Oil Fracturing Hose and Frac Pipes Introduction from Direct Manufacturer
1. Introduction of oil Industry and why do we need fracturing technology
With the continuous development of drilling technology, especially the development of shale gas and shale oil extraction technology, it is necessary to give a certain pressure on the shale formation after well drilling and completion, opening up the flow channel of oil and gas and maintaining it. It is now common to use acidification or chlorination or other suitable mixtures to apply pressure to crack the rock, establish channels and convey different sizes of silicide or other proppant to maintain the continuous flow of the channel is carried out by a combination of high-pressure fracturing trucks. This operation is a continuous work.
In the past, hard pipe is used as a conveyance tool. The hard pipe has the advantages of high pressure, low cost and good stability. At the same time, due to the impact of the terrain environment, it is not suitable for installation. Its advantages have not high wear resistance, corrosion resistance, shock absorption performances, more fittings, high safety risks, etc. The hose assembly is mainly used for conveying acidified fracturing fluid or other mixed fracturing fluid with different raw material ratios and proppants in the fracturing process after well drilling and completion to establish a flow channel for crude oil or natural gas. Once this process is started until completion, it will not stop during operation. It can also be used for other occasions requiring ultra-high pressure, ultra-wear resistance and corrosion resistance, for conveying medium or transferring power.
The hose has the advantages of high pressure, good flexibility, good stability, free from the impact of terrain environment, easy installation, high wear resistance, high corrosion resistance, high shock absorption, less fittings, no hidden dangers and so on. The hose body can be added with electric heat tracing function according to the site situation. The fracturing cement hoses are suitable for conveying mixtures of various fracturing fluids and proppants with high pressure and high velocity during fracturing of oil and gas drilling and completion formations, and they can also be used for other occasions requiring ultra high pressure, ultra wear resistance and corrosion resistance, for conveying medium or transferring power.
1.1 Importance of the oil industry
( 1 ) Energy demand: Oil is the main source of global energy consumption because it can be effectively converted into heat and power to provide energy for transportation, industrial production, heating and power generation.
( 2 ) Economic pillar: For many countries, the oil industry is an important part of their national economy. It provides huge government revenue, employment opportunities, and promotes international trade through exports.
( 3 ) Raw material supply： Petroleum is the basic raw material of many chemical products, including plastics, pharmaceuticals, fertilizers, paints and cosmetics. Without oil, the production of these products will be seriously affected.
( 4 ) Combination of technology and innovation: The investment in technology development in the oil industry has greatly promoted innovation in the field of science and engineering, and these innovative technologies can often be adopted by other industries.
1.1.2 Why the oil industry needs to develop fracturing technology:
(1) Improve resource extraction efficiency: As easy-to-exploit oil fields are gradually depleted, the oil industry needs more efficient technologies to extract hard-to-reach oil and gas resources, such as shale oil and shale gas.
(2) Increase production: The use of hydraulic fracturing technology can greatly increase the production of oil and gas reservoirs that cannot be developed through traditional methods, which is crucial to meeting the growing global energy demand.
(3) Economic feasibility: In many cases, the geological conditions of untapped oil and gas resources are complex, and traditional drilling and extraction methods are uneconomical or even impossible to implement. Fracking technology makes the development of these resources economically viable.
(4) Energy security: Hydraulic fracturing technology supports the growth of domestic oil and gas production and reduces dependence on foreign oil and natural gas, thus improving the energy security of some countries.
(5) Utilization of non-traditional oil and gas fields: The successful application of fracturing technology has made it possible to use non-traditional oil and gas fields that originally had no commercial production value, greatly expanding the geographical and resource scope of the petroleum industry.
For these reasons, hydraulic fracturing technology has become extremely important in the petroleum industry. However, compared with the economic benefits it brings, fracking also faces environmental and social challenges, such as groundwater contamination, earthquake risks, and impacts on local communities and ecosystems, which require the industry to adopt better environmental management and risk mitigation measures. With the development of related technologies and the implementation of environmental regulations, the oil industry is seeking more environmentally friendly and sustainable fracturing technologies.
1.2 The development and application of hydraulic fracturing technology
Hydraulic fracturing, commonly referred to as ' fracturing ', is a technique used to increase oil and gas production after the completion of oil and gas well drilling. This technology is particularly important for the development of unconventional reservoirs such as shale oil, shale gas, coalbed methane and tight sandstone gas. The following is a summary of the development and application of hydraulic fracturing technology:
1.2.1 Development history :
Hydraulic fracturing technology began in the late 1940s. It was initially applied in traditional reservoirs and later developed rapidly with the increasing demand for unconventional oil and gas resources development. The combination of horizontal drilling technology and hydraulic fracturing, especially after 2000, has greatly promoted the shale gas revolution.
1.2.2 Technical principle :
The basic principle of fracturing is to use a high-pressure pump to inject the fracturing fluid ( mainly a mixture of water, sand or other proppants and chemical additives ) into the well. This high pressure will cause the reservoir rock to break, resulting in a fracture network, increasing the path of oil and gas flowing out of the rock pores.
1.2.3 Key technical components :
A. Fracturing fluid: usually contains 90-95 % water, 4.5-9.5 % sand and 0.5-2 % chemical additives.
B. Proppant: Quartz sand is usually used as a proppant, which is used to keep the fracture open and ensure the flow of oil and gas.
C. Chemical additives: used to improve the performance of fracturing fluid, including reducing friction, preventing corrosion, inhibiting the growth of bacteria, etc.
D. High-pressure pump: used to transport fracturing fluid into the well.
1.2.4 Application areas:
- Shale oil and shale gas extraction.
- Coal bed methane mining.
- Compact sandstone gas extraction.
- Production enhancement from traditional oil and gas reservoirs.
