Zach Stearman Lightning Production Services

1. New High Performance Resin
for Thermoplastic Liners
Zach Stearman, LJ Guillotte
Lightning Production Services

2. Thermoplastic Liner Basics
• 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
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3. Benefits of Lined Tubing
• 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
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4. 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
• Soft, permeable
• Low temperature
• High Performance resins developed to meet the needs of more
challenging environments
• Superior performance
• Very high cost
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5. Thermoplastic Liner Resin 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% $$
POK - Modified 250° F 2 3/8" - 4 1/2" 5% 20% $$
PPS - Modified 340° F 2 3/8" - 4 1/2" 5% 20% $$$$
PEEK 500° F 2 3/8" - 4 1/2" 5% 20% $$$$$
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6. 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 Production Services developed and
tested the raised temperature POK resin for use in O&G down hole
applications having a continuous working temperature of 250˚F.
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7. Polyolefin Ketone Resin (POK)
• 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
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8. 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
• Hydrocarbons, Ketones, Esters and Ethers, Inorganic Salts, Acid/Base
• Mechanically Resilient
• Excellent Ductility broad temperature range
• Elongation and Impact
• Hydrolysis Resistance
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9. Mechanical Properties at Extreme Temperatures
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℃
at -30℃
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10. High-Temperature Performance
POK samples exposed to Multicomponent Fluid for 30 days at 300⁰ F and 4500 psig
* Multicomponent Fluid: Water/Hydrocarbon mixture with 5% H2S, 15% CO2, 80% Methane in gas phase
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11. Chemical Resistance
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
POK samples (tensile bars taken from extruded liner) exposed at various temperatures for 4 month
* Multicomponent Liquid: Benzene 1%; Toluene 7%; Xylene 11%; Cyclopentenes 6%; Cyclohexanes 6%; C4-C5 17%; C6-C10 42%; C11 10%
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12. Chemical Resistance
0
10
20
30
40
50
60
70
20 C 40 C 60 C 80 C
YieldStress,MPa Multicomponent Liquid Testing (Yield Stress)
Unexposed 4 months exposure 8 months exposure
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13. Chemical Resistance
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
Tensile Properties of POK after exposure to Nelson Fluid at 105˚C
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14. Swell Resistance
0
1
2
3
4
5
6
20 C 40 C 60 C
Swell,%
Multicomponent Liquid Testing (Swell Testing)
POK HDPE
* Multicomponent Liquid: Benzene 1%; Toluene 7%; Xylene 11%; Cyclopentenes 6%; Cyclohexanes 6%; C4-C5 17%; C6-C10 42%; C11 10%
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15. Chemical Resistance
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, ft-
lb/in
Unexposed 75.2 38.6 9.10 204
Exposed, 90 days,
120˚C, 2800 psi
76.6 33.3 9.53 233
Tensile Properties of POK after exposure to Multicomponent Fluid, 90 days, 120˚C, 2800 psi
* 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%)
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16. 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)
Allowable limit temp.: 225˚C
Wear-resistant test in room temp.
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17. Abrasion Resistance
• External Agencies (Certified test
center)
• Resin on Resin (same materials)
• Same Condition except maintaining 0.1 MPa
• Under 1.5m/s, 0.1MPa Condition, PK
abrasion loss is the lowest among the test
materials.
Case I. Case II. Case III. Condition
Block Ring
Abrasion
loss
(um/hr)
Block Ring
Abrasion
loss
(um/hr)
Block Ring
Abrasion
loss
(um/hr)
Pressure
(MPa)
Speed
m/s
(rpm)
Temp(℃)
Time
(hr)
POK POK
1
POM POM
164
PA66 PA66
66
0.1
1.00
(380)
23
1
21 202 156
1.25
(470)
1
86 263 466
1.50
(570)
1
• 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
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18. Gas Barrier Properties
0
5
10
15
20
25
30
35
40
0 20 40 60 80 100 120 140
PermeationRate
Temperature, ˚C
POK
CH4 Permeation Rate
Unit : 109 cm3 – cm/cm2s bar
PA11
HDPE
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19. Initial Field Trials
Install Date Customer Well No. Previous Run Time Run Time to Date
8/29/2016 Customer A 1 6 month maximum 695 days
9/29/2016 Customer B 2 6 month average 583 days
11/17/2016 Customer B 3 60 day average 568 days
12/8/2016 Customer B 4 New Install 594 days
2/8/2017 Customer C 5 New Install 532 days
3/13/2017 Customer A 6 6 month average 499 days
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20. Failure Rate Changes on Initial Installs
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0
0.2
0.4
0.6
0.8
1
1.2
Tubing Leaks Rod Parts Pump Failures
FailureRate

21. Economic Savings
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Failure Type Rate Average Repair Cost Total Spend
Tubing Leaks 0.97 $89,000 $86,330
Parted Rods 0.74 $54,000 $39,960
Pump Change 0.19 $45,000 $8,550
$/Well/Year $134,840
Failure Type Rate Average Repair Cost Total Spend
Tubing Leaks 0.14 $89,000 $12,460
Parted Rods 0.40 $54,000 $21,600
Pump Change 0.14 $45,000 $6,300
$/Well/Year $40,360
Prior to LF115 Pilot With LF115
To date, no wells have been pulled due to failures in the LF115 lined tubing section.

22. 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
• Around 40+ wells now using Polyketone Thermoplastic Liner with
operators in Permian Basin, Delaware Basin, and Uintah Basin
• Longest runtimes have exceeded 500 days
• Numerous wells have extended MTBF by two or three times
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