OTC-28977-MS

DeepStar Advanced Materials Program for Offshore HPHT Development

Joseph Gomes, Project Manager, DeepStar; Shakir Shamshy, DeepStar Director, Chevron

Copyright 2018, Offshore Technology Conference

This paper was prepared for presentation at the Offshore Technology Conference held in Houston, Texas, USA, 30 April–3 May 2018.

This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents of
the paper have not been reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material does not necessarily reflect any
position of the Offshore Technology Conference, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Offshore Technology Conference is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of OTC copyright.

Abstract
DeepStar is a member funded industry technology development program focused on advancing technologies
to meet its members’ global offshore business needs in collaboration with oil companies, technology
vendors, service providers, and academic/research institutes.
This paper outlines DeepStar's strategies related to its holistic approach to technology development and
the current and previous projects the program has completed related to High Pressure High Temperature
(HPHT). Within this paper, four technical projects will be highlighted summarizing the technology
development lifecycle that was developed within our program that incorporates a systematic approach to the
development of HPHT equipment. Starting with Standardized Material Selection Basis of Design(MSBOD)
and Equipment Testing Guidelines Criteria, follow by 20 ksi Systems Verification which reviews the API 17
TR8 standard. Follow by qualification testing of ultra-deepwater 20 ksi Composite Tubular, and completing
this paper by highlighting work on 20 ksi Systems Validation testing reviewing API 17 TR8 standard on
simple, moderate and complex geometry components.
Our CORE membership including over 20 organizations including international oil and gas companies,
technology developers, service companies, EPC companies, and academic universities whom employ
hundreds of thousands of people and operating in all of the world's deepwater and ultra-deepwater basins.
Our members provide the guidance of the technical program to ensure that the program is focused on the
right technical challenges and leveraged to produce meaningful and value-added results.
While the manufacturing and service sector members compete fiercely, the projects completed by our
program are considered non-competitive area between the operators and our other members, thus a suitable
space for collaboration. This includes projects which are critical to support reliable and safe operations in
which solving a problem for one deepwater operator can be integrated into the entire offshore industry. As
such, the program provides an outstanding opportunity for Subject Matter Experts (SMEs) to collaborate
and foster the exchange of ideas and potential solutions. For more information on DeepStar program, please
visit www.theDeepStar.com.

Introduction
With recent technology advancements and exploration opportunities that are expanding the commercial
viability of many of the deepwater fields, offshore operators now must grapple with ways to explore
2 OTC-28977-MS

deepwater assets that are pushing the boundary of the current on the shelf equipment entering into high
temperature, high pressure or fields with both. The need for advanced technology and equipment from
multiple operators is aligned with the DeepStar mission statement which includes: improving profitability,
execution, capability, operability, flexibility, reliability and safety of deepwater production systems.
Our members leveraged DeepStar joint industry project (JIP) to advance selected technologies from
design to commercialization, and utilize our established network and contracting strategy to initiate
technology development JIPs more efficiently and in a timelier manner than other current industry options.
The current membership rosters comprise a diverse group of major and independent operators with global
deepwater holdings- Anadarko Petroleum, Chevron Corporation, CNOOC Limited, JX Nippon Oil &
Energy Corporation, Maersk Oil, Petrobras, Statoil, Woodside Petroleum with a number of technology &
service companies.
The DeepStar Project has been in continuous operation since its inception in 1991 and has focused on
both issues and technologies that are required to successfully tackle future development and production
challenges identified by its members. Our members recognized that to safely and successfully drill, complete
and produce high pressure reservoir reserves in deep and ultra-deep waters, equipment with a pressure rating
of 20,000 psi are essential. Where DeepStar has focused its efforts within HPHT around our technology
development lifecycle, where the overall discussions are based on technology development processes from
initial equipment design, materials selection, and qualification, to implementing new subsea technology
and finally providing continuous service or decommissioning. This paper and corresponding presentation
will highlight the successes of DeepStar's HPHT effort and four projects that provides a summary of the
successful embodiment of the project related to HPHT material selection, validation, and qualification.

