how flexible steel pipe helped solve five challenges of

© 2019 FlexSteel Pipeline Technologies, Inc.

Kirill Kovalenko, Technical Services Engineer

Cost-Effective Well Site Facilities Canada Congress

February 28, 2019

How Flexible Steel Pipe Helped Solve

Five Challenges of Pipeline Construction,

Operation, and Maintenance

© 2019 FlexSteel Pipeline Technologies, Inc. | 2

Agenda

Operators Challenges

Flexible Steel Pipe

Case Studies

Summary

1

2

3

4


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Challenges: Time + Resources

STEEL CONSTRUCTION AND MAINTENANCE

CHALLENGES

CORROSION CONTROL

MAINTENANCE AND REPAIR

RESOURCES AND TIME

Time + Resources = increased project cost



Solution: Spoolable Pipeline

• Comes in long sections:– 380 to 2,000 m

• Installs much faster than steel pipe

• Accelerated time to production

• Minimal manpower and equipment requirement

• Smaller Right-of-Way

• No welding, field bending, X-ray, and coating costs

Flexible Steel Pipe


Flexible Steel Pipe Structure

Steel Reinforcement

▪ Pressure Containment Layer

Corrosion Resistant Shield

▪ HDPE/PE-RT

Corrosion Resistant Liner

▪ HDPE/PE-RT

HDPE: High-Density Polyethylene

PE-RT: Polyethylene Raised-Temperature


Flexible Steel Pipe Specifications

2 in. 3 in. 4 in. 6 in. 8 in.

DESIGN PRESSURE RANGE

750 PSI to 3000 PSI

OPERATING TEMPERATURE RANGE

- 40°C >>> 65°C >>> up to 90°C

High-pressure and high-rate capability


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Welded Steel Flexible Steel Pipe

Installation significantly faster than conventional steel line pipe



Grande Prairie, Alberta

Case Study: Water Pipeline

• A new well pad was constructed by the customer

• Frac water supply daily cost: – 22 trucks/day = $115,000/day

• A 4,000-m pipeline was urgently needed

• 8” 1500 psi Flexible Steel Pipe was chosen

• The line installed ~30% faster than their previous solution– 7 HDD bores and crossings, the longest

bore 700 m

• Trucking costs eliminated sooner than expected


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TYPICAL STEEL QUALITY

& SAFETY CHALLENGES

EXTERNAL CORROSION

INTERNALCORROSION



Solution: Corrosion-Resistant Liner

FLEXSTEEL

STEEL


Corrosion-Resistant Shield

FLEXSTEELSTEEL



Case Study: Multi-Purpose Pipeline

• Operator was adding new wells on a well pad and needed several new pipelines

• Solution was to install a single line in the ditch for the following services:

1. Fuel gas supply2. Frac water supply3. Multiphase production

• 12% reduction in the total cost of installation

• 4200 m of 6” 1500 psi Flexible Steel Pipe installed

• Pipeline was run through 3 HDD bores up to 670 m long

• Shield Integrity Testing performed

Dawson Creek, British Columbia


Challenge: Integrity Management

EXPENSIVE INTEGRITY

MANAGEMENT PIPELINE

DOWNTIME

REDUCED

FLOW RATES


Solution: Pipeline Rehabilitation

Up to 2 km of flexible steel pipe can be installed in a single pull

HOST PIPE

PIPE IN PIPE METHODOLOGY:

• Permanent solution for leak

prevention

• Minimal ground disturbance

• Host pipe can serve as a

secondary containment if integrity

maintained


Rocky Mountain House, Alberta

Case Study: Oil Emulsion Line

• Customer had integrity issues with 5,000 m of existing NPS 8 Oil Effluent pipeline– 3 river crossings, densely populated area: high

risk– Could not shut down for a long time due to

lost production

• Pipeline was rehabilitated with 6” 1500 psi Flexible Steel Pipe using pipe-in-pipe methodology– 6 pulls performed– Longest pull 1100 m

• Risk level reduced• Significant time and cost savings

– Production restored with less than 2 weeks downtime


Challenge: Pipeline Leaks

Leaks negatively affect:

The environment

Your company’s reputation

Bottom line


Fewer Joints – Less Chance for Leakage

Sample 5 km 8-Inch Pipeline Project

FLEXSTEEL: 12 CONNECTIONS STEEL: 277 WELD JOINTS

WELD JOINTS

FLEXSTEEL PIPE CONNECTIONS


Case Study: Edson, Alberta

Fiber-Optics Monitoring

4-Inch 3000 psi Flexible Steel Pipe

Installed through HDD bore

Fiber optic cables in a carrier installed

alongside FlexSteel

High-Fidelity Dynamic Sensing: integrated

acoustic + temperature + strain/vibration

- Pipeline leak detection

- 3rd party interference

*Pictures courtesy of HiFi Engineering


Summary

Fast deployment with less resources1

Environmentally friendly – HDD under sensitive areas2

Corrosion-resistant solution with little to no maintenance3

Excellent choice for cyclic service applications4

Great solution for pipeline rehabilitation using pipe-in-pipe methodology5

Leak detection capabilities reduce the chance of a leak6

Reduces overall construction and operating costs7

how flexible steel pipe helped solve five challenges of

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