Patent Application
20200207001
The present application relates to polyvinylidene fluoride (PVDF) pipes and methods of making and using same.
Disclosed herein is a method comprising flowing gas from a wellbore penetrating a subterranean formation through a wellhead to yield produced gas; flowing the produced gas through a wellhead line to one or more wellsite processing units to yield wellsite processed gas; and flowing the wellsite processed gas through a gathering line to a gas processing plant, a gas pipeline transmission system, or both, wherein the wellhead line, the gathering line, or both comprise polyvinylidene fluoride (PVDF) pipe having a nominal pipe size of equal to or greater than 2 inches and equal to or less than 16 inches.
Also disclosed herein is a method comprising producing acid gas from a wellbore penetrating a subterranean formation through a wellhead to yield produced acid gas, wherein the produced acid gas comprises methane, water, and one or more corrosive compounds selected from the group consisting of hydrogen sulfide, carbon dioxide, and combinations thereof; and flowing the produced acid gas through a gas gathering system to a gas processing facility to reduce the acidity of the acid gas and yield treated natural gas, wherein the treated natural gas has less hydrogen sulfide, carbon dioxide, or both than the produced acid gas, wherein the gas gathering system comprises one or more flow lines comprising PVDF pipe having a nominal pipe size of equal to or greater than 2 inches and equal to or less than 16 inches.
Further disclosed herein is a method comprising recovering fluid from a wellbore penetrating a subterranean formation through a wellhead to yield a recovered fluid; and flowing the recovered fluid through (i) a gathering system conveying the recovered fluid from the wellhead to a processing unit to produce a processed fluid, (ii) a pipeline transmission system transporting the processed fluid from the processing unit to a distribution point or a storage facility; (iii) a distribution system distributing the processed fluid from the distribution point or storage facility to one or more end users; or (iv) combinations thereof, wherein the gathering system, the pipeline transmission system, the distribution system, or combinations thereof comprise one or more flow lines comprising PVDF pipe having a nominal pipe size of equal to or greater than 2 inches and equal to or less than 36 inches.
Further disclosed herein is a method comprising producing hydrocarbons from a wellbore penetrating a subterranean formation through a wellhead to yield produced hydrocarbons; and flowing the produced hydrocarbons through a hydrocarbon gathering system to a pipeline transmission system, wherein the hydrocarbon gathering system, the pipeline transmission system or both comprise one or more flow lines comprising PVDF pipe having a nominal pipe size of equal to or greater than 2 inches and equal to or less than 36 inches and wherein the PVDF pipe consists essentially of PVDF.
The detailed description will reference the drawings briefly described below, wherein like reference numerals represent like parts, unless otherwise indicated.
Disclosed herein are polyvinylidene fluoride (PVDF) pipes, PVDF fittings, and methods of making and using same. A variety of PVDF pipelines, alternatively referred to as PVDF flow lines or PVDF lines, can be formed by combing one or more PVDF pipe components, PVDF fitting components, or combinations thereof as described in detail herein. The PVDF flow lines can be used in a variety of services as described herein, including but not limited to conveyance of oil and/or gas through a gathering system, a long-haul intrastate or interstate transmission pipeline system, or a distribution system.
The PVDF pipes comprise, consist essentially of, or consist of polyvinylidene fluoride fluoropolymer, also referred to as polyvinylidene difluoride; poly(vinylene fluoride); poly(1,1-difluoroethane); poly(1,1-difluoroethylene); 1,1-difluoroethene homopolymer; 1,1-difluoroethylene homopolymerise; and 1,1-difluoroethylene polymer. PVDF is also identified by CAS number 24937-79-9. PVDF has the chemical formula: —[C2H2F2]n— where n is the number of repeating units in a polymer chain:
Prior to being formed into a pipe, the PVDF can be referred to as a polymer, fluoropolymer, powder, or resin, and can be in a solid particulate form or solid granular form, for example pellets that are formed via pelletization of PVDF polymer recovered from a polymerization reactor. In an aspect, a suitable PVDF for use in the PVDF pipes of the present disclosure is PVDF 2025 (the PVDF abbreviation is in accordance with ASTM D 1600) classified as Type 2 in accordance with the PVDF material standard ASTM D3222. PVDF 2025 has physical properties and associated testing methods as set forth in Table 1.
Ahydrostatic design basis (HDB) listings are published in PPI TR-4.
In an aspect, the PVDF present in the PVDF pipe has physical properties as set forth in Table II.
1 Type IV, 1.0 mm/min
2 Mechanical properties are significantly affected by the sample preparation method.
3 Type IV, 50 mm/min
4Rate A (50° C./h), Loading 2 (50N)
5Sheet
Suitable PVDF for use in the PVDF pipes of the present disclosure is sold under a variety of brand names including KF (Kureha), HYLAR (Solvay), KYNAR (Arkema) and SOLEF (Solvay). In an aspect, the PVDF present in the PVDF pipe is SOLEF 1010 and has physical properties as set forth in Table II.
The PVDF (e.g., PVDF pellets) can be formed into PVDF pipes, for example via melt extrusion as described in more detail herein. In an aspect, the PVDF pipes are solid wall pipes. In an aspect, the solid wall PVDF pipes are extruded pipes consisting of one homogeneous layer of PVDF. In an aspect, the solid wall PVDF pipes have an about uniform wall thickness along a 360° circumferential cross-section. In an aspect, the solid wall PVDF pipes are extruded pipes consisting of one homogeneous layer of PVDF having an about uniform wall thickness along a 360° circumferential cross-section. In an aspect, the solid wall PVDF pipes have dimensions, e.g., nominal pipe size, OD, and wall thickness, as set forth in more detail herein, for example in Tables 3, 4, and 5.
The PVDF pipes can have a nominal pipe size (NPS) ranging from equal to or greater than 2 inches to equal to or less than 36 inches, alternatively ranging from equal to or greater than 2 inches to equal to or less than 24 inches, alternatively ranging from equal to or greater than 2 inches to equal to or less than 16 inches, alternatively ranging from equal to or greater than 2 inches to equal to or less than 12 inches, alternatively ranging from equal to or greater than 2 inches to equal to or less than 10 inches, alternatively ranging from equal to or greater than 3 inches to equal to or less than 36 inches, alternatively ranging from equal to or greater than 3 inches to equal to or less than 24 inches, alternatively ranging from equal to or greater than 3 inches to equal to or less than 16 inches, alternatively ranging from equal to or greater than 3 inches to equal to or less than 12 inches, alternatively ranging from equal to or greater than 3 inches to equal to or less than 10 inches, alternatively ranging from equal to or greater than 4 inches to equal to or less than 36 inches, alternatively ranging from equal to or greater than 4 inches to equal to or less than 24 inches, alternatively ranging from equal to or greater than 4 inches to equal to or less than 16 inches, alternatively ranging from equal to or greater than 4 inches to equal to or less than 12 inches, alternatively ranging from equal to or greater than 4 inches to equal to or less than 10 inches, alternatively ranging from equal to or greater than 5 inches to equal to or less than 36 inches, alternatively ranging from equal to or greater than 5 inches to equal to or less than 24 inches, alternatively ranging from equal to or greater than 5 inches to equal to or less than 16 inches, alternatively ranging from equal to or greater than 5 inches to equal to or less than 12 inches, alternatively ranging from equal to or greater than 5 inches to equal to or less than 10 inches, alternatively ranging from equal to or greater than 6 inches to equal to or less than 36 inches, alternatively ranging from equal to or greater than 6 inches to equal to or less than 24 inches, alternatively ranging from equal to or greater than 6 inches to equal to or less than 16 inches, alternatively ranging from equal to or greater than 6 inches to equal to or less than 12 inches, alternatively ranging from equal to or greater than 6 inches to equal to or less than 10 inches, alternatively ranging from equal to or greater than 8 inches to equal to or less than 36 inches, alternatively ranging from equal to or greater than 8 inches to equal to or less than 24 inches, alternatively ranging from equal to or greater than 8 inches to equal to or less than 16 inches, alternatively ranging from equal to or greater than 8 inches to equal to or less than 12 inches, alternatively ranging from equal to or greater than 8 inches to equal to or less than 10 inches, alternatively ranging from equal to or greater than 16 inches to equal to or less than 36 inches, alternatively ranging from equal to or greater than 18 inches to equal to or less than 36 inches, alternatively ranging from equal to or greater than 20 inches to equal to or less than 36 inches, alternatively ranging from equal to or greater than 22 inches to equal to or less than 36 inches, alternatively ranging from equal to or greater than 24 inches to equal to or less than 36 inches, alternatively ranging from equal to or greater than 26 inches to equal to or less than 36 inches, alternatively ranging from equal to or greater than 28 inches to equal to or less than 36 inches, alternatively ranging from equal to or greater than 30 inches to equal to or less than 36 inches, alternatively ranging from equal to or greater than 32 inches to equal to or less than 36 inches, or alternatively ranging from equal to or greater than 34 inches to equal to or less than 36 inches. The PVDF pipes can have a nominal pipe size of 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 9, 10, 11, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, or 36 inches, or any combination or range thereof.
The PVDF pipes can have an outside diameter and tolerance as set forth in Table 3 when measured in accordance with ASTM Test Method D2122. The outside diameter measurement shall be taken at a distance at least 1.5 times the average outside diameter or 11.8 in. [300 mm], whichever is less, from the cut end of the pipe. The values set forth in Tables 3, 4, and 5 shall apply at 73.4±3.6° F. [23±2° C.] without regard to humidity. Larger sizes up to NPS 36 inches (e.g., ≥26 NPS to ≤36 NPS) can also be used with same percentage tolerances, and custom wall thicknesses can be used for any outside diameter.
AOutside diameter rounded to 3 decimal places for inch dimensions or to 2 decimal places for mm dimensions.
BDetermined in accordance with Outside Surface Irregularity Test Method A or B.
Outside Surface Irregularity Test Method A: apply a rounding device to the pipe and tighten securely. At any gaps between the rounding device and the pipe circumference, fit a feeler gage or gage wire having the same thickness as the outside surface irregularity tolerance specified in Table 3 into the gap. If the gage does not fit, the pipe is in compliance. To ensure that the full circumference is checked, rotate the rounding device approximately 90 degrees, tighten securely and repeat the measurement procedure.
Outside Surface Irregularity Test Method B: apply a rounding device to the pipe and tighten securely. Determine the average outside diameter of the pipe within 2 in. [50.8 mm] to the edge of the rounding device using a circumferential wrap tape (pi-tape). Measure the pipe outside diameter at any gaps between the rounding device and the pipe outside diameter with calipers. The caliper diameter measurement shall not differ from the average outside diameter measurement by more than the outside surface irregularity tolerance specified in Table 3.
The PVDF pipes can have a pipe wall thickness for nominal pipe sizes as set forth in Tables 4 and 5 when measured in accordance with ASTM Test Method D2122. For pipe larger than nominal pipe size 12, the wall thickness variability (eccentricity) as measured and calculated in accordance with ASTM Test Method D2122 in any diametrical cross section of the pipe shall not exceed 12 percent. Standard dimension ratio (SDR), also referred to as dimension ratio (DR), is a unitless number that is equal to the average outside diameter (OD) of a pipe divided by the minimum wall thickness (t) of the pipe, with OD and t having common measurement units (e.g., inches). The SDR is a “standard” DR because the SDR is typically one of the following values per ASTM: 5.0, 6.0, 7.3, 9.0, 11.0, 13.5, 15.5, 17.0, 19.0, 21.0, 23.5, 26.0, 32.5, or 35. Larger DRs up to 36 (e.g., ≥26 DR to ≤36 DR) can also be used with same percentage tolerances, and custom wall thicknesses can be used.
AMinimum wall thickness = average outside diameter (from Table 3) divided by DR (from Table 4), and rounded to 3 decimal places for inch dimensions, or to 2 decimal places for mm dimensions.
BWall thickness tolerance = plus 12% of the minimum wall thickness, and rounded to 3 decimal places for inch dimensions, or to 2 decimal places for mm dimensions.
AMinimum wall thickness = average outside diameter (from Table 3) divided by DR (from Table 5), and rounded to 3 decimal places for inch dimensions, or to 2 decimal places for mm dimensions.
The PVDF pipes can be substantially round or circular in cross-sectional shape, in contrast to an elliptical shape. When exiting production line processing equipment but before packaging for shipment, the PVDF pipes can have an ovality (elliptical shape) that does not exceed 5 percent when determined in accordance with ASTM Test Method D2122. For example, to determine ovality measure the average outside diameter with a circumferential wrap tape (pi-tape). Determine the maximum and minimum diameter at the same location where the average diameter is measured with calipers or a tape measure accurate to 1/32 in. [0.80 mm] for 16-in. and smaller pipes or to 1/16 in. [1.59 mm] for larger pipes. When minimum (or maximum) diameter is determined, rotate calipers or tape measure approximately 90 degrees around the pipe circumference to determine the corresponding maximum (or minimum) diameter. Calculate ovality by subtracting the minimum diameter from the maximum diameter, dividing the difference by the measured average outside diameter, and multiplying by one hundred. When maximum and minimum diameter are measured at the end of the pipe, the average outside diameter shall be measured 11.8 in. [300 mm] or one pipe diameter, whichever is less, from the end of the pipe so that the average outside diameter measurement is not affected by toe-in.
The PVDF pipes can be substantially free of toe-in, i.e., there is no taper or conical shape at the cut end of a section of PVDF pipe due to a slightly smaller diameter at the cut end of the PVDF pipe. In an aspect, when measured in accordance with ASTM Test Method D2122, the outside diameter at the cut end of the pipe shall not be more than 1.5 percent smaller than the outside diameter per Table 3.
The PVDF pipes can have a pressure rating (PR), which is also referred to as the design pressure or maximum operating pressure (MOP), as determined in accordance with Equation 1. The PR is the estimated maximum pressure the PVDF pipe is capable of withstanding continuously with a high degree of certainty that failure of the PVDF pipe will not occur.
