Banyu Urip Upper Perforation Shut-off: A Success Story of Hydroformed Expandable Casing Patch Installation to Reduce GOR and Maximize Oil Production

ExxonMobil Cepu Limited (EMCL), as the operator of Banyu Urip field in Cepu Block, Indonesia, observed several oil wells with high Gas Oil Ratio (GOR) after several years of production. Oil production curtailment was expected due to limited surface gas handling capacity. Additional stand-off against reservoir gas cap shall be established by performing top perforation interval shut-off to reduce GOR and maximize oil production. Perforation shut-off became more challenging due to high concentrations of H2S and CO2, relatively high reservoir temperature, long perforation interval, and total losses experience. The remedial solution required a V0 “gas-tight” qualification, live well execution, induced minimum to no formation damage, and provided minimum reduction of tubular Inner Diameter (ID) post remedial work to avoid significant production impact and allow future wireline tools deployment. Considering the high profile of Banyu Urip field, which currently produces ~29% of Indonesia’s oil production, EMCL selected the fit-for-purpose remedial method with the highest probability of success. The hydroformed expandable casing patch (patch) with Corrosion Resistance Alloy (CRA) material and its top-down expansion method was evaluated and selected. The re-designing of inflatable element was performed to improve durability in high temperature and verified by laboratory testing. Patches were installed and overlapped to cover the top perforation interval. Seals on top and bottom of the patch extremities formed V0 “gas-tight” sealing mechanism against the casing. The patches were deployed utilizing a smart coiled tubing. All patches were successfully installed as per plan. The wells were brought online with significantly reduced GOR post patches installation. This was the first installation of the patch utilizing smart coiled tubing and ~90 feet Coiled Tubing (CT) tower in sour wells within any ExxonMobil affiliates. The detailed technical preparation, strong safety culture and leadership as well as relentless learnings application have delivered a successful project to reduce Banyu Urip wells GOR and enable EMCL to maximize oil production.

Enhancing the Mechanical Properties and Formability of Cold Rolled Closed Annealed Sheet for Automobile Applications

Designers of high pace advanced vehicles in aerospace industries particularly vehicle manufacturing types are placing more needs at the sheet metal forming enterprise by designing components from the high strength thermal resistance alloy. The principle goal of the observation is to test the mechanical, formability parameters and Erichsen cupping values of a sample of cold rolled closed annealed sheet. The quantity of strain that a metallic sheet can tolerate just before localized failure is called limit strain. The boundaries of formability in sheet metal operations are defined regarding the primary traces via the forming limit diagram (FLD). To be useful for engineering purposes, FLD needs to be simple enough so its parameters can be evaluated without difficulty ideally by way of uniaxial tests. The consequences confirmed that the formability of steel having decreased percentage of carbon is forming lesser. It changed into pressure distribution and the grain density of the sheet verifies the formability. The best grouping of strength and ductile properties are noted for metal with the low carbon and higher forming assets.

Functionally Graded SS 316L to Ni-Based Structures Produced by 3D Plasma Metal Deposition

In this investigation, the fabrication of functionally graded structures of SS316L to Ni-based alloys were studied, using the novel technique 3D plasma metal deposition. Two Ni-based alloys were used, a heat resistance alloy Ni80-20 and the solid-solution strengthened Ni625. Different configurations were analyzed, for the Ni80-20 a hard transition and a smooth transition with a region of 50% SS316L/50% Ni80-20. Regarding the structures with Ni625, a smooth transition configuration and variations in the heat input were applied. The effect of the process parameters on the geometry of the structures and the microstructures was studied. Microstructure examinations were carried out using optical and scanning electron microscopy. In addition, microhardness analysis were made on the interfaces. In general, the smooth transition of both systems showed a gradual change in the properties. The microstructural results for the SS316L (both systems) showed an austenite matrix with δ-phase. For the mixed zone and the Ni80-20 an austenite (γ) matrix with some M7C3 precipitates and laves phase were recognized. The as-built Ni625 microstructure was composed of an austenite (γ) matrix with secondary phases laves and δ-Ni3Nb, and precipitates M7C3. The mixed zone exhibited the same phases but with changes in the morphology.

Experimental analysis on characteristics of CarbidicAustempered Ductile Iron

ADI is a material known for Impact toughness, hardness and wear resistance. CarbidicAustempered Ductile Iron [CADI] is a ductile iron which contains high wear resistance alloy carbides in its matrix and is produced by selecting proper composition of material through melting route. Two different alloy compositions of carbon equivalent close to the eutectic composition with variation in the chromium content are used in this study. A detailed microstructure characterization of the material is studied. Effects of austempering parameters on the mechanical properties like impact toughness, hardness and wear resistance are evaluated. Improvements in themechanical properties are found and are correlated with the microstructure. SEM analysis of the wear surface is also studied.

Modern high-resistance alloy steel used in railway transport

The article presents an overview of modern steel used in rail transport. Directions for the development of materials, technologies and constructions used in the manufacture of rail vehicles are, on the one hand, determined by the technical and economic requirements of industry and, on the other, by the continued emphasis of environmentalists on reducing fuel consumption and CO2 emissions. This generates innovation in the use of modern materials, processing methods and new design solutions and results in reduced vehicle weight. More bold forecasts today show that at the current pace of technology development, in the near future the mass of the vehicle will reduce by an average of 30%. Observing the trends and pace of rail transport development, it can be predicted that existing restrictions on the use of modern materials, such as high prices, technological conditions and difficult automation of large-scale production, can be predicted.

Influence of SLM Process Parameters on Porosity of Nickel Base Heat Resistance Alloy EP648

In this research EP648 nickel base heat resistance alloy was used for Selective Laser Melting (SLM). This alloy can be used for producing details at high mechanical and thermal load by SLM for aerospace, automotive, shipbuilding and energy industries. To define the influence of SLM process parameters on EP648 4x4x4 mm cubic specimens were fabricated with different process parameters (scanning speed, laser power, layer thickness). The porosity of fabricated specimens was determined by scanning electron microscopy of polished cross-sections.