Nonmetallics and its Roles in Shaping the Future of Saudi Aramco

Authors: Dr. Mauyed S. Mehdi and Hussain A. Bunaiyan

ABSTRACT
In 2006, Saudi Aramco embarked on an ambitious Nonmetallic Program to help control corrosion, encourage the conversion of oil into petrochemicals and to enhance the supply chain. This article will demonstrate the role of nonmetallics in shaping the future of Saudi Aramco. The execution of the program is being delivered through five separate clusters: operation support, standards, technology, intellectual capital and supply chain. The effectiveness of the nonmetallic program is closely monitored by a set of carefully designed Key Performance Indicators (KPIs).

INTRODUCTION
Today, oil and gas exploration and recovery has entered a period of significant change in that substantially different technology and methods are utilized to recover hydrocarbon from increasingly challenging environments. In the next decade or two, the days of easy oil recovery will be behind us. Onshore and offshore operations will be utilizing broader techniques of enhanced oil recovery as well as working in much higher water levels, H2S and CO2, each of which places further strain on both metallic and nonmetallic piping, tanks and vessels, valves and other equipment. In some environments, such as sour gas containing high levels of sands, requirements for highly abrasion resistant materials with broad operating temperature windows will also be presenting new challenges. Moreover, water from maturing fields and fields requiring pressure support using water or gas, or simultaneous injection of both, bring the transportation piping, both downhole and aboveground, in contact with a potent combination of corrosive fluids. Metallic structures operating in such environments will experience more corrosion, Fig. 1, which simply means a larger budget for the extremely high cost of an already escalating cost of maintenance, and the use of exotic high cost corrosion resistance alloys (CRA). Frequent and unexpected replacement of casing, downhole tubing, flow lines, tanks and vessels and other structures on account of corrosion results is not only the higher cost of corrosion, but also production delays. Saudi Aramco is aware, through the corrosion management program (CMP), that there is no one single solution to solve the corrosion problem and the

Fig. 1. Heavily corroded downhole metallic tubing.

nonmetallic program is one important solution to control corrosion. The nonmetallic industry and the available new and matured technologies has developed several successful field tested products offering fit for purpose solutions that capture a life cycle cost saving between 25%-30%, compared to that of corrosion susceptible carbon steel materials. From a regulatory perspective, demands are already being placed on the nonmetallic industry, and in particular, the composite industry to develop more rigorous and scientifically sound predictions of the lifetime for equipment in critical service and demanding environmental conditions. The industry is faced with not just an evolutionary or incremental change in the demands on existing polymer based materials, but in fact is in the center of a substantial or revolutionary change in material property requirements, both in magnitude and application environment. Where elastomers may have served in the past, thermoplastics are likely to be required in the future; where thermoplastics may not meet demanding conditions, application specific composites may be called for. Saudi Aramco is diversifying its business and invested heavily with major petrochemical companies in establishing new petrochemical joint venture companies to provide innovative nonmetallic materials and solutions to fulfill the requirements of a wide range of industries in the Middle East. The latest joint venture with DOW is just one example of Saudi Aramcos strategy.

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remain as one of the sources that provide cost-effective solutions to Saudi Aramco, it is believed that adequate measures and tools should be made available to combat the previously mentioned challenges. The implementation of nonmetallic products is captured in the following five dynamic and functional clusters. Operation Support The volume and number of applications of composite materials have grown steadily, penetrating and conquering new applications relentlessly while continuing to gain operational confidence. Composites meet diverse design requirements with significant weight savings and a high strength-to-weight ratio compared to conventional metallic materials. Composites have proved to be a worthy alternative to other traditional materials, even in high pressure and aggressive environmental conditions. Lately, advances have been made in the areas of GRE lined downhole tubing, Fig. 2, composite flow lines and test lines, Fig. 3, water injection lines, Fig. 4, cooling towers, Fig. 5, composite repair, Fig. 6, and many other applications.