PR=2(HDS)(DFC)(DFT)/(DR−1) (Eq. 1)
For example, using Equation (1) with an HDS of 3150 psi based on a service design factor of 0.63, a chemical design factor of 1.0, a temperature design factor of 1.0 and DR 7 pipe, the pressure rating is:
The PVDF pipes can have a PR as set forth in Table 8 when measured in accordance with Equation (1) based on a 0.63 service design factor for PVDF and Plastics Pipe Institute (PPI) TR-4 Hydrostatic Design Basis (HDB) listings of 5000 psi@73° F. (23° C.), 1250 psi@248° F. (120° C.), and 800 psi@284° F. (140° C.), using PPI TR-3 long-term hydrostatic strength (LTHS) interpolation are provided as follows:
In an aspect, the PVDF pipe can have a pressure rating selected from the group consisting of 0 psig, 20 psig, 40 psig, 60 psig, 80 psig, 100 psig, 120 psig, 140 psig, 160 psig, 180 psig, 200 psig, 220 psig, 240 psig, 260 psig, 280 psig, 300 psig, 320 psig, 340 psig, 360 psig, 380 psig, 400 psig, 420 psig, 440 psig, 460 psig, 480 psig, 500 psig, 520 psig, 540 psig, 560 psig, 580 psig, 600 psig, 620 psig, 640 psig, 660 psig, 680 psig, 700 psig, 720 psig, 740 psig, 760 psig, 780 psig, 800 psig, 820 psig, 840 psig, 860 psig, 880 psig, 900 psig, 920 psig, 940 psig, 960 psig, 980 psig, 1000 psig, 1020 psig, 1040 psig, 1050 psig, and one or more ranges comprising any two endpoints selected from the pressure ratings listed in this group.
As described in detail herein, the PVDF pipe can be used for pressurized transport of various fluids such as fluids recovered from a wellbore (e.g., in an oil and gas gathering system). Accordingly, the PVDF pipe can have an operating pressure of greater than 0 psig to an upper limit defined by a pressure rating selected from the group consisting of 0 psig, 20 psig, 40 psig, 60 psig, 80 psig, 100 psig, 120 psig, 140 psig, 160 psig, 180 psig, 200 psig, 220 psig, 240 psig, 260 psig, 280 psig, 300 psig, 320 psig, 340 psig, 360 psig, 380 psig, 400 psig, 420 psig, 440 psig, 460 psig, 480 psig, 500 psig, 520 psig, 540 psig, 560 psig, 580 psig, 600 psig, 620 psig, 640 psig, 660 psig, 680 psig, 700 psig, 720 psig, 740 psig, 760 psig, 780 psig, 800 psig, 820 psig, 840 psig, 860 psig, 880 psig, 900 psig, 920 psig, 940 psig, 960 psig, 980 psig, 1000 psig, 1020 psig, 1040 psig, and 1050 psig. The PVDF pipe can have an operating pressure in a range of from greater than 0 psig to equal to or less than 1050 psig, in a range of from equal to or greater than 125 psig to equal to or less than 1050 psig, in a range of from equal to or greater than 250 psig to equal to or less than 1050 psig, in a range of from equal to or greater than 335 psig to equal to or less than 1050 psig, in a range of from equal to or greater than 400 psig to equal to or less than 1050 psig, in a range of from equal to or greater than 125 psig to equal to or less than 750 psig, in a range of from equal to or greater than 250 psig to equal to or less than 750 psig, in a range of from equal to or greater than 335 psig to equal to or less than 750 psig, in a range of from equal to or greater than 400 psig to equal to or less than 750 psig, in a range of from equal to or greater than 125 psig to equal to or less than 665 psig, in a range of from equal to or greater than 250 psig to equal to or less than 665 psig, in a range of from equal to or greater than 335 psig to equal to or less than 665 psig, in a range of from equal to or greater than 400 psig to equal to or less than 665 psig, in a range of from equal to or greater than 125 psig to equal to or less than 650 psig, in a range of from equal to or greater than 250 psig to equal to or less than 650 psig, in a range of from equal to or greater than 300 psig to equal to or less than 650 psig, in a range of from equal to or greater than 335 psig to equal to or less than 650 psig, in a range of from equal to or greater than 350 psig to equal to or less than 650 psig, in a range of from equal to or greater than 400 psig to equal to or less than 650 psig, in a range of from equal to or greater than 125 psig to equal to or less than 450 psig, in a range of from equal to or greater than 250 psig to equal to or less than 450 psig, in a range of from equal to or greater than 300 psig to equal to or less than 450 psig, in a range of from equal to or greater than 335 psig to equal to or less than 450 psig, in a range of from equal to or greater than 350 psig to equal to or less than 450 psig, or in a range of from equal to or greater than 400 psig to equal to or less than 450 psig.
In an aspect, the PVDF pipe used in an unregulated gas gathering system as described herein has an operating pressure in a range of from greater than 0 psig to equal to or less than 1050 psig for unregulated PVDF pipe having an SDR of 7, in a range of from equal to or greater than 335 psig to equal to or less than 1050 psig for unregulated PVDF pipe having an SDR of 7, or in a range of equal to or greater than 400 psig to equal to or less than 1050 psig for unregulated PVDF pipe having an SDR of 7. In an aspect, the PVDF pipe used in an unregulated gas gathering system as described herein has an operating pressure in a range of from greater than 0 psig to equal to or less than 630 psig for unregulated PVDF pipe having an SDR of 11, in a range of from equal to or greater than 335 psig to equal to or less than 630 psig for unregulated PVDF pipe having an SDR of 11, or in a range of equal to or greater than 400 psig to equal to or less than 630 psig for unregulated PVDF pipe having an SDR of 11.
In an aspect, the PVDF pipe used in a regulated gas gathering system as described herein has an operating pressure in a range of from greater than 0 psig to equal to or less than 650 psig for regulated PVDF pipe having an SDR of 7, in a range of from greater than 125 psig to equal to or less than 650 psig for regulated PVDF pipe having an SDR of 7, or in a range of from greater than 250 psig to equal to or less than 650 psig for regulated PVDF pipe having an SDR of 7. In an aspect, the PVDF pipe used in a regulated gas gathering system as described herein has an operating pressure in a range of from greater than 0 psig to equal to or less than 400 psig for regulated PVDF pipe having an SDR of 11, in a range of from greater than 125 psig to equal to or less than 400 psig for regulated PVDF pipe having an SDR of 11, or in a range of from greater than 250 psig to equal to or less than 400 psig for regulated PVDF pipe having an SDR of 11. Regulated PVDF pipe refers to pipe that is used in a pipeline or flow line that is subject to one or more U.S. state or federal regulations, e.g., pressure rating regulations, based upon the use of the PVDF pipe in a gathering system, a long-haul intrastate and interstate pipeline system, and/or a distribution system as described herein. Examples of applicable PVDF pipe regulations include but are not limited to regulations administered by the U.S. Pipeline and Hazardous Materials Safety Administration (PHMSA), for example as described in 49 CFR Part 192 and Federal Register Vol. 71, No. 50, Mar. 15, 2006. Unregulated PVDF pipe refers to pipe that is not subject to one or more U.S. state or federal regulations, e.g., pressure rating regulations, based upon the use of the PVDF pipe in a gathering system, a long-haul intrastate and interstate pipeline system, and/or a distribution system as described herein.
The PVDF pipe can be subjected to operating temperatures (e.g., ambient temperature, temperature of fluids flowing through the pipe, or both) ranging from −40° F. to 284° F., alternatively ranging from 0° F. to 284° F., alternatively ranging from 73° F. to 284° F., alternatively ranging from 100° F. to 284° F., alternatively ranging from 180° F. to 284° F., alternatively ranging from 200° F. to 284° F., alternatively ranging from 0° F. to 200° F., alternatively ranging from 73° F. to 200° F. For example as shown in Table 8, PVDF pipe having SDR values ranging from 7 to 32.5 and pressure ratings of 1050 to 32 psig can have operating temperatures ranging from 73° F. to 284° F., more specifically an operating temperature selected from the group consisting of 73° F., 100° F., 120° F., 140° F., 160° F., 180° F., 200° F., 220° F., 240° F., 248° F., 260° F., 284° F., and one or more ranges comprising any two endpoints selected from the operating temperatures listed in this group. In an aspect, the PVDF pipe can have an operating temperature selected from the group consisting of −40° F., −20° F., 0° F., 20° F., 40° F., 60° F., 73° F., 100° F., 120° F., 140° F., 160° F., 180° F., 200° F., 220° F., 240° F., 248° F., 260° F., 284° F., and one or more ranges comprising any two endpoints selected from the operating temperatures listed in this group.
The PVDF pipes can have a density of equal to or greater than 1.75 g/cm3 to equal to or less than 1.80 g/cm3, alternatively equal to or greater than 1.76 g/cm3 to equal to or less than 1.79 g/cm3, alternatively about 1.78 g/cm3, alternatively 1.78 g/cm3. In an aspect, the PVDF pipes have a homogenous density of 1.78 g/cm3 throughout PVDF pipe material.
The PVDF pipe can have tensile elongation test result such that the minimum elongation at break for each tensile specimen from the sample shall exceed 20 percent of the gauge length. Four Type III or Type IV tensile specimens per Test Method ASTM D638 are prepared from the sample, one specimen from the middle of each quadrant around the pipe circumference and cut longitudinally from the pipe wall. For small pipe, specimens prepared from adjacent lengths along the sample are acceptable. Cut surfaces of tensile specimens shall be smooth; however, the pipe inside diameter surface in the gauge area shall be left unaltered. Test Method ASTM D638 is carried out at a cross-head separation rate of 0.08 in. per minute [2.0 mm per minute].
PVDF Pipe size NPS 12 and smaller can have a minimum hoop stress at burst of 6500 psi [45 MPa] when tested in accordance with Test Method D1599 at 73.4±3.6° F. [23±2° C.] without regard to humidity. The test sample is five specimens, and specimen ruptures shall be ductile and the minimum hoop stress at burst shall be 6500 psi [45 MPa].
PVDF Pipe size NPS 2 and larger can have a minimum apparent tensile strength at yield 6500 psi [45 MPa] when tested in accordance with ASTM Method D2290 at 73.4±3.6° F. [23±2° C.] without regard to humidity. Five specimens are prepared from the sample per Test Method ASTM D2290.
At an elevated temperature of 176° F. (80° C.), the PVDF pipe exhibits Condition 1: a test pressure hoop stress of 2030 psi at a minimum average time of 200 hours before failure, or Condition 2: a test pressure hoop stress of 1950 psi at a minimum average time of 1000 hours before failure, wherein a tolerance on the elevated temperature is +/−3.6° F. (+/−2° C.) and a tolerance on the test pressure hoop stress is +/−5 psi, wherein an internal pressure is calculated according to:
When subjected to bendback testing, the bendback specimens from sample PVDF pipe do not reveal inside surface crazing or cracking. Bendback Test Method: From a PVDF pipe sample, squarely cut a pipe ring specimen with a minimum width of 1¼ in. [32 mm]. For wall thickness ⅜ in. [9.5 mm] or less test the entire wall thickness. For wall thickness above ⅜ in. [9.5 mm], remove material from the outside diameter surface of the ring specimen while maintaining an undisturbed inside diameter surface, to produce a ring specimen with consistent wall thickness of ⅜ in. [9.5 mm]. Test the ring in its entirety, or cut the ring into representative sectors to produce individual bend-back test specimens for at least each quadrant around the pipe. In a well-lit area test per the following procedure within 5 min: (1) Bend the specimen inside-out (reverse-bend so that the pipe ID surface is on the outside surface of the bent specimen). (2) Using an apparatus such as a vise or other suitable bending equipment, close the legs of the specimen together. When the specimen legs are closed together, the top of the bend-back specimen shall protrude the lesser of 1⅛ in. [29 mm] or three wall thicknesses above the point of closure (jaws). (3) With the unaided (naked) eye, visually examine the protruding reverse-bent pipe ID surface for brittle cracking or crazing.
The PVDF pipes can have slow crack growth (SCG) resistance exhibiting no failure before 500 hours, no failure before 1000 hours, or no failure before 2000 hours when tested in accordance with PENT slow crack growth testing (Test Method ASTM F1473) using compression molded plaques at a stress of 7.5 MPa, based on the unnotched area, and a test temperature of 80° C. Notch depth shall be in accordance with Table 1 in Test Method ASTM F1473. The PVDF pipe displays linear stress rupture curves as determined in accordance with ASTM D2837 at 86° F., 122° F., 212° F., 248° F., 284° F., and 302° F. as discussed in more detail in Example 3, which is further evidence of excellent resistance to slow crack growth. The PVDF pipes can have a rapid crack propagation (RCP) resistance when tested in accordance with ISO 13477 S4 Test or ISO 13478 Full Scale Test (FST) using air as the internal medium. The FST critical pressure in air shall be greater than the design pressure of the pipe with a gaseous fluid inside, and this requirement does not apply when the pipe contains a non-compressible liquid fluid.
The PVDF pipes are corrosion resistant. In an aspect, the PVDF pipes have 0% risk of corrosion compared to metallic or steel pipes in the same service (e.g., flowing the same amount and type of fluids under the same operating conditions and environment). In an aspect, the PVDF pipes are not coated, jacketed, wrapped, or otherwise supplemented with additional physical structure or support to reduce, abate, or prevent corrosion on an internal surface, external surface, or both of the PVDF pipes. In an aspect, the PVDF pipes (e.g., the inner bore surface, the outer surface, or the entirety thereof) are (i) not subjected to cathodic protection while commissioned for service; (ii) not subjected to the presence of corrosion inhibitors in fluids flowing through the PVDF pipes; (iii) are not subjected to nondestructive corrosion monitoring or in-line corrosion inspections while commissioned for service; (iv) are not subjected to moisture reduction treatments while commissioned for service such as water removal treatment of fluids prior to being placed into the PVDF pipes; (v) are not subjected to any other remedial measures or methods of corrosion control while commissioned for service; or (vi) any combination of (i) to (v). Commissioned for service includes the time from when a pipe is deemed suitable for its intended use until the time when the pipe is deemed unsuitable for its intended use. In an aspect, a corrosion resistant PVDF pipe consists essentially of, alternatively consists of, PVDF and excludes any other compound or material that is intended to improve corrosion resistance to the PVDF pipe. In an aspect, unlike steel or metallic pipes that corrode, a corrosion resistant PVDF pipe is corrosion resistant and does not contain any (i.e., 0 wt. %) corrosion inhibiting compounds.
