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Oil field operating company’s (1) flowline network in North and West Kuwait (NWK) has over 3000 wells connected through 6” carbon steel pipelines flowing from wellhead to the nearest Gathering Center (GC). Untreated wet crude is transported through the flowlines to GC’s directly or passing through the Remote Headers and Manifold (RHM) to GCs. In RHM, mixing of the wet crude takes place before it is sent to GC’s via transfer lines for further separation. The flowlines are laid aboveground except at road crossings where they are buried.
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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.
This paper presents the features of the Fusion Bonded Joint sleeve and addresses its design, manufacturing, and the outcomes of the comprehensive physical testing campaign that was performed. The summary of the tests that were carried out begin from the proof of concept phase to the integrated system tests, covering both carbon steel and High-Density PolyEthylene components assembled under conditions representative of its offshore operating conditions.The present paper covers preliminary manufacturing testing phase, electro-fusion welds qualification along with the required equipment and finally full-scale testing demonstrating the sleeve is compatible with standard welding processes. An in-depth analysis of the conditions and results of the fatigue testing campaign specifics, covering both carbon steel and electro-fusion welds dynamic behavior is proposed.
Wells in South Burgan field showed increase in water cut with drop in oil production. Some showed scale formation. Fluid sampling, radiography and ultrasonic thickness scanning were done. Recommendations were made for controlling internal corrosion and scaling. Work carried out is detailed.