1.2.5 Challenges and Controversies:
The main challenges facing hydraulic fracturing are concerns about environmental and health risks. Concerns among environmental groups include groundwater contamination, depletion of surface water resources, increased seismic activity and potential harm to the environment from chemical releases.
1.2.6 Future direction:
- Reduce environmental impact: Develop more environmentally friendly fracturing fluid formulations that reduce water consumption and the use of chemical additives.
- Improve efficiency: Use data analytics and geophysical techniques to improve the accuracy of fracturing design and construction.
- Monitoring and management: achieve better fracture monitoring and well pressure management to ensure the safety and effectiveness of fracturing operations.
- Recycling and reusing water resources: Recycling water during fracturing operations reduces dependence on freshwater resources and environmental impact.
Hydraulic fracturing technology must balance economic benefits and environmental responsibility, which requires continuous innovation by the industry and reasonable regulatory strategies by the government.
1.3- The key role of fracking pipes in hydraulic fracturing
In hydraulic fracturing operations, frac tubes (also known as frac strings or frac strings) play a vital role. It is a specially-made pipe used to transport high-pressure fracturing fluid from the surface to the target rock formation underground. Its key functions can be summarized as follows:
(1) Transporting fracturing fluid: The fracturing pipe is the channel through which fracturing fluid (containing water, proppant and additives) is transported to the underground fracture system. The pressure flowing in the pipe is extremely high, reaching thousands or even tens of thousands of pounds per square inch (psi).
(2) Withstand high pressure: Traditional pipes may rupture or fail under such high pressures, while fracturing pipes are designed to have enough strength and toughness to safely withstand these pressures without breaking.
(3) Precise control: Fracturing operations require extremely precise pressure application to target rock formations. Fracturing tubes allow operators to precisely control the flow rate and pressure of liquid to carry out fracturing operations in an optimal manner.
(4) Corrosion resistance and wear resistance: The chemical additives and sand in the fracturing fluid have strong corrosion and wear effects on the pipe. The designed fracturing pipe should have good corrosion resistance and wear resistance to extend its service life. and reduce maintenance costs.
(5) Allowing staged fracturing: With the application of horizontal drilling technology, a single well requires multiple fracturing stages. Dedicated fracturing tubes allow each stage to be completed in a designed sequence, with each stage of fracturing independently controlled.
(6) Provide back pressure support: The fracturing pipe also needs to provide sufficient back pressure (counter pressure) to maintain the integrity of the wellbore during the fracturing process and avoid well wall collapse.
(7) Start and stop fracturing: The design of the fracturing pipe also enables the operator to start or stop the fracturing process as needed, especially in the event of geological anomalies or equipment failure, which can immediately interrupt the operation.
To sum up, fracturing pipes must not only ensure safety and reliability under extreme conditions but also help improve the efficiency and output of hydraulic fracturing. Therefore, it plays an irreplaceable key role in hydraulic fracturing.
2. The basic definition of fracturing pipes
2.1- Definition of frac pipes
Fracturing pipes are specialized pipelines used in hydraulic fracturing operations in the oil and gas extraction industry. It is designed to safely and effectively transport water, sand and other chemical additives to target rock formations underground for fracturing operations in a high-pressure environment. Its purpose is to release the oil and gas stored in rock gaps for easy collection.
The design of fracturing pipes needs to meet the following requirements:
(1) High-pressure tolerance: Need to be able to withstand extremely high internal pressures, typically thousands to tens of thousands of pounds per square inch (psi), to withstand the pressures used in the fracturing process.
(2) Corrosion and wear protection: Since the transported liquid may contain corrosive chemicals and high-hardness sand, excellent corrosion protection and wear resistance are required.
(3) Size and strength: It should have the ability to adapt to different well depths and wellbore sizes, as well as sufficient material strength to cope with underground operating conditions.
Due to the importance of fracturing pipes in hydraulic fracturing operations, their quality and performance directly affect the efficiency and safety of hydraulic fracturing. High-quality frac pipe can reduce surprises and unplanned downtime on the job, saving costs and increasing productivity.
2.2- Main types and materials of fracking pipes
Frack tube type and material selection are primarily based on the specific requirements of the hydraulic fracturing operation they are to be performed with, including factors such as the depth of the well, the type of fracturing fluid, the corrosive nature of the subsurface environment, and budget. Here are some common frac tube types and materials:
(1) Composite material hoses: This type of pipe is usually made of a combination of materials, such as plastic or rubber reinforced by high-strength fibers (such as carbon fiber, aramid fiber). These pipes tend to be lighter than traditional steel pipes and have good corrosion resistance.
(2) Steel pipe: This is the most commonly used fracturing pipe material, especially seamless steel pipes, because they provide high strength and good pressure resistance. Steel pipes can also be added with various alloy elements (such as chromium, nickel, molybdenum, etc.) to improve their corrosion resistance and wear resistance.
(3) Alloy pipe: In some particularly challenging environments, to better resist corrosion and wear, different types of alloy materials can be used to manufacture fracturing pipes, such as stainless steel, nickel-based alloys, duplex steel, etc.
(4) Coated pipe: To increase the corrosion resistance of traditional steel pipes, coatings can be added to its internal and external surfaces. These coatings may be plastics, special rubbers or epoxy-based composites.
(5) Grouting line pipe: This is a grouting line used for hydraulic fracturing. It has some improvements to adapt to the transmission needs of high-pressure and chemical substances.
To meet the needs of a specific operation, the fracturing pipe may also be customized to certain specifications, including length, diameter, wall thickness, pressure rating and other performance characteristics. When selecting fracturing pipes, the economic benefits and environmental safety factors of the operation should also be taken into consideration to ensure that the operation can be completed safely and efficiently even under challenging underground conditions.