Fig. 2. GRE lined downhole tubing for aggressive oil and high salinity water.

NONMETALLIC PROGRAM
Being one of the largest oil and gas producing companies in the world, Saudi Aramco is nurturing the nonmetallic program to be ready for the future where oil and gas are expected to be more corrosive and the requirement for developing new methods to enhance oil recovery from depleted reservoirs may become critical to fulfill the obligation and demand for oil and gas. Saudi Aramco took the lead and pioneered the implementation of glass reinforced piping (GRE) in 1978 at a seawater treatment plant. Recently, and with the latest developments in materials and technologies, the company is taking the lead by increasing the levels of design, research and development, qualification as well as collaborating with other oil and gas operators to move forward into highly demanding environments. Saudi Aramco has a strong and proven record of accomplishments in the utilization of nonmetallic products through its comprehensive nonmetallic program. The company has played a major role and is encouraging the local nonmetallic industry to take part in the rapid and systematic growth in the utilization of nonmetallics. For nonmetallics to be effective and ready for changes in the chemistry of oil, gas and water, and

Fig. 4. Reinforced thermoplastic pipe in high-pressure water injection.

Fig. 3. High-pressure RTR flow line.

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Fig. 5. Cooling Tower composed of composite structures including the loadbearing components.

Fig. 6. Composite repair system applications.

Fig. 9. PTFE lined drain lines.

Fig. 10. Grooved vented thermoplastic line to rehabilitate corroded hydrocarbon and water injection pipeline. Fig. 7. Composite wrap for thrust boring operation.

Recently, the use of a grooved PE100 liner, Fig. 10, to rehabilitate water injection laterals was introduced to higher pressure and temperature levels. Standards New or modern structures are easier to implement when an infrastructure of test methods, material specifications and design codes exist. These are often absent at the beginning of any new product and need to be developed. Their availability will have a marked effect on the ability of designers to innovate in new applications or improve existing applications. This infrastructure provides an important capability and technical language for engineers to implement and maintain these structures. In the nonmetallic industry the infrastructure is not fully developed; however, Saudi Aramco engineers are not only adopting current international standards to cover operating and environmental conditions, but are also actively developing many new specifications and engineering standards supported by laboratory testing and field trials. Technologies and Joint Industry Programs (JIP) Technologies are not only the source of standards, specifications, products and/or processes, but also enhancements to supply chains and local contents.
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Fig. 8. HDPE pipeline in seawater intake application.

Saudi Aramco has pioneered and customized several nonmetallic products to be effective solutions to control corrosion, and the latest innovative idea of using composite wrap for thrust boring operations is just an example, Fig. 7. In the area of thermoplastic products, high density polyethylene (HDPE) piping, Fig. 8, has seen new utility applications, which resulted in a direct significant cost saving as well as reduced installation time. The use of thermoplastic lined drain lines, Fig. 9, in many gas-oil separation plants have significantly enhanced the drain lines performance and extended the intervals between Testing and Inspection (T&I).

Saudi Aramco has been heavily investing in the development/participation in new technologies and their deployment. Subsequently, before indulging in any new technology, experts within the Consulting Services Department design the types of technologies required to satisfy the requirements for the coming years. In general, new technologies will be invented and applied in the coming years to the global quest of reducing the cost of corrosion, extend the service life of assets and enhance production from highly hostile oil and gas reservoirs. Intellectual Capital Challenges to use of nonmetallic materials will continue to be broken down as we progress into the future. This is the result of Saudi Aramcos continued investment in training both existing and new scientists through universities and individual fellowships. Such investment is immensely important in creating the next generation of engineers for nonmetallics. More and more engineering institutes are teaching the science and engineering aspect of nonmetallic materials in their curriculums as not just a niche use but as a material of general choice. There are still challenges ahead in the use of nonmetallic materials in Saudi Aramco. The perception today is that nonmetallics are inferior to metallic materials. Such a roadblock is a lack of knowledge on the proper uses of nonmetallic materials and a general lack of knowledge in performance abilities in comparison to metallic alternatives. Supply Chain Saudi Aramco has grown from the time of the first oil discoveries to the current new offshore hydrocarbon reservoirs and is placed to strengthen the inclusion of composite materials within this supply chain. Future use of composites will include increasing use for steel rehabilitation, thermoplastic tubular, composite risers, plugs and inserts. In principal, an adequate number of nonmetallic products manufacturers/suppliers, locally and internationally, have been made available to Saudi Aramco to enhance the supply chain, create fair competition and control product cost.

