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Transcript of Thermoflex ® Tubing Reinforced Thermoplastic Gathering Lines and Downhole Tubulars Polyflow...
Thermoflex® Tubing
Reinforced Thermoplastic Gathering Lines and Downhole Tubulars
Polyflow Overview
Why Use Thermoflex Tubing
• Corrosion Resistance/ Hydrocarbon Resistance
• Rapid Installation vs. Steel
• Paraffin or Scale Issues• Reduced Pressure Drop vs. Steel
Advantages of New Polymers
– Polyethylene has been Available for Years. • Good to 60C Operating Temperatures• Paraffin Adheres to Polyethylene• Poor Permeation Properties
– New Polymers with High Strength, Improved Corrosion Resistance, and Higher Temperature Performance Now Available
– Multi-Layer Technology has Reduced the Costs of Liners for Severe Applications
New Engineered Plastics Provide Higher Temperature Strength Not Available From
Polyethylene (PE)
-
1,000
2,000
3,000
4,000
5,000
6,000
7,000
PSI
73F 250F
Tensile Strength (psi)
For
tron
Cap
ron
PE
Liner Construction & Design• Multi-layer Design
– Inner Layer for Corrosion Resistance, Low Permeation and Higher Temp Strength . . . Nylon and Fortron
– Outer Layer for Higher Temperature Strength, Abrasion Resistance . . . Capron or PP
• Fully Bonded
• Applications to 250F
Inner Barrier
Reinforced Tubing Design and Construction
• Multi-layer Design– Inner and Outer Barrier
Layers– Center Layer Provides
Higher Temperature Strength
– Fiber reinforced with Kevlar for Strength, Tensile Load, and Burst
• Tubing Strength P=(2*F*n)/D*L
0 1000 2000 3000 4000 5000 6000
Time, Hours
Wei
gh
t C
han
ge
(%)
Long Term / Elevated Temp. Fuel ExposureWeight Change - Fuel CM15 (121oC)
HTN - 35% GR
PPA - 45% GR
PPS - 40% GR
N66 - 25% GR
10%
5%
0%
0
20
40
60
80
100
120
20 60 60
degrees C
perm
eati
on
rate
(1)
PK PA11 HDPE
CO2 Permeation(0%, 50% relative humidity)
all data measured at independent laboratoryall data measured at independent laboratory
(50% relative humidity)
(1) units = (10(1) units = (1099 * cm * cm3 3 * cm) / (cm* cm) / (cm22 * s * bar) * s * bar)
CO2 Permeability
0200400600800
100012001400160018002000
0 10 20 30 40 50 60 70 80 90
Temperature oC
Per
mea
tion
Coe
ff. (c
m3
100m
icro
n)/(m
2 da
y at
m)
PPS SKX-382
PPS SKX-372
Carilon P-1000
PVDF KF 1000
Tensile Performance
Ø1.75" Elongation
0.00%
0.50%
1.00%
1.50%
2.00%
2.50%
3.00%
3.50%
4.00%
0 2500 5000 7500 10000 12500 15000
Load (lb)
% E
lon
gat
ion
Creep PerformanceØ1.75 Creep Test @ 5000 lb
-1.50%
-1.00%
-0.50%
0.00%
0.50%
1.00%
1.50%
2.00%
2.50%
3.00%
1 10 100 1000 10000 100000 1000000
Time (Minutes)
% C
ha
ng
e
% Change Length % Change Diameter
Design Strength vs. Short Term Burst Strength
2 3/8” 500PSI Rated Burst Strength
Rated Braid Strength 500PSI
Design Braid Strength 893PSI
Short Term Burst
Avg. Last 12 Months
2,297PSI
Testing Standards
• ASTM D 2513 Thermoplastic Gas Pressure Pipe Not Fully Adequate– Reflects Poor Creep Properties of Polymers
ASTM D1598– Reinforced Polymer Tubing Enhanced with
Creep Resistant Fiber
• ASTM D2292 does not Reflect Excellent Fatigue Resistance of Thermoplastics and Aramid Fibers
Paraffin TestingNo Evidence of Paraffin Adhesion
