olje- og gassnettverk helgeland dialogsamling 5 nov, … · technology for a better society olje-...

Technology for a better society

Olje- og Gassnettverk Helgeland

Dialogsamling 5 nov, 2013, Mo i Rana

Jack Ødegård, forskningsdirektør, SINTEF Materialer og kjemi

1

Hvem, hva, hvor?

Eksempler på leveranser inn mot norsk og internasjonal

Petroleums-industri:

- FoU oppdrag

- Kommersialiseringer

SINTEF


This is SINTEF 2013 May 2013


Our role

• Creating value by applying knowledge, research and innovation

• Delivering solutions for sustainable development

• Building and operating research laboratories

• Providing premises for social debate and policy decisions

Our vision: Technology for a better society


SINTEF is the largest independent research organisation in Scandinavia

• A non-commercial research foundation with subsidiaries

• Annual sales of NOK 3 billion (EUR 400 mill)

• 2050 employees from 70 countries

• Expertise in the natural sciences, social sciences, medicine and in technology

• 700 people involved in oil and gas research


Tromsø

Raufoss

Stavanger

Bergen

Ålesund

Mo i Rana

Trondheim

Oslo

Spitsbergen

Regional presence in Norway is part of our strategy


We sell research to customers all over the world Customers in 60 countries

Leading participant

in EU’s research programs.

The USA is our largest

international market. Office in

Houston.

Part-owner of aquaculture

research company in

Chile.

Petroleum and energy research.

Offices in Rio.

Extensive cooperation with

European research partners.

Environment projects in

China.

Projects on health and living

conditions in Africa.

Technology for a better society 7

We have employees from 70 countries Customers in 60 countries


We are among Europe’s largest contract research organisations


SINTEF Building and Infrastructure

SINTEF ICT

SINTEF Materials and Chemistry

SINTEF Technology and Society

A multidisciplinary research organisation with international top level expertise in specific fields

SINTEF Energy Research

SINTEF Fisheries and Aquaculture

SINTEF Petroleum Research

MARINTEK


SINVENT

SINTEF NBL

SINTEF Nord

SINTEF Raufoss Manufacturing

SINTEF Brazil

Molab

SINTEF Holding includes companies of strategic importance to SINTEF


Sources of income 2012: Percentages of gross operating revenues. Total 2966 MNOK.

More than 90 percent of our income comes from contracts

won in open competition

6 % basic grants from The ResearchCouncil of Norway

2 % strategic programmes from TheResearch Council of Norway

21 % project grants from The ResearchCouncil of Norway

10 % public-sector contracts

39 % business and industry

17 % international contracts

5 % from other sources


During the past five years, SINTEF has invested EUR 80 million in laboratories and scientific equipment.

We invest our income in laboratories and knowledge generation

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16

11 12

21

0

5

10

15

20

25

2008 2009 2010 2011 2012

million EUR


We see opportunities and develop successful solutions for our customers and partners

• We collaborate closely with universities, authorities and industry

• We combine the cultures of research and business

• We are socially responsible and maintain high ethical standards in all our activities


Close collaboration is the basis for innovation and high scientific quality

Industrial relevance – Industrial involvement – Scientific methods


Our partnership with NTNU functions at both strategic and operational levels

Joint use of laboratories and equipment

SINTEF staff teach at NTNU

NTNU personnel work on SINTEF projects

Strategic coordination

Cooperation between SINTEF and NTNU has developed over 60 years


SINTEF is a major participant in EU research programs

• Participate in 200 projects, with a

project volume of EUR 1.400 million*

• Coordinate 45 projects with a project volume of EUR 280 million*

• SINTEF research funding from EU: EUR 120 million*

* SINTEF's position in EU's 7th Framework Program for Research and Development, by March 2013

Source: KD, The Research Council of Norway

Research funding from EU to leading Norwegian institutions, FP7

0

10

20

30

40

50

60

70

80

90

100

UiB NTNU UiO SINTEF

Mill

ion

EU

R


We contribute to generation of knowledge, creation of value and improved competitiveness for our customers

• More than 7000 projects for 3000 customers every year

• We provide solutions that create new prospects for our customers

• Professional project management

• We respect our customers’ requirement for confidentiality

Fisherman’s life saved thanks to survival suit developed by SINTEF for Regatta


We maintain a high scientific standard and we are world-leading in selected fields

• We integrate engineering, natural science, health and social science

• Areas of expertise at international level:

– Energy and environment

– Oil and gas

– Biomarine

– Maritime

Photo: Ulstein


SINTEF offers unique prospects for people with ability and drive to develop their potential.

