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Collaborating Authors
Abstract Nonmetallic pipelines are gaining popularity across the Oil and Gas value chain from upstream to downstream applications. Among the top benefits are mitigation of corrosion hazards, lowering the total cost of ownership, and reducing carbon footprint. While nonmetallic pipes are increasingly deployed onshore and offshore, a focus on downhole tubular development and qualification is essential as these are lacking in literature. In this paper, the authors attempt to provide an overview of the technology status quo as well as highlighting implementation challenges on downhole applications and proposed a way forward to tackle such challenges. A detailed literature review on current technological advancements and market trends of non-metallic pipes is carried out with a particular focus on downhole R&D potentials and application progression towards more severe well conditions, while meeting the future Oil and Gas demands. A comparison of current market offerings of non-metallic pipes for onshore, offshore, and downhole applications is conducted, based on their design construction, material compositions, pipe dimensions, and operating envelope. In light of such comparison, there is a market gap of the intended target specs for downhole applications. Pipe design, material selection, and product qualification are also described in the process to highlight the effort needed for industrial standards to qualify the downhole tubulars. Manufacturing of pipe and connectors are briefly discussed as part of the challenges. A gap analysis is also conducted to address the downhole system and infrastructure challenges related to utilization of non-metallic components in drilling, completion, logging, intervention, and production conditions, as the existing qualification standards are not capable of adequately addressing the various possibility and combination of non-metallic pipe configurations and their components for the intended service conditions. This study identified the areas where R&D work is required for non-metallic pipes to be designed, tested, and qualified for application in demanding and aggressive well conditions (e.g., high temperature and pressure) in order to replace steel tubulars for improved properties.
- North America > United States (0.68)
- Asia > Middle East > Saudi Arabia (0.47)
Aramco and the American Concrete Institute (ACI) have launched a center of excellence for nonmetallic materials to develop and promote the use of nonmetallic materials in the building and construction sector. Dubbed NEx, the venture will be based at ACI headquarters in Farmington Hills, Michigan, and will leverage ACI's role as an authority and resource for the development, dissemination, and adoption of consensus-based standards for concrete design, construction, and materials. Aramco is a leader in the use of nonmetallic materials in oil and gas facilities to reduce corrosion, weight, and the cost of construction and operation. The initiative with ACI is part of the company's broader strategy to enter new markets, leveraging its hydrocarbon resources and technology to deliver advanced polymeric materials solutions across industries. The operator has laid over 6,000 miles of nonmetallic pipelines and integrated the use of a glass-fiber-reinforced polymer rebar in place of conventional steel in the construction of a flood mitigation channel at one of its refineries in Saudi Arabia.
- Energy > Oil & Gas (1.00)
- Government > Regional Government > Asia Government > Middle East Government > Saudi Arabia Government (0.94)
Abstract Non-metallic pipelines are slowly replacing steel tubulars especially in Oil and Gas industry as part of the mitigation strategy to have "corrosion-free" systems, longer life service and lower total cost of ownership. In this paper, authors attempt to provide a discussion of value proposition, technology status quo and future trends, focusing on system challenges on downhole applications, and proposed way forward to build the lacking ecosystem essential to deploy non-metallic tubular downhole. A brief discussion on current technological advancement of non-metallic pipes is supported with market trends towards higher pressure rating and higher temperature resistance pipes to meet stringent downhole well requirements. System challenges, load cases, testing requirement, financial aspect based on well construction and downhole condition are described in depth, focusing on a viable pathway to implement non-metallic tubulars in different wells throughout the lifecycle phases in different applications from water injection to oil and gas production. This study identified the lacking aspects of a fundamental ecosystem needed to confidently deploy non-metallic pipes downhole. By addressing the R&D work necessary for the industry to focus on, efforts can be guided to fill in the missing gaps to build a fundamental ecosystem in order to replace steel tubulars gradually for desired properties. Depending on application requirement, selected non-metallic pipes are designed with various constraints and practical considerations which eventually needs to be tested and qualified for application in demanding well conditions (e.g. wet high temperature and pressure). Other factors than pipe design play as integral component such as connection design and compatibility with existing casing and tubing accessories requires parallel development. Compatibility of connection, end-fittings, and supporting well accessories including drilling tools, completion packers, tubing and casing hangers requires thorough compatibility assurance. Logging tools, etc. are to be either delicately planned out or even require parallel development to accommodate the alternative pathway in place of traditional practices. Detailed study on how non-metallic tubular react to conventional drilling, completion and intervention activities is fundamental to ensure system integrity throughout the well construction process and well lifetime. Emphasis is placed on gap analysis of downhole infrastructure system and associated challenges to utilize non-metallic tubulars and related compatible components in drilling, completion, logging, intervention, and production conditions, as well as the lack of qualification standards for downhole non-metallic tubulars.
- Asia > Middle East > Saudi Arabia (0.28)
- Asia > Middle East > UAE (0.28)
- Well Drilling > Drilling Operations (1.00)
- Well Drilling > Drilling Equipment (1.00)
- Well Drilling > Casing and Cementing > Casing design (1.00)
- (9 more...)
