spoolable composite pipelines · blaine weller, p. eng 12:00 september 19, 2018 cost-effective well...
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Spoolable Composite Pipelines API 15S Qualified, Corrosion Resistant, Lower Install Cost, Time to First Oil
Blaine Weller, P. Eng
12:00 September 19, 2018
Cost-Effective Well Site Facilities
Houston, TX
AGENDA – Spoolable Composite Pipelines
Introduction
Technology
Operating Envelope
Qualification to API 15S
Challenges
Deployment History and Case
Studies
Economics
• Founded in 2001 as
Flexpipe Systems
• Now Shawcor Composite
Production Systems
• Over 20,000 miles of pipe
and 160,000 fittings
installed worldwide
• 25 product, research, and
applications engineers and
technicians
• Over 15 patents
• Division of Shawcor (6,000
employees worldwide)
Introduction – Shawcor Composite Production Systems
4
Technology – FlexPipe and FlexCord
FlexPipe
PE Jacket PE Liner
Glass Fiber
FlexCord
PE Jacket PE Liner
Galvanized Steel Cords
• Helically wrapped, unbonded
• Up to 4” ID, FP 1500 psi at 180F, FC 2250 psi at 140F
• Will focus on these technologies as representative
• Electroless Nickel (ENC) coated carbon steel – Standard
material
• Externally coated with corrosion protective tape
• Duplex Stainless Steel – Optional material
Technology - Fittings
Technology - Fittings
Technology – Fitting Reliability
• Crimping pressure is
controlled by hydraulic
pressure to each piston
• Crimper pistons and dies
move independently
• Field friendly – no need for
precise fit up and
adjustments
• One-piece fitting increases
ease of fitting installation
• API 15S “Spoolable Reinforced Plastic Linepipe”
• Requirements for the manufacture and qualification of
spoolable reinforced plastic line pipe in oilfield
applications
• Internationally recognized; monogram program
• 2016 edition - contributors included Shawcor (CoChair),
all major manufacturers, Exxon, Saudi Aramco,
Marathon, Shell, Conoco Phillips, YPF, Chevron,
Occidental, PHMSA (US DOT)
Technology - API 15S Standard, 2nd Edition
• Review of the testing
requirements 15S
• Primarily reference the
FlexPipe product line
testing, which has been
successfully completed
Operating Envelope – Design & Testing to API 15S
• Two burst
tests on each
reel of pipe
• 7,400 psi
minimum
• 8,000 psi
typical
Operating Envelope – Burst Testing FlexPipe
Operating Envelope – Regression Testing
• API 15S Section
5.3.3.3
• ASTM D2992,
Procedure B
• Minimum 18
samples; over 10,000
hours
• Design Factor
applied to obtain
pressure ratings
CONFIDENTIAL
• From API 15S - “An engineering assessment shall be
conducted to verify that the materials will retain integrity
and fitness for purpose”
• “The assessment shall be based on testing and
experience and shall predict the aging of the material
under the influence of fluids or environment”
• In general, the fluid factor is set to 1 or 0
• Either compatible, or not
• Synthetically prepared crude oil is used for testing
Operating Envelope - Fluid Service Factors
Operating Envelope – 50% Aromatics in Oil Testing
• Full pipe samples and dog bone tensile samples
• Tested with 50% aromatics/solvents (cyclohexane,
toluene, xylene plus 50% hexane, heptane, octane, etc)
• Saturated at maximum operating temperature 180 °F
• Followed by pressurized hold tests; tensile tests
CONFIDENTIAL
Operating Envelope – Pressure Cyclic Testing
14
• API 15S, Annex G regression testing to ASTM D2992
• Minimum 18 samples; over 1 MM cycles
• Service factor of 0.1 applied to obtain cyclic rating
• Shawcor – 3 generations of cyclic testing machines
CONFIDENTIAL
Operating Envelope – Elevated temperature test
• API 15S Section 5.4.3
• Check for failure modes related to possible thermoplastic
degradation within the fittings
• Elevated temperature used to accelerate failure modes
• Tested at 225 °F (for design temperature of 180 °F)
• Minimum 277 hrs, 3,500 psi
α time-temperature shift factor
tDesign Life is the design life time (hours)
tTest test time (hours)
log log base 10
ΔT test temperature minus the
product's MAOT.
