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Flowline Material Performance and Challenges in Oil and Gas sweet and sour environment

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Oil & Gas flowlines are paramount for safe and reliable production of hydrocarbons, ensuring their integrity is one of the key tasks for all operators. Petroleum Development of Oman (PDO) manages around 11,000 Km of flowlines and connects to production stations more than 400 wells across more than 50 fields every year. Applications for these flowlines vary from the traditional Oil & Gas transmission to other applications such as water injection, polymer flood and steam injection. All these diverse applications involve multiple operation environments ranging from benign fields with low CO2 < 0.5 mole% and minimum H2S to very aggressive environments with CO2 and H2S concentrations well above 10 mole%, combined with a wide range of salinities and water cuts, with chlorides concentrations ranging from 5,000 to 200,000 ppm and water cuts from almost nil to more than 95%. The challenges encountered in safe and economic development of these assets across such a wide range of conditions are numerous; therefore, the material selection and designed methods to manage flowlines integrity are complex with no single solution approach to address the myriad of different conditions. This paper present two cases of metallic and non-metallic materials installed in PDO flowlines showing their historical field performance and discusses the strategy adopted for the material selection of flowlines.  

Product Number: 51320-14722-SG
Author: Amjad Kharusi, Janardhan Rao Saithala, Antonio Ojeda Macedo, Manoj Suryanarayana, Talal Nabhani, Nasser Behlani,
Publication Date: 2020
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Picture for Quality &amp; Performance Review of Duplex Stainless Steel Products – An End Users Perspective
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51318-10568-Quality & Performance Review of Duplex Stainless Steel Products – An End Users Perspective

Product Number: 51318-10568-SG
Author: Janardhan Rao Saithala / Gurram Bhaskar Rao / Manoj Suryanarayana / Talal Nebhani / Pedro Rincon / Nasser Behlani / Mohammed Ghafri / Amjad Kharusi
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Quality assurance and procurement & construction challenges associated with DSS materials and operational best practices to ensure integrity and meet intended design life cycle of DSS components.

 
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Materials Performance and Challenges in Oil and Gas Production Wells

Product Number: 51319-13294-SG
Author: Janardhan Saithala
Publication Date: 2019
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Integrity of materials in Oil & Gas production wells is critical to meet the objectives of design and the lifecycle performance of wells. This is significant value both in economic terms and health safety and environment. Subsurface uncertainties Aging fields EOR activities and also the quality of procured equipment add to the difficulties in preventing equipment failures in wells. Failures that are especially unforeseen or unanticipated provide crucial feedback to operators and lessons to be learnt. It is imperative for operators to learn improve processes and avoid recurrence of failures.Petroleum Development Oman (PDO) as a large operator with more than 10000 wells has gained important experience and lessons from many such failures. This has contributed significantly to improve the company standards material selection reset the operating envelope and procedures enhance surveillance and improve upon quality assurance and control of new equipment.This paper is a compilation of some of the important lessons learnt from such incidents in the recent past. It discusses the operational experience and learning from different subsurface materials from CS to nickel alloys used in different components such as casing tubing packers and X-trees. 
Picture for New Material Application Limits of Duplex Stainless Steel in Sour Service
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New Material Application Limits of Duplex Stainless Steel in Sour Service

Product Number: 51319-12814-SG
Author: Janardhan Saithala
Publication Date: 2019
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Duplex Stainless steel (22Cr) also known as corrosion resistant alloy (CRA) has been extensively used in oil and gas industry for critical applications such as wet gas production flow lines and pipelines. A number of new sour Oil &amp; Gas projects with high salinity (exceeding 200000ppm NaCl) will be developed in the coming years in Petroleum Development Oman (PDO). So far DSS material is qualified upto 10mbar partial pressure of H2S (ppH2S) in 160000ppm chloride levels. The operating conditions of these new projects are outside these current material operating limits of 22Cr DSS. The objective of the study was to enable wider use of 22 Cr DSS grades (lower cost CRA) in highly sour projects in high chloride environments instead of selecting more expensive CRA materials like 25 Cr super duplex alloy 825 or alloy 625. Pitting crevice and stress corrosion cracking tests were conducted on both parent metal and representative welds in high ppH2S and in high chloride environments. The results established the new threshold sour service limits of DSS material which resulted in significant cost savings for various projects. The paper will present the test results and discuss the opportunities for DSS application.
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