polymers for the oil and gas industry
TRANSCRIPT
ISO 9001:2008 Certified
Customized SolutionsFast, Easy Installation
Superior Operating Life
Brady Walther
High Performance
Polymers for Oil and Gas
April 12, 2013, Houston TX
THE USE OF ENGINEERED POLYMERS FOR THE
TRANSPORT OF HYDROCARBONS WITH HIGH
LEVELS OF CO2, H2S AND BRINE TO ELIMINATE
CORROSION EXPERIENCED WITH STEEL PIPE LINES
IN THE OILFIELD
ISO 9001:2008 Certified
Customized SolutionsFast, Easy Installation
Superior Operating Life
AGENDA
Key Design Considerations for Reinforced Thermoplastic Pipes
Liners
Reinforcement
Outer Sheath/Jacket
Case Studies
2
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
History and Future of RTP Pipes
Available for 15 Years
Historical Focus
– Brine Flow Lines
– Natural Gas Lines
Rapid Low Cost Installation was the
Primary Driver
Lower Temperature Applications
(<140F)
Flowing Liquid Hydrocarbons
– Aromatics
– Condensates
Increased Exit Temperatures
– Horizontal Drilling Higher Flow
Rates
– Deeper Wells
H2S and CO2 Environments
• History • Moving Forward
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
What Are Reinforced (“RTP”)
Comprised of Three Distinct Layers
– Inner Liner for Fluid Transport
– Reinforcement Layer for Strength
– Outer Sheath/Jacket to Protect
Braid
Each Layer Designed for the
Application
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
Key considerations for Inner Liners
Chemical Compatibility
– Individual Components
– Interaction Among Components
Permeation
– Impact of Liquids and Fluids
– Impact of Temperature
Physical Properties
– Abrasion
– Cyclic Loading
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
Chemical Compatibility
• Nylon 11 Hydrolysis Impact in Pure Water and a CO2/Water Mix
• PPS Affects in Norsok M710 Solution for Typical Sour Solution
Volume (%) Composition
30 3% CO2, 2% H2S, 95% CH4
10 Distilled water (conductivity < 5 S)
60 70% heptane, 20% cyclohexane, 10%
toluene
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
Impact of Permeation
PPS H2S vs. CO2 Permeation Data
cc/M2-day
0.028
171
0.066
317
0
50
100
150
200
250
300
350
H2S CO2
23C 40/35C
H2S at 23 and 40 C and CO2 at 23 and 35C Source: Mocon
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
Impact of Temperature on PermeationCO2 Transmission Data
cc/M2-day
HDPE at 23 and 30C, MOCON Data Source
Nylon at 25C and 35C
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
Physical Properties of the Liners
Material
Mg
loss/1,000Cycl
es
304 Stainless 50 mg
Nylon 5 mg
PPS 17 mg
TFE 500
PP 15-20
• Taber Abrasion Performance
• Cold Temperature Cyclic Loading
Source RAL & George Fisher
• 1,000 Cycles with 300PSI
Amplitude
• 2 Degrees F
• Inspection for Crack
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
Key Design Considerations for Reinforcement Layer
Long Term Static Design Strength
Cyclic Loading Strength
Chemical Compatibility
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
Long Term Static Design Strength
Long Term Testing Per ASTM D2992
– Slope of Line is a Function of Reinforcement material
– Basis for all RTP’s
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
Impact of Cyclic Loading Utilizing Aramid Fibers
275PSI Rated Pipe
300PSI Pressure Cycle Amplitude
100,000cycles (20 year Design
Cycles for APP)
1 Cycle Per 2 Seconds
No Change in Unreinforced Product
Sample Number Burst Pressure
(PSI)
Sample 1 1,885
Sample 2 2,016
Sample 3 1,958
Baseline 1,984
Sample Average 1953.3
Standard Deviation 65.6
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
Impact of High Temperature and Acidic Environment on
Aramid Fibers
All Aramids are not the Same
Assume the Outer Jacket of RTP will be Breached
Test for Temperature and Environment
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
Key Considerations for Outer Jacket
Abrasion Resistance
Compatibility with Outside
Environment
Toughness
– Cold Temperature
– Rapid Impact
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
Case Study: High H2S Gas Line
750PSI Sour Gas
– 80,000PPM H2S
– 100,000PPM CO2
– 45C Operating Temp.
PPS Lined RTP Inside of Steel
– Annulus Sealed
– Monitored with Nitrogen for H2S
Pick Up and Pressure
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
Results After 18 Months
No Change in Fiber Strength in
High H2S/CO2 Environment
Consistent PPS Micrographs
Aramid Fiber
Break Strength
(N)
New Un-aged 900 +/- 80
Aged Fibers 910 +/- 90
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
Case Study: High Temp High CO2 Oil Flow Line
95C Operating Temperature
> 25% CO2
Oil/Brine/ Gas Flow Line
PPS Lined, Nylon Jacketed
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
Results after 2 Years
Ground was Saturated
– Nylon Subject to Hydrolysis
– Outer jacket replaced with Modified
PP
Coated Carbon Steel Couplings
Corroded
– Sand Abrades Coating
– New Lines with Solid Duplex 2205
Stainless
Customized SolutionsFast, Easy Installation
Superior Operating LifeISO 9001:2008 Certified
RTP Pipes Can be Used in Severe Oilfield Environments
Liners Must Be:
– Compatible with the Mix of Solutions
– Able to Handle Permeation at Temperature
Reinforcements Must Be:
– Withstand Long Term Loads (Static and Cyclic)
– Compatible with the External Environment
– Different Grades of Reinforcements Has Different Properties
Outer Jacket Must Protect the Reinforcment