Custom Coated Flowline Products - CCC

Custom Coated
Flowline Products
INDEX
1. Custom-Made Flowline Products with Internal Coating …………………
Page 2
2. Examples of Custom Fabricated Products by CCC Machinery ……….....
Page 3
3. Reasons to Coat Pipe Internally ………………………..………………………
Page 5
4. Cost Comparison ………........................………………..………………………
Page 5
5. Examples of Coated vs. Uncoated Internal Surfaces ….…………….……
Page 6
6. Examples of Coated Flowline Products ..……..………………………………
Page 7
7. Calculation of Hydraulic Efficiency ……….……………………………………
Page 8
8. The Effects of Internal Coating in Monetary Terms …….…………………
Page 9
9. Different Coatings for Different Applications ………….……………………
Page 10
10. Summary …………………………………………………..…………………………
Page 12
11. End User References ..…………………………………..…………………………
Page 14
12. Contact ……………………………………………………..…………………………
Page 15
Page 1
1. CUSTOM-MADE FLOWLINE PRODUCTS WITH INTERNAL COATING
CCC Machinery fabricates and internally coats pipes, fittings and spools according to customers’
designs and specifications without any limitations to size, shape or design and according to the
applicable international oil industry standards.
Scope of Products
line pipe
drill pipe
OCTG
fittings
spools
manifolds
flanged connections
sleeves for welded connections
These custom-made flowline products can be internally coated with a choice of Tuboscope Vetco’s
liquid and powder applied plastic coating products, which are highly resistant to chemical and
mechanical corrosion, thereby providing an unsurpassed longevity to drilling and flowline components.
Our flowline products also offer an economical and flexible method for field construction, tie-in’s,
terminations, modifications, and repair of internally coated lines, as they are designed for connection
by welding (in combination with Thru-Kote TM UB Sleeves) or with flanges.
A great number of upstream and downstream end-users in the oil, gas and water producing industries
worldwide have come to appreciate the the cost-saving and production-increasing properties of our
internally coated products.
Page 2
2. EXAMPLES OF CUSTOM FABRICATED PRODUCTS BY CCC MACHINERY
Manifold design by Saudi Aramco / KOC Joint Operations (Kuwait) for fabrication and internal coating by CCC Machinery
U-sections after welding
Manifold header after welding
Manifold header after sandblasting and prior to coating
Coated internal surface of pipe section
Page 3
Manifold components being packed for shipment to Kuwait
Manifold after assembly at customer’s site in Kuwait
We supply the following certificates together with all our fabricated products:
Mills’ Test Certificates for bare pipe, fittings, flanges etc. issued by manufacturers
Welding Procedure Specification (WPS)
Procedure Qualification Record (PQR)
Welder’s Performance Qualifications (WPQ)
Radiographic Examination Reports
Visual Weld Inspection Reports
Design drawings
Coating Inspection Certificates issued by Vetco Coating GmbH
Adhesion Test Report issued by Vetco Coating GmbH
Inspection Certificates for coating raw material issued by Akzo Nobel
Third party Inspection Certificate issued by customer’s prescribed inspection company
X-ray images are kept on file by us for a period of minimum 5 years from date of test certificate
and are made available to the customer upon request
Page 4
3. REASONS TO COAT PIPE INTERNALLY
protect against CORROSION
increase PRODUCTION RATES
improve HYDRAULIC EFFICIENCY by
 flow improvement
control DEPOSITION of
 paraffin, asphaltene & scale
minimize TUBING WEAR by
 erosion & abrasion
 mechanical damage
improve FLUID PURITY
reduce COSTS through
 extended tubular life
 less maintenance
 less workovers
 less fishing
 lower production costs
 lower purchasing investment compared to higher grade steel alloys (see comparison below)
4. COST COMPARISON
Steel Alloy
Cost Factor
Carbon Steel bare
Carbon Steel with Internal Coating
Stainless Steel 316L
Stainless Steel 904L
Inconel 625
Incoloy 825
100% (base cost)
150 - 200%
600%
900%
1800%
2200%
Page 5
5. EXAMPLES OF COATED VS. UNCOATED INTERNAL SURFACES
BaSO4 Scale
Non adhering BaSO4 Scale in an internal coated pipe, easy to remove/clean and easy to decontaminate.
