bob johnson of flexpipe system on reinforced thermoplastic pipe
DESCRIPTION
re-enforced thermoplastic pipes for oil and gas applicationTRANSCRIPT
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Reinforced Thermoplastic PipesPipes
A Presentation forSouth Dakota School of Mines & Technology
Sep 30, 2009
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Outline
• Introduction• Benefits
C t ti d M t i l• Construction and Materials• Manufacture• Installation• Installation• Jointing Systems• Standards and Codes• Technical Considerations
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What is Reinforced Thermoplastic Pipe?
• A cost effective alternative to using steel• A high pressure pipeline system resistant to corrosion
S l bl d d i li t• Spoolable, ready-made, pipeline system• Reels can hold long lengths of pipe• 150 300 600 and 900 ANSI product in 2” 3” 4”& 6” ID• 150, 300, 600 and 900 ANSI product in 2 , 3 , 4 & 6 ID
sizes• Can handle normal operating temperatures
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Pipe Concept
• Corrosion of steel pipelines costs the oil and gas industry billions of dollarsAlt ti t i l i l d l ti i d i id• Alternative materials include plastic pipe and rigid fiberglass pipe
• Reinforced Thermoplastic Pipe (RTP) combines theReinforced Thermoplastic Pipe (RTP) combines the best features of both• Eliminates corrosion• Resists installation abuse• Allows high operating pressures
Si ifi tl b tt i th t l i• Significantly better economics than steel pipe
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Typical Applications
Flow lines for gathering and transfer of: • Crude Oil• Gas• Water
C d t• Condensate• Single phase, 2 phase & 3 phase streams• Sour applications (H S)• Sour applications (H2S)• Gases or liquids containing CO2
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% of Total Marketshare - Pipe in Alberta (2" to 6", 150 to 600 ANSI only)
80%
90%
100%
60%
70%
80%
40%
50%
% M
S
20%
30%
0%
10%
2004 2005 2006 2007 2008 2009
Steel Poly Flexpipe Fiberspar and Flexsteel
ERCB Permitted, MOP: 200psi to 1500 psi, Sizes: 2" to 6"
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Benefits
• Same benefits as thermoplastic pipe– Ease of installation
Plowable– Plowable– No corrosion
• Higher pressure ratingsg p g• Compact product designs
– Long lengthsS it bl f lli th h f il d i li– Suitable for pulling through failed pipelines
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Construction
St t l L (R i f t )
Cover
LinerStructural Layer (Reinforcements)
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Materials – Liner and Cover
Thermoplastic resins• HDPE - High Density Polyethylene• PEX - Cross Linked Polyethylene• PA - Polyamide
PVDF P l i lid Fl id• PVDF - Polyvinylidene Fluoride
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Materials – Reinforcements
• Reinforcing fibers:– Glass fibers– Carbon fibers– Carbon fibers– Aramids, para-aramids– High performance fibers (M5, Spectra, Vectran,
Zylon etc.)– Steel strips, wires, or cords
• Reinforcement matrix (if used):– Thermoplastic resin (HDPE, PA, PVDF)
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Construction Example – Flexpipe
ECR-Glass Fibers
HDPE Cover
HDPE Liner
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Pipe Manufacture Example - Flexpipe
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Pipe Manufacture - Flexpipe
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Installation
• Trenching• Chain Ditching• Plowing• Plowing• Liner Pull• Bore• Surface Lines
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Trenching• Easily lowered into the ditch• Welders are not requiredWelders are not required
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Chain Ditching• Minimal crews and equipment required
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Plowing• Reduces size of crew required
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Plowing• Multiple lines and couplings can be plowed saving time and money
Plowing a Coupling
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Liner-Pulls• Inserted through failed steel line• Line does not have to be de-rated• No corrosion for the life of the pipeline• No corrosion for the life of the pipeline
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Bores• Short distances under roads
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Surface Lines• White jacket Flexpipe
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Mechanical Fittings
Flanged End Fitting- Compatible with standard raised
face flanges
Pipe to Pipe Coupler- Used to connect two RTP
pieces together
Weldneck Fitting- Used to connect RTP to
steel pipe usingface flanges. pieces together. steel pipe, using standard field welding procedures.
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Electrofusion Fittings
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Fittings Configuration
Tee Wye Lateral
Pre-fabricated flow joints- Fabricated in controlled shop environment- Fully inspected
Available fully coated- Available fully coated
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Standards and Codes
• Overview • API RP 15S• API 17J & K• API 17J & K• ASTM D 2992• CSA Z 662• Department of Transportation
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Standards & CodesAPI RTP d t d i d lifi d dAPI - RTP products are designed, qualified, and manufactured in accordance with API RP 15S, API 17J or API 17K.