CONFIDENTIAL
Operating Envelope – Rapid Decompression Testing
16
• API 15S Section 5.5.1 & Annex C
• Saturate with CO2 at 180 °F and 1,500 psi
• Depressurize at 1000 psi/minute
• Examine for blistering, liner collapse, etc
CONFIDENTIAL
Operating Envelope – Minimum Bend Radius
(MBR) Test
• API 15S Section 5.5.2
• Samples held at operating MBR (7 ft for 4” pipe)
• Conduct 1000-hr hold test 4,000 psi at 180F
• Also conduct 1000-hr hold test on samples pre-
conditioned with 10 bending cycles to MBR
CONFIDENTIAL
Operating Envelope – Axial Load Test
• API 15S Section
5.5.3
• Hold sample at
allowable axial
tension load for
minimum 1 hour
(6,000 lb for 4”)
• Followed by 1000-
hr hold test at
4,000 psi, 180F
• Couplings included
CONFIDENTIAL
Operating Envelope – Impact Resistance
19
• API 15S Section 5.7.3; ASTM D2444
• Strike the pipe with 20 lb steel tup dropped from varying
heights
• Conduct 1000-hr hold test at 4,000 psi and 180F
• Passed test with a drop from 10 ft
CONFIDENTIAL
• Dog-bone shape polyethylene tensile bars were subjected to
accelerated UV exposure
• Testing to ASTM G155/ASTM D2565
• UV Formula for grey PE jacket includes:
• TiO2, Anti Oxidizer, HALS (Hindered Amine Light
Stabilizers), and Carbon Black
• Minimum 20 year UV life confirmed
• Greater than 50% of original elongation at break based on
accelerated exposure testing
Operating Envelope – UV Exposure Testing
20
• Typical chemical injection fluid carriers are aromatics,
water, or methanol
• Polyethylene is compatible with most oil industry
corrosion inhibitors, hydrate breakers, biocides, scale
inhibitors, paraffin dispersants, etc.
Operating Envelope – Chemical Injection
• Flow lines or gathering lines for
transfer of:
• Crude oil
• Natural gas
• Oil emulsion
• Produced/Injection Water
• H2S and CO2 compatible
• Enhanced Oil Recovery
• Fuel Gas lines or gas lift lines
• Well test temporary surface
lines (re-spool and re-use)
Operating Envelope – Typical Applications
Operating Envelope - Application Review
• Customer
completes the form
• Shawcor
Engineering
provides comments
for long life
• Engineering provide
Approval if
acceptable
• Acceptance
document returned
to customer
• Approval before
shipment of pipe
Operating Envelope - Typical Product Applications
Oil Gathering
40%
Gas Gathering
31%
Water Transfer
15%
Water Injection
14%
FlexPipe Applications History
No
degradation
Challenges and Solutions – Cyclic Service
25
Pressure cycling can degrade composite pipes
• Centrifugal pumps, ESP’s, reservoir pressure
• Triplex pumps, frequent on/off servicesRequires
attention
• In severe cases, the line moves
with cycles, twist can build and
over time may move into a corner
and cause a kink
• Ensure surface pipe is installed
per instructions
• Remove excessive slack in line
• Anchor line with dirt or sand piles
every ~300 ft
• Inspect pipeline monthly
Challenges and Solutions – Pipe Twist on Surface
Lines
Deployment - Methods
• Plowing
• Trenching
• Chain ditching
• Liner pulls
• Boring
• Surface lines
Deployment – Liner Pulls
28
• Insert spoolable composite pipe
through a failed steel line
• 4” FlexPipe can be pulled
through a 6” steel line
• Can pull multiple lines at one
time
• Install up to 2.5 miles / day
Case Study – Australia Hot Oil Emulsion
• 3” FlexPipe HT
• Oil Emulsion operated up to 750 psi at 180 °F
• Customer decision based on:
• Rapid installation
• Product durability while handling pipe in rocky terrain
• Long term operating reliability with no concern for pipeline corrosion
• In service for ~ 6 years with no issues
Case Study – Middle East Zero Flaring
• Well Flowback Operations with
4” FlexPipe HT
• Up to 1200 psi and 180 °F
• Produced oil emulsion
• Temporary surface installation
and re-spool; multiple times
• Customers estimate 30% overall cost savings
• Material cost similar to steel pipe, installation cost much
lower
• Approximately 1/4 to 1/2 the time vs installing steel
• Faster time to production
• Lower operating costs
• Eliminate Corrosion inhibitor
• Less fouling and lower friction (smooth PE liner)
• More production
• Lower pump energy costs
Economics – Spoolable Composite Pipe vs Steel Pipe
Summary – Spoolable Composite Pipelines
• API 15S Qualified and Industry Accepted
• Corrosion Resistant
• Lower Install Cost
• Time to First Oil
Thank You.
Questions?
Blaine Weller, P. Eng
September 19, 2018