2.3- The role of fracking pipes in hydraulic fracturing
In the process of hydraulic fracturing (Hydraulic Fracturing), the fracturing pipe is one of the important equipment. Fracturing pipe is a high-pressure resistant pipe fitting that is usually used to transport liquid (fracturing fluid). Specifically in hydraulic fracturing, the functions of fracturing pipes include:
(1) Delivery of fracturing fluid: Fracturing fluid is a mixture of water, sand and some chemical additives. It needs to be injected into underground oil and gas formations under extremely high pressure. Frack pipes are used to transport this fluid.
(2) Withstand high pressure: Fracturing fluid needs to be injected into the formation at a high enough pressure to cause cracks in the rock. Therefore, the fracturing pipe must be able to withstand this high pressure to prevent the pipeline from rupture and ensure the safety and efficiency of the operation.
(3) Ensure smooth operation: During the fracturing process, the fracturing pipe needs to be able to smoothly transport the fracturing fluid to the predetermined formation location, which requires the fracturing pipe to have good flexibility and reliability to adapt to the underground environment. complex conditions.
(4) Return oil and gas: When fracturing fluid is injected to form a crack, crude oil or natural gas will be released from the rock cracks and return to the ground with part of the returned fracturing fluid. The fracturing pipe is also a channel for transporting return oil and gas.
Because fracturing pipes play a key role in the smooth progress of the entire hydraulic fracturing process, optimal design such as selecting appropriate pipe materials and diameters and designing the strength and durability of the fracturing pipes are important when implementing hydraulic fracturing projects. aspect. At the same time, to avoid groundwater contamination and environmental damage, the integrity and sealing of the fracturing pipe must also be ensured.
3. Design and manufacturing of fracturing pipes
3.1- Several commonly used fracturing pipe designs
The design of fracturing pipes must take into account pressure tolerance, corrosion resistance, wear resistance, and the ability to adapt to different use environments. The following are several frac pipe designs and features commonly used in the hydraulic fracturing field:
(1) Temporary fracturing pipe: Fracturing pipes of this design are usually used once or discarded after a few fracturing operations. By design, they are typically lightweight and relatively inexpensive, yet still able to withstand the high pressures required in fracking operations.
(2) Multiple-use fracking tubes: This type of design is more robust and designed to be reused multiple times, which requires higher-quality materials and manufacturing processes. Such pipes cost more, but they provide better value for money over long-term fracturing operations.
(3) Spiral wound pipeline: This design uses metal strips or wires to be spirally wound into pipes and connected through special joints. This design improves the flexibility of the fracturing pipe and is more suitable for situations where the pipeline needs to be moved for multi-point fracturing operations.
(4) Coated or lined pipelines: This design covers the inside of the pipeline with a corrosion-resistant or abrasion-resistant material, such as epoxy, plastic, or rubber, thereby providing an additional layer of protection against damage caused by corrosion or abrasion.
(5) Carbide pipe: This type of design uses pipelines composed of high-strength alloys that can resist wear, impact and pressure under extreme conditions.
(6) Composite material pipeline: This is a more advanced design, usually using composite materials composed of carbon fiber, aramid fiber or other high-performance fibers. These materials are characterized by being lightweight and resistant to high pressures while offering good chemical resistance.
In actual applications, technicians will select or customize the most suitable fracturing pipe design based on factors such as geological conditions, well depth, chemical properties of fracturing fluid, scale and budget of fracturing operations. These various designs are required to meet the stringent standards and specifications of the oil and gas industry to ensure operational safety and environmental protection.
3.2- Overview of the manufacturing process of fracked tubes
Ultra-abrasion-resistant acid frac hose (commonly referred to as acid-resistant frac hose) is specifically designed to transport high-pressure fluids in acid treatment and fracturing operations, especially in applications containing corrosive chemicals. To resist corrosion and high levels of wear in acidic environments, the hose uses a range of high-performance materials and advanced manufacturing techniques. The following is an outline of the basic manufacturing process for ultra-wear-resistant acidified frac hose:
(1) Raw material selection: First, you must select suitable materials, which include corrosion-resistant alloy pipe materials, such as stainless steel, and high-quality elastomer materials and reinforced materials, such as special chemical-resistant plastics, rubber or special synthetics. material, and possibly reinforcing fibers such as carbon fiber or aramid fiber.
(2) Lining production: To provide sufficient corrosion resistance, the inside of the pipe will be covered with a chemical-resistant rubber or plastic lining, which also helps reduce the friction of the internal fluid and provide higher flow.
(3) Addition of reinforcement layers: It is crucial to strengthen the structure of the hose, which is usually achieved by adding multiple layers of reinforcement materials outside the lining. These reinforcements can be wound from high-strength textile fibers or steel wires and can be spiral or braided to improve the pipe's stability and durability in high-pressure environments.
(4) Outer covering layer: Outside the reinforcement layer, an outer covering layer will be added. This layer is made of wear-resistant and weather-resistant materials to protect the pipeline from mechanical damage and the influence of the external environment.
(5) Curing: These layers are cured by heating to ensure a strong bond between different layers and to give the hose the final required physical properties.
(6) Testing and quality control: After the hose is manufactured, strict quality testing will be conducted, including burst testing, pressure testing and chemical compatibility testing, to ensure that the hose meets all performance requirements and safety standards.
(7) Accessory installation: Finally, both ends of the fracturing hose will be equipped with suitable connectors. These connectors are usually made of metal and may undergo additional processing to enhance their corrosion resistance.
Every step in the production process must comply with specific industry standards and specifications to ensure that the frac hose can work safely and stably in high-pressure environments containing corrosive chemicals.