ASTM International – Some RTP products must meet the requirements of ASTM D2992 “Standardmeet the requirements of ASTM D2992, Standard Practice for Obtaining Hydrostatic or Pressure Design Basis for Fiberglass Pipe and Fittings”.
CSA – RTP products are covered in CSA Z662-07, “Oil and Gas Pipeline Systems”, Clauses 12 and 13.
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API RP 15STitl d “R d d P ti f th Q lifi ti f• Titled “Recommended Practice for the Qualification of Spoolable Reinforced Plastic Line Pipe”
• Covers:- Product Construction- Raw Material Selection- Qualification Requirements- Quality Control Requirements
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Regression pressure testing
API RP 15S – Qualification Testing
• API RP 15S prescribes an extensive program of product testing including regression
Elevated temperature pressure testing
Low temperature pressure testing
Minimum bend radius pressure testing
Installation pressure testing – samples retrievedtesting including regression testing, cyclic testing, joint testing, gas testing, bent
Installation pressure testing samples retrieved after liner insertion *
Installation pressure testing – samples retrieved after plowing*
Short term burst pressure testing
testing, and axial load testing Cyclic pressure testing
Pressure testing of samples subjected to reverse bending
Axial load testingg
Vent testing - gases venting from annulus
Impact resistance testing*
Thermal expansion & pressure expansion testing
*Kink testing*
Fitting gas leak testing
Thermal cycle testing*
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API 17J & API 17KAPI 17 J “S ifi ti f U b d d Fl ibl Pi ”• API 17 J - “Specification for Unbonded Flexible Pipe”
• API 17K - “Specification for Bonded Flexible Pipe”• Covers:• Covers:
- Functional Requirements- DesignDesign - Materials- Manufacturing- Documentation- Acceptance Tests- Marking
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ASTM D2992 – Regression Testing
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CSA Z662
• CSA Z662-07, “Oil and Gas Pipeline Systems”• Covers the design, construction, operation, and maintenance of oil and gas industry pipeline systemsmaintenance of oil and gas industry pipeline systems • Includes composite pipeline material for gathering and distribution applications• Defers to the qualification methods given in API 15S, API 17J and API 17K
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DOT – Department of Transportation
• RTP is currently being installed in unregulated areas in the United States
• RTP is currently not included in DOT Parts 192 and 195• RTP is currently not included in DOT Parts 192 and 195• Efforts are underway to work within the DOT special
permit process to install RTP in regulated areas.
• ASTM Standard for RTP pipe is in development- Work item WK11803 has moved to the final stages gwithin subcommittee F17.11
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Technical Considerations
• Pressure Capability• Strain Behavior• Installation Parameters• Installation Parameters• Operation Parameters• Permeation• Collapse
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Pressure Capacity
• Pressure capacity is dependent on:– Temperature
Some materials are temperature dependent• Some materials are temperature dependent
– Time• Contribution of thermoplastic liner decreases over timep• Some reinforcements also exhibit creep
– Reinforcement loadingC iti hi d th h dj ti t f• Capacities are achieved through adjusting amount of reinforcement and wrap angle
– Manufacturing process• Methods of handling, applying, and bonding
reinforcements affect performance
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Strain BehaviorD i bl t i b h i b hi d th h• Desirable strain behavior can be achieved through careful selection of construction and wrap angles
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Installation Parameters
• Acceptable ranges for the following parameters are defined for a given design:– Maximum tensile loading applied to pipe and
fittingsMinimum bend radius– Minimum bend radius
– Temperature range for pipe deployment and joining system installation
– Exterior abrasions and kinks
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Operating Parameters
• Cyclic pressure– Important to match pipe and fitting designs with
li ti ithi t bl li fapplications within acceptable cyclic performance envelope
• UV resistanceUV resistance • Chemical compatibility• Pigging• Hot oiling• Heat tracing
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Permeation
• Permeation considerations:– Does gas accumulate in annulus and create a
pressure that could collapse the liner?pressure that could collapse the liner?– Can gases that permeate through the liner vent to
atmosphere?p– Will gases that permeate through the liner create
an environment that is incompatible with reinforcement materials?reinforcement materials?
– Will gases that exit the pipe due to permeation create an environmental concern?
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Collapse
• Pipe must be designed to withstand liner collapse due to:due to:– Internal vacuum– External pressureExternal pressure– Pressure in annulus due to permeation
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The Evolution of Pipelining
RTP Products provide ti l tiproactive solutions
reducing the overall costs of pipelining projectsof pipelining projects,
eliminating the threat of corrosion and reducing g
damage to the environment.
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Thank you!Thank you!
Questions?
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