Gas Production Equipment Research Articles

The impact of low-molecular carboxylic acids on carbon dioxide corrosion of steel in underground gas production equipment in the Dnipro-Donetsk basin fields

The impact of low-molecular carboxylic acids on carbon dioxide corrosion of steel in underground gas production equipment in the Dnipro-Donetsk basin fields

OPTIMIZATION OF MAINTENANCE PERIOD FOR OIL AND GAS PRODUCTION EQUIPMENT WELLS IN TUBAN EAST JAVA FIELD USING MGR AND BERNARD’S APPROACHES

Mechanical failures can cause Electric Submersible Pump (ESP) disruptions, shortening their lifespan. Despite improvements in run-time, unexpected failures still result in significant production deferment and loss, especially for oil & gas production equipment in Tuban East Java (TEJ) field. Therefore, we used Reliability Centered Maintenance (RCM) to analyze FMEA, employing two methods: Montgomery and Runger's (MGR) and Bernard's approaches. The MGR approach provided a better prediction of the failure rate. The ESP flat cable has the highest RPN, requiring maintenance of US$59,342 for an ideal 509-day period.

О МЕХАНИЗМАХ ОБРАЗОВАНИЯ НАНОСТРУКТУРНЫХ ЭЛЕКТРОЛИТИЧЕСКИХ ПОКРЫТИЙ Fe-Ni, Co-Mn, Ni-Cr С ФУНКЦИОНАЛЬНЫМИ СВОЙСТВАМИ

The evolution of modern industry is impossible without the development of new materials and technologies. Nanostructured coatings, in particular electrolytic coatings, are among the most demanded in mechanical engineering. The purpose of this work was to study the different mechanisms of obtaining Fe-Ni, CoMn, Ni-Cr galvanic alloys and their relationship with the specified universal physical and mechanical properties. Fe-Ni alloy is characterized by high microhardness and corrosion resistance in sea water, low cold brittleness; Co-Mn – by a specified phase composition (α-Co >> α-Mn, amorphous and metastable phase Co(OH)2); Ni-Cr – by high coating microhardness, specified phase composition. The main methods of production: high-frequency alternating current for Fe-Ni and Co-Mn alloys; introduction of a special additive (carbamide or H-acid) for Ni-Cr alloy. The main mechanisms are: Fe-Ni due to phase transition α-Fe ε-Fe; Co-Mn by means of high-frequency alternating current and carbamide addition, providing a specified phase composition; Ni-Cr by means of stationary method of addition of H-acid (high-chromium alloy of 68 mass percent of Cr) and carbamide (low-chromium alloy of 25 mass percent of Cr). Recommended uses for electroplating: Fe-Ni – for protection of oil and gas production equipment in the Arctic; CoMn – in modulation systems and as a nanocatalyst in the Fischer-Tropsch synthesis reaction; Ni-Cr – for corrosion-resistant protective coatings in petrochemistry and for resistive elements.

Additive manufacturing multi-material components of SAF 2507 duplex steel and 15-5 PH martensitic stainless steel

The study reports the successful deposition of 15–5 precipitation-hardened (PH) martensitic steel on SAF 2507 duplex stainless steel (and vice versa) to form functionally graded materials (FGMs) using powder-based, directed-energy-deposition (DED) technology. The evolution of the microstructure and the mechanical properties of the 15–5 PH/SAF 2507 functionally graded material in the as-built state were investigated systematically. The results proved that the microstructural transition zone (MTZ) is formed above the fusion line due to the dilution effect of both steels. The phase composition of the MTZ consists of ferrite and, in comparison to the base materials, an increased amount of austenite. The interface has the lowest hardness owing to the formation of a significant proportion of the austenitic phase. However, the tensile mechanical properties were not affected by the interface as failure occurred in both SAF 2507 and at the interface regions. The research presents a promising application of FGMs in a horizontal configuration to form a high - quality, metallurgical joint between heterogeneous materials. This study introduces a novel approach by additive manufacturing (AM) of heterogeneous multi-materials, merging the favorable properties of duplex SAF 2507 and martensitic 15-5 PH stainless steels through superior metallurgical bonding. The combination of SAF 2507 and 15-5 PH in a functionally graded material has not been previously explored, as the existing studies deal with the duplex stainless steels SAF 2507 and either martensitic stainless-steel 15-5 PH deposited separately by laser powder-bed-fusion (L-PBF) or DED methods. This research pioneers the investigation of these materials in tandem, paving the way for the development of novel FGMs with optimized properties for specific applications. The resulting FGM exhibits exceptional corrosion resistance and high strength, making it highly versatile for applications in diverse industries such as offshore oil and gas production, aerospace, aviation, and chemical processing equipment.

