Existing Underwater Pipelines with Leaks are Expensive to replace or Repair! Insertion of Thermoflex Tubing is:!
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- Reynold Jasper Ward
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1 Thermoflex Tubing! Reinforced Thermoplastic Gathering, Disposal and Injection Lines!! Offshore Rehabilitation of Existing Steel Pipelines! December 9, 2009!!!
2 Background! Existing Underwater Pipelines with Leaks are Expensive to replace or Repair! Insertion of Thermoflex Tubing is:! Low Cost! Requires Minimal Equipment! Long Term Corrosion Resistant Alternative! Can Create a Double Walled System!
3 Presentation Today! What is Thermoflex Tubing! Case Studies Of Installations! Next Steps!
4 New Engineered Plastics Provide Higher Temperature Strength Not Available From Polyethylene (PE)! Tensile Strength (psi) 7,000 6,000 5,000 4,000 PSI 3,000 2,000 1,000 PE Capron Fortron - 73F 250F
5 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 Outer Strength and Abrasion Layer
6 Long Term / Elevated Temp. Fuel Exposure Weight Change - Fuel CM15 (121 o C)! 10% N66-25% GR 5% Weight Change (%) HTN - 35% GR PPA - 45% GR PPS - 40% GR 0% Time, Hours
7 Polymer Estimated Life in Sour Environment (Years)! Temp (F)! Nylon! Fortron! HDPE! 80C! 1.2! >25! <.02! 100C!.26! >25! NA! 140C!.02! >25! NA! Source: Merl Report 2% H2S, 3% CO2, Balance methane in saturated brine water. Life defined as 50% reduction in yield strength
8 CO2 Permeability Permeation Coeff. (cm3 100micron)/(m2 day atm) PPS SKX-382 PPS SKX-372 Carilon P-1000 PVDF KF 1000 Temperature oc
9 Hydrogen permeation of Fortron (PPS) at 23 C PE PP H 2 PET 6000 Fortron PPS 4000 Vectra LCP Permeation [cm³/m² d bar]
10 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!
11 Why Aramid Fibers vs. Glass!
12 Creep Performance! Ø1.75 Creep 5000 lb 3.00% 2.50% 2.00% % Change 1.50% 1.00% 0.50% 0.00% -0.50% -1.00% -1.50% Time (Minutes) % Change Length % Change Diameter
13 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!
14 Rehabilitation Process! Pig Line to Assure Path for Thermoflex! Use Pig to Pull Rope or Cable Through the Line! Pull Thermoflex back Through Line with the Rope or Cable! Connect to Tie in Points!
15 Case Study for Crescent Existing Flexible Steel Line Failure! High Pressure Sour Gas with H2S (1,200PSI)! 6,000ft (1.83Km) between Platforms! Pulling 3.5 Thermoflex Through 8 Flex Steel! Petroleum!
16 Pull the Rope Through the Line! Rope or Cable! Rope Lighter Weight! Less Pigging Pressure! Flooding the line Reduces Drag! Pig for Pulling the Rope! Rope Rated for 34,000lbs!
17 Pulling Cone! Attached to Thermoflex Termination Coupling! 3 NPT Threads! Holes In Cone to Allow for Water to Flood the Inside of Thermoflex Tubing!
18 Prepping for the Pull! Spools had 1,800ft length of Thermoflex! Stage the Spools on the Platform!
19 Pulling the Tubing! Pull Force Never Exceeded 9,000lbs! Pull one Length of Tubing, Stop, Attach Union Coupling, Pull Next Joint! Pipe Pulled Through Flooded Steel Line!
20 Pulling From the Riser! Pipe after 6,000ft Pull (1.83Km)
21 Union/Splice Assemblies! Unions without Joints! 250lbs (113kg) Machine! 15 Minute Coupling Process!
22 Flange Assembly to original Steel Assembly to to Seal off Annulus! Terminations!
23 Hydro Test at 1850PSI! Pressure line in Stages! Stretch in Pipe Requires Topping Off Prior to Test! Ran for 24 hours!
24 Results! Total Project 8 days! 90% less expensive than Replacing Steel! Corrosion Resistant! No Disposal of Old Lines!
25 Pulling From Onshore to Offshore! Platform Gulf Of Mexico! 14,400ft Pull! Pigging Through Multiple Diameter Existing Pipe! Oil /Brine Flow Line! Install 2 3/8 Thermoflex!
26 Pre-pulling Issues! 4, 6 8 Line! Riser Radii too Small! Lift Riser onto Barge! Terminate Pull Through Before Elbow! Steel Riser but Could have used Thermoflex!
27 Pulling from Land to Platform! Staging Pipe on Land Easier! Braided Rope vs. Cable because of Drag Weight! Flooded Pipeline to minimize Drag! 14,400ft... Under 3,000lb Pull Force!
28 Results! 2 Weeks to Pig! 1.5 days to Pull! Essential to Make Sure a Pig Gets Through before Project Starts!
29 Key Planning Steps! Model the Project! Optimal Pipe Size/ Type! Pull Through Risers?! Pull Force Requirement! Determine Space Requirements! Safety / Testing Requirements!
30 Modeling! Thermoflex Tubing Steel Tubing Thermoflex ID Steel ID IDtherm = 1.220in IDsteel = 1.220in Length Operating Pressure (Gage) Operating Temp L = 14500ft P1 14.7psi = 1400psi T1 460R = 120 F Pressure Drop (psi) Thermoflex Tubing Steel Tubing Production (mcfd)
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