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Materials System Specification
Materials System Specification
1 Scope............................................................. 2
2 Conflicts and Deviations................................. 2
3 References..................................................... 2
4 Definitions....................................................... 4
5 Material for Liner Manufacturing..................... 5
6 Qualification Program..................................... 7
7 Process and Quality Assurance
Requirements........................................ 12
8 Marking......................................................... 15
9 Documentation.............................................. 15
10 Handling, Storage,
Transportation and Installation.............. 16
1 Scope
1.1 This specification defines the minimum mandatory requirements for qualifying
the liner and liner-pipe assembly used in composite lined carbon steel downhole
tubing and casing. These tubular components are utilized for handling and
transporting water, liquid and gases hydrocarbons, and multiphase fluids.
This standard was developed based on API RP 15CLT guidelines.
1.2 Composite lined tubing typically consists of a fiber reinforced polymer liner
within the steel host, providing protection of that steel host from corrosive
attack. Both API and premium connections can be employed, typically using
corrosion barrier rings to maintain corrosion resistance between ends of adjacent
liners.
1.3 This qualification procedure applies to composite lined carbon steel for systems
up to 10” (250 mm) diameter, operating at pressures up to 10,000 psi (69 MPa)
and maximum temperatures of 140°C (284°F).
1.4 This specification is not intended to define the requirements for qualification,
quality control, application and documentation of the steel downhole host tubing.
2.1 Any conflicts between this specification and other applicable Saudi Aramco
Materials System Specifications (SAMSSs), Engineering Standards (SAESs),
Standard Drawings (SASDs), or industry standards, codes, and forms shall be
resolved in writing, prior to submission of bids or start of related work, by the
Company or Buyer Representative through the Manager, Consulting Services
Department, of Saudi Aramco, Dhahran.
2.2 Direct all requests to deviate from this specification in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Consulting Services Department of
Saudi Aramco, Dhahran.
2.3 Proceed with the requested deviation only after the receipt of the Manager's
approval to deviate from this specification.
3 References
Material supplied to this specification shall comply with the latest edition of the
references listed below unless otherwise noted:
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
4 Definitions
4.1 General
Flare or end cap: Molded polymeric component used to cap the cut end of the
liner.
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
FRP liner: A thin wall pipe manufactured from fiber reinforced polymer which
is inserted within carbon steel tubing to provide corrosion protection.
Grout: Polymer or cement which fills the annulus between the liner and the
carbon steel host tubing or casing.
4.2 Abbreviations
CBR Corrosion Barrier Ring
CRA Corrosion Resistant Alloy
DMA Dynamic Mechanical Analysis
DSC Differential Scanning Calorimeter
FRP Fiber Reinforced Polymer
PTFE Polytetrafluoroethylene
Tg Glass Transition Temperature
VME Von Mises’ Equivalent Stress
5.1 Materials
5.1.1 Composite lined carbon steel tubing shall consist of a thin wall fiber
reinforced polymer (FRP) liner inserted into steel tubing. The liner
manufacturer shall specify the liner wall thickness in accordance with the
pipe diameter. The liner shall be manufactured by filament winding, in
accordance with the manufacturer’s written procedures, based on the
following materials:
Resin: Epoxy resin has been the preferred choice of thermosetting
resin, using aromatic, aliphatic or cycle-aliphatic amine as a curing
agent. Other thermosetting resins, e.g., vinyl ester or phenolic, may
provide enhanced benefits to meet particular corrosion or high
temperature requirements.
Fibers: E-glass fiber is the typical fiber used to manufacture
composite liners. Other reinforcement fibers are possible, in particular
carbon fibers because their enhanced performance properties.
5.1.2 The annulus between the pipe and tubing shall be filled with cement or
polymer grout, to transfer internal pressure loads to the steel tubing. The
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
5.1.3 The ends of the liner shall be protected from mechanical damage by an
FRP end cap or “flare”, which may protrude slightly into the bore of the
tubular. The flares are typically molded from a short-fiber reinforced
polymer material, and shall be manufactured in accordance with the
manufacturer’s written procedures. A suitable adhesive shall be used for
bonding the flares to the liners.
5.1.4 Continuity of the corrosion barrier across the coupling, between two
adjacent flares, shall be provided by a polymeric corrosion barrier ring
(CBR) ring. The amount of compression applied to the barrier ring is
controlled by the distance between the pin ends during make-up. The
corrosion barrier ring is typically made from a polymer material, usually
fiber filled PTFE. Other CBR materials may be used with prior approval
by the Non-Metallic Materials Standards Committee Chairman is required.
5.1.5 The carbon steel tubing shall have the required resistance to sulfide
stress cracking as defined by NACE MR0175/ISO 15156, based on the
bore fluid composition. Any connection covered under API SPEC 5CT
may be used with a composite lined tubing product. In addition, certain
approved proprietary connections may be used with composite lining
systems. The liner manufacturer shall verify that the liner will be able to
work with the specified connection by performing the test described in
Section 6.2.