The PVDF pipes are chemical resistant. In an aspect, a chemical resistant PVDF pipe consists essentially of, alternatively consists of, PVDF and excludes any other compound or material that is intended to improve chemical resistance to the PVDF pipe. In an aspect, a chemical resistant PVDF pipe does not contain any (i.e., 0 wt. %) chemical resistance enhancing compounds. The PVDF pipes display passing chemical resistance when tested in accordance with ASTM Test Method D543 for the chemicals set forth in Table 9 at the designated testing temperature. For passing chemical resistance: (1) the increase of weight of the test specimen is 2% or less; (2) the reduction in weight of the test specimen is less than 0.3%; and (3) the apparent tensile strength at yield has not changed by more than ±15% from initial value when tested in accordance with ASTM 2290.
a Chemical Resistance of Plastics and Elastomers from Plastic Design Library
For example, to determine chemical resistance of PVDF pipe, a test specimen is prepared. Where available, the test specimen shall be a ring cut from NPS 2 SDR 11 pipe. For PVDF materials that are not readily available as NPS 2 SDR 11 pipe, the test specimen shall be a plaque of material ¼ by 2 by 4 in. (6.3 by 50.8 by 101.6 mm) with a 1 in. (25.4 mm) wide reduced section. Five specimens are tested with each chemical. The specimens are weighted to the nearest 0.005 g and completely immersed in the chemicals for 30 days. Upon removal from the chemicals, the specimens are wiped clean with a clean dry cloth. The cleaned specimens are conditioned in air for 2 to 2¼ hours and reweighed. The increase in weight is calculated to the nearest 0.01% on the basis of initial weight. The apparent tensile strength at yield is determined for the test specimen in accordance with Test Method ASTM D2290 within ½ hour after weighing. The weight and apparent tensile strength of each specimen is evaluated for conformance to the passing requirement set forth above.
The PVDF pipes are ultra violet (UV) and ozone resistant and are suitable to extended service intervals (≥50 years, ≥75 years, or ≥100 years) when exposed to the environment and direct sunlight. In an aspect, a UV and ozone resistant PVDF pipe consists essentially of, alternatively consists of, PVDF and excludes any other compound or material that is intended to improve UV and/or ozone resistance to the PVDF pipe. In an aspect, a UV and ozone resistant PVDF pipe does not contain any (i.e., 0 wt. %) UV and/or ozone resistance enhancing compounds. The PVDF pipes do not support growth of fungi when tested as described in Method 508 of Military Standard 810B (Jun. 15, 1967). The PVDF pipes are resistant to nuclear radiation and the original tensile strength of the pipes is essentially unchanged after exposure to 100 megarads of gamma radiation from a Cobalt-60 source at 122° F. (50° C.) and in high vacuum (10-6 torr). The PVDF pipes are high purity (e.g., suitable for food and ultra-pure water use). The PVDF pipes have low flammability and low smoke characteristics. The PVDF pipes are highly abrasion resistant.
The PVDF pipes can be formed by melting PVDF polymer (e.g., pellets) to form a PVDF polymer melt and passing the PVDF polymer melt through a template (e.g., an annular shaped die) having a flow channel sized to produce the desired solid wall pipe size (e.g., a NPS having a specified DR=outside diameter/minimum wall thickness). For example, the PVDF pipes can be formed via melt extrusion wherein PVDF polymer (e.g., pellets) are placed in a hopper and fed into an extruder (e.g., having a single screw or twin screws disposed within a barrel that can be heated) wherein the PVDF polymer is melted as it is passed from the feed end of the barrel to the exit end of the barrel where the melted (i.e., molten) polymer exits the barrel and passes through a die to form the solid wall PVDF pipe having specified dimensions such as those set forth in Tables 3 to 5. The solid wall PVDF pipe exiting the extruder can be cut into straight sections having a desired length, for example, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 35, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 feet sections. In an aspect, the solid wall PVDF pipes can be formed into straight sections of any desired length, including lengths equal to or greater than 50 feet and having specified dimensions such as those set forth in Tables 3 to 5. In an aspect, the solid wall PVDF pipes are size NPS ≥2 and ≤36, alternatively NPS ≥6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) in 40 foot or 50 foot straight sections.
As an alternative to cutting the PVDF pipe into straight sections as it exits the extruder, the PVDF pipe can be spooled onto a spool or reel to form spooled PVDF pipe. Referring to
The PVDF pipe can be formed via extrusion and spooled or wound onto spool 500, for example formed and spooled concurrently. In an aspect, the PVDF pipe can be formed via extrusion, and upon exiting the die, can be connected to cylindrical central hub 525 and wound upon spool 500 in a continuous manner such that a continuous length of PVDF pipe is wound upon spool 500 to form the spooled PVDF pipe. In an aspect, the pipe exiting the die is hot PVDF pipe having a surface temperature of greater than 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, or 165° F. The hot PVDF pipe can be cooled prior to spooling, for example via air cooling in ambient air, air cooling with chilled air, fan forced air cooling, or fan forced air cooling with chilled air, or contact with a liquid cooling medium such as a water bath, water spray, water curtain, etc. In an aspect, cooling before spooling can held to avoid onset of stiffness and/or a radius of curvature (e.g., coil set, “memory,” or memory set) being set into the pipe should a hot pipe be spooled and then allowed to cool. In an aspect, the PVDF pipe (e.g., the cooled PVDF pipe) has a surface temperature in a range of from about 70° F. to about 100° F. during the spooling, alternatively in a range of from about 70° F. to about 90° F. during the spooling, alternatively in a range of from about 75° F. to about 85° F. during the spooling, alternatively in a range of from about 80° F. to about 100° F. during the spooling, alternatively in a range of from about 80° F. to about 90° F. during the spooling, or alternatively has a surface temperature equal to about 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100° F. during the spooling.
In an aspect, the PVDF pipe is spooled at a rate in a range of from about 50 to about 500 feet/hr, alternatively in a range of from about 100 to about 500 feet/hr, alternatively in a range of from about 150 to about 475 feet/hr, alternatively in a range of from about 200 to about 450 feet/hr, alternatively in a range of from about 250 to about 450 feet/hr, alternatively in a range of from about 300 to about 450 feet/hr, alternatively in a range of from about 350 to about 450 feet/hr, alternatively in a range of from about 375 to about 425 feet/hr, or alternatively is spooled at a rate equal to about 350, 355, 360, 365, 370, 375, 380, 385, 390, 395, 400, 405, 410, 415, 420, 425, 430, 435, 440, 445, or 450 feet/hr.
In an aspect, the spooled PVDF pipe has a length (e.g., a continuous length wound upon spool 500) in a range of from about 500 ft to about 4000 ft, alternatively in a range of from about 500 ft to about 3500 ft, alternatively in a range of from about 500 ft to about 3000 ft, alternatively in a range of from about 1000 ft to about 3000 ft, alternatively in a range of from about 1500 ft to about 2500 ft, or alternatively has a length of about 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800, 2900, 3000, 3100, 3200, 3300, 3400, 3500, 3600, 3700, 3800, 3900, or 4000 ft.
In an aspect, the PVDF pipe is spooled at a bending radius in a range of about 36 inches to about 112 inches, alternatively in a range of about 36 inches to about 96 inches, alternatively in a range of about 36 inches to about 84 inches, alternatively in a range of about 36 inches to about 72 inches, alternatively in a range of about 36 inches to about 60 inches, alternatively in a range of about 42 inches to about 60 inches, alternatively in a range of about 44 inches to about 60 inches, or alternatively is spooled at a bending radius of equal to or greater than 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, or 72 inches. The bending radius represents the inside curvature of the PVDF pipe as it is wound onto the cylindrical central hub 525 of spool 500. For a given spool 500, the minimum bending radius is equal to ½ the initial hub diameter 505 (i.e., the diameter of a bare or empty cylindrical central hub 525 having no pipe wound thereon). The bending radius increases from the minimum value as multiple layers of the PVDF pipe are wound on the cylindrical central hub 525, thereby increasing an effective hub diameter from the initial value.
Spooled PVDF pipe comprising a coil of PVDF pipe wound upon a spool may be obtained in accordance with (e.g., as a product of) any of the spooling processes or procedures described herein. In an aspect, the spooled PVDF pipe is solid wall pipe. In an aspect, the spooled PVDF pipe consists essentially of PVDF, alternatively consists of PVDF. In an aspect, the spooled PVDF pipe is solid wall pipe consisting essentially of PVDF, alternatively consisting of PVDF. In an aspect, the spooled PVDF pipe has a nominal pipe size of equal to or greater than 2 inches and equal to or less than 6 inches, for example having a NPS of 2, 3, 4, 5, or 6 inches and an SDR of 7 to 32.5 as set forth in Table 4. In an aspect, the spooled PVDF pipe comprises PVDF pipe having a nominal pipe size of equal to or greater than 2 inches and a spool (e.g., spool 500) having a hub diameter (e.g., diameter 505) of equal to or greater than about 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 90, 92, 94, 96, 98, 100, 102, 104, 106, 108, 110, or 112 inches. In an aspect, the spooled PVDF pipe comprises solid wall PVDF pipe consisting essentially of (or consisting of) PVDF and having a nominal pipe size of equal to or greater than 2 inches and equal to or less than 6 inches and a spool (e.g., spool 500) having an initial hub diameter (e.g., diameter 505) of equal to or greater than about 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 90, 92, 94, 96, 98, 100, 102, 104, 106, 108, 110, or 112 inches.
The solid wall PVDF pipes can be formed without adding any colorant or pigments to the PVDF polymer during extrusion. Furthermore, the solid wall PVDF pipes can be formed without adding any components or additives such as UV stabilizers, plasticizers, processing aids, lubricants, reinforcing fibers, additional polymers, and the like during extrusion. Furthermore, the solid wall PVDF pipes do not contain any additional structural support or reinforcing components such as reinforcing fibers, fiber windings, composite materials, metal casings, metal jackets or sleeves, or the like. In an aspect, the solid wall PVDF pipes are not part of, a component of, or integral with a composite material flow line or a metal jacketed flow line, for example where the PVDF component of the composite material flow line or metal jacketed flow line functions primarily as a liner for corrosion resistance or the like and the remaining components of the composite flow line or metal jacketed flow line function primarily to provide pressure containment and structural integrity. In an aspect, the solid wall PVDF pipe is not a jacketed metal flow line (e.g., not a subsea umbilical, riser, or flow line (SURF)) suitable for use as in a subsea completion to flow fluids from a subsea wellhead to location at or near the surface. Accordingly, the solid wall PVDF pipes formed via melt extrusion can consist essentially of, alternatively consist of, PVDF polymer, and thereby exclude additives, reinforcing components, composite materials, metal jackets, and the like. In an aspect, the solid wall PVDF pipes formed via melt extrusion can contain ≥95, 96, 97, 98, 99, 99.9, or 99.99% by weight PVDF. In an aspect, the solid wall PVDF pipe formed via melt extrusion contains 100% by weight PVDF. The solid wall PVDF pipe can be formed with identification characteristics, for example colored stripes coextruded into the outside surface of the pipe wall during the extrusion process. In an aspect, the solid wall PVDF pipe has stripes conforming to the APWA Uniform Color Code, for example yellow stripes for regulated PVDF pipes intended for gas distribution or regulated gas gathering. In an aspect, the solid wall PVDF pipes are size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) in 40 foot or 50 foot straight sections having yellow stripes indicating that the solid wall PVDF pipes are intended for regulated gas distribution or gas gathering, and wherein the solid wall PVDF pipes consist essentially of PVDF except for the additives used to form the yellow stripes in the outside wall of the PVDF pipe.
The PVDF polymer can be formed into PVDR fittings for use in joining sections of solid wall PVDF pipe to form a fluid flow conduit (e.g., a PVDF flow line) having desired fluid flow characteristics (e.g., size, length, capacity, direction). The PVDF fittings can be formed via melting the PVDF polymer in an extruder as described herein, and passing molten PVDF into a die or mold suitable to form a solid wall fitting having specified shape and dimensions. The solid wall PVDF fittings can have cross-sectional dimensions corresponding to the solid wall PVDF pipe to be joined by the fittings, for example having specified dimensions such as those set forth in Tables 3 to 5. The solid wall PVDF fittings can be selected from the group consisting of tees, elbows, flanges, 3-way fittings, 4-way fittings, 5-way fittings, connectors, reducers, expanders, couplings, nipples, and any combination thereof. In an aspect, the solid wall PVDF fittings correspond to PVDF pipe of size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) and can be selected from the group consisting of tees, elbows, flanges, 3-way fittings, 4-way fittings, 5-way fittings, connectors, reducers, expanders, couplings, nipples, and any combination thereof.
PVDF pipe sections (e.g., 40 or 50 foot sections of straight pipe and/or lengths of unspooled PVDF pipe that may be optionally straightened) can be joined together (e.g., connected, coupled, fused, etc.) to form PVDF flow lines (e.g., flow line segments comprised of a plurality of PVDF pipe sections and/or PVDF fittings) having desired fluid flow characteristics (e.g., size, length, capacity, direction). PVDF flow lines are flow lines that comprise any combination of PVDF pipe described herein (also referred to as PVDF pipe components) and/or PVDF fittings as described herein (also referred to as PVDF fitting components). PVDF flow lines can comprise PVDF pipe components and/or PVDF fitting components as required to form a flow line having specified design criteria. For example, two or more PVDF pipe sections (e.g., 40 or 50 foot sections of straight pipe and/or lengths of unspooled PVDF pipe that may be optionally straightened) can be joined directly to each other (e.g., via butt fusion) or indirectly to each other (e.g., via a fitting such as a tee or elbow) to form a PVDF flow line.