3.3- Quality Standards and Certification of Frac Pipes
Quality standards and certifications for fracking pipes are critical to ensuring safety, efficiency, and durability. Globally, there are many organizations within the oil and gas industry that have developed specialized standards and certification procedures. These include, but are not limited to, the following:
(1) API (American Petroleum Institute): API provides many key standards for the oil and gas industry, among which API Spec 5CRA, API Spec 5L and API Spec 7-1 respectively involve corrosion-resistant alloy pipes, oil and gas pipelines and drilling equipment. API certification is widely considered the benchmark for equipment quality in the oil and gas industry.
(2) ISO (International Organization for Standardization): ISO 9001 is a widely recognized quality management system that requires fracturing pipe manufacturers to establish a comprehensive quality management program, including every aspect from design, manufacturing to delivery. ISO 14001 is a standard for environmental management that ensures the environmental friendliness of the production process. ISO 13628-10 covers downhole equipment and tools for use in offshore oil and gas fields.
(3) NACE (National Association of Corrosion Engineers): NACE has issued many standards related to anti-corrosion. If the pipeline is used in a corrosive environment, such as an environment containing CO2 and H2S, then the standards related to NACE (such as NACE MR0175/ISO 15156) is very important.
(4) DNV GL: DNV GL, jointly formed by Det Norske Veritas and Germanischer Lloyd, provides certification services and provides a series of guidelines and standards involving offshore and onshore pipelines.
Fracturing pipes usually need to be certified by these agencies before being put into fracking operations in oil and gas fields. During the review and certification process, the following aspects are examined:
- Chemical composition and mechanical properties of the material.
- Resistance to corrosion, especially in environments containing acidic, alkaline or saline solutions.
- Pressure testing to ensure no rupture or leakage occurs under specified operating conditions.
- The accuracy of the dimensions and the quality of the manufacturing process.
- Wear resistance testing, especially for pipes used to transport particles or chemicals that are highly abrasive.
- Additional inspection of welds and joints, which are often high-risk areas for failure.
Compliance with these standards and certifications is not only a regulatory requirement but is also extremely important to protecting the safety of workers, the environment, and assets.
4. Installation and maintenance of fracturing pipes
4.1- Key steps in fracturing pipe installation
Installing fracturing pipes is a key link in oil and gas fracturing operations, requiring precise and careful operations to ensure the safety and efficiency of the operation. Here are some key steps in the frac pipe installation process:
(1) Design and planning:
- Design pipeline layout according to the specific environment and operating needs of oil and gas fields.
- Determine required frac tube size, length and strength.
- Perform stress analysis to ensure piping design can withstand expected pressures and loads.
(2) On-site preparation:
- Clean the job site to ensure the installation area is flat and free of obstacles.
- Carry out required land grading work and lay temporary roads to facilitate transportation of equipment and materials.
- Ensure all necessary safety measures and emergency plans are in place.
(3) Material transportation and inspection:
- Safely transport frac pipe and related accessories to the job site.
- Inspect the received materials to ensure there is no damage caused in transit.
(4) Pipe assembly:
- Connect the pipes in the correct order and direction according to the design plan.
- Use specialized tools to connect pipes and fittings, such as crimping, threading or welding.
- To ensure the integrity of the connection, all welding points should be operated by qualified welders and subjected to non-destructive testing.
(5) Test:
- Before the pipe is put into service, perform a hydrostatic test or air test to check for leaks.
- Pressure test the installed piping system to ensure it can withstand the intended operating pressure.
- Additional testing such as leak detection, unit operation, etc. may be required to verify the overall performance of the system.
(6) Fracturing pipe fixation and stability:
- Use suitable brackets and clamps to secure the frac tube to prevent vibration or movement during the fracking process.
- Make sure the pipe has a sufficient bending radius and will not be damaged by excessive force.
(7) Cleaning and rinsing:
- Thoroughly clean and flush pipes before they are put into service to remove any dirt or residue that may affect performance.
(8) Final inspection and documentation:
- Conduct final inspections upon completion to ensure everything meets design specifications and safety standards.
- Prepare completion reports and piping logs to record all relevant installation details such as piping locations, joint types, test results, etc. for future maintenance and repairs.
(9) Safety training:
- Ensure that all operating personnel have received appropriate training and understand safety measures and emergency response procedures for operating fracking pipes.
(10) Protection measures and anti-corrosion treatment:
- Carry out necessary protective measures for fracturing pipes, such as external coatings, anti-corrosion treatments, etc., to extend their service life.
Every step must strictly adhere to industry best practices, safety regulations and environmental protection requirements to ensure that the entire installation process is both safe and effective. Throughout the process, quality assurance and quality control are crucial, and all steps and results should be recorded in detail to facilitate traceability and future inspection.
4.2- Maintenance and inspection points of fracturing pipes
Fracturing pipes are a critical component of oil and gas fracturing operations, and proper maintenance and inspection are critical to ensuring operational efficiency and avoiding potential environmental and safety issues. Here are some key points for frac pipe maintenance and inspection:
(1) Regular inspection:
- Conduct regular inspections according to the established maintenance plan, including visual inspection and non-destructive testing using professional tools (such as ultrasonic, magnetic particle, radiography, etc.).
(2) Cleaning:
- Keep the inside and outside of the frac tube clean to avoid sediment, dirt and other foreign matter that may cause corrosion or blockage.
(3) Monitor corrosion:
- Regularly monitor the corrosion status of pipelines. If high corrosion rates are detected in a specific area, the frequency of inspections and protective measures in that area should be increased.
(4) Stress test:
- Perform regular pressure tests to ensure that the piping system can safely withstand operating pressures.
(5) Pipe wall thickness measurement:
- Regularly measure pipe wall thickness to assess pipe wear and predict its remaining life cycle.
(6) Inspection of joints and connecting parts:
- Pay special attention to welded joints, threaded connections and other sealing areas as these are potential weaknesses.
(7) Deformation and damage inspection:
- Look for any signs of surface damage, cracks, dents or bends, which may indicate excessive stress or damage.
