, 2002.
Projected Completion Date: October 31, 2002
Project Cost: $600,000 ($370,000 currently available funds)
Participants: Arnco Technology, BP International, ChevronTexaco, Dominion Expl. & Prod. Inc., ICO Tubular Services, Amorphous Technologies Intl., Minerals Management Service, Petrobras, Shell Intl. Expl. & Prod., Transocean, US Dept. of Energy-NETL
Cost per Participant: $35,000 for DEA-42 Participants and $40,000 for others

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Update: 8/14/01

DEA Project Number: 137
Project Title: Minimizing Wear in Deepwater Risers, Flex Joints, and BOPs
Contractor: Maurer Technology Inc.; 2916 West T.C. Jester; Houston, TX 77018; 713/683-8227 ext.238
Email: mti@maurertechnology.com
World Wide Web Site: http://www.maurertechnology.com
Startup Date: February 1, 2001
Scope of Work: Severe wear problems in risers, flex joints and BOPs are anticipated to increase in greater water depths due to higher rig tension loads, increased riser deflections, and other factors which lead to difficulty in station-keeping of the drilling vessel over the well. Offshore operators and contractors have already encountered unexpected riser and system component failures resulting in costs ranging in excess of $3 million per well and near loss of the well. This project should significantly reduce the cost and risk of deepwater drilling by stimulating development of wear-resistant risers; improved flex joints, BOPs, and wear surface materials; and an accurate riser wear computer model. Working with an exchange of information derived from Participants, riser-system component manufacturers, contractors, operators and suppliers of materials, the tasks to be achieved include: evaluation of the wear properties of risers; analyses of factors that affect riser-system wear; investigation of the wear resistance of various linings and coatings; documentation of riser flex joint and BOP field wear problems; evaluation of improved BOP and flex joint wear properties and alternatives; development of the DRILLRISER riser-wear model; determination of drill-string lateral loads in BOPs and flex joints; stimulation of riser-wear inspection tool development; and investigation of improved tool-joint hardmetals.
Current Status: A quarterly project review meeting took place in the offices of BP on May 15. Approximately 25 Participants and guests attended. The meeting included brief updates from “E Committee” members on performance of their respective tasks. A review of meetings in Brazil on deepwater drilling and the initial wear test results on Kawasaki and Mannesmann riser materials were also presented. Kawasaki introduced the idea of alternative steels which might better perform in deepwater drilling risers. Dr. Russell Hall of MTI presented an analysis of the influence of contact pressure exerted between a rotating drill string in either riser or casing. He also introduced for consideration a standardized system for rating wear performance of various hardbanding materials. The Nautronix organization introduced their Riser Profiling System and explained the type of data it can gather and stream to the surface for processing with a program, such as our proposed DRILLRISER. Following lunch, the meeting was concluded with brief technical discussions and a proposal to meet next in August. The planned date has now been rescheduled for September 20, and MTI will announce the location.
Projected Completion Date: January 31, 2003
Project Cost: $600,000
Participants: There are currently 10 Participants
Cost per Participant: $40,000 ($35,000 for Participants in DEA-42 Phase V)
Comments: Significant interest has been generated by the initial findings of this project within the offshore industry. Please contact MTI for more information and a complete proposal.

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New Proposal Summary (Revised)

DEA-137
“Minimizing Wear in Deepwater Risers, Flex Joints, and BOPs”
Technical Area: Deepwater Drilling

Sponsor: BP

Title: Minimizing Wear in Deepwater Risers, Flex Joints and BOPs

Project Objective: To minimize or avoid the economic and environmental impact of drilling riser, flex joint and BOP damage or failures which are caused by wear.

Benefits To The Industry: Severe wear problems in risers, flex joints and BOPs are anticipated to increase in greater water depths due to higher rig tension loads, increased riser deflections, and other factors which lead to difficulty in station keeping of the drilling vessel over the well. Offshore operators and contractors have already encountered unexpected riser and system component failures resulting in costs ranging in excess of $3 million per well and near loss of the well.

This project should significantly reduce the cost and risk of deepwater drilling by stimulating development of wear-resistant, and possibly lined, risers; improved flex joints, BOPs, and wear surface materials; and an accurate riser wear computer model.

Technical Tasks: Working with an exchange of information derived from Participants, riser system component manufacturers, contractors, operators and suppliers of materials, the tasks to be achieved include: evaluations of the wear properties of risers; analyses of factors that affect riser system wear; investigation of the wear resistance of various linings and coatings; documentation of riser flex joint and BOP field wear problems; evaluation of improved BOP and Flex Joint wear properties and alternatives; development of DRILLRISER riser wear model; determination of drill string lateral, loads in BOPs and Flex Joints; stimulation of riser wear inspection tool development; and investigation of improved tool joint hardmetals.

Deliverables: Technical and quarterly reports; DRILLRISER riser wear model; software User’s Manual.

Start-up Date: Anticipated October 19, 2000, but funding may delay to December 15, 2000

Project Duration: 24 Months

Project Cost: $600,000

Cost Per Participant: $40,000/ $35,000 for former DEA 42 Phase V members

Financial Terms Available: Payment can be made on a monthly, quarterly, semi-annual, annual, or a total one-time payment basis. To accommodate inclusion in your company budget for the years 2000 through 2002, an agreed Letter of Intent to participate will be accepted.

Questions? Please contact:  Tom Prosser: e-mail, prosser@maurereng.com, or Telephone: 713-683-8227, ext. 260