On the PipingThere is Adhesion to Unlined
Metal Fittings
Delivery of Tubing
• Comes in Spools
• Length Dependent Upon OD and Pressure Rating
• Spools can be Broken Down after Use
Couplings and Terminations
• Couplings Swedged on Both Ends
• Duplex Stainless Grade
• Any Thread or Connection Available
• Swedged in the Field or Plant
Coupling Requirements
• Couplings are Duplex Stainless or Plated Carbon Steel
• Swedged in the Field
• Flanged Connections Available
Portable Coupling Machines
• 55 KG
• 1” to 3.5” Couplings
• Hand Pump or Enerpac
Installation Methods
• Direct Bury • Continuous Plowing• Trenching
• Pulled Through Existing Steel Pipe– Sizing Dependent
Upon Restrictions in Steel
– Pig with wire line and pull pipe
Direct Bury
• Plow, Continuous or Backhoe Trenching
• Pre-trenched ditches = 2 Km per Hour
• Pull Pipe off Stationary Spools
• Savings: $5-6/ft Installed vs. Steel
West Virginia Brine Disposal Line
• 4.5” Thermoflex, 500PSI & 750PSI
• 10ft. Spools for Shipping
• Unwind or Drag Off
Water Disposal Line
• Spool Weight 2,500lbs
• No Trench Padding
Inserting In Steel Pipe
• Pig Cable Through
• Pull Pipe Back Through
• Tensile Load Based Upon Drag
• Capable of Multiple Kilometer Pulls
Pull Through Steel Pipe
• Pull with Coupling or with Bolts
• Pull Strength Varies by Longitudinal Braids
• Polyflow Models Pulls
Pulling Thermoflex Through
• 2 3/8” in 3” ID Steel
• Do not Recommend Pulling through Elbows
• Pull Speed 100ft/min
Termination Connections
• Threaded. Flanged or Weld Style
• Pull Tubing, Clamp it, Couple It, Pulls Back into Tube
Double Walled System
• Pull Thermoflex Through Carbon Steel
• Flanged Terminations
• Fill Annulus with Packer Fluid/ Inert Fluid
• Monitor Pressure on the Annulus
Brine Disposal Example
• 2,200bbl/day
• 300psi Operating Pressure
• 85C Operating Temperature
• Ditched and Pulled in Pipe
Installation Through Hills
• Pull from Top to Bottom if Possible
• No Special Backfilling Requirements
• Utilize Load Cell to Limit Pull Force
Gas Flow Line
• 300MCF/day
• 500psi Operating Pressure
• 1.75” OD Pipe
• Fortron Lined for Corrosion Issues
Line Terminations
• Threaded, Flanged or Welded Terminations
• Couplings for Standard Sized Threads, Flanges or Pipe Sizes
So Why Use Polymer Liners and Reinforced Tubing?
• Rapid Installation Time and Reduced Cost
• Enhanced Corrosion Resistance/ Hydrocarbon Resistance
• Flexibility for Tight Applications
• Reduced Pressure Drops
Modeling Gathering Lines
• Single or Multi-phase flow
• Comparison to Steel– Smaller Diameter for
Equal Pressure Drop
– Less Effects Due to Continuous Runs
Thermoflex ID
ID 1.880in
Operating Pressure(Gage)Length Operating Temp
L 9500ft P 400psi T 460°F 120°F
0 500 1000 1500 2000 25000
100
200
300
400
500
600
Thermoflex TubingSteel Tubing
Flow Rate (bbl/day)
Pre
ssur
e D
rop
(psi
)
Thermoflex
2 3/8” Steel
Where to Get Help
• www.polyflowinc.com
• Call Main Office: 610 666 5150
• Call Dale Sannipoli: 951
Reinforced Thermoplastic Tubing for Velocity String and Downhole Tubing Applications
for Oil and Gas Production
Technical Background and Case Studies
EOG Lunch and Learn
January 16, 2008
Why Use Thermoflex® Tubing For Gas Wells?