• 2050 employees

• 1400 researchers

• 51 percent of our researchers hold doctorates.

• Colleagues from 70 countries

• 33 percent of our staff are women

• One of the most attractive workplaces in Norway


SINTEF employees 2012

Three out of four employees are researchers

73 % researchers

5 % technical personnel

9 % engineers

13 % administration


Since 1970, SINTEF and NTNU have established companies that have created 2000 jobs, with a combined annual turnover of EUR 650 million

0,1

1,1

3,6

8,7

10,3

0

2

4

6

8

10

12

1970-79 1980-89 1990-99 2000-09 2010-12

Evolution of number of new companies started annually from research environments in Trondheim

Source: Impello Management (2012)


Research that creates value and delivers solutions

Sub-sea technology Tracking of foodstuffs Advanced heat-pumps


CO2 capture Smart survival suits GPS for brain surgeons



GSM technology for mobile phones

Technology for solar cells Floating offshore wind turbines



Organisation


SINTEF Oil & Gas R&D

Exploration Operation

Injector Producer

Producer

Field

development Installation De-commisioning

HSE Energy efficiency

Arctic conditions


Oil and gas research

constitutes 30% of SINTEF's activities

Oil-pollution research Testing an advancedsurvival suit

CO2 storage

Field laboratory



Reservoir laboratory experiments

Modelling oil and gas generation

Reservoir description and modelling



Advanced drilling

Simulator

Rock mechanics laboratory

Simulator used for training drilling team



LNG Simulating pipeline

designs and route

Testing equipment for direct eletrical heating of pipelines


SINTEF provides independent research based information

to authorities, descision makers and public

Example:

Shale gas

Illustration Statoil


Some examples

33


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SINTEF Oil & Gas R&D Activities covering the whole value chain

Exploration Field

development Operation

De-commisioning Installation

seismics

formation physics

basin modeling

reservoir techn.

well & prod. techn.

drilling

concept

technology

design

construction

operations

install. simulations

”ready for use”/ commissioning

ops. support

monitoring

maintenance

modifications

increased output

HSE

reuse

removal

Injector Producer

Producer

Altogether 6-700 researchers in SINTEF working full-time on oil and gas related research


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Several flow loops, ranging from 1” to 12 “ diameter

Ris

er

to s

up

po

rt

ve

rtic

al flo

w e

xp

erim

en

ts

Unique laboratory facilities

Ocean basin Multiphase Flow laboratory

Flexible riser

test rig

Materials and Structural lab’s


Applied Mechanics and Corrosion

Fracture assessment of pipelines

Degradation mechanisms altering component/structure integrity over life-time

Corrosion protection

Welding technology (incl. hyperbaric welding) and residual stress simulation

Crashworthiness of light-weight automotive structures

Testing/verification

Mechanical testing and analyses; from small scale specimens – to full scale

Focus: Characterisation and reliable use of materials under demanding conditions. Our most important customers are; material producers, offshore (incl. manufacturing) industry and automotive industry.


Large scale structural testing (1)

• SINTEF has test rigs that are routinely used for large scale pipeline testing

– Load capacity up to 200 tons

– Pipe diameters up to 18 "

– Internal pressure

– Camber for corrosive environments and temperature up to 80 deg C

– Cyclic loading

• Services offered by SINTEF include: – Validation testing of strain capacity of pipes

– Validation and calibration of numerical models


Large scale structural testing (2)

• Full-scale testing in resonance rig (15-40 Hz)

• Full-scale testing in 4-point bending (0-2 Hz)

• Small-scale testing

– 10 parallel rig, environmental fatigue (0-2 Hz)

– Multiaxial loading (0-15 Hz) at elevated temperature


Small scale structural testing and characterization

• SINTEF has an in-house machine shop and a well equipped test laboratory

– All standard test machines for structural testing – SEM, TEM, Light microscopes etc. – Nanoindenter and atomic force microscope

• Services offered by SINTEF include: – Tensile testing (w/ temperature) in base material

and welds, Charpy, DWTT, hardness measurements etc.

