new technologies
New Technologies
Subsea systems required to produce oil and gas reservoirs are being extended into environments of higher temperatures, higher pressures and extreme water depths. These new deepwater horizons introduce challenges that require innovative, new material solutions. Reliability is paramount due to the large capital investment, intervention costs and lost production, placing added demands on materials for subsea equipment.
Materials used in deepwater applications must meet new criteria for temperature extremes, pressure differentials, collapse resistance, chemical resistance, methanol and sour gas containment, and thermal insulation.
Subsea Umbilicals
Customers report that increased water depths combined with higher electrical power demands are starting to exceed the material performance capabilities of traditional hose materials such as PA11 and super Duplex steel. The next generation of superior performance thermoplastic umbilicals is now available by incorporating tubes made from VICTREX® PEEK™.
These new umbilicals are reportedly capable of performing reliably at depths of up to 2,000 meters, whereas standard materials are often limited to lesser depths.
These game-changing hoses will significantly reduce the detrimental effect of methanol permeation, which in turn could be expected to increase product lifetime, and address Health and Safety Environmental (HSE) concerns.
Potential benefits of using VICTREX PEEK polymers for umbilical tubes:- Improved delivery of aggressive chemicals such as methanol and biocides with significantly reduced permeation of chemicals into the umbilical and the environment
- Ability to better deliver products at higher pressures and pump rates through a smooth bore HCR hose without an internal carcass
- Available at long, continuous lengths that reduce the umbilical costs and long lead times associated with super Duplex umbilicals which require welding at regular intervals
- With a PEEK sheath, it is possible to substantially reduce the detrimental effects of power cable overheating of umbilical components, including super Duplex stainless steel
Tubulars
High pressure and high temperature onshore and subsea oil and gas operations require sour-specification and corrosion-resistant alloys for production tubing and associated completion equipment. For example, VICTREX PEEK polymers have the potential to solve the problem of sulfide-induced stress cracking in steel components.
VICTREX PEEK production tubing provides an alternative to premium steel or epoxy-coated tubulars. In some cases, these more conventional materials can be prone to long lead times, escalating costs or insufficient material performance.
Benefits of using VICTREX PEEK polymers can include:- Improved flow assurance due to high thermal insulation properties and resistance to scale and paraffin deposition
- Improved production performance as a result of lower coefficient of friction compared to steel
- Extension of lined tubulars in hotter, more aggressive applications
- Larger cross-sectional flow area compared to other lined tubular systems for improved production performance
Composites
Marine Risers
The industry has seen great innovations on riser systems with regards to steel catenary risers, riser towers, hybrid risers and flexible risers. Challenges remain to provide new riser systems that can fill the technology gaps with respect to water depth, riser diameter, and higher temperatures. Composite materials incorporating VICTREX PEEK polymers offer the potential to meet these challenges.
Benefits of using VICTREX PEEK polymers can include:- Improved mechanical, chemical and thermal performance compared to currently used materials in flexible systems
- Potential to extend life as a non-corrosive, reliable liner for steel and bonded composite risers
- Protects functional wrappings from incidental damages when pipes are spooled, reeled, transported and installed
Drill string technology requires advanced materials to expand the extended reach drilling envelope to 15.2 km and beyond. This need for longer departure wells is leading towards non-steel drill pipe, one example of which is based on carbon fiber composites using PEEK.
Potential benefits of using VICTREX PEEK polymers as a component in composite drill pipe:- Enhanced structural properties such as torsional strength, tensile capacity, and pressure integrity
- Increased inside diameter of pipe that is thin-walled, which yields the necessary hydraulic performance through the pipe and the drill bit
- High strength-to-weight ratio for addressing the torque and drag requirements of extended reach wells