Calcium Carbonate Scale
Scale deposits in uncoated pipe.
No scale deposits found in a coated pipe.
Salt Incrustation
Salt blocking after 5 hours in a non internally coated pipe.
No salt incrustation after 336 hours in internally coated pipe.
The difference between coated and uncoated pipe.
Page 6
6. EXAMPLES OF COATED FLOWLINE PRODUCTS
Coatings for
Drill Pipe
Tubing and Down Hole-Accessories
Casings
Valves
Line Pipe & Flow Lines
Spools and Fittings
Custom Coating
Line Pipe Coating
Jointing system UB Sleeve for internal coated line pipe
Page 7
7. CALCULATION OF HYDRAULIC EFFICIENCY (BARE VS. COATED 28" LINE PIPE)
Base Data
•
•
•
•
OD pipe:
ID pipe:
Length of Pipe String:
Gas Pressure:
•
•
Medium:
Density
•
Dynamic Viscosity:
•
Kinematic Viscosity:
•
Velocity of Medium:
Scenario a) 8,0 MPa
28"
27.25" (WT 0.375") = 692.15 mm
100 km, no geodetic difference
Scenario a) 8.0 MPa
Scenario b) 6.4 MPa
natural gas (rich on methane) at 20 °C
ρ: 0,78 kg/m³ at 0.1 Δp 013 MPa absolute pressure
at 8.1 MPa: 58.74 Kg/m³ (ρ = p / R x T)
at 6.5 MPa: 41.14 Kg/m³, (absolute pressure)
11.1 x 10^-6 pas at 0.1013 MPa absolute pressure,
gas constant, R, at 20°C: 470.38 j/kg k
ν=ηxRxT/p
ν = 11.1 x 10^-6 x 470.38 x 293.15 / (p+1) x 10^5
ν = 0.1889 x 10^-6 m²/s at 8.0 MPa
ν = 0.2355 x 10^-6 m²/s at 6.4 MPa
10 m/s
BARE PIPE - pressure 8,0 MPa
COATED PIPE - pressure 8,5 MPa
Roughness Factor, k
Reynolds No.
RE = v x ID / ν
Factor ID / k
acc. to Nomogram of
Prandtl-Colebrook
friction factor λR
Pressure Loss
Δp = ρ/2 x v² x λR x L/ID
0,08 mm (80 microns)
RE = 10 x 0,69215 / 0,1889 x 10^-6
= 36.641.080
= 8.651,8
λR = 0.0122
0,005 mm (5 microns)
RE = 10 x 0,69215 / 0,1889 x 10^-6
= 36.641.080
= 138 4300
λR = 0.0085
Δp = 58,74/2 x 10² x 0,0122 x 100000/0,69215
Δp = 5.176.826 Pa ~ 52 bar (5,2 MPa)
52 bar pressure loss (uncoated)
Δp = 58,74/2 x 10² x 0,0085 x 100000/0,69215
Δp = 3.606.805 Pa ~ 36 bar (3,6 MPa)
36 bar pressure loss (internally coated)
Conclusion:
Flow Improvement with Coating = 30,8%
Scenario b) 6,4 MPa
BARE PIPE - pressure 6,4 MPa
COATED PIPE - pressure 6,5 MPa
Roughness Factor, k
Reynolds No.