In an aspect, spooled PVDF pipe of the type described herein is unspooled to form a length of unspooled PVDF pipe, for example transported to a worksite and unspooled for installation as a flow line at the worksite (e.g., a worksite that is located at a wellbore fluid gathering system, for example as shown in
In an aspect, a method comprises unspooling the spooled PVDF pipe of the type described herein to form unspooled PVDF pipe, optionally straightening the unspooled PVDF pipe, optionally fusing the unspooled PVDF pipe with another PVDF pipe segment to form a PVDF flow line comprising fused PVDF pipe, and optionally coupling the unspooled PVDF pipe or PVDF flow line into fluid communication with a flow line or other component in an oil and gas gathering system, long-haul intrastate or interstate transmission pipeline system, or distribution system, for example as shown in
In an aspect, a method comprises optionally transporting spooled PVDF to a worksite; at the worksite, unspooling a first length of spooled PVDF pipe comprising PVDF pipe having a nominal pipe size of equal to or greater than 2 inches to form a first length of unspooled PVDF pipe having a first end; optionally cutting the first length of unspooled PVDF pipe to form a second end; and butt fusing the first and/or second end of the first length of unspooled PVDF pipe with a first end of another PVDF pipe segment to form a PVDF flow line comprising fused PVDF pipe. In an aspect, the PVDF pipe is solid wall pipe, the PVDF pipe consists essentially of PVDF, the PVDF pipe has a nominal pipe size of equal to or less than 6 inches, or combinations thereof. The method can further comprise straightening the first length of unspooled PVDF pipe prior to the butt fusing, for example by passing the unspooled PVDF pipe through a straightening tool comprising one or more sets of hydraulically controlled rollers that remove coil set and re-round the unspooled PVDF pipe such that the straightened unspooled pipe meets or exceeds ASTM D2513 ovality requirements. In an aspect, the worksite is located at an oil and gas gathering system, long-haul intrastate or interstate transmission pipeline system, or distribution system, for example as shown in
In an aspect, a butt fusion process is used to join two or more PVDF pipe sections (e.g., two PVDF pipe sections having the same DR, e.g., 40 or 50 foot sections of straight pipe and/or lengths of unspooled PVDF pipe that may be optionally straightened) directly together, to join a section of PVDF pipe directly to a corresponding PVDF fitting (e.g., a PVDF pipe and PVD fitting having the same DR), or combinations thereof to form a PVDF flow line having desired fluid flow characteristics (e.g., size, length, capacity, direction). In a butt fusion process, the mating surfaces of corresponding butts (or ends) of the PVDF pipe and/or PVDF fitting to be joined together are cleaned, faced, aligned, and simultaneously melted (e.g., with a hot-plate heater). The heater is removed and the melted mating surfaces are pressed together and held under pressure. As the molten PVDF materials of the combined mating surfaces cool, they mix and fuse into a permanent, monolithic joint. An example of a butt fusion procedure that may be used in combination with PVDF pipe of the type disclosed herein is set forth in Example 5 below.
In an aspect, a fusing method comprises butt fusing a first end of a first PVDF pipe section with a first end of a second PVDF pipe section to form a PVDF flow line comprising fused PVDF pipe, wherein the first PVDF pipe section and the second PVDF pipe section have a nominal pipe size of equal to or greater than 2 inches. The first ends of the first and second PVDF pipe sections can be heated using a heating tool having a surface temperature in a range of from about 400 to about 550° F., alternatively in a range of from about 425 to about 525° F., alternatively in a range of from about 450 to about 500° F., or alternatively a surface temperature equal to about 425, 430, 435, 440, 445, 450, 455, 460, 465, 470, 475, 480, 485, 490, 495, 500, 505, 510, 515, 520, or 525° F., preferably about 475° F., wherein the heating tool is a hydraulic pressure fusion machine such as a McElroy ACROBAT 160 or a McElroy ROLLING 28 commercially available from McElroy Mfg of Tulsa, Okla. The first ends of the first and second PVDF pipe sections can be heated by contact with a heating surface of the heating tool for a time in a range of from about 120 seconds to about 240 seconds, alternatively in a range of from about 150 seconds to about 210 seconds, alternatively in a range of from about 180 seconds to about 210 seconds, or alternatively at a time equal to 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, 200, 201, 202, 203, 204, 205, 206, 207, 208, 209, or 210 seconds, preferably about 190 seconds. The first ends of the first and second PVDF pipe sections can be heated by contact with the heating tool for a period of time sufficient for each first end to form a melt bead having a width of about 1/32 inch when the PVDF pipe has an outside diameter of less than 2.37 inches; a melt bead having a width of about 1/16 inch when the PVDF pipe has an outside diameter of equal to or greater than 2.37 inches and less than 3.5 inches; a melt bead having a width of about 3/16 inch when the PVDF pipe has an outside diameter of equal to or greater than 3.5 inches and less than 8.62 inches; a melt bead having a width of about ¼ inch when the PVDF pipe has an outside diameter of equal to or greater than 8.62 inches and less than 12.75 inches; or a melt bead having a width of about ⅜ inch when the PVDF pipe has an outside diameter of equal to or greater than 12.77 inches and equal to or less than 24 inches. Upon forming such a melt bead on each of the first ends, the first ends may be removed from contact with the heating surface of the heating tool, quickly inspected, and fused together by pressing the melted mating surfaces together at a designated interfacial pressure and holding the mated surfaces together at the designated interfacial pressure until the fused butt joint cools and hardens. The first ends of the first and second PVDF pipe sections can be fused by contact at an interfacial pressure in a range of from about 60 to about 90 psi, alternatively in a range of from about 65 to about 85 psi, alternatively in a range of from about 70 to about 80 psi, or alternatively at a pressure equal to about 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, or 90 psi, preferably about 75 psi. Such interfacial pressure can be converted to a gauge pressure for use with a given fusion machine as explained in more detail in Example 5.
Butt fusion methods and procedures as described herein may be used to fuse the ends of two sections of any of the PVDF pipe described herein, including without limitation 40 or 50 foot sections of straight pipe and/or lengths of unspooled PVDF pipe that may be optionally straightened, to form fused PVDF pipe. In an aspect, the fused PVDF pipe is solid wall pipe consisting essentially of, or consisting of, PVDF, wherein (i) the first and second PVDF pipe sections have a nominal pipe size of equal to or greater than 2 inches and less than or equal to 24 inches and an SDR of 7 to 32.5, (ii) the first and second PVDF pipe sections are lengths of straight pipe (e.g., not previously spooled) having nominal pipe size of equal to or greater than 6 inches and less than or equal to 16 inches and an SDR in a range of 7 to 32.5, or (iii)) the first and second PVDF pipe sections are lengths of unspooled PVDF pipe, optionally straightened, having a nominal pipe size of equal to or greater than 2 inches and less than or equal to 6 inches and an SDR in a range of 7 to 32.5. In an aspect, the fused PVDF pipe comprises a length of unspooled PVDF pipe that has optionally been straightened prior to or after fusing. In an aspect, the fused solid wall PVDF pipe consists essentially of, or consists of, PVDF and has a nominal pipe size of equal to or greater than 2 inches and less than or equal to 24 inches, alternatively a nominal pipe size of equal to or greater than 2 inches and less than or equal to 16 inches, or a nominal pipe size of equal to or greater than 2 inches and less than or equal to 6 inches. In an aspect, the fused PVDF pipe is solid wall pipe consisting essentially of, or consisting of, PVDF and having a nominal pipe size of 2 or 4 inches and an SDR of 11. In an aspect, the fused PVDF pipe comprises unspooled solid wall pipe consisting essentially of, or consisting of, PVDF and having a nominal pipe size of 2 or 4 inches and an SDR of 11.
Where two PVDF pipe sections having the same DR are joined and/or a where a PVDF pipe and a PVD fitting having the same DR are joined, the monolithic joint that is formed provides no reduction in the flow capacity of the joined pipe segment at the fused joint. In an aspect, two or more PVDF pipe sections having different SDR values are joined and/or a PVDF pipe and a PVD fitting having different SDR values are joined to form a PVDF flow line, wherein the different SDR values are adjacent values selected from the group consisting of 5.0, 6.0, 7.3, 9.0, 11.0, 13.5, 15.5, 17.0, 19.0, 21.0, 23.5, 26.0, 32.5, and 35. Where two PVDF pipe sections having different SDR values are joined and/or a PVDF pipe and a PVD fitting having different SDR values are joined, the monolithic joint that is formed can have a non-uniform interior flow surface such that there is an expansion or reduction in the inside diameter of the flow path formed by the joint.
PVDF flow lines formed from a plurality of PVDF pipe components (e.g., 40 or 50 foot sections of straight pipe and/or lengths of unspooled PVDF pipe that may be optionally straightened) and/or PVDF fitting components of the type described herein can be used in a variety of end uses to convey a corresponding variety of fluids, as described in more detail herein.
Fluids (e.g., liquid and/or gas) recovered via a well drilled into a subterranean formation can be transported from the wellsite to another location via three major types of pipelines along the transportation route: the gathering system, the long-haul intrastate and interstate transmission pipeline system, and the distribution system. An example of an oil and gas gathering, long-haul transmission, and distribution system 100 is shown in
Referring to
A plurality of oil wells 50 are drilled and penetrate a subterranean formation, for example a subterranean formation comprising shale rock that contains oil and gas, also referred to as an oil and gas shale play 55. A plurality of oil gathering pipelines 60 (also referred to as oil gathering flow lines or oil gathering lines) are used to gather oil from the wellheads of each individual well 50 and further combine production flows into a combined oil gathering line 65. The individual oil gathering lines 60 can have a size (e.g., flow capacity) relatively smaller than the size (flow capacity) of the combined oil gathering line 65. The oil gathering lines 60 and 65 supply oil (e.g., raw crude oil) from the wells 50 to an oil processing plant 70 (e.g., a tank battery 200 as shown in
In an aspect, the oil processing plant 70 can be a separation facility that separates gas from oil and provides the separated gas (e.g., wellsite processed gas) via gas pipeline 75 to a gas processing plant 80 for further treatment and provides the separated oil (e.g., wellsite processed oil) via a long-haul intrastate or interstate oil transmission pipeline 90 to an oil refinery 95 for further treatment. Gas processing plant 80 can be the same gas processing plant 30, or can be a different gas processing plant located a distance away. Accordingly, gas transmission line 75 can be a relatively short or long haul transmission pipeline depending upon the distance required. Gas processing plant 80 can function similarly to gas processing plant 30 to produce pipeline quality dry natural gas that is transported via a long-haul intrastate or interstate gas transmission pipeline 85 to a destination such as a storage facility or gas distribution company 40. As noted previously, the gas distribution company 40 distributes the dry natural gas via a gas distribution system comprising a plurality of gas distribution pipelines 45 (also referred to as gas distribution flow lines, gas distribution lines, or customer lines) and associated customer gas meters 47.
Any of the flow lines shown in
Oil refinery 95 (optionally in combination with one or more chemical production units) processes the oil (e.g., crude oil) into (i) one or more refined products such as motor fuel (e.g., gasoline, diesel, etc.), lubricants, and chemical products (e.g., petrochemicals, including aromatics such as benzene, toluene, and xylene) or feedstocks (e.g., naphtha and gas oil for further processing by the chemical production units to form chemical products, by-products, and waste streams), (ii) one or more by-products, or (iii) one or more waste streams. In addition to oil refinery 95, or as an alternative to oil refinery 95, other industrial processes can employ PVDF flow lines of the type described herein, for example to transport process fluids (e.g., at operating temperatures and operating pressures described herein) within petrochemical plants, industrial chemical plants (e.g., flow lines conveying industrial chemicals), mining operations (e.g., flow lines conveying mining chemicals such as solvents and extraction agents), nuclear facilities (e.g., flow lines conveying radioactive material), fertilizer plants, landfills (e.g., flow line conveying landfill gases), geothermal facilities (e.g., flow lines conveying hot water or steam), wastewater treatment facilities (e.g., flow lines conveying sewage), and the like. Some of the refined products, chemical products, process fluids, by-products, or waste streams can be considered hazardous substances according to applicable regulations. The refined products, chemical products, process fluids, by-products, waste streams, or combinations thereof, including any hazardous substances therein, can be passed through a variety of flow lines related to manufacture, storage, transport or disposal thereof, and one or more of these flow lines can comprise a PVDF flow line formed from one or more sections of PVDF pipe of the type disclosed herein, one or more PVDF fittings of the type disclosed herein, or combinations thereof. For example, one or more of the various flow lines can comprise a plurality of straight, solid wall PVDF pipe sections (e.g., 40 or 50 foot sections) joined together directly (e.g., butt fused as described herein) or indirectly (via one or more solid wall PVDF fittings as described herein), wherein the solid wall PVDF pipe sections, the solid wall PVDF fittings, or both have dimensions specified in Tables 3 to 5, for example the solid wall PVDF pipes are size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) in 40 foot or 50 foot straight sections and/or the solid wall PVDF fittings correspond to PVDF pipe of size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) and can be selected from the group consisting of tees, elbows, flanges, 3-way fittings, 4-way fittings, 5-way fittings, connectors, reducers, expanders, couplings, nipples, and any combination thereof, and wherein the PVDF pipe sections, the PVDF fittings, or both consist essentially of, or consist of, PVDF.
In an aspect, a method for transporting fluids from a wellbore comprises recovering fluid (e.g., liquids such as crude and water, gases such as raw natural gas, or multi-phase fluids containing both gases and liquids) from a wellbore penetrating a subterranean formation through a wellhead to yield a recovered fluid; and flowing the recovered fluid through a gathering system, a long-haul intrastate or interstate transmission pipeline system, or a distribution system, wherein one or more flow lines in the gathering system, the long-haul intrastate or interstate transmission pipeline system, or the distribution system comprise a plurality of straight, solid wall PVDF pipe sections (e.g., 40 or 50 foot sections) joined together directly (e.g., butt fused as described herein) or indirectly (via one or more PVDF fittings as described herein), wherein the solid wall PVDF pipe sections, the PVDF fittings, or both have dimensions specified in Tables 3 to 5, for example the solid wall PVDF pipes are size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) in 40 foot or 50 foot straight sections and/or the PVDF fittings correspond to PVDF pipe of size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) and can be selected from the group consisting of tees, elbows, flanges, 3-way fittings, 4-way fittings, 5-way fittings, connectors, reducers, expanders, couplings, nipples, and any combination thereof, and wherein the PVDF pipes sections, the PVDF pipe fittings, or both consist essentially of, or consist of, PVDF.
In an aspect, a method for transporting fluids from a wellbore comprises recovering fluid (e.g., liquids such as hydrocarbons and water, gases such as raw natural gas, or multi-phase fluids containing both gases and liquids) from a wellbore penetrating a subterranean formation through a wellhead to yield a recovered fluid; and flowing the recovered fluid through (i) a gathering system conveying the recovered fluid from the wellhead to a processing unit to produce a processed fluid, (ii) a pipeline transmission system transporting the processed fluid from the processing unit to a distribution point or a storage facility; (iii) a distribution system distributing the processed fluid from the distribution point or storage facility to one or more end users; or (iv) combinations thereof, wherein the gathering system, the pipeline transmission system, the distribution system, or combinations thereof comprise one or more PVDF flow lines comprising solid wall PVDF pipe having a nominal pipe size of equal to or greater than 2, 4, or 6 inches and equal to or less than 36, 24, 22, 20, 18, or 16 inches (e.g., solid wall PVDF pipe of size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5)). The recovered fluid can comprise gaseous hydrocarbons, crude oil, multi-phase fluids, water, carbon dioxide, hydrogen sulfide, or combinations thereof. For example, the recovered fluid can comprise crude oil, raw natural gas, wet natural gas, dry natural gas, shale gas, acid gas, sour gas, natural gas liquids, produced water, wellbore treatment fluids (e.g., injection steam condensate, acid treatment fluids, fracturing fluids, etc. that are flowed from the surface into the wellbore and/or surrounding formation as part of ab enhanced oil recovery process and then flowed back to the surface and recovered) or combinations thereof.
