Innovative Field Trial Results of Flangeless Grooved HDPE Liner Application in a Super Gigantic Field for Oil Flow Line Internal Corrosion Management

Abstract

Abstract Objectives The ADNOC super gigantic onshore field suffered many cases of loss of containment in oil flow lines due to internal corrosion. The loss of containment caused by internal corrosion and need to determine specifications and accurate future flow line integrity management plan, led to a field trial application of Grooved and Flangeless HDPE Liner technology in 3.0km Schedule 80 API 5L Gr. B 6"flow line to eliminate this problem in the super gigantic ADNOC Onshore Field. Methods The field trial was initiated in June 2011 and installed in April 2012. The HDPE lined flow line was monitored for 5 years between April 2012 and December 2017. This paper presents the detailed extrusion of the HDPE material, installation, thorough monitoring program, results and integrity challenges of the technology validation in 3.5km and 3.0km pipe lines. A rolling machine reduced the OD of HDPE liner by 7% before drawing into the flow line by a pulling machine, the HDPE OD expands back to full size in the flow line. The trial was monitored closely with intensive program. An optimization process was followed (frequent monitoring of test spool vent, sample analysis, possible re-injection of any flow line vent pressure) assisted by thorough testing and analysis at the Borouge Innovation Center (BIC). Results This paper describes the successful 5 years field application of HDPE Liner as a cost efficient innovative method that eliminates oil flow line internal corrosion and ensures that Asset value is maximized. The results show that there is no chemical degradation after 5 years of use in oil well, few scratches were found that did not propagate into cracks. The outcome of this technology is a major breakthrough of a cost efficient technology for Company oil flow line internal corrosion management. Field validation of this technology had a positive impact on operator's flow line integrity management, giving more options for proactive flow line internal corrosion management and resulting in total cost reduction and improved HSE performance. Additionally, results from 6 spool sections of the tried oil flow line allows for extending the cost effective HDPE Liner technology to oil flow lines with less risk associated. This technology eliminates internal corrosion threats with huge Opex savings in chemical treatment programs as no chemical treatment is required. Novel This paper explains the value added to the company and the feasibility of using grooved/ PERT liners for high temperature and high GOR oil flow lines for maximum benefits. Finally, the paper advances knowledge in the clear impact on the internal corrosion management process that guarantee proper flow line design strategy that prevents uncontrolled release of hydrocarbons (oil) and loss of containment caused by leaks due to internal corrosion.