Thermoflex® Tubing - ExPERT by Polyflow

Thermoflex® Tubing Reinforced Thermoplas8c Gathering, Disposal and Injec8on Lines Overview and Case Studies May 22, 2013 Agenda •  Introduc8ons •  Key Considera8ons for Composite RTP •  Thermoflex® Product Overview •  Installa8on Case Studies •  Service and Technical Support •  Why Thermoflex® What are Reinforced Thermoplas8c Pipes (RTP) •  Constructed of three dis8nct layers •  Inner Liner –  Chemical Resistant Barrier Layer for Flow Stream –  Permea8on Barrier –  Smooth to minimize pressure drop •  Reinforcement Layer –  Sta8c and Cyclic Pressure Loading –  Withstand permea8on through the inner Liner •  Outer Jacket –  Abrasion resistant cover to protect reinforcement –  UV Protec8on Why Use Spoolable Reinforced Thermoplas8c Pipes? •  Minimize Corrosion Issues in Hydrocarbons, Brine, CO2 and H2S •  Significantly Reduce the Capital Cost Requirements Versus Steel for Surface Piping •  Rapid Installa8on 8es in Wells Fast (10 X faster than steel) •  Rehabilita8on of Exis8ng Flow Lines without Digging What makes Polyflow Unique ? •  Nylon, Polyphenylene Sulfide (PPS) and Kynar (PVDF) Liners –  No Ven8ng of Annulus –  High Temperature Applica8on •  Extremely Lightweight and Flexible Elimina8ng Conven8onal Equipment •  Aramid Fiber Reinforcement –  Superior Cyclic Loading Proper8es to glass –  Resistance to Corrosion and Chemical A_ack •  Pull Through Exis8ng Pipelines with Tight Clearances and Bends Key Considera8ons for Thermoflex® Surface Lines •  Reinforced Thermo Plas8c Pipes are Comprised of a Liner, Reinforcement Layer and Outer Jacket •  Liner Compa8bility with Fluids and Permea8on •  Water only – HDPE •  Water with Hydrocarbons, CO2 -­‐ Nylon •  Water with Hydrocarbons, CO2, H2S -­‐ PPS •  Reinforcement Layer Requires Sta8c and Cyclic Strength along with Chemical Resistance –  Aramid Fibers •  Outer Jacket to Protect the Reinforcement •  Couplings to Withstand the Environments –  Coated vs. Solid Stainless Liner Construc8on & Design •  Mul8-­‐layer Design –  Inner Liner •  Corrosion Resistance •  Low Permea8on •  No Sodening /Swelling –  Polymer Selec8on •  Nylon . . Hydrocarbons, CO2, Brine •  PPS . . . Hydrocarbons, CO2, Brine, H2S –  Backer Provides Low Cost Toughness •  Polypropylene, Nylon •  Mul8-­‐layer Keeps Costs A_rac8ve Inner Barrier Outer Strength and Abrasion Layer Nylon Chemical Compa8bility Fortron Chemical Compa8bility Why We Avoid HDPE Liners with Hydrocarbons Impact of 30% Swelling of HDPE on Pressure Drop Paraffin Tes8ng There is Adhesion to Unlined Metal Fihngs No Evidence of Paraffin Adhesion On the Piping Hot Oiling Thermoflex® •  Hot Oiling does not Soden and Swell Nylon or Fortron (PPS) •  Tes8ng at 210F •  Does not Reduce ID •  No Significant Change in Permea8on •  No Limit to Frequency of Hot Oiling •  Hot Oiling at 50% of MAOP for Coupling Reten8on Conclusions for Inner Liner Construc8on •  Liners should be Compa8ble with the Flowing Fluid –  Doesn’t Soden, Swell or Get Bri_le –  Does Effect Permea8on •  Swelling does Reduce the Diameter of the Pipe Increasing Pressure Drop •  Tes8ng Individual Components is not Always Accurate. . . Interac8on Between Fluids CO2 Transmission Data cc/M2-­‐day HDPE at 23 and 30C, MOCON Data Source Nylon at 25C and 35C PPS H2S vs. CO2 Permea8on Data cc/M2-­‐day 350 317 300 250 200 171 150 100 50 0 0.066 0.028 H2S CO2 23C 40/35C H2S at 23 and 40 C and CO2 at 23 and 35C Source: Mocon Permea8on Conclusions •  Permea8on does not Necessarily Harm Inner Liner •  Increased Permea8on Caused by Temperature and Sodening and swelling of Polymers •  Can Cause Jacket to Swell or Rupture if not Vented and Highly Temperature Dependent •  Permea8on of CO2 and H2S can Affect Certain Reinforcement Layers Reinforcement Layer Considera8ons •  Mul8-­‐layer Design –  Cross Braids Provide Axial Strength –  Longitudinal Braids Provide Tensile Strength to Minimize Stretch –  Aramid Fibers for Fa8gue and Strength •  Tubing Strength P=(2*F*n)/D*L Reinforcement Op8ons Aramid Steel Glass Strength High Medium High Cyclic Loading Excellent Excellent Poor H20 Environment Excellent Good Poor CO2/H2S Good Poor Good Rapid Impact Good Good Poor Cyclic Loading Impact on Aramid vs. Glass Burst Pressure (PSI) Sample 1 1,958PSI Sample 2 2,016 PSI Sample 3 1,958 PSI Baseline Un-­‐aged Samples 1,984PSI Avg/SD Aged Samples 1,953 +/-­‐ 66PSI 275PSI Rated 3” Thermoflex 300PSI Min Amplitude 100,000 Cycles 2 Seconds Per Cycle Short Term Burst (ASTM D1599) Ader Aging Glass Fibers in Contact with Water Aramid Fibers In Contact with Water Not all Aramids are Created Equal •  The Grade of Aramid is Very Important •  Select the Proper Grade for the Applica8on •  Not All Manufacturers are Created Equal Conclusions for Reinforcement •  Non Compressible Fluids See Cyclic Loading from Rod Pumps, PD Pumps, –  Need for Cyclic Loading –  Steel and Aramid Provide Superior Results •  Some Levels of Permea8on can Degrade Reinforcement –  Aramid Superior to Steel or Glass •  One must Assume the Outer Jacket can be Breached • 
Outer J
acket UV Resistance? Not Resistant Forever •  Prefer TiO2 package –  White keeps pipe cooler than black –  Long term Data on the addi8ves to the plas8c •  Does not help in Fire •  PP and Nylon Great Abrasion Resistance QC Control in Plant •  Con8nuous Wall Monitoring of Each Layer of Liner •  Lot Pressure, Elonga8on, Braid Pitch Tes8ng •  ISO 9001 Specifica8ons •  API 15S Is a Recommended Prac8ce not a Spec –  Working for Specifica8on Development –  Polyflow Follows the standard and Tests to the ASTM Standards of the Specifica8on –  Standard Focus is on Strength and Operators should ask the Compa8bility Ques8ons •  Plas8c Pipe Ins8tute (PPI) has formed a Composite Pipe Energy Group Couplings and Termina8ons •  Required for Each End of the Tubing •  Threaded, Weld, & Flange & Splice Styles Available •  Zinc Chromate Plated Carbon or Duplex Stainless Steel •  Fortron Lined Couplings 4” 10,000bbl/day Brine Flow Line 200K PPM of Salt Ader 4 Years of Flow with no Damage to Fortron Proper Material Selec8on •  West Texas •  Brine Disposal Line –  H2S and CO2 –  Zinc Chromate Carbon Steel Coupling –  High Velocity Sand Eroded Zinc Chromate •  Pinhole in Three Years •  NACE MRO175 Does not allow for Coa8ng in Sour Environments •  Solu8on Duplex 2205 Couplings Elimina8ng Welding •  Pre-­‐fab Risers –  Shop Fabricated –  Pre Tested –  Any Configura8on •  Couples Right to Thermoflex Tubing Tools For Coupling •  Portable Coupling Machines (250lbs) •  Up to 6.0” •  For Termina8on and Union Couplings •  10,000PSI Hydraulic Pump Installing a Splice Coupling Delivery of Tubing •  Comes on Spools •  Length Dependent Upon OD and Pressure Ra8ng •  Spools –  Minimum Deposit –  Easy to Break Down Installa8on Methods •  Direct Bury •  Con8nuous Plowing •  Trenching •  Pulled Through Exis8ng Steel Pipe –  Sizing Dependent Upon Restric8ons in Steel –  Pig with wire line and pull pipe Direct Bury •  Plow, Ditch witch or Backhoe •  Pre-­‐trenched ditches Over 10miles/day •  Pull Pipe off Sta8onary Spools •  Savings: $5-­‐6/d. Installed vs. Steel Equipment Required •  Trenching Equipment –  Backhoe, Excavator etc. –  