In an aspect, a method for transporting fluids from a wellbore comprises recovering fluid (e.g., liquids such as hydrocarbons and water, gases such as raw natural gas, or multi-phase fluids containing both gases and liquids) from a wellbore penetrating a subterranean formation through a wellhead to yield a recovered fluid; and flowing the recovered fluid through a gathering system, wherein one or more flow lines in the gathering system comprise a plurality of straight, solid wall PVDF pipe sections (e.g., 40 or 50 foot sections) joined together directly (e.g., butt fused as described herein) or indirectly (via one or more PVDF fittings as described herein), wherein the solid wall PVDF pipe sections, the PVDF fittings, or both have dimensions specified in Tables 3 to 5, for example the solid wall PVDF pipes are size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) in 40 foot or 50 foot straight sections and/or the solid wall PVDF fittings correspond to PVDF pipe of size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) and can be selected from the group consisting of tees, elbows, flanges, 3-way fittings, 4-way fittings, 5-way fittings, connectors, reducers, expanders, couplings, nipples, and any combination thereof, and wherein the PVDF pipes sections, the PVDF pipe fittings, or both consist essentially of, or consist of, PVDF.
The PVDF pipe and/or PVDF fittings of the type described herein can be used to form all or a part of one or more fluid flow lines in the gathering system. For example, a gathering system is the flow line network and process facilities that transport and control the flow of fluid (e.g., oil and/or gas) from the wells to a storage facility, processing plant or shipping point. A gathering system includes pumps, headers, separators, emulsion treaters, tanks, regulators, compressors, dehydrators, valves and associated equipment. There are two types of gathering systems, radial and trunk line. The radial type brings all the flow lines to a central header, while the trunk-line type uses several remote headers to collect fluid. The latter is mainly used in large fields. The gathering system is also called the collecting system or gathering facility. An example of a wellbore fluid gathering system 200, also referred to as a tank battery, is shown in
Referring to
A fluid comprising a combination of oil and water can be conveyed from G/L separators 220, from gas scrubber 240, or both to an oil-water (O/W) separator 260 via O/W flow lines 255, which can be referred to as G/L separator-to-O/W separator flow lines and/or gas scrubber-to-O/W separator flow lines. Oil and water are partially separated in the O/W separator, which can be any suitable separator such as a free water knockout drum. Free water refers to water that is not part of an oil/water emulsion and thus separates easily by gravity from the other components present (e.g., crude oil, emulsions, etc.) Water is recovered from the O/W separator 260 and is conveyed to a water tank 275 (and held for subsequent use, treatment, or disposal) via water flow lines 261, which can be referred to as O/W separator-to-water tank flow lines. A mixture of oil and water (O/W) is recovered from the O/W separator 260 and is conveyed to one or more treaters 270A and 270B via O/W flow lines 263, which can be referred to as O/W separator-to-treater flow lines. Depending upon the condition of the O/W mixture recovered from the O/W separator, all or a portion of the O/W mixture can be conveyed to different types of treaters (e.g., 270A or 270B) for additional treatment to remove water and/or gas from the oil. For example, where all or a portion of the O/W mixture exiting the O/W separator is an emulsion, the O/W mixture can be conveyed to treater 270A, for example a heater treater which uses heat to break O/W emulsions and recover oil, water, and optionally gas. Where present, gas is recovered from treater 270A and conveyed to gas sales meter 250 via flow line 247 and 245, which can be referred to as treater-to-gas meter flow lines. Oil is recovered from treater 270A and conveyed to one or more oil storage tanks 280 (also called run tanks) via oil flow line 249, which can be referred to as treater-to-run tank flow lines. Water is recovered from treater 270A and conveyed to a water tank 275 (and held for subsequent use, treatment, or disposal) via water flow lines 267 and 261, which can be referred to as treater-to-water tank flow lines.
In addition to or as an alternative to conveying the O/W mixture from O/W separator 260 to treater 270A, all or a portion of the O/W mixture from O/W separator 260 can be conveyed to treater 270B via oil flow lines 263, which can be referred to as O/W separator-to-treater flow lines. Where the O/W mixture recovered from O/W separator 260 can be further separated over time by gravity segregation forces, the treater 270B can be a settling tank such as a gun barrel separator (also referred to as a wash tank). Water is recovered from treater 270B and conveyed to a water tank 275 (and held for subsequent use, treatment, or disposal) via water flow lines 269 and 261, which can be referred to as treater-to-water tank flow lines. Oil is recovered from treater 270B and conveyed to one or more oil storage tanks 280 (also called run tanks) via oil flow line 251, which can be referred to as wash tank-to-run tank flow lines.
Oil from oil storage tanks 270 can be conveyed to LACT unit 285 via oil flow lines 283, which can be referred to oil meter flow lines. After being metered by LACT unit 285, oil (which can also be referred to as wellsite processed oil or wellsite processed crude) is conveyed to a long haul intrastate or interstate oil transmission pipeline via flow line 287, which can be referred to a meter-to-pipeline flow line. Tanks 275, 280, and 270B can have a gas recovery flow line (typically exiting the tank at or near the top thereof) to convey residual gas from the tanks to a vent, flare, or vapor recovery unit (VRU) 290 via gas flow lines 288, which can be referred to as tank-to-VRU flow lines. Gas is recovered from the VRU 290 and conveyed to a gas sales meter 252 via gas flow line 291, which can be referred to as a VRU-to-meter flow line. After being metered by gas meter 250 and/or gas meter 252, the gas (which can also be referred to as wellsite processed gas) can be conveyed to a gas processing unit (e.g., gas processing unit 30 of
Any of the flow lines shown in
In an aspect, a method for transporting fluids from a wellbore comprises producing a fluid (e.g., gas and/or liquid hydrocarbons) from a wellbore penetrating a subterranean formation through a wellhead to yield produced hydrocarbons; and flowing the produced hydrocarbons through a hydrocarbon gathering system directly or indirectly (e.g., via one or more treatment systems such as an gas liquid separator and/or a gas processing plant) to a long-haul pipeline transmission system, wherein the hydrocarbon gathering system, the long-haul pipeline transmission system or both comprises solid wall PVDF pipe having a nominal pipe size of equal to or greater than 2, 4, or 6 inches and equal to or less than 36, 24, 22, 20, 18, or 16 inches (e.g., solid wall PVDF pipe of size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5)) and wherein the PVDF pipe consists essentially of, or consists of, PVDF.
In an aspect, a method for transporting fluids from a wellbore comprises producing a fluid (e.g., gas and/or liquid hydrocarbons) from a wellbore penetrating a subterranean formation through a wellhead to yield produced hydrocarbons; and flowing the produced hydrocarbons through a hydrocarbon gathering system directly or indirectly (e.g., via one or more treatment systems such as an gas liquid separator and/or a gas processing plant) to a long-haul pipeline transmission system, wherein the hydrocarbon gathering system, the long-haul pipeline transmission system or both comprise a plurality of straight, solid wall PVDF pipe sections (e.g., 40 or 50 foot sections) joined together directly (e.g., butt fused as described herein) or indirectly (via one or more PVDF fittings as described herein), wherein the solid wall PVDF pipe sections, the PVDF fittings, or both have dimensions specified in Tables 3 to 5, for example the solid wall PVDF pipes are size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) in 40 foot or 50 foot straight sections and/or the solid wall PVDF fittings correspond to PVDF pipe of size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) and can be selected from the group consisting of tees, elbows, flanges, 3-way fittings, 4-way fittings, 5-way fittings, connectors, reducers, expanders, couplings, nipples, and any combination thereof, and wherein the PVDF pipes sections, the PVDF fittings, or both consist essentially of, or consist of, PVDF.
Gas gatherings system consists of low pressure, relatively small diameter pipelines (in contrast to intrastate or interstate transmission pipelines) that transport gas from the wellhead to the processing plant. Should gas from a particular well have high hydrogen sulfide and/or carbon dioxide contents (i.e., an acid gas or sour gas), a specialized sour gas gathering pipe should be installed such as the PVDF pipe described herein. Acid gas or sour gas is corrosive, thus its transportation from the wellhead to the sweetening plant must be done carefully. The gas from a gas well is collected using gathering lines that are relatively small (e.g., ≤18″ diameter or ≤16″ diameter) PVDF pipes that carry pressurized unodorized gas and are typically buried four feet underground. Similar to a tree branch type pattern, gas gathering lines collect gas from smaller lines and move it to a central collecting point such as a gas processing facility, storage tanks awaiting movement to the main pipeline, or marine terminal. When the quality of the gas is not suitable for the main pipeline, it is fed to a gas processing plant.
The gathering of gas comprises aggregating gas produced from various wells through relatively small diameter gathering lines (in contrast to intrastate or interstate transmission pipelines) to local or regional gas processing plants. Natural gas has a widely varying composition depending on the field, the formation and the reservoir from which it is produced. The processing of gas consists of the extraction of imbedded natural gas liquids (NGLs) and the removal of water vapor and other contaminants (e.g., hydrogen sulfide, carbon dioxide, or both) to form (i) a stream of marketable natural gas, commonly referred to as residue or dry gas, and (ii) a stream of mixed NGLs (e.g., ethane, propane, butane, pentane or heavier hydrocarbons, and combinations thereof). Once processed, the residue gas is transported to markets through long-haul intrastate and/or interstate transmission pipelines that are owned by either the gatherers and processors or third parties. The residual gas is transported to pipeline terminals, where the gas is stored or further provided to one or more end-users for use or distribution. End-users of residue gas include large commercial and industrial customers, as well as natural gas and electric utilities serving individual consumers via a vast regulated gas distribution system. Transportation of gas from the wellhead via the gathering system to a processing plant and/or through a long-haul intrastate and/or interstate transmission pipeline to a receiving terminal can be referred to as a midstream transmission system or network.
In an aspect, a method for transporting gas from a wellbore comprises flowing gas from a wellbore penetrating a subterranean formation through a wellhead to yield produced gas; flowing the produced gas through a wellhead line to one or more wellsite processing units to yield wellsite processed gas; and flowing the wellsite processed gas through a gathering line to a gas processing plant, a gas pipeline transmission system, or both, wherein the wellhead line, the gathering line, or both comprise a plurality of sections of solid wall polyvinylidene fluoride (PVDF) pipe having a nominal pipe size (NPS) ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5). The produced gas, the wellsite processed gas, or both can be flowed through a collection header (also referred to as a collection manifold), wherein all or a portion of the collection header (manifold) comprises PVDF pipe having a nominal pipe size (NPS) ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5). The produced gas, the wellsite processed gas, or both can be compressed prior to flow through the PVDF pipe. The one or more wellsite processing units can comprise a heater, a gas-liquid separator, or both. For example, the tank battery 200 of
In an aspect, a method for transporting gas from a wellbore comprises flowing gas from a wellbore penetrating a subterranean formation through a wellhead to yield produced gas; flowing the produced gas through a wellhead line to one or more wellsite processing units to yield wellsite processed gas; and flowing the wellsite processed gas through a gathering line to a gas processing plant, a gas pipeline transmission system, or both, wherein the wellhead line, the gathering line, or both comprise a plurality of straight, solid wall PVDF pipe sections (e.g., 40 or 50 foot sections) joined together directly (e.g., butt fused as described herein) or indirectly (via one or more PVDF fittings as described herein), wherein the solid wall PVDF pipe sections, the PVDF fittings, or both have dimensions specified in Tables 3 to 5, for example the solid wall PVDF pipes are size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) in 40 foot or 50 foot straight sections and/or the solid wall PVDF fittings correspond to PVDF pipe of size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) and can be selected from the group consisting of tees, elbows, flanges, 3-way fittings, 4-way fittings, 5-way fittings, connectors, reducers, expanders, couplings, nipples, and any combination thereof, and wherein the PVDF pipes sections, the PVDF fittings, or both consist essentially of, or consist of, PVDF.
In an aspect, a method for transporting fluids from a wellbore comprises recovering fluid (e.g., liquids such as crude oil and water, gases such as raw natural gas, or multi-phase fluids containing both gases and liquids) from a wellbore penetrating a subterranean formation through a wellhead to yield a recovered fluid; and flowing the recovered fluid through (i) a gathering system conveying the recovered fluid from the wellhead to a processing unit to produce a processed fluid, (ii) a pipeline transmission system transporting the processed fluid from the processing unit to a distribution point or a storage facility; (iii) a distribution system distributing the processed fluid from the distribution point or storage facility to one or more end users; or (iv) combinations thereof, wherein the gathering system, the pipeline transmission system, the distribution system, or combinations thereof comprise solid wall PVDF pipe consisting essentially of, or consisting of, PVDF, wherein the processed fluid is natural gas and wherein the pipeline transmission system, the distribution system, or both comprise one or more flow lines comprising PVDF pipe having an SDR of 7 and a maximum operating pressure (MOP) of 666 psig, an SDR of 9 and a MOP of 500, an SDR of 11 and a MOP of 400, an SDR of 17 and a MOP of 250, an SDR of 21 and a MOP of 200, or a SDR of 26 and a MOP of 160, wherein the MOP is determined according to the equation:
MOP=[2(HDB)(DF)/(SDR−1)],
where MOP is maximum operating pressure in psig, HDB is hydrostatic design basis in psi as determined in accordance with ASTM Test Method D2837 at a temperature of 73° F.=5000 psi, DF is the service deign factor=0.4 for regulated natural gas distribution systems, and SDR is standard dimension ratio which is the outside diameter of the pipe in inches divided by the pipe minimum wall thickness in inches.