KPI. It is the main measurable parameter, which is the life cycle cost saving for each application. KPI = Actual amount of installed commodity multiplied by the life cycle cost saving factor per each commodity.

CONCLUSIONS
The ongoing Saudi Aramco nonmetallic program has so far provided actual evidence that nonmetallic products are gradually taking over as a superior alternative to other traditional materials even in high pressure and aggressive environmental situations. Applications of composite are increasing tremendously along with the concurrent development in the area of knowledge generation. This knowledge is being built successfully through new technologies, field trials, adaptation of international standards and development of new specifications. Moreover, with technology innovations and developments in processes and products, composites have become attractive candidates for applications in oil gas piping systems, water injection lines, topside applications, downhole tubing in both onshore and in subsea, and many more crucial applications.

ACKNOWLEDGMENTS
The authors would like to thank Saudi Aramco management for their permission to present and publish this article.

KEY PERFORMANCE INDEX (KPI)

The effectiveness of the nonmetallic applications is measured using the Key Performance Index (KPI). This KPI measures accomplishments in the main five clusters. KPI =
Number of completed items Number of program planned items

The effectiveness represents the weight factor, e.g., 0.65, of the KPI. The impact represents the weight factor; 0.35, of the
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BIOGRAPHIES
Dr. Mauyed S. Mehdi joined Saudi Aramco in December 2001, as an Engineering Nonmetallic Specialist. He is currently a Senior Engineering Consultant and the Nonmetallic Standards Chairman within the Consulting Services Department (CSD). His industrial experience extends to 30 years where he was involved in nonmetallic products utilized by the oil and gas industry, including but not limited to, pipes, seals, valves, composite structures, tanks and vessels, etc. For the last 11 years Mauyed taught polymer science and engineering, carried out research and development projects, developed several mandatory documents on materials specification and engineering procedures, best practices, failure analysis, material selection, product specifications, etc. He received his Ph.D. degree in Polymer Science in 1984. In addition, Mauyed has published several technical papers in many referred journals, conferences and technical meetings. He also has extensive knowledge and experience in both plastic and rubber industries as well as academic experience gained before and after receiving his doctorate.

Hussain A. Bunaiyan is an Engineering Consultant at Saudi Aramcos Consulting Services Department. He is the Team Leader of the Nonmetallic Group. Since joining Saudi Aramco in 1978, Hussain has worked as an Operations Engineer in the Ras Tanura Refinery (RTR), Juaymah Tank Farm and Berri Gas Plant, Supervisor of the NGL Unit at the RTR Laboratory Division, Supervisor Laboratory Unit, Environmental Coordinator, Projects Coordinator, Supervisor Process Unit and Supervisor Project Support & Coordination Unit at Berri Gas Plant. In 2003, he was selected to lead a multidiscipline Sulfur Initiative Team to develop a long-term sulfur disposition strategy for Saudi Aramco, and in 2007, Hussain was selected to lead the initial Fully Integrated PMT (FIPMT) initiative, whereby the Asset Manager with Project Management support proposes, plans, develops, designs and executes projects. Hussain received his B.S. degree in Chemical Engineering and an MBA degree, both from King Fahd University of Petroleum and Minerals (KFUPM), Dhahran, Saudi Arabia, in 1979 and 1984, respectively.

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