RE = v x ID / ν
Factor ID / k
acc. to Nomogram of
Prandtl-Colebrook
friction factor λR
Pressure Loss
Δp = ρ/2 x v² x λR x L/ID
0,08 mm (80 microns)
RE = 10 x 0,69215 / 0,2355 x 10^-6
= 29.390.658
= 8651,8
λR = 0,0124
0,005 mm (5 microns)
RE = 10 x 0,69215 / 0,2355 x 10^-6
= 29.390.658
= 138 4300
λR = 0,087
Δp = 41,14/2 x 10² x 0,0124 x 100000/0,69215
Δp = 3.685.155 Pa ~ 37 bar (3,7 MPa)
37 bar pressure loss (uncoated)
Δp = 41,14/2 x 10² x 0,087 x 100000/0,69215
Δp = 2 585 552 Pa ~ 26 bar (2,6 MPa)
26 bar pressure loss (internally coated)
Conclusion:
Flow Improvement with Coating = 29,8%
Page 8
8. THE EFFECTS OF INTERNAL COATING IN MONETARY TERMS
Effects of Internally Coated Tubing
Lower Flowing Pressures
Lower Abandonment Pressure
Lower Injection Pressure
Accelerated Revenues from Increased Production
Protection from Corrosion
Protection from mechanical damage
Protection from stimulation
Gas Production Field Results
Coating:
Reservoir Pressure:
Wellhead Pressure:
Tubing Size:
Coating Roughness:
Gas Capacity Coated Pipe:
Gas Capacity Bare Pipe:
TK-236
2,500psi
1,500 psi
5 ½” 13CR
< 5 microns (after 10 years)
1.88 million m3 per day
1.64 million m3 per day
The operator realizes a 15% increase in production capacity with internal coating.
$1.400.00
0
$1.200.00
0
$1.000.00
0
$800.000
80
60
50
40
30
20
Gas Rate MMCFD
70
$600.000
$400.000
10
$200.000
0
A
B
C
D
E
$0
We lls
Bare
A
Coated
Gas Production Field Results
B
C
D
E
Cost of Coating vs. Increased Revenues
Page 9
9. DIFFERENT COATINGS FOR DIFFERENT APPLICATIONS
Tuboscope Vetco Coating Product Line
Coating Type
Temperature
°F
°C
TK-2
Phenolic
(liquid)
Modified Phenolic
(liquid)
Epoxy Polyamide
(liquid)
Modified Novolac
(powder)
Urethane
(liquid)
Modified Ep-Phenolic
(liquid/powder)
Epoxy mod. Phenolic
(liquid/powder)
400°
204°
400°
204°
150°
66°
300°
149°
225°
107°
*
*
250°
121°
TK-70
Epoxy (powder)
175°
79°
TK-99
Polyamide
(nylon powder)
Modified Ep-Phenolic
(powder)
225°
107°
200°
95°
Modified Novolac
(powder)
400°
200°
TK-7
TK-21
TK-15
TK-33
TK-34
TK-69
TK-216
TK-236
Principal Service
Oil Production, Water injection, Co2 and organic acid
resistance.
Sour gas and oil to 300 °F, oil, gas and Co2 to 400 °F
Water, crude oil, mild caustic, mild hydrocarbons.
Oil, natural gas, fresh and salt water,sweet
corrosion(Co2), mild H2S, and alkaline service.
Paraffin and scale prevention.
Drill Pipe
Oil, fresh and salt water, Co2 acids, caustic
completion fluids, and gases in miscible injection
systems.
Oil, fresh and salt water handling service. Excellent in
stimulation acids.
High flexible coating for line pipe and tubing in oil,
fresh and saltwater service.
Surface and subsurface, water handling systems,
crude oil, mild caustic and mineral acids, and
disposal wells.
High pressure, sweet and sour oil/gas wells, and
tertiary oil recovery systems.
Coating Chemistry
Chemistry
Characteristics
Epoxy
Temperature limit 225ºF (95°C), the amount of flexibility and temperature
resistance are inversely related. Inherently have a fair amount of chemical
resistance.
Phenolic
Temperature limit 400ºF (204°C), high abrasion and temperature
resistance along with good chemical resistance. Can be brittle.
