Non-Metallic Technology Deployment for the Next Generation of ADNOC Production Facilities
Authors: Burke Raymond Nicholas , Al Tamimi Abdallah Mohd AR , Al Shouly Wael Salem , Baetsen David Erik 
Published: December 2021

Industry-wide, the degradation and corrosion of steel infrastructure and the associated maintenance to prevent or mitigate this, poses a heavy environmental and operational burden across many industry segments. To address these challenges, ADNOC Group Technology, led by our Non-Metallic Steering Committee and ADNOC Upstream, in partnership with several selected specialist product companies, is deploying a range of innovative solutions as pilot trials within a holistic R&D program – which is aiming to transform our production and processing facilities, with a close focus on integrity management – and specifically we are assessing the deployment of non-metallic pipelines, storage and process vessels as well as downhole tubing and casing.

Focusing specifically on flowlines and pipelines - traditional steel pipes used in the oil patch are burdensome to store, transport and install, as well as susceptible to degradation, corrosion-driven wall loss in challenging operational environments, such as those found Onshore and Offshore Abu Dhabi. This vulnerability results in increased operating risks as facilities mature, adding cost and time for inspection, maintenance and eventually - replacements that will lead to production deferrals or interruptions.

A range of non-metallic pipeline technologies are being assessed and piloted in this program, including stand-alone extruded polymeric pipe and liners, Reinforced Thermoplastic Pipe (RTP) used Onshore and Offshore, specialized non-metallic flexible pipelines for Offshore including Thermoplastic Composite Pipe (TCP) and downhole tubulars. The methodology involves placing segments of RTP into live pipeline systems for a finite duration of operation – usually one year – and then removing sections to assess any degradation in performance, or capability of the RTP during that time. These test results will be the subject of a further publication at the end of this trial period.

In this paper, we will focus on RTP piloting Onshore and specifically mention a unique trial in an ultra-sour gas field, where the technology has already delivered the required performance: safely transporting gas with levels of H2S up to 10% by volume. This trial also proves that specifically engineered non-metallic products may be successfully operated at the high temperature and high pressure (HPHT) levels that are characteristic of our reservoirs.

As a result of this qualification program, ADNOC will see an increase in the longevity of pipeline assets and will enjoy significantly higher reliability and availability, with lower maintenance cost over time. It has been demonstrated that RTP can provide life-cycle savings exceeding 60% when compared to carbon steel pipes [1]. As the polymer feedstock that is used to manufacture these products can be produced regionally, including material supplied in the UAE by Borouge, the manufacturing/use/recycling will close a vital and sustainable full cycle, promoting In-Country Value (ICV) and generating additional economic opportunities in the emerging non-metallic industrial ecosystem for the nation. The multi-faceted value proposition is described in more detail in Figure 1 below.

Figure 1 Value and sustainability benefits from increased use of non-metallic materials

This is a clear example whereby ADNOC and the UAE continue to demonstrate global leadership by creating and investing in sustainable and energy-efficient technology solutions across the entire value chain while diversifying the national economy.