Study of carbon dioxide corrosion products by the X-ray diffraction method

The internal carbon dioxide corrosion is one of the most common types of corrosion in the gas fields development. The results of studying the composition of carbon dioxide corrosion products by X-ray diffraction method are presented. FeCO3 is the main product resulting from dissolution of steel upon carbon dioxide corrosion. Siderite is characterized by the phenomenon of isomorphism in the crystal structure (a change in the chemical composition of the phase at the same crystal structure). In this case, some of the iron ions in FeCO3 can be replaced by manganese, calcium, and magnesium ions. It is shown that phases of the precipitates of non-stoichiometric composition (CaxMgyMnzFe)CO3 thus formed are poorly crystallized which is attributed to the presence of defects in the crystal structure. They will exhibit inferior protective properties compared to stoichiometric FeCO3. The film of FeCO3 is packed, uniformly distributed and tightly adhering to the steel surface. An analysis of the diffraction patterns revealed a good crystallization of FeCO3. The shape of FeCO3 particles tends to a regular hexagonal habitus. The results obtained can be used in studying the resistance of corrosion products formed on the internal surfaces of gas production equipment under aggressive conditions in the presence of CO2 in produced and transported hydrocarbons.

A New Ultrasonic Reactor for CaCO3 Antiscaling in Pipelines and Equipment

Summary Calcium carbonate (CaCO3) scaling is one of the main drawbacks in oil and gas production pipelines and equipment, contributing to the reduction or shutdown of production in petroleum extraction industries. This work shows a new device for the prevention of calcium carbonate scale in oil and gas production units. Three cells containing five ultrasonic transducers each (60 W×40 kHz) were used to reduce carbonate scaling in pipelines. Long-term tests were carried out in a semi-industrial hydraulic system that was properly instrumented to allow us to simulate CaCO3 production by injection of CaCl2·2H2O and NaHCO3. A proof valve was positioned downstream of the equipment. Pressure drop in the valve, scale mass on the pipe samples, and morphology of crystals were evaluated after 2 hours of testing. Well-marked reductions in pressure drop (up to 96%) on the proof-valve and scale thickness (up to 95%) in pipe samples were verified when compared with the system without any scale prevention device. Scanning electron microscopy (SEM) images showed alteration of the geometry and reduction of the particle size as the main reason for the reduction of scaling.