(8) Environmental factors:
- Consideration should be given to the impact of environmental factors on pipelines, such as vibration, temperature changes and chemical exposure, which may affect the integrity of the pipeline.
(9) Records and reports:
- All inspection and maintenance activities must be recorded in detail and reported. This is important both for tracking the historical condition of the pipeline and for planning future maintenance work.
(10) Maintenance equipment and safety tools:
- Ensure that all equipment and tools used for frac pipe maintenance and inspection are properly maintained and calibrated to ensure the accuracy of test results.
(11) Emergency plan:
- Prepare and update an emergency response plan for a frac pipe leak or rupture, and conduct regular training exercises to ensure all personnel are aware of the operating procedures in an emergency.
(12) System upgrade:
- Evaluate whether certain parts of the fracking system need to be replaced or upgraded based on test results and the latest technical standards.
(13) Valve and control system inspection:
- Regularly inspect valves, control systems and associated operating equipment to ensure they can correctly regulate flow and pressure when required.
(14) Leak detection:
- Use leak detection systems to monitor possible leaks and regularly verify the performance and accuracy of leak detection equipment.
(15) Training and qualifications:
- Ensure that personnel performing maintenance and inspections are appropriately trained, qualified and certified.
(16) Follow manufacturer’s recommendations:
- Follow the frac pipe and component manufacturer's recommended guidelines for maintenance and inspection.
Through these maintenance and inspection steps, problems with fracturing pipes can be discovered and solved in time to avoid accidents and failures. In addition, these measures can improve the efficiency and reliability of oil and gas fracturing operations. Throughout the process, relevant industry standards and safety regulations must be adhered to.
4.3- Common problems and solutions during the use of fracturing pipes
When using fracturing pipes in oil and gas fracturing operations, you may encounter a series of problems. Here are some common problems and corresponding solutions:
(1) Corrosion:
- Problem: Fracturing pipes may suffer from corrosion due to the fact that the transported fluid may contain corrosive substances.
- Solution: Use corrosion-resistant materials or coatings, such as stainless steel, special alloys, special rubber, and corrosion inhibitors.
(2) Wear:
- Problem: High-speed flowing particles (such as sand) can cause mechanical wear on the inner wall of the pipe.
- Solution: Use hard materials, such as wear-resistant alloys, or install wear-resistant liners in wear-prone areas of the pipe.
(3) Cracks and breaks:
- Problem: Frac pipes can crack or break due to high pressure or stress concentrations.
- Solution: Ensure that frac pipes meet pressure requirements during design and production, perform regular inspections to detect fatigue cracks, and replace damaged parts.
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(4) Connection leakage:
- Problem: The connection may be leaking due to a poor seal or a loose connection.
- Solution: Check and tighten the connections regularly, and replace seals and other connection components if necessary.
(5) Blockage:
- Problem: Particles, chemical deposits or scale can cause blockage in frac tubes.
- Solution: Implement cleaning and flushing programs, use chemical or mechanical methods to remove blockages, and improve fluid formulations to reduce deposits.
(6) Temperature changes:
- Problem: High temperatures underground or fluctuations in ambient temperature may affect the properties and performance of pipe materials.
- Solution: Choose suitable materials and designs to resist extreme temperature changes and implement temperature monitoring.
(7) Vibration and shock:
- Problem: Vibrations and shocks generated during equipment operation may cause damage to the fracturing tubes.
- Solution: Optimize equipment layout and operation, mitigate vibration, and use shock-absorbing brackets and bushings.
(8) Pressure exceeds limit:
- Problem: During the fracturing operation, the pressure may exceed the pipeline design pressure.
- Solution: Use pressure control equipment such as safety valves, burst disks, and strict compliance with operating parameters to prevent pressures from exceeding safe limits.
The above solutions need to be selected and adjusted according to specific construction conditions and site conditions. Safety, economics and ease of operation should be factors considered in decision-making. At the same time, all maintenance and repair work requires appropriate safety measures to ensure the safety of workers.
5. Development trend of fracturing pipe technology
5.1- Research and application of new fracturing pipe materials
The research and application of new fracturing pipe materials aims to improve the performance of pipes under extreme conditions, extend their service life and improve overall economic benefits. The following is an overview of several research and application areas:
(1) Composite materials:
- These materials typically combine high-strength fibers (such as carbon fiber or glass fiber) with a resin matrix to provide superior strength and corrosion resistance while maintaining light weight. Composite fracking pipes have potential advantages for improving operating efficiency and reducing transportation costs.
(2) High corrosion resistance alloy:
- Materials such as super duplex stainless steel and nickel-based alloys are developed for use in more severe environments, such as fluids containing acids or high sulfides.
(3) Functional coating:
- Such as coatings containing carbon nanotubes, graphene or other nanomaterials that provide excellent resistance to wear and corrosion without unduly increasing the weight of the pipe.
(4) Intelligent pipes:
- Pipes equipped with sensors can monitor their status, such as temperature, pressure, corrosion level, etc., in real time to provide preventive reminders of maintenance and potential failures.
(5) Shape memory alloy:
- This material can return to its original shape under certain temperature or pressure conditions, helping to reduce deformation of the fracturing tube due to improper operation.
(6) Self-healing materials:
- Researchers are developing materials containing microcapsules or specific polymers that can release "healing agents" to seal cracks when they occur.
(7) Temperature-resistant and pressure-resistant materials:
- As the depth of oil and gas wells continues to increase, higher requirements are placed on the temperature and pressure resistance of fracturing pipe materials. The development of new high-temperature and high-pressure resistant materials has become a research hotspot.
In the research and application of new materials, remaining challenges include cost-benefit analysis, industrial production capabilities, environmental impact assessment, and compliance with industry safety and performance standards. As technology advances, these materials may be widely used in various fracturing operations for oil and gas production in the future.
