New High Performance Resin
for Thermoplastic Liners
Taming Deviated Wells
Zach Stearman, LJ Guillotte, Juan Cangas
Lightning Rod & Pipe, Can-Altek International
Thermoplastic Liner Basics
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Plastic resin is extruded to pipe
profile
Mechanically bonded to the
interior of the tubing
Protects against wear and
corrosion
Eliminates the need for rod
guides
Many different resins are used
for different environments
Taming Deviated Wells
Benefits of Lined Tubing
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Extends the life of rods and tubing by eliminating rod on tubing
wear
Protects tubing from abrasion from solids
Resistant to all chemicals found in well fluid including H2S and CO2
Eliminates the need for rod guides in rod pumping applications
Does not crack or chip like other coatings
Flexible to withstand deviation in the wellbore
More economic than some other technologies such as boronized
tubing
Taming Deviated Wells
3
Thermoplastic Liner History
Used in downhole applications for over twenty years
• Initially designed for injection wells, but quickly adapted because
of success in mitigating rod on tubing wear
• High-density Polyethylene (HDPE) was the first resin used
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Soft, permeable
Low temperature
High Performance resins developed to meet the needs of more
challenging environments
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Superior performance
Very high cost
Taming Deviated Wells
Thermoplastic Resin Liner Options
General Specifications
Material Type
Max Temp.
Dimensions
H2S
CO2
Cost
HDPE
140° F
2 3/8" - 4 1/2"
2%
10%
$
HDPE - Modified
210° F
2 3/8" - 4 1/2"
2%
10%
$$
POK - Modified
240° F
2 3/8" - 4 1/2"
5%
20%
$$
PPS - Modified
340° F
2 3/8" - 4 1/2"
5%
20%
$$$$
PEEK
500° F
2 3/8" - 4 1/2"
5%
20%
$$$$$
Taming Deviated Wells
History of POK use in the Oil Industry
Originally developed by Shell as “Carilon” for offshore corrosion
control and chemical resistance
• Resin production was discontinued in 2000, and the technology
was sold to Hyosung
• Initially, Hyosung’s POK had a maximum continuous operating
temperature of 210˚F.
• 2015 Hyosung and Lightning Rod & Pipe developed and tested the
raised temperature POK resin for use in O&G down hole
applications having a continuous working temperature of 240˚F.
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Taming Deviated Wells
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Polyolefin Ketone Resin (POK)
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Unique engineering plastic with a carbon-only backbone
Highly crystalline with a compact crystal structure
Stable at high temperatures
Has excellent abrasion/chemical/fuel resistance
Gas barrier properties
Its linear molecular chains are perfectly alternating carbon
monoxide and alpha olefin structures
Physical and chemical properties make the resin well suited for
downhole applications
Taming Deviated Wells
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Results from POK lab testing
Heat Deflection Temperature (HDT) 220° F allows for high
continuous operating temperature
• High Melting Point of 222° C (433° F)
• Excellent permeation performance – Wet H2S and CO2
• Resistance to Attack or Swelling
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Mechanically Resilient
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Hydrocarbons, Ketones, Esters and Ethers, Inorganic Salts, Acid/Base
Excellent Ductility broad temperature range
Elongation and Impact
Hydrolysis Resistance
Taming Deviated Wells
8
Properties of Polyketone
Physical Properties
Test Methods
Unit
Value
Density
ASTM D792
g/cm3
1.24
ASTM D570
%
0.5
Test Methods
Unit
Value
Water Absorption
23˚ C, 50RH
Mechanical Properties