INVESTIGATION OF MACHINABILITY PERFORMANCE IN TURNING OF Ti–6Al–4V ELI ALLOY USING FIREFLY ALGORITHM AND GRNN APPROACHES

Ti–6Al–4V ELI alloy is one of the most familiar materials for orthopedic implants, aeronautical parts, marine components, oil and gas production equipment, and cryogenic vessel applications. Therefore, its appropriate quality of finishing is highly essential for these applications. But the characteristics like lower modulus of elasticity, lesser thermal conductivity, and high chemical sensitivity placed it in the categories of difficult-to-cut metal alloys. Also, tooling cost is one of the prime issues in the machining of this alloy. Therefore, this research is more inclined to use a low-budget uncoated carbide tool in turning the Ti–6Al–4V ELI alloy. Also, the selection of suitable levels of machining parameters is highly indispensable to get the appropriate surface finish with a low tooling cost. So, the [Formula: see text] experimental design is utilized to check the performances of the uncoated carbide tool in the turning tests. The performance indexes like surface roughness (Ra), flank wear of tool (VBc), and material removal rate (MRR) are measured and studied with the help of surface plots and interaction plots. Further, the Firefly Algorithm optimization is employed to find the optimal cutting parameters and cutting response values. The local optimal values of the input parameters a, f, and Vc are estimated as 0.3241[Formula: see text]mm, 0.0893[Formula: see text]mm/rev, and 82.41[Formula: see text]m/min, respectively. Similarly, the global optimal values for the responses Ra, VBc, and MRR are reported as 0.6321[Formula: see text]μm, 0.09253[Formula: see text]mm, and 24.61[Formula: see text]g/min, individually. Additionally, to predict the responses, Generalized Regression Neural Network (GRNN) modeling is employed and the average absolute error for each response is noticed to be less than 1%. Therefore, the GRNN modeling tool is strongly recommended for various machining applications.

A hybrid modeling approach to estimate liquid entrainment fraction and its uncertainty

Liquid entrainment fraction is a key parameter for designing and optimizing downstream oil and gas production equipment and needs to be reliably estimated. In this study, a hybrid modeling approach, which combines semi-mechanistic and data-driven models, is introduced to estimate entrainment fraction and its uncertainty. The hybrid model incorporates three data-driven models developed using Gaussian Process Modeling trained with 1,662 experimental data. The performance of three different Gaussian Process Models (GPMs), GPM with known noise, GPM with estimated noise, and bagging GPM, is studied in the hybrid model to obtain a more robust and accurate result. The performance metrics used are the root mean square error (RMSE), area metric (AM), and calibration score (CS). The results reveal that the RMSE of the hybrid model is about 70% lower than the RMSE of the semi-mechanistic models. Bagging GPM gives the best result considering RMSE, AM, and CS.

In Situ Investigation of Under-Deposit Microbial Corrosion and its Inhibition Using a Multi-Electrode Array System.

Carbon steel pipelines used in the oil and gas industry can be susceptible to the combined presence of deposits and microorganisms, which can result in a complex phenomenon, recently termed under-deposit microbial corrosion (UDMC). UDMC and its inhibition in CO2 ambiance were investigated in real-time using a multi-electrode array (MEA) system and surface profilometry analysis. Maps from corrosion rates, galvanic currents, and corrosion potentials recorded at each microelectrode allowed the visualization of local corrosion events on the steel surface. A marine bacterium Enterobacter roggenkampii, an iron-oxidizing, nitrate-reducing microorganism, generated iron deposits on the surface that resulted in pitting corrosion under anaerobic conditions. Areas under deposits displayed anodic behavior, more negative potentials, higher corrosion rates, and pitting compared to areas outside deposits. In the presence of the organic film-forming corrosion inhibitor, 2-Mercaptopyrimidine, the marine bacterium induced local breakdown of the protective inhibitor film and subsequent pitting corrosion of carbon steel. The ability of the MEA system to locally measure self-corrosion processes, galvanic effects and, corrosion potentials across the surface demonstrated its suitability to detect, evaluate and monitor the UDMC process as well as the efficiency of corrosion inhibitors to prevent this corrosion phenomenon. This research highlights the importance of incorporating the microbial component to corrosion inhibitors evaluation to ensure chemical effectiveness in the likely scenario of deposit formation and microbial contamination in oil and gas production equipment.

ПЕРСПЕКТИВЫ РАЗВИТИЯ РОССИЙСКО-ИТАЛЬЯНСКОГО ЭКОНОМИЧЕСКОГО СОТРУДНИЧЕСТВА

The trade restrictions imposed by the European Union in relation to Russia have the most negative impact on the state of the Italian-Russian trade and economic cooperation. In terms of economic indicators, the Italian economy is in recession. Italian exports to Russia fell by more than a third, which negatively affects small and medium-sized businesses, suppliers of high-tech products (gas and oil production equipment for work, in particular, in the Arctic latitudes), military-technical cooperation, which has always been evidence of the traditionally trusting partnership between Russia and Italy.