The primary function of the lined tubing system is to protect the carbon steel base
pipe from the corrosive effects of the wellbore fluids. Several factors may affect
the performance of the liner material. It is required that the liner to be qualified in
accordance with Section 6 to evaluate its performance under these factors:
Degradation of the FRP liner due to chemical attack.
Failure, or absence, of the CBR.
Mechanical damage by downhole tools, e.g., impact and abrasion.
Failure of, or damage to, the liner or other components caused by combined
load effects, such as combination of tension-compression-bending, pressure
and temperature cycling, and connection over-torqueing.
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
6 Qualification Program
The capability of the materials used in liners, flares and CBR shall be
demonstrated by the successful completion of the tests described in this section.
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
Performance tests shall be carried out with lined tubing samples, including
connectors. Tests for lining system shall be carried out with the designated
connection. Where connections are modified to accommodate the liner system,
tests shall be carried out with the modified connection.
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
design must account for the potentially much higher operating pressures
that could be exerted on the outside of the liner.
The make and break connection tests shall be carried out following the
connection manufacturer’s procedures (typically 5 multiple). There shall
be no galling at any time, and no significant changes in makeup
properties from the standard product. There should be no damage to
liners, flares or CBR. Actual torque values should be available for
review by the buyer.
The manufacturer shall demonstrate that the lined system has suitable
structural integrity for the mechanical, pressure and thermal loads to be
seen during installation and use in any given service. The combined load
testing shall be conducted in accordance with 6.3.4. The liner system
shall not detract from connection performance. The liner system and the
connection shall not fail in pressure containment nor change the makeup
characteristics of the connection. Holiday testing should detect no
defects either before or after testing.
6.3 Test Procedures to Evaluate Liner Material and Lined Pipe System
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
permeated gas in the annulus should the pressure fall within the tubular
with potential for liner collapse.
Test coupons of FRP liner shall be prepared from larger diameter tubing
with a 3 mm minimum wall thickness to minimize the effect of the
inherent variation in thickness on the measured flexural properties.
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
manufacture. All quality control records required by this specification shall be signed
and dated, as established by the manufacturer's procedures.
7.1 Materials
All materials used in the production of the liners and flares, and in the lining
process shall be fully traceable. This also applies to the materials for the CBR.
The manufacturer's inspection and test plans for liner and flare manufacture
shall be reviewed and approved by the Buyer in advance of manufacture. A
single length of liner shall be used in each length of steel tubing.
7.3 The glass transition temperature of the cured liner shall be determined by
Differential Scanning Calorimeter (DSC), in accordance with ISO 11357-2 or
Appendix C of API SPEC 15HR, at a frequency of 10% or once per machine per
shift. Other methods of measuring Tg, as dynamic mechanical analysis (DMA),
may be used as agreed between manufacturer and Buyer. The value shall not be
lower than 5°C of the value quoted by the liner manufacturer.
7.5 Dimensions
The nominal inside diameter and wall thickness of the liner shall be quoted
by the manufacturer.
The inside diameter shall be within -±10% of the specified inside diameter
or as otherwise agreed.
The wall thickness shall be within -±10% of the specified thickness or as
otherwise agreed.
7.6 The drift diameter of the lined tubing shall be quoted by the manufacturer.
The manufacturer shall check, using a caliper, that each joint meets the required
drift diameter. No obstruction or damage of the liner/flare is acceptable.
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
7.7 The liner shall be free from visible cracks, holes, protrusions, foreign inclusions,
or other injurious defects, as established by the manufacturer. The liner shall be
uniform within the manufacturer’s acceptable limits in terms of color,
roundness, density and physical properties. The defect types, acceptance criteria
and recommended corrective action are listed in Table C.1 in Appendix C.
7.8 Similar process should be carried out for the CBR manufacture conditions.
The molding process conditions for the elastomer CBR or the PTFE billets used
for CBR manufacture shall be documented. The filler content and the tensile
properties of the processed PTFE material shall be determined in accordance
with ASTM D4745. The CBR shall be molded and/or machined to the exact
dimensions required for the specific type of steel connection used.
The internal surface of the pipe shall be as per the steel manufacturer’s specified
finish. Thorough visual inspection of both flares and liners shall be performed
prior to installation in accordance to Appendix C.
The viscosity of the grout shall be within the specified limits in the
manufacturer's quality document. The minimum injection and backfill pressures
shall be stated within the quality control plan. All viscosity checks shall be
recorded as a part of the quality plan. Filling the annulus with grout shall be
carried out in accordance with the manufacturer's procedures.
The manufacturer shall demonstrate, only once, that liner fills the annulus with
minimum voids. This shall be exhibited by visual inspection of lined tubing cross
section. The quality of lining process shall be documented and stored by the
manufacturer to have it available when requested. Other means of demonstrating
annulus fill may be agreed upon between the manufacturer and Buyer.