Ditch witch •  A-­‐Frame •  Coupling Machine •  Backhoe can move Spools The Pipe is Light Weight •  2-­‐3/8” .78lbs/d. •  4.5” 2.2lbs/d. •  Pull Off Spool by Hand •  Minimize the Equipment Requirements Trenching Requirements •  No Sand Bedding •  Trench Depth Dependent on Frost Condi8ons •  Can be Used for Boring Applica8ons West Texas Brine Injec8on Line •  1,000PSI 4” Line •  2,500d with 22Line Crossings •  Installa8on Time 4.5 Hours (Excludes Trench) CO2 Injec8on System •  1” ID Thermoflex $4.10/d Replaced 1” ID Stainless for $14.30/d from 20d to 1600d –  Wet CO2 –  H2S from 200PPM to 10,000PPM •  40% Reduc8on in Installa8on Cost •  5 Times more Rapid Installa8on vs. Steel •  Reference Jessie Perkins Whi8ng Pulling Lengths •  Reel Remain in Place •  Drag out Single or Mul8ple Lines •  Mul8ple Colors for Different Type Lines •  Pull Two 5,000d Lines per Day Ditch Witching •  Great for “Virgin Land” –  8” Wide –  6d Deep •  Not Effec8ve for –  Numerous Pipe Crossings –  Large Rocks Laying with Steel •  Lay Parallel with Steel •  Steel will Slow down Installa8on Boring •  Same Procedure as Steel •  Conduit not Necessary but can be Used •  Polyflow can Determine the Pull forces Required Creek Crossings and Swampy Areas •  Pipe Floats In Water •  Cement Bags Hold it down •  Distance of River Crossing Tight Right of Ways Cold Weather Install •  Preheat Spools –  Increase Relaxa8on Time –  Minimize Cracking •  Polymers Great Insulators –  Long Time to Heat Up –  Long Time to Cool Down Installa8on Costs and Learning Curve for Contractors Cost per 7 $1.00 $0.90 $0.80 $0.70 $0.60 $0.50 $0.40 $0.30 $0.20 $0.10 $-­‐ 1 3 5 7 9 11 13 15 17 19 21 23 Inser8ng Thermoflex Inside of Exis8ng Pipelines •  Drama8cally Reduces Cost by Elimina8ng Trenching •  Steel, Fiberglass or HDPE Pull Through Steel Pipe •  Pull with Coupling or with Bolts for Tight Annulus •  Pull Strength Varies by Longitudinal Braids and Pipeline Layout •  Polyflow Models Pulls Pulling Cone Pulling Thermoflex Through •  2-­‐3/8” in 3” ID Steel •  Do not Recommend Pulling through Elbows •  Pull Speed 100d/min Inser8on into Exis8ng Pipe •  Pull Through Steel, Fiberglass, HDPE, Composite •  Pig Through Cable and Pull Pipe Back •  Rapid Inexpensive Repair Double Walled Salt Water Disposal System •  HDPE SDR9 Jacke8ng 3.5” 1500PSI SWD Line •  Annulus Piped Back to Storage Tank if a Problem with the Primary Pipe •  Replaced a Corroded Steel Line that Caused Contamina8on Monitored Double Walled System •  750PSI Sour Gas –  80,000PPM H2S –  100,000PPM CO2 •  Thermoflex Inside of Steel –  Annulus Sealed –  Monitored with Nitrogen for H2S Pick Up and Pressure Double Walled System •  Pull Thermoflex Through Carbon Steel •  Flanged Termina8ons •  Fill Annulus with Packer Fluid/ Inert Fluid •  Monitor Pressure on the Annulus Modeling Gathering Lines •  Liquid or Gas Modeling •  Comparison to Steel –  Smaller Diameter for Equal Pressure Drop –  Con8nuous Runs reduces Pressure Drops •  Less Erosion Issues vs. Steel 2 3/8” Steel Thermoflex Servicing •  Stock for the Local Market –  Pipe –  Stock of Couplings and Installa8on Equipment •  Local Sales Field Technicians –  Training for Local Contractors –  Spooler, Coupling Machines etc. Available •  Technical Design Support Why Thermoflex® •  Polymers Designed for Hydrocarbons –  No Sodening and Swelling –  Low Permea8on •  Aramid Fibers –  Cyclic Loading Resistance (Hydraulic Hammer) –  Resistance to Water •  Rapid Low Cost Installa8on •  Lightweight to Minimize Equipment Requirements •  No Issues with Paraffin –  Hot Oiling –  Blow Through Paraffin