On detection of crack-like welding defects by existing quality control methods

Introduction. The research materials devoted to the operability assurance of welded structures of hazardous technical devices — components of oil and gas production equipment are summarized. The factors determining the operational strength of welded joints and structures are systematized and diagrammed. The causes for the decrease in their service properties are described. We have defined the role of volumetric and crack-like welding defects, which were not detected during quality control at the manufacturing stage and in determining the residual life while in operation, in ensuring the life cycle of the structure. Measures to improve the practice of detecting crack-like defects under visual- and-dimensional and ultrasonic methods of quality control of welded joints are proposed. Materials and Methods. In accordance with SNiP 2.05.06–85, the structures of main oil and gas pipelines, vertical cylindrical tanks, and other oil and gas production equipment (OGPE) are made of dead-killed and semikilled low- carbon and low-alloy steels with tensile strength of up to 686.5 MPa. Regardless of the class and strength level of steel, it should be well welded by all methods prescribed by standard process documentation (SPD). At the same time, regardless of the state of supply, the carbon equivalent Сэкв should not exceed 0.46 %. The research methods are calculation-experimental ones. To calculate the stress-strain state of welded joints, the following methods were used: finite elements (FEM), fracture mechanics using the stress intensity coefficient Kt. Methods of mathematical statistics were used to estimate the geometric dimensions of crack-like welding defects. Welding defects were detected by standard quality control methods prescribed by the SPD and GOST standards. Results. Welded structures operating in the fatigue mode are considered. Some factors characteristic of welded joints are analyzed. It is shown how they affect the formation of strength performance properties. The role of dangerous crack-like defects, which with high probability can be formed in welded joints in the manufacture of structures and during operation, is established. Often, the reason is a decrease in mechanical properties due to aging and loss of plasticity caused by accidental mechanical actions. Note that it is impossible to identify these defects by existing quality control methods, both during the control process under production and during diagnostics while in operation. This reduces the accuracy of predicting the operational life of the welded structure. Discussion and Conclusion. It is proposed to include the following requirements in the SPD: to the quality of welded joints of hazardous technical devices of OGPE, to detection of sharp crack-like defects with a radius of curvature in the range of 1-0.25 mm. However, the reliability of detection of such defects by the control methods used remains low due to the human factor. To increase the reliability of detection of sharp crack-like defects, the directions of improvement of ultrasonic quality control of welded joints are determined.

Исследование режимов эксплуатации газовых скважин в осложненных условиях

The influence of reservoir rock properties on sand production in wells is considered. It was concluded that the rock should be considered rather not from the point of view of its strength, but from the point of view of the type of cementitious substance and its distribution. When predicting sand production, it is necessary to take into account the internal stresses of the rocks, as well as the change in these stresses during drilling, perforation and operation of the formation due to the violation of their initial state. Within the framework of this work, an analysis of the main causes of sand production during the operation of gas wells and the negative consequences of sand production for gas production equipment is presented. It has been established that water breakthrough, formation depletion, pressure drop at the bottom of the wells due to their frequent shutdown are the main prerequisites for the removal of sand from the bottomhole formation zone. Sand production is associated with such negative consequences as plugging in wells, erosion of underground and surface equipment, collapse of the top of the bottomhole formation zone and production strings. The main technologies for the prevention and elimination of accidents associated with the removal of mechanical particles from the reservoir are considered. Based on the research results, an algorithm was proposed for selecting technological modes of well operation in conditions of water and sand. The parameters for choosing the optimal operating mode of a gas well are substantiated, in which sand is not extracted with the subsequent disabling of downhole and wellhead equipment, the integrity of the bottomhole zone is not violated, and the well is not selfcontained. The results obtained can be applied to improve the efficiency of gas wells operation and predict their trouble-free operation.