Project Overview
Systematic approach to technology development
1. Understanding Design Conditions
2. Engineering & Design
3. Technology Selection & Qualification
4. Inspection Monitoring Surveillance & Repair
5. Continued Service / Decommissioning

12503 Standardized Materials Selection Basis of Design and Equipment

Testing Criteria
The performance of a metallic material depends on the nature of the material, the applied stress and the
environment. The nature of the material depends on the manufacturing process, the intrinsic anisotropy, a
distribution range of its extrinsic properties, and internal stresses resulting from the manufacturing process.
The applied stress resulting from internal pressure or tensile loads as well as local external stresses occurs
within the environment consists of physical parameters (temperature and pressure), chemical parameters
(the composition of the oil, gas, and brine), and finally, process parameters (such as flow in combination
with solids). While all of these parameters are well known, the effects resulting from the convergence of
each of these within HPHT environments is less documented.
OTC-28977-MS 3

Figure 1—Performance of materials depends on the nature of the material, applied stresses, and the environment.

A comprehensive methodology aimed toward material selection in the design stage of HPHT oil/gas wells
was developed on the basis of a complete system analysis against a background of a solid understanding
of the thermodynamics, analytical procedures, and test methodologies. The focus of this project was on
HPHT materials and the effects of the environment on the selection and qualification of materials. Advanced
selection and testing of materials in the HPHT environment requires a multidisciplinary approach which
is supported by experience, literature study, sound engineering practice, and classical and non-classical
thermodynamics. The performance of the said material is in addition to the nature of the materials itself
which is determined through the manufacturing process, anisotropy, uniformity of properties, residual stress
and applied stresses.
A particular focus should be placed on identifying the true nature of the production environment
(regarding chemical activity) such that it could be simulated in test equipment for the qualification of
acceptable materials. One of the significant lessons learned in the development of the project's methodology
for the materials selection basis of the design was in understanding the identify material and critically
evaluate current practices used to analyze and define the environment (e.g., reservoir, drilling, completion,
stimulation and workover fluids). To determine the physical parameters pressure and temperature, chemical
parameters gas, brine and oil mixture, and process parameters flow rates, which has a significant effect in
defining the proposed testing requirements (criteria) for material and equipment qualification and validation.

12302 20 ksi Systems

The design and use of equipment with working pressures of 20 ksi and above for subsea equipment has
been in discussion for several years now, particularly in the context of deep water production. This area is
gaining traction with various operators, who generally perform independent work in (HPHT) component
design and implementation. The purpose of this project was to demonstrate the use of the various design
methods discussed in API 17TR8 to evaluate a 5 inch 20 ksi tee assembly. This exercise provides an
example of independent usage of API 17 TR8 and in the process of completing this project allowed current
20 ksi contributors and operators to comment on the scope of work, the results of the evaluation and the
verification analysis. This project helped put the use of the API 17TR8 document into practice and provide
an independent example of its usage on an industry specified 5-inch 20,000 psi tee assembly.
4 OTC-28977-MS

Figure 2—Design and FEA of 5 inch 20 ksi tee assembly

Case Study
The objectives of this project were to provide a case study to the verification pathway under API 17 TR8 to
provide an example analysis which includes independent usage of this standard with a 20,000-psi specified
component.
Three evaluation methods were analyzed, and they are:
1. ASME VIII-2 linear elastic evaluation (ASME VIII-2 LE)
2. ASME VIII-2 elastic plastic evaluation (ASME VIII-2 EP)
3. ASME VIII-3 elastic plastic evaluation (ASME VIII-3 EP)
Perform design life assessment of a 20 ksi tee assembly using methodology from:
1. ASME VIII-2, Linear Elastic Fatigue
2. ASME VIII-2, Elastic Plastic Fatigue
3. ASME VIII-3, Elastic Plastic Fatigue
4. ASME VIII-3, Elastic Plastic Fracture Mechanics
The project provides an example of validation of the previously described analysis methods, investigates
the effect of hydrostatic tests on the life of a 20 ksi tee system, compares the conservatisms in the design
fatigue life to life calculated based on actual loading from operational data, recommends "state of the art"
non-destructive examination methods and the implications of welding on cladding, and evaluates proposed
extreme and survival limits assessment for 20 ksi components.
This project evaluates a tee with associated flanges and bolts. The design pressure for the tee was assumed
to be 20,000 psia (absolute pressure). The design in accordance with API 6A/17 with the drawings and
other design information for the flange used on the tee was provided to support this project by a member
company Freudenberg Oil and Gas Technologies (FOGT). This case study includes the generation of
both a Functional Specification for the tee assembly and a Failure Mode, Effects, and Criticality Analysis
(FMECA). This follows guidance from ASME VIII-2 User's Design Specifications, ASME VIII-3 User's
Design Specifications, and ISO 13879, in addition to the requirements of API 17 TR8. Included in the
creation of the FMECA was a demonstration of the generation of a validation strategy which, when used
in conjunction with appropriate material qualification testing, results in outputting a complete validation
program for the assembly. This included evaluation of performance requirement levels. The intent of this
project was not to validate a specific flange design, but instead to demonstrate the use of the current
industry standards and investigate and compare the varying methodologies in each of the standards. In
each evaluation, capacity calculations are presented to identify a series of failure mechanisms (for example,
global collapse, localized failure, ratcheting, hydrostatic test integrity, serviceability requirements and bolt
OTC-28977-MS 5