5.2- Intelligent fracturing pipe system and monitoring technology
Intelligent fracturing pipe systems and monitoring technology are a continuously developing direction in the oil and gas industry, mainly to improve resource recovery efficiency, reduce operational risks, optimize production management, and reduce environmental impact. These technologies usually include the following aspects:
(1) Real-time data collection:
- Intelligent fracturing pipe systems can embed sensors to monitor key parameters such as pressure, flow rate, and temperature in the pipe in real time, allowing operators to obtain key data in a timely manner and perform necessary adjustments and controls.
(2) Predictive maintenance and fault detection:
- By analyzing data collected from fracked pipe systems, machine learning and other algorithms can be used to predict potential failures or maintenance needs, which can help reduce downtime, reduce repair costs, and prevent possible large-scale environmental pollute.
(3) Automation control system:
- Automation technology enables precise control of hydraulic and chemical injection during the fracturing process, optimizing resource recovery and reducing the need for workers to work in high-risk environments.
(4) Visualization and user interface:
- Modern monitoring technology provides advanced data visualization tools and user-friendly interfaces, allowing operators to easily monitor the entire fracturing operation process and make timely decisions.
(5) Integrated system:
- All data and control systems on site can be integrated into a central processing center to achieve information sharing and coordination between operations.
(6) Communication technology:
- High-speed communication technologies, such as 5G networks, make remote real-time data transmission possible, even in remote or extreme conditions in oil fields.
(7) Safety and Regulatory Compliance:
- Intelligent systems ensure continuous monitoring to ensure operations comply with all relevant health, safety and environmental regulations.
With the rapid advancement of technology, it is expected that intelligent fracturing pipe systems and monitoring technologies will increasingly adopt Internet of Things (IoT) devices, artificial intelligence (AI) analysis tools, and automated operating systems in the future. The purpose is to achieve a safer, environmentally friendly and economical way to extract oil and gas.
5.3- The need and significance of environmentally friendly petroleum fracturing pipes
Environmentally friendly oil fracturing pipes refer to pipe products with special consideration of environmental factors in design and material selection. They can reduce environmental impact while providing the performance required for oil and gas well fracturing operations. The demand and significance of this type of product mainly lies in the following aspects:
(1) Reduce environmental pollution:
- The use of environmentally friendly materials can significantly reduce the risk of contamination during operations. For example, the use of pipes that are less likely to release harmful substances can prevent ground and groundwater contamination.
(2) Reduce waste and recycling efficiency:
- Environmentally friendly fracking pipes can generally be recycled and reused more easily, reducing waste generated by oilfield operations and complying with waste reduction principles.
(3) Comply with strict environmental regulations:
- Many countries and regions have enacted increasingly stringent laws and regulations to protect the environment. Fracturing pipes using environmentally friendly materials can make it easier to comply with these environmental regulations.
(4) Social responsibility and company image:
- As public awareness of environmental protection increases, the use of environmentally friendly products by oil and gas companies can enhance their socially responsible image and have a positive impact on public relations and brand value.
(5) Long-term cost savings:
- While the initial investment for environmentally friendly fracking may be higher, it may result in cost savings in the long term by reducing potential fines, cleaning fees and maintenance expenses from environmental contamination.
(6) Sustainability:
- The use of environmentally friendly fracturing pipes is a step towards a sustainable oil and gas extraction industry. It helps balance the relationship between the effective use of resources and environmental protection and is in line with global sustainable development goals.
To meet these needs, environmentally friendly fracking pipes may employ the following strategies:
- Choose materials with low environmental impact, such as recyclable or biodegradable synthetic materials.
- Improve the manufacturing process and reduce energy consumption and carbon emissions during the manufacturing process.
- Improved pipe durability and reliability, resulting in less frequent maintenance and replacement, lowering long-term environmental costs.
- Adopt advanced design to achieve more efficient installation and use of pipelines and reduce environmental interference during operation.
In short, the development and application of environmentally friendly petroleum fracturing pipes is a positive response to the environmental performance and social responsibility requirements of the oil and gas industry. It has broad market demand and far-reaching social significance.
6. Fracturing pipe market and industry analysis
6.1- Fracturing Pipe Market Size and Forecast
Market size: The hydraulic fracturing market will exceed USD 62 billion by the end of 2035 and expand at a CAGR of 7% during the forecast period from 2023 to 2035. The global market size of hydraulic fracturing in 2022 will be approximately US$35 billion. The rise in crude oil costs can be attributed to the expansion of the market. Globally, crude oil prices have risen above $80 per barrel. As oil and gas prices rise, companies can invest more in unconventional resource extraction techniques such as fracking. Apart from this, the expansion of refineries will also help in the expansion of the hydraulic fracturing market. There are currently 825 active refineries globally, and this capacity is expected to increase by approximately 15% between 2023 and 2027.
Hydraulic Fracturing Market: Key Insights
Hydraulic Fracturing Market: Growth Drivers and Challenges
• Rising oil and gas investment: from 2015 to 2023, the global investment in oil and gas exploration and extraction reached an all-time high of usd 528 billion. By increasing investment, oil and gas companies can expand their fracturing operations to reach new deposits and increase production.
• Increasing Global Energy Demand - According to The International Energy Agency (IEA), the demand for oil will reach a new high of 102.1 million barrels per day (bpd) in 2023. More oil and gas production is required to meet rising demand as the world's energy demand rises.
• Growing Per Capita Income - As per capita income rises, so does the standard of living. This frequently resulted in an increase in the need for water, electricity, and transportation, which in turn raised the demand for energy.
Challenges
• Environmental Concerns Associated with Hydraulic Fracturing - The fracturing caused various harms to the environment such contamination of water, emission of methane, and even put pressure on the land and induce seismicity. All these concerns are imposing huge challenges to market growth.