Care shall be taken to prevent damage of the seal shoulder of the connector.
The flare/liner adhesive shall be checked visually for voids and other
unacceptable defects.
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
8 Marking
Composite lined tubing and casing which have been lined in conformance with this
specification shall be marked by the manufacturer, with date of manufacture (month and
year) and a unique manufacturer’s lot identification number. Markings shall be readily
visible, applied by water resistant paint or ink stencil. Markings shall not overlap and shall
be applied in a manner not to damage the pipe or couplings. Markings shall be applied
within three feet of the connection. Additional marking as specified by the manufacturer or
Buyer are not prohibited, e.g., marking of the word “LINED” on the pipe.
9 Documentation
The end-user shall provide the design and operating conditions for the lined
tubing, including:
System design pressure (and pressure range in the case of cyclic service),
Maximum and minimum design temperature,
Internal fluids, and
Design lifetime.
The full information that shall accompany a purchase order for composite lined
tubing is outlined in Appendix A.
The manufacturer shall provide the Buyer with a written description of the liner
system. As a minimum, this will include:
Dimensions, including the nominal inside diameter, wall thickness and
weight of the liner, and the drift diameter of the lined tubing
Description of all materials used
Minimum and maximum operating temperatures
Limitations with respect to chemical exposure.
A full qualification test report shall be made available to the Buyer on request.
The Buyer shall define the data which is to be provided in the Qualification Test
Report.
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
The manufacturer shall provide running and handling procedures, for review and
approval by the Buyer. As a minimum, these should include:
Requirements for handling, storage and transportation,
Preparations for running and equipment required,
Running procedures, and
Break-out procedures.
Thread condition is critical to the sealing effectiveness of any composite lined system.
The manufacturer shall provide pin end thread protection to protect the pin ends of the
lined tubular from damage under normal handling and transportation, as well as to
prevent damage by ultra-violet radiation and other weather elements. Threaded box
ends do not require protection, unless requested by the Buyer. Non-threaded
connections may have special end protection requirements, subject to agreement
between manufacturer and Buyer.
Field repair kits should be available for rebonding flares to an otherwise intact liner
section. Any repairs shall be carried out in accordance with the manufacturer’s written
procedures.
Particular attention should be taken with the design of interfaces between composite
lined tubing and other downhole equipment, such as packers and safety valves. Such
interfaces must be designed to accommodate the appropriate CBR.
Installation procedures shall specifically mention actions required to check that all CBR
are inserted, and inserted correctly.
Revision Summary
16 January 2014 Major revision to capture comments from Operations/end users.
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
The Buyer should provide the following information with all purchase orders for
composite lined tubing.
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
B.1 General
All criteria should be assessed after the relevant immersion time periods.
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
B.2.1 Appearance
Color of the mold surface, after immersion in the medium, color change
should be assessed on a scale of 0 to 5. No change to the translucent
initial color (performance level - 0) to complete color change and
darkening (performance level - 5).
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
The performance level score from each test should be multiplied by the
weighting factor for each criterion and combined to form a total for the range of
tests carried out (Table B.1). The total should be compared with the maximum
total, obtained by summing the product of each weighting for each criterion with
the poorest performance rating for each of the tests carried out. For example, if
color, tackiness, crazing, retention of flexural modulus and retention of (flexural
or tensile) strength are the measured criteria for immersion/double side exposure
then the maximum (worse) score would be
( 2 x 5 ) + ( 4 x 5 ) + ( 5 x 5 ) + ( 5 x 10 ) + ( 5 x 10 ) = 155.
(Note: Higher score means lower performance)
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
Where no deterioration has occurred over the duration of the assessment, i.e., the
assessment score is less than 50 % of the total possible score then, the material
performance for long term exposure (6.1.1.1) should be appraised as suitable for the
services. In the case of the short exposure fluid (6.1.1.2), the score should be lower
than 25%.
C.1 General
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Document Responsibility: Non-Metallic Standards Committee 01-SAMSS-045
Issue Date: 16 January 2014 Qualification Requirements for Composite Materials
Next Planned Update: 16 January 2019 used in Lined Carbon Steel Downhole Tubing and Casing
Corrective
Defect Type Description Criteria
Action
Area of incomplete surface film
where the reinforcement has not
Dry spot None permitted Reject
been wetted by resin, leaving bare
exposed fibers.
Rupture of laminate with complete
penetration. Majority of fibers
Fracture None permitted Reject
broken. Visible as lighter colored
area of inter-laminar separation.
Light area with or without broken
Impact damage None permitted Reject
fibers
Inclusion Foreign matter wound into laminate None permitted Reject
Lack of fibers Resin/fiber ratio too high None permitted Reject
Diameter greater than
Small crater in the inner surface of 0,8 mm, and/or depth
the laminate, with width (max. greater than liner
Pit (pinhole) Reject
diameter) similar to or smaller than thickness or 10% of
depth liner wall thickness,
and/or damaged fibers
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