British Petroleum (B.P) Rumaila Oil Field

1 Project Overview and Environmental Challenges

The Rumaila Oil Field, one of the largest oil fields in Iraq, operates under extreme conditions, including high temperatures (up to 50°C ambient), abrasive sandstorms, and highly corrosive soil and produced fluids (e.g., H₂S, CO₂, and chlorides). The project demands materials and components that ensure long-term integrity, minimal maintenance, and resistance to corrosion and erosion.

2 Key Advantages of Specified Components

2.1 SMLS (Seamless) and Saw-Cut Pipes (1/2″-48″) with 3LPE Coating

• Superior Corrosion Protection:

  • 3LPE (3-Layer Polyethylene) coating provides robust barrier protection against soil moisture, chemicals, and electrolytic corrosion.

  • Adhesion strength ≥15 MPa, ensuring coating integrity during handling and installation.

• Structural Reliability:

  • SMLS pipes lack weld seams, eliminating risks of weld defects and ensuring uniform strength for high-pressure applications (e.g., well injection lines).

  • Saw-cut pipes offer precise length control (±1 mm), reducing on-site fabrication time and waste.

• Temperature Resilience:

  • 3LPE coating remains stable at temperatures from -40°C to 80°C, suitable for Rumaila’s climate and operational thermal cycles.

2.2 BW (Butt Weld) Fittings (1″-32″) with 3LPE Coating

• Seamless Integration:

  • Pre-coated fittings ensure continuous corrosion protection across welded joints, critical for buried pipelines and splash zones.

  • Beveled ends compliant with ASME B16.25, facilitating full-penetration welds with minimal defects.

• Erosion Resistance:

  • 3LPE coating reduces internal surface roughness, minimizing turbulence and erosion in high-flow produced water lines.

2.3 Flanges (2″-28″), Gaskets, and Insulation Kits

• Flange Design:

  • Raised face (RF) or ring-type joint (RTJ) flanges forged from ASTM A105/LF2, with galvanized or epoxy coatings for surface protection.

  • Dimensional compliance to ASME B16.5, ensuring interoperability with existing infrastructure.

• Gasket and Insulation Kits:

  • Spiral-wound gaskets (SS316 + flexible graphite) for leak-tight seals under thermal cycling.

  • Insulation kits prevent galvanic corrosion between dissimilar metals (e.g., carbon steel flanges and stainless bolts).

2.4 Stud Bolts and Nuts

• High-Strength Material:

  • ASTM A193 B7 stud bolts with ASTM A194 2H nuts, hot-dip galvanized or Xylan-coated for corrosion resistance.

  • Torque preload accuracy ±10%, ensuring uniform gasket compression and flange sealing.

• Vibration Resistance:

  • Prevailing-torque nuts maintain tension under mechanical vibration (e.g., near pumps and compressors).

2.5 Y-Type Strainers, Paddle, Plate, and Flat Steel

• Y-Type Strainers:

  • Perforated mesh (SS304/316) with blow-down valves, capturing sand and debris to protect downstream equipment (e.g., control valves and pumps).

• Paddle Blades and Flat Steel:

  • AR400/500 steel paddles for agitators and mixers in produced water treatment, resistant to abrasive slurries.

  • Flat steel used for structural supports and bracing, hot-dip galvanized for corrosion protection.

3 Project-Specific Benefits

3.1 Corrosion and Abrasion Mitigation

• 3LPE-coated pipes and fittings reduce lifecycle costs by extending service life beyond 25 years without major repairs.

• Abrasion-resistant paddles and strainers minimize downtime in sand-laden produced water systems.

3.2 Modularization and Installation Efficiency

• Pre-cut, pre-coated pipes and fittings enable rapid deployment, reducing field labor by 30% and avoiding on-site coating defects.

• Standardized flange and bolt kits simplify maintenance and spare parts management.

3.3 Compliance with International Standards

• Materials meet ISO 21809-1 (3LPE coating), NACE MR0175 (sour service), and ASME B31.4/B31.8 (pipeline integrity).

4 Conclusion

The integration of 3LPE-coated SMLS pipes, BW fittings, flanges, and specialized components in the Rumaila Oil Field Project delivers:

1. Enhanced Durability: Resistance to corrosion, erosion, and thermal cycling.

2. Cost Efficiency: Reduced maintenance and installation costs through prefabrication and long service life.

3. Operational Reliability: Protection of critical equipment via strainers and robust materials.

This specification is tailored to Rumaila’s harsh environment, ensuring safe and sustainable operations.