Polymeric materials based on epoxy oligomer DER-331 and hardeners of different physical and chemical nature for repairing of gas production equipment

The optimal content of PEPA and TETA hardeners and polymerization temperature during matrix formation on the basis of epoxy oligomer DER-331 were determined. The dynamics of dependence of hardener content on physical and mechanical properties of epoxy matrix was investigated. According to the results of the study, materials with the optimal content of hardener and temperature range of polymerization for the formation of a composition with high physical and mechanical properties and its further use for the repair of gas equipment are proposed. Developed polymeric materials containing the hardener TETA with a content of q = 8–10 weight parts per 100 weight parts of epoxy oligomer DER-331 are characterized by high physical and mechanical properties, in particular: the fracture stresses during the flexion are σfl = 80.0–95.1 MPa, the modulus of elasticity E = 2.8–2.9 GPa, impact strength W = 7.9–13.5 kJ/m2. The fracture structure of such composites is characterized by less deep branched chip lines with relatively uniform transitions, which makes it possible to state a slight stress state of the polymer, and hence its increased resistance to fracture.

Numbrigal simulation of a thermodynamic process to decompose gas hydrate in a gas production well using, radiofrequency electromagnetic radiation

The formation of gas hydrate deposits on the inner surface of gas production equipment is a frequently occurring type of complication in gas production, leading to a significant decrease in the useful section of pipes and gas pipelines. The intensity of their formation can lead to a complete overlap of the lifting pipes and annular channels in the annulus in certain areas, which necessitates repair work to clean the wells of gas hydrates. Based on the analysis of methods for cleaning wells from gas hydrate deposits, it was revealed that in some cases one of the effective methods of preventing their formation and combating them is to use the energy of high-frequency and superhigh frequency electromagnetic fields. The article explores the processes of heating and decomposition of gas hydrate deposits in the wellbore. About 30% of the thermal energy released in the wellbore interacting with the electromagnetic field is consumed to heat the medium surrounding the well. The need for timely removal of the gas-water mixture formed in the annulus for the decomposition of gas hydrate along the entire length of the well is established.

Isolipidic replacement of krabok oil by whole krabok seed reduces in vitro methanogenesis, but negatively affects fermentation.

The background of the current in vitro study involves the issue of methane (CH4 ) production inherent to rumen fermentation. One of the dietary strategies to reduce enteric CH4 production by ruminants involves the supplementation of medium-chain fatty acids in diets. As such, oils containing high amounts of MCFA, such as coconut, palm kernel and krabok oil, are of much interest to formulate energy efficient and environmentally friendly rations for ruminants. Krabok oil (KO) reduces methanogenesis, but the appropriate inclusion level of dietary KO is unclear. We therefore investigated the dose-response relationship between krabok oil and CH4 production. In practice, the use of whole krabok seed (WKS), instead of KO, is easier, but the efficacy of WKS to inhibit methanogenesis was hitherto unknown. Thus, we also investigated whether WKS provides an alternative tool to inhibit CH4 production. The experimental substrates contained either KO, WKS, the residue of WKS after fat extraction residue (FER) or FER+KO. Appropriate amounts of WKS or its derivatives were added to a basal substrate so as to attain either a low, medium or high content of KO, that is, 37-46, 90-94 and 146-153g/kg dry matter respectively. The experimental substrates were formulated to keep the amounts of incubated fat-free OM, crude protein, neutral detergent fibre and acid detergent fibre constant in order to avoid biased results through potential differences in fermentability between WKS and its derivatives, and the basal substrate. The latter resembled the ingredient composition of a total mixed ration commonly used in Thai dairy cows. Fully automated gas production (GP) equipment was used to measure gas- and CH4 production. Irrespective of the type of substrate (p≥.115), both the absolute (ml/g fat-free OM) and relative (% of total GP) CH4 production was reduced at the highest inclusion level of WKS or its derivatives (p≤.019). Total GP (ml/g fat-free OM), however, was reduced after incubation of FER, FER+KO, and WKS, but not KO, at the highest inclusion level of the respective substrates (p=.019). Volatile fatty acids were likewise affected (p≤.001). Krabok oil can inhibit CH4 production but only when the dietary KO content is at least 9.4% (DM). Supplementation of KO in the form of WKS, however, is considered not opportune because the fat extracted residue of WKS is poorly degraded during fermentation.