Epoxy Phenolic
Temperature limit 250ºF, produce a middle of the road coating with good
flexibility, temperature resistance, and chemical resistance.
Novolac
(Phenol /Epoxy/Cresol)
Temperature limit 400ºF (204°C), excellent chemical resistance in acid and
alkaline environments, temperature resistance close to a phenolic, and
flexibility similar to a phenolic.
Nylon
Temperature limit 225ºF (95°C), a thermoplastic, excellent flexibility and
abrasion resistance with very good chemical resistance.
Page 10
Polymeric Coating Systems for Down Hole Applications
Liquid applied, baked on
Powder applied, baked on
Factors determining Coating Selection
Environments
Pressure
Temperature
ph level
Velocities
Well/Line design
Well treatments
Types of Downhole Corrosion
Chemical corrosion: CO2, H2S, Cl, Oxygen, Water
Mechanical corrosion: SCC, Erosion, Fatigue
Electro-chemical, Galvanic corrosion
Coating Performance Influenced by
Pipe quality
Pipe handling systems
Pipe running procedures
Connection systems
Well intervention and wire line work
Design of wire line equipment
Primary Factors Influencing Flow Inside Pipe
Velocity of medium
Viscosity of medium
Geometry of pipe
Roughness of pipe surface
Primary Considerations When Selecting Internal Coatings
Compatibility with service environment
Applicator procedures & quality program
Pipe handling practices
Production practices
Mechanical properties of coating
Are formulator, coating manufacturer & applicator unified?
Page 11
10.
SUMMARY
IMPROVEMENT OF TUBING EFFICIENCY BY ELIMINATION OF INTERNAL CORROSION AND/OR SCALING
To a great extent, the profitability of production and injection wells depends on the lifetime of the used tubing string. The
replacement of a tubing string always creates additional costs for buying new tubes, for workover services, the inspection and
transportation of pipe. Also, lost production has to be considered as a major cost item.
Taking above facts into consideration it is easy to conclude the following:
The extension of the operational time between workovers means to be the key function regarding the profitability of the
production and/or injection well.
Among several possibilities such as the utilization of corrosion inhibitors or the utilization of high alloy steel, internal coating of
tubular has proven to be successful in practice:
Coating + inhibitors
Coating + high alloy steel
Almost all types of corrosion which appear in connection with oil production and water injection today, can be fought by
application of Tuboscope's internal powder coating systems.
Types of Corrosion:
CO2-Corrosion
H2S-Corrosion (up to 30% H2S content)
Oxygen Corrosion
Bacterial Corrosion
Saltwater Corrosion
Following the latest materials and application techniques, new internal coatings had been developed which can be utilized at
temperatures up to 200°C with a totally holiday free surface. Even gas pressures > 500 bar inside the production tubular with
rapid decompressions will not create any problem to Tuboscope Vetco's internal coating systems today.
Most of the tubing connections in use - which admittedly represent critical areas inside the string with regard to the
homogeneity of the internal coating - can reliably be coated according to Tuboscope's Coating's Procedures and Tuboscope's
SOP. With some caution during the trip-in (using Stabbing Guides) these critical areas remain holiday-free even after
installation.
OTHER ADVANTAGES OF INTERNAL COATING SYSTEMS
Among its major task to prevent corrosion, the internal coating provides other advantages, i.e. prevention of scale built-up and
improvement of volumetric performance.
Paraffin, carbonate deposits and salt scale as well as deposits of radioactivity containing materials can be delayed up to three to
four times if using internally coated pipe. This can be achieved because of the very smooth coating surface of < 5 µm. This very
low surface roughness also leads to a tremendous improvement of the hydraulic conditions (volumetric efficiency), which works
out very positively with higher production respectively injection rates. Production increase of > 20 % is achieved.