In an aspect, a method for transporting fluids from a wellbore comprises recovering fluid (e.g., liquids such as hydrocarbons and water, gases such as raw natural gas, or multi-phase fluids containing both gases and liquids) from a wellbore penetrating a subterranean formation through a wellhead to yield a recovered fluid; and flowing the recovered fluid through (i) a gathering system conveying the recovered fluid from the wellhead to a processing unit to produce a processed fluid, (ii) a pipeline transmission system transporting the processed fluid from the processing unit to a distribution point or a storage facility; (iii) a distribution system distributing the processed fluid from the distribution point or storage facility to one or more end users; or (iv) combinations thereof, wherein the gathering system, the pipeline transmission system, the distribution system, or combinations thereof comprise solid wall PVDF pipe consisting essentially of, or consisting of, PVDF, wherein the processed fluid is natural gas and wherein the pipeline transmission system, the distribution system, or both comprise one or more flow lines comprising PVDF pipe having an SDR of 7 and a maximum operating pressure (MOP) of 666 psig at an HDB of 5000 psi and a temperature of 73° F., a MOP of 166 psig at an HDB of 1250 psi and a temperature of 248° F., or a MOP of 106 psig at an HDB of 800 psi and a temperature of 284° F., wherein the MOP is determined according to the equation:
MOP=[2(HDB)(DF)/(SDR−1)],
where MOP is maximum operating pressure in psig, HDB is hydrostatic design basis in psi as determined in accordance with ASTM Test Method D2837, DF is the service deign factor=0.4 for regulated natural gas transmission or distribution systems, and SDR is standard dimension ratio which is the outside diameter of the pipe in inches divided by the pipe minimum wall thickness in inches.
In an aspect, a method for transporting fluids from a wellbore comprises recovering fluid (e.g., liquids such as hydrocarbons and water, gases such as raw natural gas, or multi-phase fluids containing both gases and liquids) from a wellbore penetrating a subterranean formation through a wellhead to yield a recovered fluid; and flowing the recovered fluid through (i) a gathering system conveying the recovered fluid from the wellhead to a processing unit to produce a processed fluid, (ii) a pipeline transmission system transporting the processed fluid from the processing unit to a distribution point or a storage facility; (iii) a distribution system distributing the processed fluid from the distribution point or storage facility to one or more end users; or (iv) combinations thereof, wherein the gathering system, the pipeline transmission system, the distribution system, or combinations thereof comprise solid wall PVDF pipe consisting essentially of, or consisting of, PVDF, wherein the recovered fluid is natural gas and wherein the gathering system comprises one or more flow lines comprising PVDF pipe having an SDR of 7 and a maximum operating pressure (MOP) of 1050 psig at an HDB of 5000 psi and a temperature of 73° F., a MOP of 262 psig at an HDB of 1250 psi and a temperature of 248° F., or a MOP of 168 psig at an HDB of 800 psi and a temperature of 284° F., wherein the MOP is determined according to the equation:
MOP=[2(HDB)(DF)/(SDR−1)],
where MOP is maximum operating pressure in psig, HDB is hydrostatic design basis in psi as determined in accordance with ASTM Test Method D2837, DF is the service design factor=0.63 for unregulated oil and gas gathering systems or non-hazardous liquid pipelines, and SDR is standard dimension ratio which is the outside diameter of the pipe in inches divided by the pipe minimum wall thickness in inches. For regulated oil and gas gathering and transmission systems or hazardous liquid pipelines the design factor, DF=0.4.
Any of the PVDF flow lines described herein, for example and without limitation those used in an oil and gas gathering system, long-haul intrastate or interstate transmission pipeline system, or distribution system (e.g., as shown in
Any flow lines described herein, for example and without limitation conventional flow lines (e.g., metallic flow lines such as steel or aluminum) used in an oil and gas gathering system, long-haul intrastate or interstate transmission pipeline system, or distribution system (e.g., as shown in
The chemical resistance of SOLEF PVDF to crude oil was considered in: (i) typical service consisting in mostly non-aromatic hydrocarbons (maximum 5% aromatics), chlorides, carbon dioxide, hydrogen sulfide and carbonates at pH 4-6 up to 60° C.; and (ii) “pain points” service with high chloride and hydrogen sulfide contents up to 120° C.
Internal tests in crude oil show that PVDF is resistant even above 120° C. No relevant swelling was observed in immersion tests at 125° C. and no decrease in maximum admissible stress compared to a non-aggressive medium for the polymer as water was observed in bursting tests at 150° C. (see below for further details).
In the typical service conditions mentioned, the resistance of PVDF is expected to be even better than the general resistance to crude oil due to the low aromatic content. Moreover, PVDF is resistant to chlorides, carbon dioxide, hydrogen sulfide and carbonates at pH 4-6 up to 60° C.
Also in “pain points” service, PVDF is expected to be resistant. High chloride content is not critical for PVDF since in relevant literature PVDF is reported to be resistant in concentrated chloride solutions up to 135° C. Regarding hydrogen sulfide, investigations performed by external laboratories show that no significant alterations of PVDF occur when exposed to 64% H2S at 130° C., and only some discoloration was observed due to the well-known partial degradation of residues from polymerization in acid environments, which do not have any influence on the polymer performance during service.
Hence basing on the available data, the chemical resistance of PVDF, e.g., SOLEF, is expected to be satisfactory in crude oil, both in typical service and in “pain points”.
Hereafter is the available data concerning SOLEF PVDF behavior in contact with crude oil.
Immersion test was performed with 100% crude oil at various temperatures as set forth below. An increase of the weight of +0.7% after 30 days was observed. The PVDF achieved a “+” rating at each temperature.
A “+” rating means: SOLEF PVDF is resistant. The increase in the weight is 2% or less. Any reduction in the weight is less than 0.3%. The tensile yield strength has not altered by more than 15% from its initial value.
A “O” rating means: Use of SOLEF PVDF is limited. The response to one of the criteria above is negative. For instance, the increase in the weight is between 2% and 5%. However, SOLEF PVDF can be used in the medium, provided that it is not submitted to undue stress (linings, reinforced or supported structures).
A “-” rating means: SOLEF PVDF is not resistant. There is a considerable alteration to the SOLEF PVDF: dissolution, chemical or physical degradation. For instance, the increase in the weight is greater than 5%.
Bursting test in the Console DECHEMA at 150° C. with a 100% crude oil was performed:
The above results show that there is no relevant reduction in maximum hoop stress without breaks compared to water, i.e. a non-aggressive medium for the polymer.
In an aspect, the PVDF pipe has a crude oil chemical design factor (DFC) of 1.0 for PVDF pipe applications with up to 100% crude oil with temperatures up to 300° F. (150° C.), wherein pipe samples were tested with a hoop stress of 5.5 MPa at 300° F. (150° C.) with 100% crude oil on the inside and had no failures before 2000 hours.
Regarding gas permeation, below are the permeability coefficients measured according to ASTM D1434 on methane, carbon dioxide and hydrogen sulfide in SOLEF PVDF at 120° C. from a gas mixture of 85% CH4/5% CO2/10% H2S/400 ppm H2O at 100 bar pressure using 6 mm thick samples.
Slow crack growth (SCG) is a failure mechanism that can occur in the field with certain materials in certain circumstances. SCG resistance is a key material property of plastic piping materials because it is a factor in determining the pipe's long-term performance. When higher operating pressures or larger diameter pipes are being considered, SCG resistance is even more important.
During rehabilitation or other installation techniques, pipes can be scored, scratched or damaged on the outside surface. These external scratches could lead to slow crack growth and eventual failure of the pipe, unless the pipe has very high resistance to SCG. The higher SCG resistance of PVDF pipes results in substantially improved long-term performance. This is especially important as PVDF pipes are used in higher-pressure and higher-temperature applications.
In ASTM D2837 stress rupture curves, the log-stress vs log time regression curve is generally linear over the range of ductile failures. For some thermoplastic pipe materials, the failure mode changes from the ductile to brittle or slit at longer times and lower stress. This is the SCG failures mode and it has a steeper slope compared to the ductile failure mode slope. This is sometimes referred to as the “knee” in the stress rupture curve as shown in
PVDF 2025 material has extremely high resistance to SCG as evidenced by its long-term stress rupture data.
Using LTHS extrapolation methodology, based on the longest data point (25 years) for the 120° C. regression line, we can project that the knee at 20° C. will not occur for over 2000 years. Thus, the slow crack growth failure mode is not a concern for the PVDF 2025 material.
A PVDF pipe spooling trial was conducted where PVDF pipe of the type described herein was spooled to form spooled PVDF pipe. The PVDF pipe had a nominal pipe size of 2 inches and an SDR of 11 (2″ SDR 11 PVDF pipe) and consisted essentially of, or consisted of, SOLEF 1010 PVDF homopolymer. The spool 500 was configured as shown in
A PVDF pipe butt fusion trial was conducted where two separate PVDF pipe components of the type described herein were fused together to form a single length/segment of PVDF pipe. The PVDF pipe components (also referred to more simply as components) were butt fused according to the following butt fusion procedure to obtain fused PVDF pipe segments:
Overview
In butt fusion (also referred to as heat fusion joining), mating surfaces (e.g., a first end of a first PVDF pipe section/component and a first end of a second PVDF pipe section/component) are prepared by cleaning and facing, and simultaneously melted with a hot-plate heater (e.g., a heater surface disposed between the first ends of the first and second PVDF pipe components). The heater is removed and the melted surfaces are pressed together and held under pressure. As the molten materials cool, they mix and fuse into a permanent, monolithic joint.
Equipment and Set-Up Parameters
The PVDF pipe was faced, heated, and fused using either an ACROBAT 160 pipe fusion machine or a ROLLING 28 pipe fusion machine, both of which are commercially available from McElroy Mfg., Tulsa, Okla. The fusion machine includes a heating tool, and the heating tool surface temperature was between a minimum 450° F. and maximum 500° F. (232-260° C.) with a target surface temperature of 475° F. (246° C.). Heating tool surfaces must reach the specified temperature range before the fusion process is started, which includes any and all portions of the heating surface that will come in contact with the pipe. Heating tool surfaces must be clean and Teflon coated to allow proper fusion. Temperature of heating tool surfaces must be checked with an accurate flat surface probe digital thermocouple thermometer before each fusion.
Gauge Pressure
Gauge pressure is the pressure setting and/or reading associated with a fusion machine, for example a pressure setting and/or reading associated with one or more hydraulic cylinders on a fusion machine. For hydraulic fusion machines, the gauge pressure is a function of interfacial pressure, fusion surface area, fusion machine's carriage hydraulic cylinder size and drag pressure. When calculated, gauge pressure is what the operator will input as a setting into the fusion machine. The total effective piston area can be obtained from the machine manufacturer. The drag pressure is the pressure that is required to overcome movement in the carriage. Interfacial pressure and gauge pressure are not the same. Manually operated machines do not require a calculation for gauge pressure. Below is the equation used to calculate for gauge pressure in psi. A slide rule or a gauge pressure calculator obtained from the machine's manufacturer can be a substitute for this calculation.
Fusing Procedure
Secure.
Clean the inside and outside of the component (pipe or fitting) ends by wiping with a clean, dry, lint-free cloth or paper towel. Align the component ends in the fusion machine. Do not force pipes into alignment against open fusion machine clamps. Component ends should protrude past the carriage clamps enough so that facing will be complete. Bring the pipe ends together and check high-low alignment. Adjust alignment as necessary by tightening the high side down. Make sure clamps are properly secured to prevent slippage of the component ends.
Face.
Place the facing tool between the component ends and face them to establish smooth, clean, parallel mating surfaces (e.g., on the pipe ends). If stops are present, face the component (e.g., pipe) down to the stops. Remove all shavings from pipe ends after facing. Do not touch the component ends after facing.
Align.
Bring the component ends together, check alignment (e.g., axial alignment along a common axis) and check for slippage of the pipe within the carriage upon application of fusion pressure (i.e., the calculated gauge pressure of the machine corresponding to the desired interfacial pressure). Look for complete contact all around both ends with no detectable gaps and outside diameters in high-low alignment.
Melt.
Verify that the heating tool is between 450° F.-500° F. with a target surface temperature of 475° F. Use an accurate flat surface probe digital thermocouple thermometer to verify surface temperature. Place the heating tool between the component ends and move the ends against the heating tool. The initial contact should be under fusion pressure to ensure full contact. Once full contact is made, hold the ends against the heating tool without force. For hydraulic machines, ensure that no pressure has been captured in the cylinder. Beads of melted PVDF will form against the heating tool at the component ends. When the proper melt bead size is formed for a given pipe size as set forth in Table 10, quickly separate the pipe ends and remove the heating tool. For 14″ and larger pipes, a minimum heat soak time of 4.5 minutes per inch of pipe wall thickness and the minimum melt bead size must be achieved.
Join.
Immediately after removing the heating tool, quickly inspect the melted ends and then bring them together (e.g., in less than about 10 seconds, alternatively in less than about 7 seconds), applying the correct joining force using the calculated Gauge Pressure for the particular fusion machine being used. Do not slam the ends together. The correct joining force will form a double bead fusion joint that is rolled over to the surface on both pipe ends.
Hold.
Hold the joining force against (i.e., maintain the gauge pressure on the fusion machine) the ends until the joint is cool. Maintain joining force (i.e., maintain gauge pressure on the fusion machine) against the pipe ends for a minimum cool time rate of 11 minutes per inch of pipe wall thickness. Holding the joining force may also be referred to as holding fusion pressure (e.g., holding the gauge pressure and thus the corresponding interfacial pressure) Avoid pulling, installing, pressure testing and rough handing for at least an additional 30 minutes. Heavier wall thickness pipes may require longer cooling times. Upon completion of cooling, fused PVDF pipe segments are obtained.
Inspect.
On both sides of the fusion joint, the double bead should be rolled over to the surface and be uniformly rounded and consistent in size all around the joint. Verify joint with a McElroy Data Logger.
The butt fusion procedure described above was performed on 10 test pairs (identified as test 4″-1 to test 4″-10) of solid wall PVDF pipe ends having a nominal pipe size of 4 inches and an SDR of 11 and on 2 test pairs (identified as test 2″-1 and test 2″-2) of solid wall PVDF pipe ends having a nominal pipe size of 2 inches and an SDR of 11. The 4″ and 2″ PVDF pipe test pairs consisted essentially of, or consisted of, SOLEF 1010 PVDF homopolymer. The heating tool surface temperature was between a minimum 450° F. and maximum 500° F. with a target surface temperature of 475° F., and the interfacial pressure ranged from 60 psi to 90 psi with a target of 75 psi. Each PVDF pipe test pair was fused under the conditions specified in Table 11. The resultant fusion joints were visually inspected for quality and ranked from 1st to 4th in quality as well as last in quality. Table 11 also contains observations regarding fusion of each test pair. The trial demonstrated successful butt fusing of 4″ SDR 11 PVDF pipe and 2″ SDR 11 PVDF pipe, and such butt fusion procedure may be employed with any of the PVDF pipe disclosed herein, for example to form a PVDF flow line for use as described herein (e.g., transport of a fluid such as gas and/or liquid recovered from a wellbore).