• Geographical Hindrance to The Procedure
• Substantially High Usage of Water
Hydraulic Fracturing Segmentation
Well Sites (Onshore, Offshore)
In the upcoming years, it is anticipated that the onshore segment will control 60% of the global hydraulic fracturing market. The increase in new discoveries in the onshore wells is to blame for the segment's expansion. To continue exploring in the onshore wells, Norway obtained new 54 licenses. Lndia and Egypt then obtained 29 and 11. In order to increase oil production, hydraulic fracturing is used in onshore wells for both natural gas extraction and microbially enhanced oil recovery.
Fluid Type (Sick Water-Based, Foam-Based, Gel-Based)
During the anticipated period, the foam-based segment of the hydraulic fracturing market is expected to grow by a sizeable share of about 46%. Of all the fluid types used in the process, foam is thought to be the most suitable. The need to take a sustainable approach is blamed for the segment's expansion. Foam-based areas are the most practical due to a severe water shortage. Additionally, they are appropriate for formation in water-sensitive environments.
Hydraulic Fracturing Industry- Regional Synopsis
North American Market Forecast
By the end of 2035, North America's hydraulic fracturing market is expected to be the largest, with a 35% market share. The region's expanding reserves are a major factor in the market growth. The nation's current reserves total 8.2 billion metric tons. 3.7 billion tonnes, an increase from the decade's beginning. In addition. Market expansion in the area is also anticipated to be fueled by the expansion of advanced machinery oil extraction.
APAC Market Statistics
In the near future, it is anticipated that the hydraulic fracturing market in the Asia Pacific will register a share of about 28%. The expanding trade in oil and gas from the area is a major factor in the market's expansion. Due to improved transportation, China is expected to import the most crude oil by the end of 2023. following the COVID-19 restriction's relaxation. The demand for liquid fuels would increase by roughly 50% and 30%, respectively, for petroleum and jet fuel.
6.2- Challenges and opportunities in the fractured pipe industry
The fracked pipe industry is closely related to the challenges and opportunities of the entire oil and gas industry. Here are some key points:
Challenge:
(1) Environmental regulations:
- Fracking technology, especially hydraulic fracturing, faces increasingly stringent environmental regulations because it can affect water resources, cause earthquakes, and increase greenhouse gas emissions. These regulations may restrict fracking activities and thereby limit the market for fracked pipe products.
(2) Market fluctuations:
- Volatility in the oil and gas markets, particularly oil prices, can rapidly change the economics of fracturing activities and, in turn, impact demand in the frac pipe industry.
(3) Technical challenges:
- Fracturing pipes are subjected to extremely high pressures and corrosive fluids during operations, requiring continuous technological innovation to ensure safety and reliability.
(4) Capital investment:
- The manufacturing and use of fracked pipes requires high upfront capital investments, and market uncertainty makes such investments risky.
(5) Alternative energy competition:
- The rapid development of renewable and other alternative energy sources may reduce reliance on oil and gas, thereby affecting fracking activity and frac pipe demand.
Opportunity:
(1) Non-traditional resource development:
- With the exploration and development of unconventional oil and gas resources (such as shale gas, tight oil, etc.), fracturing activities are expected to increase, bringing demand for fracturing pipes.
(2) Global energy demand growth:
- Global energy demand is expected to continue to grow, especially in developing countries, which is likely to boost the growth of the fracking industry.
(3) Technological progress:
- Technological innovations, such as more efficient fracturing techniques, greener fracturing fluids, intelligent and automated fracturing equipment, etc., can increase fracturing activities and can also help overcome environmental and safety challenges.
(4) Environmentally friendly fracturing technology:
- As environmental awareness increases, the development of environmentally friendly fracturing technologies and products may become an important growth point.
(5) Geopolitical factors:
- Political instability in certain regions may lead to a quest for local energy self-sufficiency, prompting increased investment in fracking activities and related equipment in these regions.
7. Conclusion
7.1- Importance of fracked tube technology in the petroleum industry
Frac tube technology plays a vital role in today’s petroleum industry. As the core component of hydraulic fracturing operations, fracturing pipes are used to transport fracturing fluid to the bottom of oil wells under high pressure conditions to achieve effective extraction of oil and natural gas. In the development process of unconventional oil and gas resources, especially in the exploitation of shale gas and tight oil fields, fracturing tube technology is indispensable. This not only increases energy supply, but also promotes energy market diversification and energy security.
7.2- Continue research and development to promote innovation in fracturing pipe technology
In order to meet the challenges of environmental regulations, improve operational efficiency, and ensure operational safety, continued research and development is critical to the future of frac pipe technology. New materials and designs for fracking pipes for high-pressure and highly corrosive environments are continually being developed to ensure performance and durability in harsh conditions. In addition, the integration of intelligent and automated technologies can further improve the safety and efficiency of fracturing operations. Sustainable innovation, such as the development of environmentally friendly fracturing fluids, is also an important direction in fracturing tube technology research.
7.3- Prospects and vision of the future fracturing pipe industry
Looking ahead, the fracked pipe industry is expected to continue to witness technological advancements and market expansion and adjustments. As global energy demand grows and unconventional oil and gas resource exploration continues to deepen, the demand for high-performance fracturing pipes will continue to grow. At the same time, increasingly stringent environmental regulations and the pursuit of renewable energy will drive the fracturing pipe industry to become more efficient and environmentally friendly. The vision is for a more sustainable fracking operation that not only meets energy needs but also minimizes environmental impact. Through interdisciplinary collaboration and investment, the fracked pipe industry can move toward a greener, more efficient future that aligns with the global pursuit of clean, reliable energy.
Introduction about fracturing hose from Shandong Yitai Hydraulic Technology Co., Ltd.