Tensile Strength at Yield
23˚
ASTM D638
MPa
56
Nominal Strain at Break
23˚
ASTM D638
%
270
Flexural Strength
23˚
ASTM D790
MPa
48
Flexural Modulus
23˚
ASTM D790
GPa
1.2
Thermal Properties
Test Method
Unit
Value
Melting Temperature
ASTM D3418
˚C
222
Heat Deflection Temperature
ASTM D648
˚C
104
Taming Deviated Wells
Mechanical Properties at Extreme Temperatures
at -30℃
Tensile Property
(ASTM D638)
POK
PA11
BESNO P40TL
PVDF
Kynar 710
PVDF
Solef 1010
HDPE
PE3408
Modulus, Kpsi
484.6
170.7
368.4
402.4
303.6
Yield Stress, psi
12380
6815
11320
11210
5889
Yield strain, %
13.3
34.8
6.98
7.27
10.1
Tensile Property
(ASTM D638)
POK
PA11
BESNO P40TL
PVDF
Kynar 710
PVDF
Solef 1010
HDPE
PE3408
Modulus, Kpsi
86.00
19.13
76.16
76.20
15.99
Yield Stress, psi
5600
-
2934
3064
-
Yield strain, %
22.97
-
12.3
12.8
-
at 120℃
Taming Deviated Wells
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Chemical Resistance
POK samples (tensile bars taken from extruded liner) exposed at various temperatures for 4 month
Exposure
Temp. ℃
Young’s Modulus, Mpa (kpsi)
Yield Stress, Mpa (psi)
Elongation at Yield, %
Control
exposed
Control
exposed
Control
exposed
20
1274
(183)
1173
(169)
61.6
(8863)
57.6
(8288)
33.8
34.4
40
1042
(150)
989
(142)
56.0
(8057)
54.4
(7827)
35.7
32.2
60
693
(100)
978
(141)
50.4
(7252)
54.8
(7885)
36.8
29.6
80
593
(85)
837
(120)
45.8
(6590)
50.7
(7295)
37.4
30.2
100
505
(72.7)
664
(95)
41.0
(5899)
40.2
(5784)
38.3
20.3
120
413
(59)
525
(75)
36.4
(5237)
30.3
(4360)
34.9
15.2
* Multicomponent Liquid: Benzene 1%; Toluene 7%; Xylene 11%; Cyclopentenes 6%; Cyclohexanes 6%; C4-C5 17%; C6-C10 42%; C11 10%
Taming Deviated Wells
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Chemical Resistance
Multicomponent Liquid Testing (Yield Stress)
70
60
Yield Stress, MPa
50
40
30
20
10
0
20 C
40 C
Unexposed
Taming Deviated Wells
4 months exposure
60 C
8 months exposure
80 C
Chemical Resistance
Tensile Properties of POK after exposure to Nelson Fluid at 105˚C
Exposure Time,
days
Modulus, MPa
Yield Stress,
MPa
Yield Strain, %
Break Stress,
MPa
Break Strain, %
Volume
Change, %
Weight
Change, %
0
1,699
62
22
84
322
--
--
2
718
52
36
62
217
7.0
5.3
34
754
53
30
61
218
6.4
4.7
92
676
55
34
57
49
6.4
4.6
230
754
57
39
56
114
6.5
5.0
* Multicomponent Liquid: Benzene 1%; Toluene 7%; Xylene 11%; Cyclopentenes 6%; Cyclohexanes 6%; C4-C5 17%; C6-C10 42%; C11 10%
Taming Deviated Wells
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Swell Resistance
Multicomponent Liquid Testing (Swell Testing)
6
5
Swell, %
4
3
2
1
0
20 C
40 C
POK
Taming Deviated Wells
HDPE
60 C
Chemical Resistance
Tensile Properties of POK after exposure to Multicomponent Fluid, 90 days, 120˚C, 2800 psi
Hardness,
Shore D
Peak Load,
lbf
Flexural
Strength, ksi
Modulus,
ksi
Yield Stress,
ksi
Elongation at
Yield, %
Tensile Stress,
ksi
Elongation at
Break, %
Unexposed
75.2
38.6
9.10
204
7.84
18
7.84
28
Exposed, 60
days, 110˚C,
2500 psi
75.2
27.1
6.80
139
8.383
28
8.383
28
Exposed, 90
days, 120˚C,
2800 psi
76.6
33.3
9.53
233
8.211
18
8.222
34
Width, in
Depth Under Notch,
in
Impact Energy, ft-lb
Impact Strength, ftlb/in
Unexposed
75.2
38.6
9.10
204
Exposed, 90 days,
120˚C, 2800 psi
76.6
33.3
9.53
233
* Multicomponent Fluid: 33% water + 42% Hydrocarbon (Aromatic, Aliphatic – Benzene 1%, Toluene 7%, Xylene 11%, Cyclopentene 6%, Cyclohexane 6%,
C4-C5 17%, C6-C10 42%, C11 10%) + 25% “Ph4” Gas (CO2 10%, H2S 5%, CH4 85%)
Taming Deviated Wells
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Abrasion Resistance
Certified test center (external agencies)
Test Method: ASTM G 137
• With the pressure on the block, total abrasion on the ring which rotates is measured
• The conditions:
• Temperature of specimen (Room temp. or 130-200˚C). Rotational speed of rings (0.01~2m/s).