From time to time most production wells need to be stimulated with acid. Also for this type of work the coating will protect the
tubing string effectively. The best results for the extension of the operational time of a production well will be achieved if in
addition to the coated tubing all other components used for
production and injection are coated, i.e. packers, pup joints, subs, tubing hanger etc. Other downhole equipment in contact
with corrosive fluids should be coated as well.
Above ground the gathering lines, valves etc. should be coated to prevent corrosion.
Page 12
Example: CORROSION PROTECTION AND IMPROVED HYDRAULIC EFFICIENCY OF DRILL PIPE
Internally coated drill pipe are increasingly used since more than three decades. As a passive corrosion protection the coating is
acting as a barrier to avoid direct contact between the steel pipe and the corrosive medium (fluid/gases etc.), thus avoiding
corrosion.
Drilling:
Today's used drilling fluids can be classified as 'non corrosive' up to 'extremely corrosive'. Since within the lifetime of a drill
string the utilization will be for all different environments, possible corrosion caused by aggressive muds have to be considered.
Testing and Stimulation:
Downhole tests as well as stimulation services very often initiate extremely corrosive environments. Especially CO2 and H2S are
influencing the corrosion rate. Acids used for stimulation purposes in connection with high bottom hole temperatures lead to
high corrosion rates although stimulation periods are relatively short.
Storage of Drill Pipe:
Practically all drill pipes remain in storage for shorter resp. longer periods. This can happen directly at the rig site or at the pipe
yard. During this time the uncoated internal drill pipe surface very often is subject to the so-called rack corrosion. Left drilling
fluid, oxygen and condensate are generating a corrosive environment especially attacking the internal surface of drill pipe.
ADVANTAGES OF INTERNAL COATING
Corrosion Protection
Primarily corrosion within drill pipe is starting as a type of pitting corrosion. Due to cyclical stresses as encountered in drilling
any given section of the drill pipe in operation is permanently under tensile stress (weight of the string), internal respectively
external pressure (mud system) and under alternate compressive and tensile stresses due to the deviation of the hole being
drilled, the corrosion pittings develop into transversal cracks (notch effect). This phenomenon, which is called “stress corrosion
cracking”, is developing perpendicular to the main stress direction. Although the transversal cracks inside a drill pipe generally
develop over the entire length, a certain preference for the end areas is found in practice due to the change in cross sectional
areas. Washouts and/or ruptures predominantly up to one meter behind the upsets are known in the drilling industry.
With today's application of internally coated drill pipe the internal corrosion can be controlled. Without internal corrosion no
notch effect can occur.
Stress corrosion cracking with all consequences such as washouts and/or pipe ruptures does not represent a problem anymore
if drilling companies uses internally coated drill pipe. Even wireline cuts which may develop after some time in service especially within the tool joint and upset areas - do not limit the positive performance of internal coatings.
Hydraulic Efficiency
One major advantage of internally coated drill pipe is found in the improved hydraulic efficiency. Effected by the very smooth
(glossy) internal surface of the drill pipe, the pressure drop can be reduced considerably inside the drill string. This results in
either energy savings during drilling or (more probably) in a higher drilling speed since a higher pressure is available at the bit.
Energy savings of > 9 % and better
Circulation rates of > 14 % can be achieved
An additional positive effect is the reduction in scale build-up achieved by the glossy and smooth internal surface. Moreover, the
cleaning of internally coated pipe is much easier and more efficient.
Summary
Today more than 90% of the western world drill pipe are internally plastic coated providing a less risk drilling operation, an
increased life time and energy savings while drilling. It is standard to the drilling industry to day to utilize coated drill pipe even
during harsh drilling environments.

Corrosion mitigation costs are reduced by extending life of down hole tubular goods.

Lower descaling costs and longer production schedules.

Increased production in high volume wells or smaller pipe sizes can be utilized.

Greater mud velocities in drilling or reduced pump maintenance by reduction of pressure.

Eliminates contamination of a reservoir with corrosion products during water flooding.