integrity). The results indicate that the operating conditions, outlined in the function specification, satisfy
the respective capacity calculation requirements for each of the three evaluated methodologies.
In addition to the capacity calculations, a design life assessment is presented, evaluating the need for a
fatigue assessment per the requirements in ASME VIII-2, presenting the required fatigue assessments per
ASME VIII-2 and ASME VIII-3, and finally considering postulated cracks in accordance with an ASME
VIII-3 fracture mechanics evaluation. As part of the design life, ASME VIII-3 fundamentally addresses the
existence of a crack, or the possibility of a crack, considering the NDE threshold for crack detection. It
is shown that a potential crack on the outside surface of the flange neck would be susceptible to extreme
and survival loading using the currently proposed loading conditions for API 17TR8. All postulated cracks
assessed are shown to grow slowly enough to be considered non-critical for 25 years of operation when
using the crack growth methodology. An investigation of the effect of the magnitude of hydrostatic test
pressure on the assembly was also performed. This included looking at a range of pressures from the rated
working pressure to 150% of the rated working pressure. The results show that the range of hydrostatic
stress does affect the components.
For this project, it provided our members with a detailed case study on how to utilize industry standards
to verify a 20,000-psi component and provide verification of API 17TR8 using all three evaluation options.
There were a number of lessons learned developed from this project and recommendation that were supplied
to both ASME and API. Regarding this project, the full paper and relevant data were transferred to API
to be used amongst its next standards update. Some of the lessons learned may provide useful information
in future designs as the operator continues to move into yet higher pressure and temperatures designs in
the decades to come.

12403 Ultra Deepwater 20 ksi Composite Tubular

A technical challenge that was identified by our members was to develop and demonstrate a 20 ksi rated
tubular which would be suitable to successfully and safely drill, complete and produce high pressure
reservoir reserves in deep and ultra-deep water. The goal was to develop and demonstrate by qualification
a 20ksi rated tubular based on the use of a peek & carbon fiber composite tubular.
The objective of the project was to demonstrate that a 4in 20ksi pipe composite pipe for a factory
acceptance test. Additionally, the design of the pipe would take hypothetical operation conditions at a
temperature of 100 °C and a water depth of 10,000ft into account.
The technology selected was a high-quality product with a significant performance step from current
technology with preliminary designs which showed at a 20,000psi capability a fraction of the weight of
existing pipe technologies, improved fatigue performance, corrosion resistant to seawater, H2S and CO2, as
well as high temperature capability and enhanced erosion and wear resistance when compared to steel. The
commercially manufactured 15,000psi pipe was already completed and available-proving the technology,
manufacturing method and verifying the design tools with the step to 20,000psi being well within the
capabilities of the technology. The project achieved the following activities that will be discussed in the
presentation:

• FMECA session

• Manufacturing of a 4in 20ksi pipe, 2.5in 20ksi pipe, and 3in 10ksi pipe

• Bore seal testing

• Four pressure tests

• Development of a new end fitting design for composite pipe

6 OTC-28977-MS

The conclusion of the project results in the engineering of a 20ksi composite pipe, manufactured and
successfully completed a factory acceptance test at a pressure of 32ksi (2200bar). The test demonstrated the
pressure capacity of the pipe body and the options of bore seal and connecting joints that were reviewed
by our members. However further testing of the pipe will be required to qualify it for a specific application
or case.