Диагностическое обслуживание оборудования и трубопроводов нефтегазовых производств при риск-ориентированном подходе к эксплуатации

Диагностическое обслуживание оборудования и трубопроводов нефтегазовых производств при риск-ориентированном подходе к эксплуатации

INTERACTION OF HIGH-FREQUENCY ELECTROMAGNETIC FIELDS WITH A GAS HYDRATE WELL

The formation of gas hydrate deposits on the inner surface of gas production equipment is a frequently occurring type of complication in gas production, leading to a significant decrease in the useful section of pipes and gas pipelines. The intensity of their formation can lead to a complete overlap of the lifting pipes and annular channels in the annulus in certain areas, which necessitates repair work to clean the wells of gas hydrates. Based on the analysis of methods for cleaning wells from gas hydrate deposits, it was revealed that in some cases one of the effective methods of preventing their formation and combating them is to use the energy of high-frequency and superhigh frequency electromagnetic fields. The article explores the processes of heating and decomposition of gas hydrate deposits in the wellbore. About 30 % of the thermal energy released in the wellbore interacting with the electromagnetic field is consumed to heat the medium surrounding the well. The need for timely removal of the gas-water mixture formed in the annulus for the decomposition of gas hydrate along the entire length of the well is established.

Совершенствование нефтегазопромыслового оборудования на основе анализа эволюции систем

Совершенствование нефтегазопромыслового оборудования на основе анализа эволюции систем

Studies on operation and types of drilling pump valves

The current issue of the machine building industry is improvement of oil and gas production equipment performance. However, despite the improved design and technological parameters, its reliability is still low. The time between failures depends on both severe operating conditions and quality characteristics of parts. With an increase in drilling depths, complexity of operating conditions and abrasiveness of the drilling mud, the life time of the hydraulic part of the pump decreases. Operation of drilling pumps largely depends on the design features of the valves. According to the results of theoretical studies, wear of the valve pair occurs on the bearing surface. The design of valves with different seating surfaces and shapes of the sealing element was studied. Based on the research on the improvement of the drilling pump valves, the conclusions were drawn and the tasks for further research were formulated.

CONCERNING TO REMOVAL METHODS HYDRATE FORMATION (ON EXAMPLE OF URENGOY FIELD)

Background At present, the development of gas fields is in most cases complicated by the increase in moisture content in natural gas. The main reason for this phenomenon is a decrease in pressure, gas temperature and, as a result, this leads to the appearance of water vapor that has condensed and accumulated in wells and gas pipelines. Further saturation of natural gas at an elevated pressure and positive temperature can lead to the formation of solid physicochemical compounds - hydrates. The occurrence of such crystalline substances can lead to the blockage of wells, gas pipelines, separators, disruption of the work of stabilizing and gauging devices, and as a result to a decrease in the level of oil production. Often, pressure regulators and fittings fail, gas is throttled, accompanied by a sharp decrease in temperature, and the disruption of the normal operation of the oil and gas production equipment. Aims and Objectives Determination of factors affecting the intensity of hydrate formation, and the study of methods to combat the formation of gas hydrates on the example of the Urengoy field. Results The factors that directly affect the intensity of hydrate formation are determined: moisture content, temperature, pressure, component composition of the gas. The possible places for gas hydrates formation are given: at fittings, in piping of pipes, in separators, in loops, on diafragms of metering sections. The main methods of preventing the hydrate formation and removal of hydrate plugs are present: increasing the gas temperature, reducing the gas pressure, removing moisture from the gas using absorbents and adsorbents, inhibitors. Methods for the control of hydrate formation, using in Urengoi field, are presented. A thermal calculation of the plume was performed, which allows determining the temperature change along the gas pipelines and determining the possible place of hydrate formation.