Flexible plastic line pipe
Lennert Bakker
Technical Service & Development Engineer
Pipelife is .....
One of worlds leading producers
of plastic pipe systems
Part of Wienerberger
Head office in Vienna, Austria
Active in 27 countries
27 production locations
Europe
N America
Soluforce production plant
Soluforce is a business unit within Pipelife International,
producing and installing High Pressure Thermoplastic
Reinforced pipelines, based in Enkhuizen, The Netherlands
What is Soluforce ?
3
2
1
1. Fluid-tight , corrosion resistant HDPE liner
High density pipe quality polyethylene, a proven material for crude oil, gas &
water
2.
Fibre reinforcement for strength
Ultra high strength steel wire for high pressure pipes
or Aramid fibres
3. Ambient resistant white HDPE cover, to protect from UV,
abrasion and solar heating
A highly UV-stabilised white PE100 grade to block solar heating, and to protect
against external damage
Construction of Soluforce
Delivered on coils
Soluforce pipe systems
There are 3 different Soluforce pipe systems:
– Soluforce Light
(upto 36 bar / 522 psi)
– Soluforce Classic (upto 90 bar / 1305 psi)
– Soluforce Heavy (upto 223 bar / 3234 psi)
The maximum operating temperature is 65°C/150°F
In 4” and 6”ND
Soluforce testing
To comply with the international API and DNV standards,
extensive testing is per performed
• Long term pressure resistance
• Wire and tape strength
Pipelife’s Flexirig®: Simultaneous dynamic testing
of pressure, torsion, and axial load
Tape tensile testing
regression testing
Regression testing is
- testing the long term strength of the Soluforce RTP pipe.
- Pipe testing is done at 65°C
- Fitting testing at elevated temperatures of 85°C
- Tests up to 10000 hors/ 14 months
Burst pressures
- 350 Bars for Soluforce Classic
- 500 Bars for Soluforce Heavy
Long term pressure resistance
(aramid reinforced)
Soluforce Light regression curve
(pressure vs time)
Pressure [bars]
1000
100
1.
Testing supervised by
DNV and Shell Global
Solutions
2.
Test duration >1 years
3.
Procedure according to
ISO 9080, ASTM2992
10
1
10
100
1000
10000
100000
Time [hours]
Samples Light
Light HDB-mean
Samples Classic
Samples Light
Light HDB-LCL
Classic mean
Light mean
Ongoing
Samples Classic
Classic HDB-LCL
Light HDB-LCL
Classic mean
Classic HDB-LCL
Approvals and Certification
•
API RP 15 S, certified by Bureau Veritas (BV)
•
API 17J, certified by DNV
•
DVGW VP642, certified by MPA and SKZ
•
Design and Production verified and certified
by Det Norske Veritas (DNV)
•
Qualification testing according to ASTM2992,
verified and certified by: DNV, KIWA, MPA, SKZ,
BV
•
ISO 9001, KIWA approved
•
Impact, earth quake and “third party interference”
resistance by IPN and NYGAS (USA)
•
Product approvals at: Shell, Saudi Aramco,
PDO, KOC, TÜV Germany, MIGAS (Indonesia),
and many other oil companies
•
Pemex PEP Approved by IPN and GAID
(nueva nrf-185-pemex-2008
Approvals and Certification
• Product design and qualification supervision by Det
Norske Veritas (DNV)
• Tested and certified according to international
standards like ISO9080, ASTM 2992 and EN1555,
API 17J, API RP15s
• Conforms to “Recommended Practice” of “Joint
Industry Project”. (Members: Shell, BP, Saudi Aramco,
Gaz de France, British Gas, Petrobrás)
• Approved for oilfield service by Shell, Saudi Aramco,
Kuwait Oil Company, Petroleum Development of
Oman, ADNOC
• Approved for gas distribution and transport by TÜV,
under German standard DVGW VP642
• QA/QC according to ISO9001
Soluforce for Nigerian market
Why is Soluforce the perfect
solution for Nigeria?
Soluforce Nigeria
Please look at document:
Benefits of Soluforce in Nigeria.pdf
Installation in Nigeria
Pilot oil flowline installed in 2010.
Test finallized in December 2013
To be analized with Shell Global Solutions
Small footprint on environment
Because of flexibility and toughness, no high
requirements on trench and soil conditions
2010: External foil
To eliminate permeation of hydrocarbons, the Soluforce
pipe was wrapped in aluminum foil
2013: internal foil layer
Today the Soluforce introduces a new product called
Soluforce GT. Gas Tight, to eliminate permeation.
A permeation barrier is imbedded in the pipe
Soluforce Light & Classic
Electrofusion Coupling system
Coupling system based on “electrofusion”
Advantages:
• Reliability, proven technology
• Automated CNC controlled welding equipment
• No fluid contact with metals or seals (except at
end- fittings), NO CORROSION !!