17001 20 ksi Systems Validation

An example design verification analysis referenced above provides an illustration of the use of API 17TR8
to the industry. The validation program proposed provides the basis for the current proposed scope of work
for the validation of design verification of an assembly with similarly complex geometry, performed in
accordance with API 17TR8. The results of the study will be used to support the standard developments
in the HPHT discipline and provide the industry with additional case studies for the application of design
verification and validation of design analysis in accordance with of API 17R8 utilizing general/typical
subsea geometry and components. The scope of this study is to perform validation testing of the structural
capacity of an assembly with complex geometry and perform an update to the verification analysis to
demonstrate the overall verification and validation process. This validation testing includes actual material
and component testing. Focused on the analysis for load capacities of an assembly geometry of complex
configuration is in accordance global criteria with actual material/tensile properties to determine the
capacities under Normal, Extreme and Survival conditions at two points. Validation of design analysis for
an assembly with complex geometry, and correlate validation testing results with Finite Element Analysis
modeling.

Conclusions
This paper highlights DeepStar's HPHT accomplishments through a collaborative workspace amongst
operators, technology provider, service companies and EPC companies. Through this joint effort, members
have developed, executed, completed, and transferred to industry a collective group of HPHT projects to
advance the technical discussion around understanding design condition, utilizing sufficient engineering &
design parameters, and technology qualification related to HPHT environment.
The HPHT projects completed within the program have provided our members with additional experience
related to the systematic approach needed for the verification and validation of HPHT equipment, while also
providing the industry with case study related to 5inch 20 ksi tee assembly. Continuing in these endeavors
the current Satellite project related to 20 ksi Systems Validation will provide our members with case studies
to the validation process within API 17TR8 for nonproprietary simple, advanced, and complex geometry
components.
DeepStar's Management and Technology Committee will continue its time-honed processes which have
served its membership well, directing funds and resources to those collaborative areas most highly ranked by
the operators. Its ‘holistic’ approach with our four Technical Committees and advisory committees provides
a synergy that is greater than just the sum of the individual committees. The program will continue to fund
‘individual projects’ within all the technical committees that are operator driven and anticipates adopting
with a few areas of focus on 20 ksi systems, long distance tie back, continued service and floating systems
technologies with an emphasis on supporting safer operations with a lower overall cost.
The world's offshore, deepwater and ultra-deepwater basins hold tremendous resource promise to help
meet global energy needs at any commodity price point. The program and its membership network has
processes, procedures and most importantly hundreds plus SMEs to help ensure that the most appropriate
technologies are identified and then pursued and pulled through to commercialization. Our successes are
numerous, and we have had long term impact due in large part to the framework that has been built over
the past 26 years of operation. Our recent accomplish within HPHT have started to be circulated within
OTC-28977-MS 7

the industry and drafted into standardized, progression into validation testing, or being developed in full
test qualification.
Our program looks forward to thinking about the future and our vision that what is normal today was
impossible ten years ago, and believes that what is impossible today will be normal ten years from now.
Our vision and commitment to the development of offshore technology today will be essential to achieve
success in the future.

Acknowledgments
The authors gratefully acknowledge the contributions of the member organizations for their input and
support from the DeepStar Management Committee and the hundreds of SME's from all the technical
committees who initiated and directed the technical discussions and contributed to the work presented
within this report, and whom their efforts have built this program. The authors would recognize those
that championed the work completed within, the work starting with the former DeepStar Director Greg
Kusinski, Kirk Baker and Chris Carlton, Barry Brasher Christopher Curran, Chris Kocurek and Richard
White, Jean-Philippe Roques and Jonathan Bowman and finally the current projects Man Pham, Flora
Yiu, Matt Vaclavik, Anish Simon, and Jeffrey Jones. This work was funded by the collective members of
DeepStar 2017 CORE program through a collaborative effort and DeepStar Satellite project 20 ksi Systems
Validation. The results from work highlighted within this paper can be found with the following DeepStar
Projects; Phase XII 12503 Methodology for Materials Selection, Basis of Design, and Equipment Testing
Criteria, Phase XII 12302 20 Ksi Systems, Phase XII 12403 Ultra Deepwater 20 Ksi Composite Tubular
and Satellite Project 17001 20 ksi Systems Validation. For all documents mentioned in this paper and
highlighted during the presentation, please visit our website at www.thedeepstar.com or contact DeepStar
Program Manager or DeepStar Director.