• Reduced Pressure Drop & Increased Gas Flow Rates
• Excellent Corrosion Resistance
• Minimum Ongoing Maintenance
• Low Cost Installation
Why Thermoforming Plastics?• Polyethylene Should not be used in Wells
– Poor Hydrocarbon Resistance
– 60C Max Operating Temperature
• Higher Temperature/Corrosion Resistant Polymers Available– Polyphenylene Sulfide (Fortron/PPS) (120C)
– Nylon (85C)
• Extrusion Options for Engineered Plastics
Target Applications
• Low Pressure Wells
• Wells with Liquid Loading Issues
• High H2S and CO2 Environments
• Wells with Paraffin or Scale Buildup Issues
• Used In Conjunction with a Submersible Pump to Remove Water and Solids from CBM Wells
What Are Thermoflex Strings• Multi-layer Reinforced
Polymer Coiled Tubing– Inner Layer Corrosion/Flow
Layer
– Aramid Fibers for Strength and Creep
– Center Layer for Strength to 120C max.
– Sizes Compatible with Coil Tubing Injectors
– Less Force Requirements
– Required Couplings on Each End
Channeling the Gas
• Small Diameter Tubes . . . No U-Tubing
• Set Above Lowest Gas
• Packer or Cone
Benefits of Thermoflex® For Velocity Strings
Reduced Surface Roughness of Engineered Plastics vs. Steel – Steel Relative Roughness .005
– Thermoflex Relative Roughness .00005
• Material Compatibility of Polymers . . .– Enhanced Corrosion Resistance
– Minimizes Buildups of Paraffin and Asphaltenes
Interesting FindingsWell Energy Balance
cp Tbh cp TscVsc
2
2 g L f
L
IDtubing
Vsc2
2
kVsc
2
2
2 L40 ft
cp Tloss
Bottom Hole Energy
Exit Energy
Velocity
Gravity Friction Couplings ThermalTransfer
Where is the Energy LostDye #2 Well @ 8ft/sec.
0.1% 2.5% 0.1%
70.3%
27.0%
0%
10%
20%
30%
40%
50%
60%
70%
80%
Velocity Friction Couplings Thermal Gravity
Steel Pipe Energy Loss
Where is the Energy LostDye #2 Well @ 27ft/sec
0.1%
40.5%
0.5%
38.9%
20.0%
0%5%
10%15%20%25%30%35%40%45%
Velocity Friction Couplings Thermal Gravity
Steel Energy Loss
Pressure Drop 1 3/4 ThermoflexWHP=5psi, WHT=60°F, 3500ft Dp., Ø1.75 Tubing
0 20 40 60 80 100 120 1400
5
10
15
20
25
30
35
40
45
50
ThermoflexSteel
Velocity (ft/s)
Pre
ssur
e D
rop
(psi
)
Steel
Thermoflex
Liquid Loading Example• 1.75” Velocity String for
2,591M Well• Weight 1,560Kg• Thermoflex inside of
2 3/8” Steel• Conventional Coil
Tubing Unit
Safety Considerations
• Diamond Cut Slips Only
• Same Pack Off
• Shears Work
• 5,818Kg Tension Before Pipe Slipped in Coil Tubing Blocks
Installation
• Install at 30M/min
• Couplings Through Injector
• Bottom Plugs Float Tubing
• Set 3 Meters above Perf Zone
•
Reed A1 Performance
160
240
5065
MCF/day psi
Steel Polymer
Slim Hole Completion Case
Background
• 1,959M, 2 7/8” Casing
• 28 Bar Shut In
• Liquid Loading
• Swabbing or Shut in to Reduce Water Level
Results From Thermoflex®
595
1,473
-
200
400
600
800
1,000
1,200
1,400
1,600
M3/day
Multi-Zone Case
• Five Perforation Zones over 304M
• Weekly Soaping and Blowing/ Monthly Swabbing
• Where to Set the Tubing?
Results of Multi-zone Case
Benefits of Thermoflex Tubing
0
50
100
150
200
1 7 13 19 25 31 37 43 49 55 61 67 73 79 85 91 97
Cumulative Days
MC
F/d
ay
Injection Applications
• Gas Injection
• Chemical/ Fluid Injection
• Banded to Tubing or Free Hanging
• Submersible Production Applications
Utilizing Submersible Pumps off of Thermoflex Tubing
• Increases Fluid Velocity to Lift Solids
• Rapid/Low Cost Installation and Removal
• Suitable for CBM
• Resists CO2