Marketplace and Quality Assurance Presentation - Vincent Chirchir
NEW HIGH PERFORMANCE RESIN FOR THERMOPLASTIC LINERS
1. New High Performance Resin
for Thermoplastic Liners
Zach Stearman, LJ Guillotte
Lightning Production Services
2. Thermoplastic Liner Basics
• Plastic resin is extruded to pipe profile
• Mechanically bonded to the interior of the tubing
• Protects against wear and corrosion
• Eliminates the need for rod guides
• Many different resins are used for different
environments
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3. Benefits of Lined Tubing
• Extends the life of rods and tubing by eliminating rod on tubing wear
• Protects tubing from abrasion from solids
• Resistant to all chemicals found in well fluid including H2S and CO2
• Eliminates the need for rod guides in rod pumping applications
• Does not crack or chip like other coatings
• Flexible to withstand deviation in the wellbore
• More economic than some other technologies such as boronized
tubing
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4. Thermoplastic Liner History
• Used in downhole applications for over twenty years
• Initially designed for injection wells, but quickly adapted because of
success in mitigating rod on tubing wear
• High-density Polyethylene (HDPE) was the first resin used
• Soft, permeable
• Low temperature
• High Performance resins developed to meet the needs of more
challenging environments
• Superior performance
• Very high cost
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5. Thermoplastic Liner Resin Options
General Specifications
Material Type Max Temp. Dimensions H2S CO2 Cost
HDPE 140° F 2 3/8" - 4 1/2" 2% 10% $
HDPE - Modified 210° F 2 3/8" - 4 1/2" 2% 10% $$
POK - Modified 250° F 2 3/8" - 4 1/2" 5% 20% $$
PPS - Modified 340° F 2 3/8" - 4 1/2" 5% 20% $$$$
PEEK 500° F 2 3/8" - 4 1/2" 5% 20% $$$$$
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6. History of POK use in the Oil Industry
• Originally developed by Shell as “Carilon” for offshore corrosion
control and chemical resistance
• Resin production was discontinued in 2000, and the technology was
sold to Hyosung
• Initially, Hyosung’s POK had a maximum continuous operating
temperature of 210˚F.
• 2015 Hyosung and Lightning Production Services developed and
tested the raised temperature POK resin for use in O&G down hole
applications having a continuous working temperature of 250˚F.
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7. Polyolefin Ketone Resin (POK)
• Unique engineering plastic with a
carbon-only backbone
• Highly crystalline with a compact crystal
structure
• Stable at high temperatures
• Has excellent abrasion/chemical/fuel
resistance
• Gas barrier properties
• Its linear molecular chains are perfectly
alternating carbon monoxide and alpha
olefin structures
• Physical and chemical properties make
the resin well suited for downhole
applications
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8. Results from POK lab testing
• Heat Deflection Temperature (HDT) 220° F allows for high continuous
operating temperature
• High Melting Point of 222° C (433° F)
• Excellent permeation performance – Wet H2S and CO2
• Resistance to Attack or Swelling
• Hydrocarbons, Ketones, Esters and Ethers, Inorganic Salts, Acid/Base
• Mechanically Resilient
• Excellent Ductility broad temperature range
• Elongation and Impact
• Hydrolysis Resistance
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10. High-Temperature Performance
POK samples exposed to Multicomponent Fluid for 30 days at 300⁰ F and 4500 psig
* Multicomponent Fluid: Water/Hydrocarbon mixture with 5% H2S, 15% CO2, 80% Methane in gas phase
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16. Abrasion Resistance
Certified test center (external agencies)
Test Method: ASTM G 137
• With the pressure on the block, total abrasion on the ring which rotates is measured
• The conditions:
• Temperature of specimen (Room temp. or 130-200˚C). Rotational speed of rings (0.01~2m/s).
• Pressure on the block (5~30Mpa)
• Specimen Standard: Ring (50mm Dia. X 28mm width, Block (6.35mm x 12.7)
Allowable limit temp.: 225˚C
Wear-resistant test in room temp.
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17. Abrasion Resistance
• External Agencies (Certified test
center)
• Resin on Resin (same materials)
• Same Condition except maintaining 0.1 MPa
• Under 1.5m/s, 0.1MPa Condition, PK
abrasion loss is the lowest among the test
materials.
Case I. Case II. Case III. Condition
Block Ring
Abrasion
loss
(um/hr)
Block Ring
Abrasion
loss
(um/hr)
Block Ring
Abrasion
loss
(um/hr)
Pressure
(MPa)
Speed
m/s
(rpm)
Temp(℃)
Time
(hr)
POK POK
1
POM POM
164
PA66 PA66
66
0.1
1.00
(380)
23
1
21 202 156
1.25
(470)
1
86 263 466
1.50
(570)
1
• Materials : POK = M630A base resin, POM = Duracon M90-44 base resin, PA66 = Zytel 101 base resin
• PK is inferior than other materials under over 1.5m/s, 0.1MPa Condition.
• Abrasion loss (1.75m/s, 0.1MPa) : PK=1,078um/h, POM=619um/h, PA66=1,135um/h
• Abrasion loss (1m/s, 0.175MPa) : PK=48,226um/h, POM=49um/h, PA66=149um/h
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19. Initial Field Trials
Install Date Customer Well No. Previous Run Time Run Time to Date
8/29/2016 Customer A 1 6 month maximum 695 days
9/29/2016 Customer B 2 6 month average 583 days
11/17/2016 Customer B 3 60 day average 568 days
12/8/2016 Customer B 4 New Install 594 days
2/8/2017 Customer C 5 New Install 532 days
3/13/2017 Customer A 6 6 month average 499 days
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20. Failure Rate Changes on Initial Installs
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0
0.2
0.4
0.6
0.8
1
1.2
Tubing Leaks Rod Parts Pump Failures
FailureRate
21. Economic Savings
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Failure Type Rate Average Repair Cost Total Spend
Tubing Leaks 0.97 $89,000 $86,330
Parted Rods 0.74 $54,000 $39,960
Pump Change 0.19 $45,000 $8,550
$/Well/Year $134,840
Failure Type Rate Average Repair Cost Total Spend
Tubing Leaks 0.14 $89,000 $12,460
Parted Rods 0.40 $54,000 $21,600
Pump Change 0.14 $45,000 $6,300
$/Well/Year $40,360
Prior to LF115 Pilot With LF115
To date, no wells have been pulled due to failures in the LF115 lined tubing section.
22. Conclusion
• POK is a new high performance resin that is being extruded to
increase the life of artificially lifted wells
• Meets temperature needs for hot oiling at a much lower cost than
other high performance resins
• Excellent mechanical properties, chemical resistance, abrasion
resistance, and barrier properties
• Around 40+ wells now using Polyketone Thermoplastic Liner with
operators in Permian Basin, Delaware Basin, and Uintah Basin
• Longest runtimes have exceeded 500 days
• Numerous wells have extended MTBF by two or three times
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