– Fracture mechanics testing (SENT, SENB) w/ surface cracks, embedded cracks, misalignment, straining and artificial ageing etc.

– Fracture mechanics modelling, qualification and testing

– Metallographic characterization – Failure assessment/failure characterization – Fatigue testing and fatigue design evaluations


Hydrogen induced stress cracking (HISC)

• SINTEF has the equipment and the capabilities for:

– Fracture mechanical testing under influence of hydrogen

– Hydrogen quantification in metals

– Hydrogen diffusion testing

• Services offered by SINTEF include:

– HISC testing

– Hydrogen quantification

Technology for a better society 41 41

Stress corrosion cracking

• SINTEF has the equipment and the capabilities for: – H2S lab capable of handling 100% H2S test gas

– Autoclaves up to 300 bar and 300 °C

– Static and dynamic test rigs simulating O&G environments

– 4-point bend, C-ring, constant load, slow strain rate, fatigue

• Services offered by SINTEF include: – Pre-qualification according to most international standards

– Advanced failure analysis and investigations

– Test methodology development

SSRT

Duplexweld

Base material 13% Cr


Protective coatings


– Cyclic coating tests

– Cathodic disbonding tests (room temperature, high temperature)

– Testing of mechanical properties of coatings

• Services offered by SINTEF include:

– Coating pre-qualification testing

– Failure analysis


Wear, erosion and tribo-corrosion


– Environmental pin on disc

– Infinite focus image analysis

– Erosion up to 100 m/s flow rate

– Thermal spray of hard coatings

• Services offered by SINTEF:

– Testing of wear, erosion and tribo-corrosion

– Evaluation of coatings and surface treatments

– Failure analysis


Full scale crack arrest in pressurized gas pipelines

– Crack arrest and crack propagation are essential mechanisms to understand in order to ensure safe transport of hydrogen and CO2

– Full scale test at Giskås

• the world first ”crack arrest” test with pressurized hydrogen

– Coupling to numerical analyses activities

S. Aihara, U. Tokyo


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Modeling, analysis, procedure development

• Advanced modelling of static or dynamic structural problems with ABAQUS, LS DYNA or LINKpipe

– Advanced material model development (metals, composites)

– Multi-scale modelling

• Advanced fracture mechanics modelling – 3D analyses of pipes and structures with defects

– Constraint corrections

– Modelling of ductile crack growth

– Weld design (i.e. weld cap reinforcement)

– Fluid-structure interaction for modelling of ductile crack propagation in gas pipelines

• Welding procedure development, qualification and ECA

• Weld simulation and modelling – Residual stress

• Corrosion prediction

• Modelling of HISC (cohesive zone modelling)

• Fatigue assessments


Arctiv Materials I

Key figures

■ Duration: 5 years (2008-2012)

■ Total budget: 63,75 mill kr (39% from the Research Council of Norway)

■ Partners:

Oil companies: Statoil, ENI and Total

Engineering: Aker Solutions, Technip, GE Oil & Gas

Material suppliers: Scana Steel Stavanger, Nippon Steel Corporation, JFE

Steel Corporation, Trelleborg Offshore, Bredero Shaw, Brück Forgings,

MIRAS

■ Performers: NTNU, SINTEF (project management) and DNV (guidelines)


Arctic Materials - Workpackages

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• WP 1 - Steel fabrication and mechanical characterisation (comprises of extensive mechanical and fracture toughness testing, including standard welding processes and new, innovative weldments)

• WP 2 - Strength and toughness criteria for safe materials utilisation (micro-mechanisms in brittle fracture, special tests, various experimental techniques, modelling of brittle fracture, multiscale modelling, ......)

• WP 3 - Polymer coatings

• WP 4 – Light weight concepts and materials solutions


Fracture Control Offshore Pipelines Coupling between experimental results and numerical modelling


Fracture Control Offshore Pipelines Use of numerical modelling to derive simplified assessment approaches

Mismatch

Misalignment

Biaxial loading


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• Residual stresses are unavoidable in welded structures

– They affect the fracture, fatigue, and stress corrosion cracking behaviour in welded joints

– The welded structures and constructions suffers from restrictions set by these stresses

RESIA: Weld Residual Stress Simulation for Integrity Assessment - Project motivation

How to accurately quantify the stresses and assessing their effect on structural integrity are still fundamental issues: There is no easy way to characterise and quantify residual stresses

Present simulation tools are either too complex in use, or they are too simple for giving reliable results

Today’s practice for integrity assessment is quite conservative when it comes to residual stresses Residual stresses are usually conservatively assumed to be equal to the yield stress

Significant savings could be made: If the level and distribution of residual stresses could be predicted and included in integrity

assessment


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Fracture mechanics

testing and analyses

of offshore pipelines

From design to

decommissioning

Development of

procedures for

testing and

qualification of

offshore pipelines.

