Airborne推出的新型输油管线颠覆了传统油气管道概念，安装与维护都得到了显著优化。
编译 | 惊蛰
在当前低油价的严峻形势下，开发商面临着前所未有的海底作业成本控制压力。输油管线的采购成本与安装成本，以及硬质钢管卷筒昂贵、费时的计量与安装，促使开发商寻找成本更低的可缠绕柔性管线解决方案。
同时，还需要考虑降低运营成本，在低油价背景下获得更多的收益。管线的完整性管理，特别是腐蚀控制、监测、预防与修复，是影响管线运营成本的主要因素之一。
Airborne公司的热塑性复合管（TCP）管线是市场上唯一兼具柔韧性、易安装性、可长距离使用的产品。TCP具有独特的轻质、耐腐蚀性能。得益于上述优点，TCP管线成为海上输油作业的最佳选择，从而减少了成本与运营支出。
Airborne油气公司为马来西亚国家石油公司制造了全球第一条TCP油气管线，取代了现有的钢制管线。马来西亚国家石油公司之所以选择TCP管线来替换现有管线，是为了永久防止管道腐蚀。而且，与钢制管道相比，TCP管线的安装成本更低。
与传统的刚性管道相比，TCP管线的安装具有以下优点：1、可以使用低成本的作业船来安装TCP管线。不需要铺管船。TCP管线可以使用标准的海上支持船进行铺设，该船具有足够的甲板空间来容纳包括卷盘在内的安装设备。2、无需平整海床或校正管道自由跨度，柔性TCP管线能够贴合海床的轮廓。3、无需海底的管道端接部件(PLET)或卷筒。无需海底连接即可安装TCP管线。4、在单次作业中，可使用同一船舶完成管线与平台的连接。5、无需计量与潜水员即可完成安装。6、凭借该管线的柔韧性，可轻松与现有管道形成交叉。
目前来看，TCP管线可以避免腐蚀，是新油田与老油田中安装成本最低的解决方案。Airborne油气公司设计与制造了这款用于油气生产、气举、化学注入的TCP管线产品。它的耐腐蚀性、重量轻、可卷性与现场可切断能力，使其成为油田输油管线、回接、单井探边测试、(准)静态立管的最佳解决方案。
这种坚固的管道结构不易腐蚀，在腐蚀性环境中具有出色的性能。它拥有一个内部完全粘合的、光滑的聚合物衬里，可确保最佳的流动性，同时仍可执行清管作业。TCP的热性能显著优于钢管。凭借行之有效的机械夹紧方法，我们的端接配件简单且坚固。利用这种端接配件，无论是陆上还是海上，都可在管道的任何位置轻松组装管道。
TCP管线的可卷绕长度很长，从而实现经济高效的卷筒铺设作业与最低的安装成本。此外，由于不会发生腐蚀，降低了与腐蚀相关的成本，如泵送缓蚀剂、清管作业等。
TCP管线的设计与材料选择，都是基于每个项目的具体要求，确保为所有项目提供最优、经济效益高的解决方案。Airborne油气公司制造的TCP管线内径可达7.5寸，额定温度达到121摄氏度(250华氏度)，额定作业压力达到10000psi。
储存、运输与安装卷筒：该管线由存储、运输和/或安装卷筒提供，可与卷筒驱动系统一起部署。可以购买或租赁方式提供卷筒。
辅助设备与安装：海底管线饱受金属腐蚀或频繁更换的影响，造成的相关成本对新资产与现有资产的运营利润构成了严重威胁。
通过引入Airborne公司的非金属、完全粘合的TCP管线，腐蚀不再是问题。这大幅减少了运营支出。这种TCP管线还可制成可卷绕的长管，与钢制管道相比，显著降低了安装成本。
技术优点：
- 不会腐蚀，柔韧性强，可卷绕；
- 内外额定压差较高，光滑的内径，可进行清管作业；
- 简单、可靠且可现场安装的端接配件；
- 连续长度为3000至6000米，具体取决于直径与压力等级；
- 通过卷筒铺设或地面拖曳方法，实现快速安装；
- 最低的总安装成本与总运营成本。
该管线专为浅海与深水使用而设计，适用于暴露在海水、不含/含硫化氢油气混合物、油田化学品中的油田条件。为了满足压力与温度要求，TCP管线使用合适的材料进行了优化。这包括玻璃或碳纤维材料，以及PE、PA12与PVDF的聚合物。
In the current challenging climate of low oil prices, more than ever, the pressure is on operators to reduce the cost of subsea operations. Flowline procurement cost, installation cost and typically expensive and timeconsuming rigid steel spool metrology & installation, drive operators to identify cheaper spoolable flexible pipe solutions.?
