Project Overview

Project Background

Gudong Oil Production Plant is a mature oilfield where water cut has increased significantly after years of production. The average produced fluid contains approximately 97.2% water, while some production blocks exceed 98% water content.

The transported medium consists of heavy crude oil mixed with produced water, gas and formation sand, creating one of the most demanding operating environments for surface gathering pipelines.

The plant experienced recurring failures caused by:

• Internal corrosion from highly mineralized produced water

• External corrosion in harsh field environments

• Severe erosion caused by sand-laden fluids

• Frequent leakage at elbows, reducers and valve manifolds

• High maintenance costs and production interruptions

• Environmental risks associated with crude oil leakage

Traditional carbon steel pipelines could no longer provide satisfactory service life under these operating conditions.

Project Objectives

The pipeline upgrade project aimed to achieve the following objectives:

• Improve corrosion resistance in high-water-cut production systems

• Increase resistance to abrasive wear from sand-containing fluids

• Reduce pipeline perforation and unplanned shutdowns

• Improve environmental and operational safety

• Simplify field installation without welding

• Extend pipeline service life while lowering life-cycle maintenance costs

Engineering Solution

Gudong Oil Production Plant selected PAMC Reinforced MC Nylon Lined Steel Pipes to replace conventional steel piping in well drain valve groups and critical process pipelines.

The project covered:

• Well drain valve groups

• Process manifolds

• Elbows

• Reducers

• Short spool sections

• Main process pipelines inside combined stations

By the end of 2022, the complete valve group system at Dongsi Combined Station had been upgraded, while pipeline replacement continued in Dongyi, Donger and Dongsan stations under a phased implementation plan.

Why PAMC Nylon Lined Steel Pipes?

The selected pipeline combines the mechanical strength of carbon steel with the corrosion and wear resistance of reinforced MC nylon.

Corrosion Resistance

The PAMC nylon liner isolates corrosive produced water from the steel shell, reducing internal corrosion caused by highly mineralized fluids.

Abrasion Resistance

The reinforced nylon liner offers excellent resistance to erosion caused by sand particles, especially at elbows, reducers and manifolds where wear is typically most severe.

High Structural Strength

The external steel shell provides mechanical strength and impact resistance required for oilfield surface facilities.

Improved Hydraulic Performance

The smooth internal surface lowers flow resistance, reducing pressure loss and improving transportation efficiency.

Safe Installation

All pipelines are connected using flanges, eliminating hot work such as field welding and reducing construction risks.

Project Implementation

The project has been implemented in phases since 2015.

Application Areas

• Dongyi Combined Station

• Donger Combined Station

• Dongsan Combined Station

• Dongsi Combined Station

Pipeline Services

• Heavy crude oil

• Produced water

• Oil-water mixtures

• Oil-gas-water multiphase flow

Installation Method

Ground-mounted pipeline systems with standard flanged connections.

Operating Performance

The upgraded pipelines have remained in continuous operation for many years under high-water-cut production conditions.

Observed operating performance includes:

• Stable operation without large-scale corrosion failures

• No significant sand erosion perforation reported in upgraded sections

• Reduced maintenance frequency

• Reliable sealing performance

• No liner separation during long-term service

One representative example is the Dongsi well drain valve group, which has remained in stable operation since 2015, handling oil, gas and produced water without major corrosion-related failures.

Project Results

Following implementation, Gudong Oil Production Plant achieved measurable operational improvements.

Reduced Pipeline Failure

The frequency of corrosion and erosion-related pipeline perforation was significantly reduced compared with conventional steel pipelines.

Lower Maintenance Costs

Reduced repair frequency minimized maintenance labor, replacement costs and production downtime.

Improved Environmental Protection

Fewer leakage incidents lowered environmental risks associated with crude oil transportation.

Longer Service Life

The composite pipeline system provides substantially longer service life than traditional carbon steel piping in abrasive and corrosive service conditions.

Improved Operational Safety

Flanged installation eliminated on-site welding, reducing hot-work hazards during construction and maintenance.

Technical Advantages

Key engineering benefits of the PAMC nylon lined steel piping system include:

• Excellent corrosion resistance for produced water service

• High abrasion resistance in sand-containing fluids

• Suitable for heavy oil gathering systems

• Reliable performance in high water-cut production

• Smooth bore for reduced pressure loss

• High structural strength

• Flanged installation for simplified construction

• Low life-cycle maintenance requirements

Future Expansion

Based on the positive operating performance, Gudong Oil Production Plant continues to expand the use of PAMC nylon lined steel pipelines under its rolling surface facility optimization program.

Future applications include:

• Main gathering pipelines

• Oil-water separation systems

• Produced water transportation

• Station process pipelines

• Additional valve groups and manifolds

Conclusion

The Gudong Oil Production Plant project demonstrates the long-term performance of PAMC reinforced MC nylon lined steel pipes in challenging oilfield environments characterized by:

• High water cut

• Heavy crude oil

• Sand-containing production fluids

• Corrosive produced water

• Severe erosion at critical pipeline sections

After years of continuous operation, the upgraded pipeline system has reduced corrosion-related failures, lowered maintenance requirements and improved operational reliability. The project provides a practical reference for pipeline upgrades in mature oilfields where corrosion, abrasion and high life-cycle maintenance costs remain ongoing challenges.