• Standard ANSI flange dimensioned hook-up
connections
Soluforce in-line connection
Soluforce hook-up
end-fitting
Soluforce Light & Classic
end-fitting steel parts assembly
-
End fitting electrofused to pipe end
Pipe end prepared by hand tool
O-rings seal the pipe from the fluid
Flange part onto pipe end
Half shells interlock flange to pipe end
Housing ring secures the half shells
Soluforce Light & Classic
Pipe to Pipe (P2P)
-
Pipe to pipe plug
To make a pipe to pipe connection
Easy installation
Simular to end flange
Perfect for re-coiling, minutes to dismantle
Soluforce Heavy
Swaged fitting system
Swaging priciple
Soluforce 2 step swaging process
Step 1: Internal swaging
Step 2: external swaging
Pulling a dolly through the stem
Pushing the fitting through a die
Connecting swaged fittings
Swaged connection: Grayloc
Connecting swaged fittings
Swaged connection: weld stub
Weld neck flange
Weld neck inline
Pipe packaging
• 400 / 220 meters per coil for Soluforce Classic / Heavy
• Disposible wooden frame
• Center hole for axel positioning
Transport & Packaging
Users of Soluforce
A overview of the companies
using Soluforce
General Properties of Soluforce
•
As flexible as polyethylene pipe
–
–
–
–
Supplied on long-length coils (220 meters / 400 meters)
Very fast installation (up to 2 km/day)
No prefabricated bends
Can be installed by trenching machine and horizontal drilling
•
As corrosion resistant as polyethylene pipe
•
As strong as steel pipe
–
•
Very good fire resistance
–
•
Comparable impact strength as steel pipe, and very much better than GRE
Environmentally friendly
–
•
6 minutes in a jet-fire, while steel lasts only seconds
Tougher than any other pipe
–
•
Pressure rating up to 223 Bar / 3230psi
No leaks, and made from 100% recyclable materials
More throughput
–
Up to 50% higher flow compared to steel pipe thanks to a very smooth inner surface
Flexibility of Soluforce
-
Over-bending to a radius of only 300 mm still does not
harm.
-
The specified minimum bending radius in operation is
3000 mm
-
Miminum bending radius in storage is 1500 mm
Toughness of Soluforce
Soluforce does not only
survive elephant attacks,
but also:
1. Accidentally crossing vehicles
2. Dropping tools
3. Most transport and installation
accidents
Soluforce Data Sheet
Products
Properties
Soluforce
Light
units
Soluforce
Classic
Soluforce
Heavy
L450
L540
M480
M570
H415
H515
Liquid Hydrocarbon Service
Maximum Operating Temperature
[°C]
65
65
65
65
65
65
Operating Lifespan
[yrs]
20
20
20
20
20
20
Maximum Allowable Operating Pressure
[Barg]
26
21
65
52
150
150
Maximum Operating Temperature
[°C]
65
65
65
65
65
65
Operating Lifespan
[yrs]
20
20
20
20
20
20
Maximum Allowable Operating Pressure
[Barg]
36
29
90
72
223
178
H415PA
H515PA
Oilfield Water Service
Natural Gas Distribution & Transport
Maximum Operating Temperature
[°C]
25
25
25
25
65
65
Operating Lifespan
[yrs]
50
50
50
50
20
20
Maximum Allowable Operating Pressure
[Barg]
25
25
42
42
150
150
A more detailed datasheet can be found in the Soluforce brochure
Uncoiling / stringing
- Easy uncoiling
- From Soluforce trailer
- Or from crane + slings
- Unrolling or pulling
Welding Soluforce Classic
Soluforce inline
electrofusion equipment
Typical setup in the field
Soluforce Classic Pipe system
Soluforce end fittings to
manifold
Inline fitting in a trench
Soluforce ERS system
Soluforce Emergency Repair System
- Easy and quick to install
- Clamped system
- Special Soluforce design
- Hand tools only
Track record overview
PipeLife Onshore Experience with Soluforce (selected data)