Page 13
11.
END USER REFERENCES
The following customers are using coated industrial items for the oilfield, drinking water, waste water and sewage, as well as
for the mining industry.
Coated items are: pipes, pipe spools, fittings, flanges, valves (ball valves, gate valves, check valves) etc. coated with fusion
bonded powder coatings or thermal cured liquid phenolics.
Customer
Country
Customer
Country
ADNOC (Abu Dhabi National Oil Co.)
United Arab Emirates
Mobil
Germany
Agip
Congo
Mokveld Valves
Netherlands
Aker Subsea
Norway
NAM B.V. (Nederl. Aardolie Maatsch.)
Netherlands
Al-Furat Shell
Syria
NIGC
Iran
AMOCO
Scotland
NOC
Libya
AMOCO
Gabon
Normec Oilfield Products
Germany
ARAMCO
Saudi Arabia
OMV AG
Austria
Baker Hughes Inteq
Germany
Orbit Valve
Italy
Baker Oil Tools
Germany
Petro Valve
Italy
BEB Erdgas und Erdöl GmbH
Germany
Preussag AG
Germany
Bjorge Offshore
Norway
Raimondi
Italy
BP (British Petroleum)
North Sea
Ring-O-Valve
Italy
BP Expro (Britoil)
United Kingdom
RMA
Germany
BRDR Christensens Haner A/S
Denmark
Ruhrgas AG
Germany
CONOCO
Scotland
RWE
Germany
CONOCO
North Sea
SDT Valve
France
Conoco (UK) Ltd.
United Kingdom
Shell Expro
North Sea
DEA Mineralöl AG (formerly Texaco)
Germany
Shell Expro
Scotland
DEE (Deilmann Erdöl Erdga GmbH)
Germany
Solber & Andersen
Norway
Dong
Denmark
Sonatrach
Algeria
EA Mineralöl AG
Germany
Sonatrach
Algeria
EDECO
Netherlands
Statoil
Norway
EE Caledonia (formerly Occidental Petrol.)
Scotland
Sun Oil
Scotland
Elf Acquitaine
France
TOMEK (Total Oil Marine Aberdeen)
North Sea
Frames Process Systems
Netherlands
Tormene SpA
Italy
Gaz de France
France
UNOCAL
Netherlands
Gazprom
Russia
VAG
Germany
Haugesund Mek. Verkst
Norway
Vitas Srl
Italy
KOC (Kuwait Oil Company)
Kuwait
Waha
Libya
Kvaerner Subsea Contr.
Norway
Wintershall AG
Germany
Marathon Oil
United Kingdom
Zueitina
Libya
Please contact us if any detailed field reports from the existing end users are required.
Page 14
12.
CONTACT
Company Residence
Postal Address
CCC Machinery GmbH
Tubular Division
Palmaille 67
D-22767 Hamburg
Germany
CCC Machinery GmbH
Tubular Division
PO Box 50 10 40
D-22710 Hamburg
Germany
Name
Title / Function
Direct Tel.
E-mail
Detlev Wahl
Managing Director
+49 40 38022 7401
[email protected]
Sabine Kürtz
Assistant
+49 40 38022 7402
[email protected]
Ekkehard M. Ebert
Director Tubular Div.
+49 40 38022 7454
[email protected]
Björn Laubscher
Area Manager Sales
+49 40 38022 7453
[email protected]
Mohamed Drahmoune
Area Manager Sales
+49 40 38022 7452
[email protected]
Jorge Alejandro Prado
Area Manager Sales
+49 40 38022 7429
[email protected]
Niklas Hemptenmacher
Area Manager Sales
+49 40 38022 7456
[email protected]
Christian Wille
Order Processing
+49 40 38022 7476
[email protected]
Fax Number Tubular Division
+49 40 38022 7444
VAT Registration Number
DE 812668979
Company Registration Number
HRB 77678
Page 15