1 Classifications and Structure
1.1 Classification
1.1.1 The fracturing hose assembly can be divided into 70MPa, 103.5MPa, 138MPa according to rated working pressure grade.
1.1.2 The fracturing hose assembly can be divided into acidizing fracturing and conventional fracturing according to the conveying mediums.
1.2 Specifications and sizes are shown in Table 1 and Figure 1.
Figure 1 Schematic Diagram of Main Specifications and Sizes
1.3 Product models are prepared according to the following rules:
For Example, YT 102×70 represents a fracturing hose assembly with a nominal bore of 102mm; the rated pressure grade is 70MPa.
1.4 Conventional Structure
1.4.1 The fracturing hose assembly consists of two parts, the hose body and the end connector, as shown in Figure 1.
1.4.2 The fracturing hose body is successively composed of polymer composite sealing layer, wear identification layer, shock absorption layer, steel wire reinforcement layer, shock absorption layer, rubber outer layer from inside to outside, as shown in Figure 2.
NOTE: 1. Polymer composite sealing layer 2.Wear identification layer 3. Shock absorption layer 4. Steel wire reinforcement layer 5. Shock absorption layer 6. Rubber outer layer
2. Basic Requirements
2.1 Fracturing cement hose assembly
2.1.1 The minimum burst pressure, test pressure and minimum bending radius for the fracturing hose assembly
shall meet the requirements of Table 2.
2.1.2 The fracturing hose assembly is suitable for H2S (hydrogen sulfide) oil, brine, fracturing fluid, proppant
and other mediums.
2.1.3 The size gauge of the fracturing hose assembly should pass and meet the requirements in Table 1.
2.1.4 The length tolerance of the fracturing hose assembly should conform to the values given in Table 3.
2.1.5 Applicable ambient temperature: ﹣29℃～121℃
2.1.6 Color identification of the fracturing hose assembly: Wear identification layers of different colors should
be placed outside the hose body seal to indicate the available, warning and scrapping.
2.1.7 Pressure resistance: Hydrostatic pressure test shall be carried out for each fracturing hose. The test pressure is shown in Table 2. The pressure holding time shall be at least 15 minutes.
2.1.8 Reference standard:
GB/T 20174 Petroleum and Natural Gas Industries - Drilling and Production equipment-Drill-through Equipment
GB/T 24145-2009 Rubber Hoses and Hose Assemblies for Rotary Drilling and Vibration Application--Specification
API Spec 7K Specification for Drilling and Well Servicing Equipment
Table 3 Length Tolerances for Acidizing Fracturing Hose Assemblies
2.2 Hose Body
2.2.1 Material of hose body
2.2.1.1 The polymer composite material seal adopts the wear-resistant composite rubber layer which is resistant to the erosion of the oil, brine, drilling fluid containing H2S(hydrogen sulfide).
2.2.1.2 Wear identification layer adopts wear-resistant composite rubber layer corroded by fluid such as oil, brine, drilling fluid containing H2S(hydrogen sulfide), which is distinguished by different colors.
2.2.1.3 The outer coating should be weather-resistant and wear-resistant rubber layer.
2.2.1.4 The physical properties of rubber material, such as abrasion resistance, corrosion resistance, elongation at break, tension and adhesion, should meet the requirements of use.
2.2.1.5 The shock absorbing and cushioning layer is processed by multi-layer polyester or nylon silk fiber hanging glue.
2.2.1.6 The reinforcement layer is made of copper plated steel wire and wound in alternate directions, and its performance requirements are shown in Table 4.
Table 4 Performance Requirements of Reinforced Skeleton Layer Steel Wire
2.2.2 Length change rate: Length change rate at normal temperature under rated working pressure is 2%.
2.2.3 Bending flexibility: See Table 2 for minimum bending radius
2.3 End connector
2.3.1 The end connector is made of union core pipe with integral forged structure. 75K should be selected according to the pressure class requirements. According to the rated working pressure class of the fracturing
2.3.2 The mechanical properties and chemical composition of the locking ring, the sealing ring, the intermediate sleeve and the protective sleeve should conform to the provisions of Q345E in GB/T 8162.
2.3.3 After the union core pipe of end connector is quenched and tempered, it should be non-destructive tested (NDT) following GB/T 5777 standard and meet the requirements of class II.
2.3.4 If the customer has nondestructive testing (NDT) requirements for the intermediate sleeve and the protective sleeve, it should be carried out per GB/T 5777 standard and meet the requirements of class II.
2.3.5 The tolerance medium performance of the end connector should be matched with the hose body. (Providing site pictures, product pictures, inspection and production equipment)
Introduction about Shandong Yitai Hydraulic Technology Co., Ltd.
Yitai Hydraulic is mainly engaged in the R&D, production, and sales of oil field fracturing hoses, high-pressure oil drilling hoses, flexible choke and kill hoses, well control high-pressure fire-resistant hose assembly, high-end mechanical hoses, and mining hydraulic hoses. The company's products are widely used in onshore and offshore oil drilling， exploration， exploitation, and transportation.
The company is a national high-tech enterprise with independent import and export rights, integrating R&D, production, sales, and service. Taking scientific and technological innovation as the fundamental way out for development, we established a national high-pressure rubber hose laboratory in conjunction with Tsinghua University, established a scientific research achievements transformation base of Tsinghua University, improved the scientific and technological content of various rubber products such as ultra-high pressure, fire-resistant, large diameter rubber hose and multi-purpose rubber hose with leading scientific and technological transformation, and continued to gain new advantages in domestic and international market competition.
Our company has passed four system certifications: ISO9001:2015 quality management system certification, ISO14001:2015 environmental management system certification, API Spec Q1 quality system certification, API Spec 7K, API Spec 16C, API Spec 16D product certification, ABS and CCS double classification society type certification
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