Date
2000
2001
jul 02
sep 02
sep 02
sep 02
dec 02
mar 03
2003
nov 03
feb 04
feb 04
apr 04
jun 04
aug 04
aug 04
oct 04
oct 04
aug 05
oct 05
oct 05
feb 06
mar 06
may 06
jun 06
Customer
PDO Oman
PDO Oman
PDO Oman
Saudi Aramco
Saudi Aramco
PDO Oman
PDO Oman
Saudi Aramco
PDO Oman
Fahum Gas Egypt
KOC Kuwait
Saudi Aramco
VNG
ADCO UAE
PDO Oman
Badenwerk Gas GmbH
Ruhrgas Germany
KOC kuwait
Shell Brunei
E-on Germany
PDO Oman
Conoco Phillips
KOC
Zueitina oil
Conoco Phillips
Field
Serveral
Serveral
Bahja
Hawtah
Hawtah
Fahud
Hawqa
Hawtah
several
El Fayoum
West GC17
Hawtah
Berlin Plant
Shah
Several
Büchig-Oberacker
Hannover relining
West
Seria
Hirschbach
Several
Puyuh
West Kuwait
Libya
Suban II
Service
Press / temp
Multi flow (W,G,O)
Crude Oil
Crude Oil
Crude Oil
55 bar / 40°C
Injection Water
Crude Oil
Crude Oil
Injection Water
69 bar / 40°C
Crude Oil
Gas distribution
36 bar / 20°C
Effluent Water
40 bar / 40°C
Water injection
Brine Gas waste line
Fire water line
All
Gas distribution
25 bar / 15°C
Gas distribution
25 bar / 15°C
Waste water
40 bar / 40°C
ULLG
50 bar / 25°C
Gas
22-42 bar / 15°C
All
Waste water
62 bar/ 50°C
Waste water
27.5 bar/ 30°C
Oil
128 psi / 50°C
Waste water
62 bar/ 50°C
Type
M480
M480
M570
M480
M570
M570
M570
M570
M570
M480
M570
M480
M570
L440
M570
M570
M480
M570
M570
M480
M570
M480
M570
L450
M480
Length [m]
3600
36000
21500
2400
1680
3200
18300
840
32000
380
3218
2000
60
2800
50000
4500
600
3000
18000
440
25000
680
1700
4200
5400
Track record overview
PipeLife Onshore Experience with Soluforce (selected data)
Date
feb 07
mei 07
jun 07
sep-07
sep-07
oct 07
oct 07
feb-08
mrt-08
mrt-08
jul-08
jul-08
okt-08
nov 08
nov-08
dec-08
mrt-09
mei-09
jun-09
jul-09
okt-09
okt-09
nov-09
dec-09
dec-09
Customer
KOC kuwait
PDO Oman
KOC kuwait
OEID Iran
OEID Iran
KOC kuwait
KOC kuwait
KOC Kuwait
PPE Qatar
KOC Kuwait
PDO Oman
Al Khorayef Kuwait
KOC Kuwait
Brunei
Portugal
KOC kuwait
Nigeria Shell
Kuwait KOC
Libya ZOC
Qatar PPE
Oman Shell
Kuwait KOC
Iran Tasdid
Oman Shell
Libya ZOC
Field
West GC17/27/28
PDO
West GC 28
Gascharan
Gascharan
North field
North field
West Field
Dukhan Oilfield
North field
PDO
East Field
West Field
Seria
Plateau
Wafra
Shell
West field
Safsaf
QP
Yibal
Burgan
Service
Effluent Water
Oil / water
Effluent Water
Salt water Project
Salt water Project
Effluent Water
Effluent Water
Effluent Water
Water Supply line
Effluent Water
Oil / water
Effluent Water
Effluent Water
Oil / Gas lift
Sludge
Sour oil
Gas
Effluent water
Water injection
system lines
Water injection
Water injection
Press / temp
40 bar / 40°C
PDO
Hakim
Oil / water
Water injection
50 bar / 40°C
100 bar / 45°C
40
20
20
40
40
40
65
40
bar
bar
bar
bar
bar
bar
bar
bar
/
/
/
/
/
/
/
/
55 bar /
40 bar /
40 bar /
125 bar
50 bar /
25 bar /
60 bar /
100 bar
80 bar /
100 bar
125 bar
40°C
55°C
55°C
40°C
40°C
40°C
65°C
40°C
40°C
40°C
40°C
/ 30°C
65°C
30°C
45°C
/ 45°C
40°C
/ 45°C
/ 45°C
Type
M570
L540
M570
M480
L540
M570
M570
H415
M570
M570
M570
M570
H515
M480
M480
M570
H515
M480
H515
H515
M480
M570
H515
Length [m]
15000
30000
25000
8000
1200
6000
26900
10000
595
2200
16800
6000
26400
500
230
14400
3200
9200
8800
1600
230
6600
9600
9600
16060
Customer Benefits
• Properties
- Flexible
- Tough
- Proven Quality
• Ease of installation
- Up to approximately 2 km/day feasible with small crew
- Easy installation
- Limited manpower (4 persons)
- Only light equipment
• Early production gain (Oil production)
• Maintenance free
- No corrosion
- No scaling
- No inspection
• Install and forget, just use
Questions?
Thank you for your attention