Non-Metallic Materials & Technology for Pressurized Applications, Prospective and Value-Added
Qamar, S. (Department, University, City, State, Country โ Engineering Services, UET, Lahore, Punjab, Pakistan) | Al. Awadhi, I. (Company, City, State, Country โ ADNOC GAS, Abu Dhabi, UAE) | Gongade, A. S. (University/Company, City, State, Country)
Abstract Use of non-metallic and composite materials into process industry can avoid the most common problem of corrosion which will lead to better assets integrity, life-cycle cost reduction and faster projects delivery. However, there are several technical challenges with respect to the selection and utilization of Non-metallic materials. The objective of this paper is to promote the cost-effective non-metallic solutions in ADNOC Group Companies through development of new specifications, vendor support and single point responsibility. The desired performance of non-metallic materials in different applications for the designed life can be achieved through involvement of pre-qualified technology providers in design, engineering and installation based on proven performance track record. Exploring the non-metallic materials and related technology solutions at an early stage of project can ensure and maximize the payback. On the other hand, developing engineering procedures, technical & operational expertise, and standardizing qualification programs can fast track Non-metallic materials deployment for the identified opportunities. ADNOC Gas and Group companies have already been using non-metallics and composite materials in some applications, however it should be reviewed based on whole life cycle cost against the specific application and advance technology to benefit more. Generally, the projects viability is founded on capital expense (CAPEX) which is based on selection of specific material for application resulting into lower cost. However, in case of non-metallics it is important to analyze the potential application in totality before identifying non-metallic material. Whole life cycle cost analysis may be compared with carbon steel as a base case considering all the scenarios of using lined carbon steel, carbon steel with corrosion inhibition and other alternatives like HDPE pipe and Reinforced thermoplastic pipe (RTP). On the other hand, utilization of liners in rehabilitation of old pipelines when properly assessed can result into significant economical solutions depending on application and technology. The integrity management of such assets is always through the Inspection of non-metallics which is a major challenge, yet there are various conventional Non-destructive Testing (NDT) techniques are available which are selectively used for non-metallics in oil and gas industry based on their effectiveness and limitations. Technologies are being explored and recommended by non-metallic industry as it evolves for further development & qualification before considering for a field trial. Mandatory requirements for strict compliance are a must for overall project success and sustainability of non-metallics applications during operation. Developing and benchmarking design specifications, procedures, manufacturing process, QA/QC requirements and installation methods for non-metallic materials can result into shorter delivery period of projects, low construction costs, better assets integrity and without or negligible maintenance of assets of ADNOC Group Companies. Learning from experience of other reputed operators around the world having benchmarked their deployment of non-metallics would further enhance benefits and confidence of ADNOC Group in utilizing technologies and promoting the in-country value.
- Water & Waste Management > Water Management > Water Supplies & Services (1.00)
- Energy > Oil & Gas > Upstream (1.00)
- Energy > Oil & Gas > Midstream (1.00)
- (3 more...)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (1.00)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Piping design and simulation (0.95)
- Reservoir Description and Dynamics > Improved and Enhanced Recovery (0.94)
- Management > Strategic Planning and Management (0.88)
Abstract Corrosion in oil and gas operations is generally caused by water, carbon dioxide (CO2) and hydrogen sulfide (H2S), and can be aggravated in downhole applications where high temperatures combination with H2S introduce other challenges related to corrosion and iron sulfide (FeS) scale formation. The repair costs from corrosion attacks are very high and associated failures have effects on plant production rates and process integrity. To overcome this existing problem in upstream, nonmetallic composite materials were introduced for drilling, tubular and completions in high risk, corrosive environments. The goal being to increase the well life cycle and minimize the effect of corrosion, scale and friction in carbon steel tubulars. The new proposed materials have light weight, high strength, and superior fatigue resistance in addition to an outstanding corrosion resistance that is able to surpass many metallic materials. The economic analysis shows that utilization of nonmetallic tubulars and internal linings will yield substantial life cycle cost saving per well mainly due to the elimination of workover operations. However, with these advantages, composite materials pose several challenges such as single source provision, high initial cost of raw materials, the manufacturing process and the limitation of standards. As results, the polymer and composite solutions for upstream oil and gas are still very limited even in targeting low risk applications such as low temperature and pressure scenarios. Therefore, research & development (R&D) efforts are ongoing to increase the operation envelope and introduce cost effective raw materials for high-pressure, high temperature (HPHT) subsurface applications. The present paper highlights practical examples of nonmetallic materials selection and qualification for upstream water injection/producer and hydrocarbon wells. Several future NM applications in upstream will be summarized. Challenges and R&D forward strategies are presented in order to expand the operation envelope of current materials and increase NM deployment to more complex wells, i.e., extended reach drilling (ERD).
- North America (1.00)
- Asia > Middle East > UAE (0.29)
- Energy > Oil & Gas > Upstream (1.00)
- Materials > Chemicals > Commodity Chemicals > Petrochemicals (0.48)
- Asia > Middle East > Iran > Arabian Gulf > Arabian Basin > Arabian Gulf Basin > South Pars Field > Upper Khuff Formation (0.99)
- Asia > Middle East > Iran > Arabian Gulf > Arabian Basin > Arabian Gulf Basin > South Pars Field > Upper Dalan Member (0.99)
- Asia > Middle East > Iran > Arabian Gulf > Arabian Basin > Arabian Gulf Basin > South Pars Field > Sudair Formation (0.99)
- (4 more...)
- Well Drilling > Drilling Operations > Directional drilling (1.00)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (1.00)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Materials and corrosion (1.00)