An HPHT project in the Gulf of Mexico for a Major US operator presented 18000psi and 300degF downhole conditions. The initial discussions on the project were held 3 years prior to project spud. The tie-back was going to be made of 3 strings due to well constraints. One string required a new dimension and grade combination of pipe. Two other strings were 'off the shelf' designs.
To satisfy the operator's requirement for a new pipe dimension, a study was conducted to validate the supply route. Also additional data was needed for validation of the pipe properties and repeatability of production.
Vallourec organized a mini-roll of the new pipe dimension, and 1000ft were produced. A dedicated Quality Plan was generated to support the intense mechanical testing regime required and generate pipe data. Working with the customer, the parties agreed upon the analysis method of results. The pipe was also provided for the connection
tests due to the new design requested.
To ensure quality and performance Material Performance Reviews were conducted. Within 6 months the mini-roll was produced to the agreed commitments and quality plan. This included pipe mapping for sample taking, optimizing pipe usage, and ensuring enough pipe was available for connection testing.
The data was generated at the mill both in MTR and database format. The mechanical properties – yield, strength, UTS, hardness, toughness had a quality assurance analysis performed, assessing it against the material specification and the window of production statistical consistency.