The Challenge

As a result of shifting to multi-well pad drilling, a large Canadian oil and gas producer began to see a dramatic increase in water consumption from longer drills and larger fracs. Because the water was being hauled to frac sites by tank trucks, the cost to transport more water increased in direct proportion to the larger number of water delivery trips made. At the same time, the local provincial government increased the environmental regulatory requirements aimed at reducing fresh water consumption. To manage costs and remain compliant with regulations, the company decided to build a water hub system to transport water from massive retention ponds. They also wanted a pipeline technology capable of being used for a dual application: initially, delivering highly corrosive produced fracing water, and produced natural gas at a later time. Because of the corrosive fluids the pipeline would convey, the company also wanted to mitigate the costs associated with pipeline maintenance programs.

The Solution

For the operator’s application, FlexSteel recommended its 6-inch 2,250-psi (155 bar) line pipe. The pipe is designed to resist the corrosive effects of produced gas substantially better than steel pipe and could be efficiently installed by smaller crews with less equipment. In addition, FlexSteel developed a plan to train the operator’s employees on the best practices for handling the pipe and connections using FlexSteel’s proprietary processes.

The Result

Three crews completed the installation of the 65-mile produced gas line in just four months. The exterior and interior layers of FlexSteel line pipe provided the operator with a pipeline that ensured the reliable flow of the produced gas. Using smaller crews, reducing equipment, and completing the installation quickly enabled the operator to realize substantial savings. By minimizing the construction spread along the right-of-way, deforestation was limited during installation. And because the pipe required no long-term maintenance, the operator could allow the jungle vegetation to grow over the right-of-way. The FlexSteel pipeline reduced installation time by 65% compared to construction of a steel pipeline. The success of this job prompted the operator to place orders of FlexSteel pipe for additional projects in the region.