• Pressure on the block (5~30Mpa)
• Specimen Standard: Ring (50mm Dia. X 28mm width, Block (6.35mm x 12.7)
Wear-resistant test in room temp.
Allowable limit temp.: 225˚C
Taming Deviated Wells
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Abrasion Resistance
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External Agencies (Certified test
center)
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Resin on Resin (same materials)
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Same Condition except maintaining 0.1 MPa
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Under 1.5m/s, 0.1MPa Condition, PK abrasion
loss is the lowest among the test materials.
380 rpm
Case I.
Block
Ring
Case II.
Abrasion
loss
(um/hr)
Block
Ring
1
POK
POK
21
86
Case III.
Abrasion
loss
(um/hr)
Block
Ring
164
POM
POM
570 rpm
470 rpm
202
Abrasion
loss
(um/hr)
Pressure
(MPa)
66
PA66
263
PA66
156
0.1
466
• Materials : POK = M630A base resin, POM = Duracon M90-44 base resin, PA66 = Zytel 101 base resin
• PK is inferior than other materials under over 1.5m/s, 0.1MPa Condition.
• Abrasion loss (1.75m/s, 0.1MPa) : PK=1,078um/h, POM=619um/h, PA66=1,135um/h
• Abrasion loss (1m/s, 0.175MPa) : PK=48,226um/h, POM=49um/h, PA66=149um/h
Taming Deviated Wells
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Condition
Speed
m/s
Temp(℃)
(rpm)
1.00
(380)
1.25
23
(470)
1.50
(570)
Time
(hr)
1
1
1
Gas Barrier Properties
CH4 Permeation Rate
40
35
Permeation Rate
30
HDPE
25
20
PA11
15
10
POK
5
0
0
20
40
60
80
Temperature, ˚C
Unit : 109 cm3 – cm/cm2s bar
Taming Deviated Wells
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120
140
Initial Field Trials
Install Date
Customer
Location
Previous Run Time
Run Time to Date
8/29/2016
Customer A
Midland County
6 month maximum
267 days
9/29/2016
Customer B
Reeves County
6 month average
236 days
11/17/2016
Customer B
Reeves County
90 day average
187 days
12/8/2016
Customer B
Reeves County
New Install
166 days
2/3/2017
Customer C
Midland County
New Install
109 days
3/13/2017
Customer A
Midland County
6 month average
71 days
Taming Deviated Wells
Conclusion
POK is a new high performance resin that is being extruded to
increase the life of artificially lifted wells
• Meets temperature needs for hot oiling at a much lower cost than
other high performance resins
• Excellent mechanical properties, chemical resistance, abrasion
resistance, and barrier properties
• Field trials are underway and initial results are promising
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Taming Deviated Wells
Thank you!
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Hyosung Corporation
Can-Altek International
Southwest Research Institutes
SWPSC Association
Audience for listening!
Taming Deviated Wells