Involved in

development of all

new fields on the

Norwegian shelf

since 1997


Fracture Control – Offshore Pipelines I

Sponsors: Statoil, BP, Norsk Agip, Hydro,Technip, and Norwegian Research Council

Duration: 2002-2006

Total budget: 20 MNOK

Aim: To develop a methodology for

design against fracture and plastic collapse in offshore pipelines

Suitable for including calibrated partial safety factors

Compatible with current design standards

Compatible with other failure modes

PoF as function of crack depth and Length

1.0E-05

1.0E-04

1.0E-03

1.0E-02

1.0E-01

1.0E+00

0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0

Crack depth (mm)

Po

F

2c = 50mm

2c = 75mm

2c = 100mm

2c = 150mm

2c = 200mm

2c = 250mm


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Fracture Control Offshore Pipeline –

Phase II

Main aim of the project:

To develop a procedure for fracture assessment of pipelines subjected to plastic deformation including partial safety factors – building upon results from Phase I

Main tasks in the project:

Materials mismatch effects

Embedded/stacked defects

Strain history effects

Assessment models

Large-scale testing

Guideline

Duration: 2008-2012

Sponsors: StatoilHydro, ENI Norge, Exxon Mobil, Shell, Conoco Phillips Gasco, Technip, Tenaris,

Large-scale

testing

Numerical

modelling

Materials

characterization

Guideline


Enhanced Drill string Fatigue Calculation Joint Industry development Project

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Software for drilling tools design and integrity analyses

Real-time monitoring of drill string degradation

Drillstring material

characterization

Structural investigation

Fatigue

Material degradation

modelling

Realmod

AD

AT

T

D

A

AD

RVE

databases, testing

and simulations

Technology

implementation

and case studies Drillstring Trajectory

0 0.2 0.4 0.6 0.8 1 1.2

6000

5000

4000

3000

2000

1000

Damage

Depth

5% 95%

Failure Probability

5 mm


Hyperbaric Welding SINTEF is responsible for all welding procedure development and qualifications for pipeline tie-ins and repair welding for Statoil and the PRS consortium


DEEPIT – Deep water repair welding and hot tapping

2009-2013 Statoil NTNU Gassco SINTEF Technip IFE EFD Induction

http://www.deep-water.ne/


The SmartPipe project

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The SmartPipe vision

An on-line system reporting the technical condition of the pipeline through a combination of sensors, degradation models, and analysis tools

Self-contained, distributed sensors packages with locally produced power and wireless communication


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Lithium

batteries

Seawater

battery

61/30


Phase 1: Concept development

2006-2010

Budget 42 MNOK

Phase 2: Pilot test

2011-2013

Budget 35 MNOK

SmartPipe

http://www.forcetechnology.no/


Aasta Hansteen Design and

Qualification of Steel Catenary Risers

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The risers transporting the gas from the seabed to

the platform and further to Polarled will be pure

steel, which will be first of its kind on the

Norwegian continental shelf.

SINTEF is running test programs and analyses to

develop a design basis as well as input to

qualification procedures for the risers.


Offshore Services

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• Materials selection and qualification

• Corrosion and corrosion protection

• Surface and coating technology

• Welding and weldability testing

• Underwater/hyperbaric welding

• Fatigue and fracture mechanics

• Structural and pipeline integrity assessment

• Failure investigation and analyses

• Erosion and sand management

• Polymers and composites

• Materials Testing Laboratory

• Large Scale Testing Laboratory

• Structural Impact Laboratory

• Welding Laboratory

• Hyperbaric Welding Station

• Metallographic Laboratories

• Electron Microscopy Laboratory

• Corrosion Laboratory (incl. sea water loop)

• Multiphase Flow Loop

Some Laboratory Facilities

olje- og gassnettverk helgeland dialogsamling 5 nov, … · technology for a better society olje-...

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