At the same time, there is a need to reduce operational cost. One of the main contributors to operational cost for flowlines is pipeline integrity management and in particular corrosion management, monitoring, prevention and repair.?
Airborne’s Thermoplastic Composite Pipe (TCP) Flowline is the only product in the market that combines flexibility, ease of installation, and a product which is available in long lengths. TCP has unique low-weight and corrosion resistant properties. It is this combination that makes TCP Flowline the best option for offshore flowline applications, reducing both capital and operating expenditure.
Airborne Oil & Gas has manufactured the world’s first hydrocarbon transport TCP Flowline for Petronas to replace existing rigid steel flowline. Petronas has selected the TCP Flowline to permanently ban pipeline corrosion, the root cause for the replacement of the existing pipelines and to achieve a reduction of the asinstalled cost compared to rigid steel pipeline.
TCP Flowline Installation In comparison with conventional rigid pipe, installation of TCP Flowline has the following advantages:? ? Installation of the TCP Flowline can be carried out with low cost installation vessels. No pipelay barge is required. Instead? the TCP Flowline can be laid with a standard offshore support vessel with sufficient deck space for the deployment equipment including the reel ? No seabed preparation or free span corrections are required, the flexible TCP Flowline will follow the seabed profile ? No subsea pipeline termination (PLET) or spools are required. The TCP Flowline can be installed without subsea connections ? Platform tie-in can be completed with the same vessel in one operation? ? No metrology and no divers are required to complete the installation? ? Crossings with existing pipelines are simple thanks to the pipe flexibility
TCP Flowline eliminates corrosion and is the lowest total installed cost solution for greenfield and brownfield applications.
Airborne Oil & Gas designs and manufactures TCP Flowline products for hydrocarbon production, water, gas lift, and chemicals injection. Its non-corrosiveness, light weight, spoolability and ability to terminate in the field make it the best solution for in-field flowlines, tiebacks, single well step-outs, and (quasi) static risers.
The solid pipe structure is impervious to corrosion, resulting in outstanding performance in corrosive environments. It has an inner, fully bonded, smooth bore polymer liner that ensures the best attainable flow properties while still being piggable. The thermal performance of TCP is considerably better than that of steel (reinforced) pipe. Our end-fittings are simple and robust, relying on a well-proven mechanical clamping method. Assembly of the pipe with our end-fittings is straightforward, can be done both onshore and offshore and at any location on the pipe.
Our TCP Flowline is supplied in long spoolable lengths for cost-effective reel lay and lowest as-installed cost. This leads to a radical 30% saving on as-installed cost as shown in the TCP Flowline business case. In addition, the lack of corrosion reduces corrosion-related cost such as pumping of corrosion inhibitors, relating pigging, etc.
Our designs and selection of materials are adapted to the specific requirements of each project, ensuring a fit-for-purpose and highly cost-effective solution for each project. We manufacture TCP Flowline up to 7.5 inch ID, 121 degrees C (250 F) and 10 ksi working pressure.
Storage, Transportation and Installation Reels
Flowlines are supplied on storage, transportation and/or installation reels, allowing deployment with a reel drive system. The reels can be offered on a purchase or rental basis.
Ancillaries & deployment
Costs associated with the prevention of metallic corrosion or replacement of affected subsea flowlines are a serious threat to profitable operation of new and existing assets.
With the intro duction of our non-metallic, fully bonded TCP Flowline, corrosion is no longer an issue. This reduces the operational expenditure dramatically. Our TCP Flowline is manufactured in long, spoolable lengths, reducing installation cost significantly, even compared to carbon steel.
The TCP Flowline offers the following advantages:
- No corrosion
- Flexible and spoolable
- High internal and external pressure ratings
- Smooth bore – fully piggable
- Simple, reliable and field-mountable end fittings
- Low U-value compared with steel pipe
- Continuous lengths of 3,000 to 6,000 metres depending on diameter and pressure rating
- Quick installation by reel lay or surface tow method
- Lowest total installed cost and total cost of ownership
The flowline is developed for offshore use in shallow and deep waters and is designed for oil field conditions with exposure to seawater, sweet and sour hydrocarbon mixtures and oil field chemicals.
To meet pressure and temperature requirements, the TCP Flowline is optimised by using the right materials for the job. This includes glass or carbon fibre reinforcements, and polymers including PE, PA12 and PVDF.
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