Present and future non-metallic requirements

:
An end user perspective
Denis MELOT – TOTAL EP

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 Scope of presentation
O&G production process and internal corrosion-Material selection
(Carbon steel/CRA/Polymer)

Identified potential use of composite/polymer

Composite pipes (existing and new products) and feedback

Composite gratings

conclusions

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 Oil and gas process-Material selection

O&G is a « metal-based » industry, and more specifically, a Carbon

Steel based industry

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 Oil and gas process-Material selection

For Production fluids :

• Mix of crude/gas/water
• No oxygen
• Corrosion is associated with acid gases (CO2 and H2S) and water phase
composition

CO2 corrosivity for production fluids is evaluated via Companies

specific software
Gives a typical corrosivity in mm/yr and practical likelihood of failure
within design life
The degradation process for steel is well known and can be mitigated !

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 Oil and gas process - Mitigation measures for CS corrosion control

• Corrosion allowance (up to 10mm WT)

• Chemical injection (inhibition/biocides…)

• O2 removal (water injection)

• Cleaning pigs

• Dehydration (for gas)

+ Corrosion monitoring via corrosion probes, fluid chemical analysis

and chemical injection monitoring

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 Oil and gas process - Material selection

If corrosion mitigation not possible :

CS  CRA

CRA represent less than 2% of total amount of steel

The use of polymer materials must be linked to identified specific

business cases !

Not only corrosion, but also weight savings or ease of installation

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 Identified potential business cases of composites/polymers

Internal corrosion
• Non treated seawater (water intake/fire fighting piping)-high corrosivity
• Mature fields (high water content above 80%)-high corrosivity and big quantity of
chemicals
• Mix of sea water and produced water for reinjection-high corrosivity/unreliable
treatment
• Process drains-unknown mix of fluids with O2 entry
External corrosion
• Splash zone area/gratings and secondary structures-coating and cathodic protection
not efficient
Weight saving
• Offshore structures (TLP’s…)
• Deep offshore-riser tensions on topside
Any possible Cost savings vs CRA/Chemicals/Installation

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 High Pressure Low Pressure
CS/CRA Rigid
Complex loading Simple loading (Burst-Tension)
pipes
(Burst-Tension-Bending-Collapse-Fatigue) Onshore
Onshore/offshore
GRE pipes
+ Track record
Thermoplastic Composite Pipes (TCP) + Availability
+ Spoolable - Rigid
+ Complex loading as per DNV RPF119 - Connexion every 6-10m
+ Cut to length on site in some cases - Fire rating
- Ageing process in contact with Gas/HC
- No feedback for permanent use
- Monitoring Ease of installation
- Diameter limitations Low cost
Flexible pipe
+ Highly flexible Reinforced Thermoplastic
+ Track record Pipes (RTP)
+ Ease of installation + Spoolable (500-700m)
- Cost (long lines) - Limited contact with HC/Gas
- Thermal insulation - Monitoring
- Diameter vs pressure vs
water depth limitations

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 Some feedback within TOTAL

Glass Reinforced Epoxy pipe

• Fire fighting system on FPSO’s
• Mature fields near Paris since the 80’s
– Low Pressure (10b) / 80°C max operating / 2 to 8 inch
130 km installed

Reinforced Thermoplastic Pipes

• For water injection flowline (4 inch) onshore – 6 km
• For industrial water distribution onshore (3 inch) – 10 km
Thermoplastic Composite Pipes
• Jumpers for water injection susbea
• Under qualification as per DNV RPF-119
• Next step
– Contact with production fluids
– Higher Temperature
– Risers…

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 External corrosion and weight saving : composite gratings

Base case is galvanized steel gratings

• Standard item
• Available everywhere in the world
BUT :
• Galvanized steel has limited lifetime in offshore environment, specially splash
zone areas (about 5 years)
• They are 50 to 70% heavier than composite gratings.

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 External corrosion and weight saving : composite gratings

Composite grating are used for external corrosion mitigation or weight

savings
• Maintenance free
• Lighter than steel : On 8800 m2, weight saving was 275T vs steel
BUT :
• They are not standard items (depends upon suppliers)
• Fire rating is an issue (like for most composite in offshore)
• Main Contractors or construction yards use CS gratings…
• Business case only if replacement of steel grating every 5 years or
less…unless HSE issue

• A few examples within TOTAL (NL, Congo…)

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 External corrosion and weight saving : composite gratings

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 CONCLUSIONS

Carbon steel is the base-case for the O&G industry

Corrosion is mitigated via fluid treatment and chemical injections for internal corrosion
and coating + CP for external corrosion
Steel ageing process (ie corrosion) and failure modes are well known and can be
monitored and inspected in most cases

Corrosion Resistant Allows represent a small percentage of all steel used (<2%)

The use of polymer materials is linked to specific business cases where corrosion might
not be the only (or main) driver, but also light weigth or ease of installation

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 CONCLUSIONS

Polymer and composite materials are not used up to their full potential in the O&G
industry due to :
• Lack of industry knowledge/Lack of detailled business case
• Lack of simple qualification process and non standardized solutions
• Unknown failure modes and difficulty to extrapolate the ageing to the end-of-life of the
equipment (Arrhenius does not work)
• Lack of qualified contractors for installation on site (construction yards use CS !)
• Lack of inspection techniques (NDT’s) for installation and monitoring during operation

Yet, their instrinsic characteristics make them the solution of choice for the future of the
industry for maintenance free and easy to install solutions
With improved knowledge and track records, it might also be used in the future for new
developments such as ultra deep offshore

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 MERCI
THANK YOU

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