A first aspect which is a method comprising: flowing gas from a wellbore penetrating a subterranean formation through a wellhead to yield produced gas; flowing the produced gas through a wellhead line to one or more wellsite processing units to yield wellsite processed gas; and flowing the wellsite processed gas through a gathering line to a gas processing plant, a gas pipeline transmission system, or both, wherein the wellhead line, the gathering line, or both comprise polyvinylidene fluoride (PVDF) pipe having a nominal pipe size of equal to or greater than 2 inches and equal to or less than 16 inches.
A second aspect which is the method of the first aspect further comprising flowing the produced gas, the wellsite processed gas, or both through a collection header, wherein all or a portion of the collection header comprises PVDF pipe having a nominal pipe size of equal to or greater than 2 inches and equal to or less than 16 inches.
A third aspect which is the method of the first or second aspect, wherein the flowing the produced gas, the wellsite processed gas, or both are compressed prior to flow through the PVDF pipe.
A fourth aspect which is the method of any one of the first through third aspects, wherein the one or more wellsite processing units comprise a heater, a gas-liquid separator, or both.
A fifth aspect which is the method of any one of the first through fourth aspects, wherein the wellhead line, the gathering line, or both comprise a plurality of PVDF pipe segments, wherein all or a portion of the PVDF pipe segments are connected via butt fusion.
A sixth aspect which is the method of any one of the first through fifth aspects, wherein the produced gas comprises methane, water, and one or more corrosive compounds selected from the group consisting of hydrogen sulfide, carbon dioxide, and combinations thereof.
A seventh aspect which is the method of any one of the first through sixth aspects, wherein the subterranean formation comprises shale and the wellhead is onshore.
An eighth aspect which is the method of any one of the first through seventh aspects, where the PVDF pipe has an operating temperature ranging from −40° F. to 284° F., alternatively 73° F. to 284° F.
A ninth aspect which is the method of any one of the first through eighth aspects, wherein the PVDF pipe has an operating pressure selected from the group consisting of a range of from greater than 0 psig to equal to or less than 1050 psig for unregulated PVDF pipe having an SDR of 7; a range of from greater than 0 psig to equal to or less than 630 psig for unregulated PVDF pipe having an SDR of 11; a range of from greater than 0 psig to equal to or less than 650 psig for regulated PVDF pipe having an SDR of 7; and a range of from greater than 0 psig to equal to or less than 400 psig for regulated PVDF pipe having an SDR of 11.
A tenth aspect which is the method of any one of the first through ninth aspects, wherein the PVDF pipe is solid wall pipe.
An eleventh aspect which is the method of any one of the first through tenth aspects, wherein the PVDF pipe consists essentially of, or consists of, PVDF.
A twelfth aspect which is the method of any one of the first through eleventh aspects, wherein the PVDF has properties set forth in Table 1 or Table 2.
A thirteenth aspect which is the method of any one of the first through twelfth aspects, wherein the PVDF pipe has dimensions set forth in Table 3, Table 4, or Table 5.
A fourteenth aspect which is the method of any one of the first through thirteenth aspects, wherein the PVDF pipe has a pressure rating set forth in Table 8.
A fifteenth aspect which is the method of any one of the first through fourteenth aspects, wherein the PVDF pipe (i) displays a linear stress rupture curve as determined in accordance with ASTM D2837 at 248° F. over a time period of from about 25 years extrapolated to about 2000 years; (ii) shall not fail before 2000 hours when tested in accordance with Test Method ASTM F1473 using compression molded plaques at a stress of 7.5 MPa, based on the unnotched area, and a test temperature of 80° C.; or both (i) and (ii).
A sixteenth aspect which is a method comprising: producing acid gas from a wellbore penetrating a subterranean formation through a wellhead to yield produced acid gas, wherein the produced acid gas comprises methane, water, and one or more corrosive compounds selected from the group consisting of hydrogen sulfide, carbon dioxide, and combinations thereof; and flowing the produced acid gas through a gas gathering system to a gas processing facility to reduce the acidity of the acid gas and yield treated natural gas, wherein the treated natural gas has less hydrogen sulfide, carbon dioxide, or both than the produced acid gas, wherein the gas gathering system comprises one or more flow lines comprising PVDF pipe having a nominal pipe size of equal to or greater than 2 inches and equal to or less than 16 inches.
A seventeenth aspect which is the method of the sixteenth aspect, wherein the PVDF pipe consists essentially of PVDF.
An eighteenth aspect which is a method comprising: recovering fluid from a wellbore penetrating a subterranean formation through a wellhead to yield a recovered fluid; and flowing the recovered fluid through (i) a gathering system conveying the recovered fluid from the wellhead to a processing unit to produce a processed fluid, (ii) a pipeline transmission system transporting the processed fluid from the processing unit to a distribution point or a storage facility, (iii) a distribution system distributing the processed fluid from the distribution point or storage facility to one or more end users, or (iv) combinations thereof, wherein the gathering system, the pipeline transmission system, the distribution system, or combinations thereof comprise one or more flow lines comprising PVDF pipe having a nominal pipe size of equal to or greater than 2 inches and equal to or less than 36 inches.
A nineteenth aspect which is the method of the eighteenth aspect, wherein the recovered fluid comprises gaseous hydrocarbons, liquid hydrocarbons, water, carbon dioxide, hydrogen sulfide, or combinations thereof or wherein the recovered fluid comprises crude oil, raw natural gas, wet natural gas, dry natural gas, shale gas, acid gas, sour gas, natural gas liquids, produced water, injection steam condensate, fracturing fluid, or combinations thereof.
A twentieth aspect which is the method of any one of the eighteenth through nineteenth aspects, wherein the processed fluid is natural gas and wherein the pipeline transmission system, the distribution system, or both comprises PVDF pipe having an SDR of 7 and a maximum operating pressure (MOP) of 666 psig, an SDR of 9 and a MOP of 500, an SDR of 11 and a MOP of 400, an SDR of 17 and a MOP of 250, an SDR of 21 and a MOP of 200, or a SDR of 26 and a MOP of 160, wherein the MOP is determined according to the equation:
MOP=[2(HDB)(DF)/(SDR−1)],
where MOP is maximum operating pressure in psig, HDB is hydrostatic design basis in psi as determined in accordance with ASTM Test Method D2837 at a temperature of 73° F.=5000 psi, DF is the deign factor=0.4 for regulated natural gas distribution systems, and SDR is standard dimension ratio which is the outside diameter of the pipe in inches divided by the pipe minimum wall thickness in inches.
A twenty-first aspect which is the method of any one of the eighteenth through nineteenth aspects, wherein the processed fluid is natural gas and wherein the pipeline transmission system, the distribution system, or both comprises PVDF pipe having an SDR of 7 and a maximum operating pressure (MOP) of 666 psig at an HDB of 5000 psi and a temperature of 73° F., a MOP of 166 psig at an HDB of 1250 psi and a temperature of 248° F., or a MOP of 106 psig at an HDB of 800 psi and a temperature of 284° F., wherein the MOP is determined according to the equation:
MOP=[2(HDB)(DF)/(SDR−1)],
where MOP is maximum operating pressure in psig, HDB is hydrostatic design basis in psi as determined in accordance with ASTM Test Method D2837, DF is the deign factor=0.4 for regulated natural gas distribution systems, and SDR is standard dimension ratio which is the outside diameter of the pipe in inches divided by the pipe minimum wall thickness in inches.
A twenty-second aspect which is the method of any one of the eighteenth through nineteenth aspects, wherein the recovered fluid is natural gas and wherein the gathering system comprises PVDF pipe having an SDR of 7 and a maximum operating pressure (MOP) of 1050 psig at an HDB of 5000 psi and a temperature of 73° F., a MOP of 262 psig at an HDB of 1250 psi and a temperature of 248° F., or a MOP of 168 psig at an HDB of 800 psi and a temperature of 284° F., wherein the MOP is determined according to the equation:
MOP=[2(HDB)(DF)/(SDR−1)],
where MOP is maximum operating pressure in psig, HDB is hydrostatic design basis in psi as determined in accordance with ASTM Test Method D2837, DF is the deign factor=0.63 for unregulated gas gathering systems, and SDR is standard dimension ratio which is the outside diameter of the pipe in inches divided by the pipe minimum wall thickness in inches.
A twenty-third aspect which is a method comprising: producing hydrocarbons from a wellbore penetrating a subterranean formation through a wellhead to yield produced hydrocarbons; and flowing the produced hydrocarbons through a hydrocarbon gathering system to a pipeline transmission system, wherein the hydrocarbon gathering system, the pipeline transmission system or both comprise one or more flow lines comprising PVDF pipe having a nominal pipe size of equal to or greater than 2 inches and equal to or less than 36 inches and wherein the PVDF pipe consists essentially of PVDF.
A twenty-fourth aspect which is an oil and gas gathering system, long-haul intrastate or interstate transmission pipeline system, or distribution system, for example as shown in
A twenty-fifth aspect which is the oil and gas gathering system, long-haul intrastate or interstate transmission pipeline system, or distribution system of the twenty-fourth aspect, wherein the PVDF flow line comprises a plurality of straight, solid wall PVDF pipe sections (e.g., 40 or 50 foot sections) joined together directly (e.g., butt fused as described herein) or indirectly (via one or more PVDF fittings as described herein), wherein the solid wall PVDF pipe sections, the PVDF fittings, or both have dimensions specified in Tables 3 to 5, for example the solid wall PVDF pipes are size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) in 40 foot or 50 foot straight sections and/or the solid wall PVDF fittings correspond to PVDF pipe of size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) and can be selected from the group consisting of tees, elbows, flanges, 3-way fittings, 4-way fittings, 5-way fittings, connectors, reducers, expanders, couplings, nipples, and any combination thereof, and wherein the PVDF pipes sections, the PVDF fittings, or both consist essentially of, or consist of, PVDF.
A twenty-sixth aspect which is a PVDF flow line in an oil and gas gathering system, long-haul intrastate or interstate transmission pipeline system, or distribution system, for example as shown in
A twenty-seventh aspect which is a PVDF flow line in a hazardous material transmission system, a refined product transmission system, a chemical product transmission system, wherein the PVDF flow line is formed from PVDF pipe as described herein, PVDF fittings as described herein, or both, wherein the PVDF pipe, the PVDF fittings, or both comprise, alternatively consist essentially of, alternatively consist of, PVDF.
A twenty-eighth aspect which is the PVDF flow line of the twenty-sixth or twenty-seventh aspect, comprising a plurality of straight, solid wall PVDF pipe sections (e.g., 40 or 50 foot sections) joined together directly (e.g., butt fused as described herein) or indirectly (via one or more PVDF fittings as described herein), wherein the solid wall PVDF pipe sections, the PVDF fittings, or both have dimensions specified in Tables 3 to 5, for example the solid wall PVDF pipes are size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) in 40 foot or 50 foot straight sections and/or the solid wall PVDF fittings correspond to PVDF pipe of size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) and can be selected from the group consisting of tees, elbows, flanges, 3-way fittings, 4-way fittings, 5-way fittings, connectors, reducers, expanders, couplings, nipples, and any combination thereof, and wherein the PVDF pipes sections, the PVDF fittings, or both consist essentially of, or consist of, PVDF.
A twenty-ninth aspect which is a method of making a PVDF flow line comprising joining, for example via heat fusion, PVDF pipe as described herein, PVDF fittings as described herein, or both, wherein the PVDF pipe, the PVDF fittings, or both comprise, alternatively consist essentially of, alternatively consist of, PVDF.
A thirtieth aspect which is the method of the twenty-ninth aspect, wherein the PVDF flow line comprises a plurality of straight, solid wall PVDF pipe sections (e.g., 40 or 50 foot sections) joined together directly (e.g., butt fused as described herein) or indirectly (via one or more PVDF fittings as described herein), wherein the solid wall PVDF pipe sections, the PVDF fittings, or both have dimensions specified in Tables 3 to 5, for example the solid wall PVDF pipes are size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) in 40 foot or 50 foot straight sections and/or the solid wall PVDF fittings correspond to PVDF pipe of size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) and can be selected from the group consisting of tees, elbows, flanges, 3-way fittings, 4-way fittings, 5-way fittings, connectors, reducers, expanders, couplings, nipples, and any combination thereof, and wherein the PVDF pipes sections, the PVDF fittings, or both consist essentially of, or consist of, PVDF
A thirty-first aspect which is PVDF pipe, PVDF fittings, or both as described herein, wherein the PVDF pipe, the PVDF fittings, or both comprise, alternatively consist essentially of, alternatively consist of, PVDF.
A thirty-second aspect which is the PVDF pipe of the thirty-first aspect, comprising one or more straight, solid wall PVDF pipe sections (e.g., 40 or 50 foot sections) having dimensions specified in Tables 3 to 5, for example the solid wall PVDF pipe sections having size NPS ≥2 and ≤36, alternatively NPS >6 and ≤24, alternatively NPS >6 and ≤16, (e.g., as described in Tables 3 to 5) in 40 foot or 50 foot straight sections, and wherein the PVDF pipes sections consist essentially of, or consist of, PVDF.
A first aspect which is a method comprising forming polyvinylidene fluoride (PVDF) into pipe having a nominal pipe size of equal to or greater than 2 inches, and spooling the PVDF pipe onto a spool to form spooled PVDF pipe.
A second aspect which is the method of the first aspect wherein the PVDF pipe has a nominal pipe size of less than or equal to 6 inches.
A third aspect which is the method of the first or the second aspect wherein the PVDF pipe is solid wall pipe.
A fourth aspect which is the method of the first, the second or the third aspect wherein the PVDF pipe consists essentially of or consists of PVDF.
A fifth aspect which is the method of any of the first to the fourth aspects wherein the PVDF has a density in a range of from about 1.75 g/cc to about 1.80 g/cc when measured in accordance with ASTM test method D792.
A sixth aspect which is the method of any of the first to the fifth aspects wherein the PVDF has a tensile modulus in a range of from about 1700 to about 2500 MPa when measured in accordance with ASTM test method D638.
A seventh aspect which is the method of any of the first to the sixth aspects wherein the PVDF pipe has a surface temperature in a range of from about 70° F. to about 100° F. during the spooling, alternatively in a range of from about 70° F. to about 90° F. during the spooling, alternatively in a range of from about 75° F. to about 85° F. during the spooling, alternatively in a range of from about 80° F. to about 100° F. during the spooling, alternatively in a range of from about 80° F. to about 90° F. during the spooling, or alternatively has a surface temperature equal to about 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100° F. during the spooling.
