Partnerships Crucial in Developing Nonmetallic Downhole Tubulars

This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper IPTC 23491, “Role of Ecosystem Partners To Make Nonmetallic Downhole Tubulars a Reality,” by Ahmed Aladawy, SPE, and Ameen Malkawi, SPE, Baker Hughes, and Omar El Shamy, SPE, Novel Non-Metallic Solutions. The paper has not been peer reviewed. Copyright 2024 International Petroleum Technology Conference. Nonmetallic (NM) downhole tubulars offer a longer lifetime than their steel counterparts while eliminating corrosion concerns and lowering total cost of ownership. Making them a reality, however, requires a rigorous ecosystem with multidisciplinary skill sets and technology expertise. The complete paper discusses the challenges that face the development of such tubulars starting from academia and research institutes to complement expertise and computer computational power and moving through to material suppliers and manufacturing facilities for pipe prototyping. NM pipes also can include metallic elements, where a hybrid system of NM layers is incorporated into multilayered pipe structures that assume specific roles, similar to a metallic pressure armor layer in subsea flexible risers, jumpers, and flowlines. Another example is polymer-lined steel rigid pipes with glass-fiber reinforced epoxy (GRE), or a dual-layer thermoplastic-lined reinforced pipe (Fig. 1). Composite-based NM pipes can broadly be categorized into reinforced thermoplastic pipe (RTP) and reinforced thermoset pipe (RTR), with glass-fiber reinforced plastic pipe (GRP) and GRE considered a subset of RTR. RTP consists of thermoplastic matrices and layers that can soften after heating and can harden when cooled in a reversible process, thus having the potential to recycle. Because of the flexibility of thermoplastic polymer, RTP pipes up to hundreds of meters long can be spooled on reels and deployed through rigless operation, with reduced system cost and deployment time. This synopsis will concentrate, as does the complete paper, on RTP. RTP pipe design can be classified as unbonded, semibonded, or fully bonded. Essentially, three layers of constituents for RTP exist: the inner layer is a fluid barrier (liner), the second layer is a load-bearing component (reinforcement), and the outer layer is external protection (cover). Unbonded RTP pipe means that the layers are not heat-fused to one another during manufacturing and are free to move between layers. This type of RTP pipe usually is low to medium in pressure rating, especially with regard to collapse rating, but also is lower in manufacturing cost and is suitable in onshore applications for fluid transportation. To increase the pressure rating, semibonded RTP pipes can be considered if pipe thickness is a limitation. For offshore and downhole applications, however, where higher pressure and temperature ratings are required, fully bonded RTP pipes, more commonly known as thermoplastic composite pipes, are preferred to handle high burst and collapse-pressure requirements and more-consistent load transfer across the structure. All RTP types can be manufactured continuously into pipe lengths of hundreds of meters because of their flexibility, but fully bonded RTP may be limited to larger-bend radii than unbonded or semibonded RTP; consequently, a need exists to consider reel-size limitations or even carousels to wind long pipe lengths during manufacturing. Conversely, fully bonded RTP structures may be easier to model and analyze than unbonded pipe.