An eighth aspect which is the method of any of the first to the seventh aspects wherein the PVDF pipe is spooled at a rate in a range of from about 50 to about 500 feet/hr, alternatively in a range of from about 100 to about 500 feet/hr, alternatively in a range of from about 150 to about 475 feet/hr, alternatively in a range of from about 200 to about 450 feet/hr, alternatively in a range of from about 250 to about 450 feet/hr, alternatively in a range of from about 300 to about 450 feet/hr, alternatively in a range of from about 350 to about 450 feet/hr, alternatively in a range of from about 375 to about 425 feet/hr, or alternatively is spooled at a rate equal to about 350, 355, 360, 365, 370, 375, 380, 385, 390, 395, 400, 405, 410, 415, 420, 425, 430, 435, 440, 445, or 450 feet/hr.
A ninth aspect which is the method of any of the first to the eighth aspects wherein the PVDF pipe is spooled at a bending radius in a range of about 36 inches to about 112 inches, alternatively in a range of about 36 inches to about 96 inches, alternatively in a range of about 36 inches to about 84 inches, alternatively in a range of about 36 inches to about 72 inches, alternatively in a range of about 36 inches to about 60 inches, alternatively in a range of about 42 inches to about 60 inches, alternatively in a range of about 44 inches to about 60 inches, or alternatively is spooled at a bending radius of equal to or greater than 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, or 72 inches.
A tenth aspect which is the method of any of the first to the ninth aspects wherein the spooled PVDF pipe has a length in a range of from about 500 ft to about 4000 ft, alternatively in a range of from about 500 ft to about 3500 ft, alternatively in a range of from about 500 ft to about 3000 ft, alternatively in a range of from about 1000 ft to about 3000 ft, alternatively in a range of from about 1500 ft to about 2500 ft, or alternatively has a length of about 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800, 2900, 3000, 3100, 3200, 3300, 3400, 3500, 3600, 3700, 3800, 3900, or 4000 ft.
An eleventh aspect which is the method of any of the first to the tenth aspects wherein the PVDF pipe is formed by extruding the PVDF to form molten PVDF and passing the molten PVDF through a die to form hot PVDF pipe having a surface temperature upon exiting an extruder of greater than 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, or 165° F., and cooling the PVDF prior to spooling.
A twelfth aspect which is the method of the eleventh aspect wherein the cooling is air cooling in ambient air, air cooling with chilled air, fan forced air cooling, or fan forced air cooling with chilled air, or contact with a liquid cooling medium such as a water bath, water spray, water curtain, etc.
A thirteen aspect which is the method of any of the first to the twelfth aspects wherein the PVDF pipe is formed and spooled concurrently.
A fourteenth aspect which is a spooled PVDF pipe made by the method of any one of the first to the thirteenth aspects.
A fifteenth aspect which is a spooled PVDF pipe comprising PVDF pipe having a nominal pipe size of equal to or greater than 2 inches and a spool having a hub diameter of equal to or greater than about 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 90, 92, 94, 96, 98, 100, 102, 104, 106, 108, 110, or 112 inches.
A sixteenth aspect which is the spooled PVDF pipe of the fifteenth aspect wherein the PVDF pipe is solid wall pipe, the PVDF pipe consists essentially of or consists of PVDF, the PVDF pipe has a nominal pipe size of equal to or less than 6 inches, or combinations thereof.
A seventeenth aspect which is a method comprising unspooling the spooled PVDF pipe of the fourteenth, the fifteenth, or the sixteenth aspect to form unspooled PVDF pipe, optionally straightening the unspooled PVDF pipe, optionally fusing the unspooled PVDF pipe with another PVDF pipe segment to form a PVDF flow line comprising fused PVDF pipe, and optionally coupling the unspooled PVDF pipe or PVDF flow line into fluid communication with a flow line or other component in an oil and gas gathering system, long-haul intrastate or interstate transmission pipeline system, or distribution system, for example as shown in
An eighteenth aspect which is an unspooled PVDF pipe made by the method of the seventeenth aspect, optionally straightened and optionally fused.
A nineteenth aspect which is a method comprising at a worksite, unspooling a first length of spooled PVDF pipe comprising PVDF pipe having a nominal pipe size of equal to or greater than 2 inches to form a first length of unspooled PVDF pipe having a first end, optionally cutting the first length of unspooled PVDF pipe to form a second end, and butt fusing the first end of the first length of unspooled PVDF pipe with a first end of another PVDF pipe segment to form a PVDF flow line comprising fused PVDF pipe.
A twentieth aspect which is the method of the nineteenth aspect wherein the PVDF pipe is solid wall pipe, the PVDF pipe consists essentially of PVDF, the PVDF pipe has a nominal pipe size of equal to or less than 6 inches, or combinations thereof.
A twenty-first aspect which is the method of the nineteenth or the twentieth aspect further comprising straightening the first length of unspooled PVDF pipe prior to the butt fusing, for example by passing the unspooled PVDF pipe through a straightening tool comprising one or more sets of hydraulically controlled rollers that remove coil set and re-round the unspooled PVDF pipe such that the straightened unspooled pipe meets or exceeds ASTM D2513 ovality requirements.
A twenty-second aspect which is the method of any of the nineteenth to the twenty-first aspects further comprising transporting the spooled PVDF pipe to the worksite.
A twenty-third aspect which is the method of any of the nineteenth to the twenty-second aspects wherein the worksite is located at a wellbore fluid gathering system, for example as shown in
A twenty-fourth aspect which is the method of any of the nineteenth to the twenty-third aspects wherein the another PVDF pipe segment is a length of unspooled PVDF pipe that optionally has been straightened and re-rounded to meet or exceed ASTM D2513 ovality requirements, for example by passing the unspooled PVDF pipe through a straightening tool comprising one or more sets of hydraulically controlled rollers that remove coil set from the unspooled PVDF pipe.
A twenty-fifth aspect which is the method of any of the nineteenth to the twenty-fourth aspects further comprising unspooling a second length of spooled PVDF pipe to form a second length of unspooled PVDF pipe having a first end, optionally cutting the second length of unspooled PVDF pipe to form a second end, and further lengthening the PVDF flowline by butt fusing (i) the first end of the second length of unspooled PVDF pipe with a second end of the another PVDF pipe segment, (ii) the first end of the second length of unspooled PVDF pipe with the second end of the first length of unspooled PVDF pipe, (iii) the second end of the second length of unspooled PVDF pipe with the second end of the another PVDF pipe segment, or (iv) the second end of the second length of unspooled PVDF pipe with the second end of the first length of unspooled PVDF pipe.
A twenty-sixth aspect which is the method of any of the nineteenth to the twenty-fifth aspects 25 further comprising connecting the PVDF flow line to an oil and gas gathering system, long-haul intrastate or interstate transmission pipeline system, or distribution system, for example as shown in
A twenty-seventh aspect which is the method of the twenty-sixth aspect further comprising flowing a fluid recovered from a well through the PVDF flow line, wherein the recovered fluid comprises gaseous hydrocarbons, liquid hydrocarbons, water, carbon dioxide, hydrogen sulfide, or combinations thereof or wherein the recovered fluid comprises crude oil, raw natural gas, wet natural gas, dry natural gas, shale gas, acid gas, sour gas, natural gas liquids, produced water, injection steam condensate, fracturing fluid, or combinations thereof.
A twenty-eighth aspect which is a method comprising butt fusing a first end of a first PVDF pipe section with a first end of a second PVDF pipe section to form a PVDF flow line comprising fused PVDF pipe, wherein the first PVDF pipe section and the second PVDF pipe section have a nominal pipe size of equal to or greater than 2 inches.
A twenty-ninth aspect which is the method of the twenty-eighth aspect wherein the first ends of the first and second PVDF pipe sections are heated using a heating tool having a surface temperature in a range of from about 400 to about 550° F., alternatively in a range of from about 425 to about 525° F., alternatively in a range of from about 450 to about 500° F., or alternatively a surface temperature equal to about 425, 430, 435, 440, 445, 450, 455, 460, 465, 470, 475, 480, 485, 490, 495, 500, 505, 510, 515, 520, or 525° F., preferably about 475° F., wherein the heating tool is a force fusion machine such as a McElroy ACROBAT 160 or a McElroy ROLLING 28.
A thirtieth aspect which is the method of the twenty-eighth or the twenty-ninth aspect wherein the first ends of the first and second PVDF pipe sections are heated by contact with the heating tool for a time in a range of from about 120 seconds to about 240 seconds, alternatively in a range of from about 150 seconds to about 210 seconds, alternatively in a range of from about 180 seconds to about 210 seconds, or alternatively at a time equal to 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, 200, 201, 202, 203, 204, 205, 206, 207, 208, 209, or 210 seconds, preferably about 190 seconds.
A thirty-first aspect which is the method of any of the twenty-eighth to the thirtieth aspects wherein the first ends of the first and second PVDF pipe sections are heated by contact with the heating tool for a period of time sufficient for each first end to form a melt bead having a width of about 1/32 inch when the PVDF pipe has an outside diameter of less than 2.37 inches; a melt bead having a width of about 1/16 inch when the PVDF pipe has an outside diameter of equal to or greater than 2.37 inches and less than 3.5 inches; a melt bead having a width of about 3/16 inch when the PVDF pipe has an outside diameter of equal to or greater than 3.5 inches and less than 8.62 inches; a melt bead having a width of about ¼ inch when the PVDF pipe has an outside diameter of equal to or greater than 8.62 inches and less than 12.75 inches; or a melt bead having a width of about ⅜ inch when the PVDF pipe has an outside diameter of equal to or greater than 12.77 inches and equal to or less than 24 inches.
A thirty-second aspect which is the method of any of the twenty-eighth to the thirty-first aspects wherein the first ends of the first and second PVDF pipe sections are fused by contact at an interfacial pressure in a range of from about 60 to about 90 psi, alternatively in a range of from about 65 to about 85 psi, alternatively in a range of from about 70 to about 80 psi, or alternatively at a pressure equal to about 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, or 90 psi, preferably about 75 psi.
A thirty-third aspect which is the method of any of the twenty-eighth to the thirty-second aspects wherein the first and second PVDF pipe sections have a nominal pipe size of equal to or greater than 2 inches and less than or equal to 24 inches, a nominal pipe size of equal to or greater than 6 inches and less than or equal to 16 inches, or alternatively a nominal pipe size of equal to or greater than 2 inches and less than or equal to 6 inches and wherein the pipe has an SDR in a range of 7 to 32.5, for example first and second PVDF pipe sections having a nominal pipe size of 2 inches and an SDR or 11 or having a nominal pipe size of 4 inches and an SDR of 11.
A thirty-fourth aspect which is the method of any of the twenty-eighth to the thirty-third aspects wherein the first and second PVDF pipe sections are lengths of unspooled PVDF pipe having a nominal pipe size of equal to or less than 6 inches, and optionally wherein the lengths of unspooled PVDF pipe have been straightened, for example by passing the unspooled PVDF pipe through a straightening tool comprising one or more sets of hydraulically controlled rollers that remove coil set and re-round the unspooled PVDF pipe such that the straightened unspooled pipe meets or exceeds ASTM D2513 ovality requirements.
A thirty-fifth aspect which is the method of any of the twenty-eighth to the thirty-third aspects wherein the first and second PVDF pipe sections are straight sections of solid wall PVDF pipe having a nominal pipe size equal to or less than 16 inches.
A thirty-sixth aspect which is the method of any of the twenty-eighth to the thirty-fifth aspects wherein the first and second PVDF pipe sections are solid wall pipe, the first and second PVDF pipe sections consists essentially of PVDF, or both.
A thirty-seventh aspect which is the method of any of the twenty-eighth to the thirty-sixth aspects further comprising connecting the PVDF flow line to an oil and gas gathering system, long-haul intrastate or interstate transmission pipeline system, or distribution system, for example as shown in
A thirty-eighth aspect which is the method of the thirty-seventh aspect further comprising flowing a fluid (e.g., gas or liquid) recovered from a well through the PVDF flow line, wherein the recovered fluid comprises gaseous hydrocarbons, liquid hydrocarbons, water, carbon dioxide, hydrogen sulfide, or combinations thereof or wherein the recovered fluid comprises crude oil, raw natural gas, wet natural gas, dry natural gas, shale gas, acid gas, sour gas, natural gas liquids, produced water, injection steam condensate, fracturing fluid, or combinations thereof.
A thirty-ninth aspect which is a fused PVDF pipe made by the method of any one of the twenty-eighth to the thirty-sixth aspects.
A fortieth aspect which is the fused PVDF pipe of the thirty-ninth aspect comprising a length of unspooled PVDF pipe that has optionally been straightened prior to or after fusing.
A forty-first aspect which is a fused solid wall PVDF pipe consisting essentially of, or consisting of, PVDF and having a nominal pipe size of equal to or greater than 2 inches and less than or equal to 24 inches, alternatively a nominal pipe size of equal to or greater than 2 inches and less than or equal to 16 inches, or a nominal pipe size of equal to or greater than 2 inches and less than or equal to 6 inches.
This application claims priority to U.S. Provisional Application No. 62/817,731, filed on Mar. 13, 2019, and entitled “PVDF Pipe and Methods of Making and Using Same,” the disclosure of which is hereby incorporated by reference in its entirety. This application is a continuation-in-part of and claims priority to U.S. patent application Ser. No. 16/223,821, filed Dec. 18, 2018, which is a continuation of and claims priority to PCT/US2018/050905 filed Sep. 13, 2018 and entitled “PVDF Pipe and Methods of Making and Using Same,” which claims priority to U.S. Patent Application No. 62/558,188 filed Sep. 13, 2017 and U.S. Patent Application No. 62/571,104 filed Oct. 11, 2017, which applications are incorporated by reference herein in their entirety. This application is a continuation-in-part of and claims priority to PCT/US2018/050905 filed Sep. 13, 2018 and entitled “PVDF Pipe and Methods of Making and Using Same,” which claims priority to U.S. Patent Application No. 62/558,188 filed Sep. 13, 2017 and U.S. Patent Application No. 62/571,104 filed Oct. 11, 2017, which applications are incorporated by reference herein in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62817731 | Mar 2019 | US | |
| 62558188 | Sep 2017 | US | |
| 62571104 | Oct 2017 | US | |
| 62558188 | Sep 2017 | US | |
| 62571104 | Oct 2017 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/US2018/050905 | Sep 2018 | US |
| Child | 16223821 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16223821 | Dec 2018 | US |
| Child | 16815703 | US | |
| Parent | PCT/US2018/050905 | Sep 2018 | US |
| Child | PCT/US2018/050905 | US |
