Improvement of the Process Equipment Reliability
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Planning and implementation of actions for improvement of the process equipment reliability is based on the results of monitoring its technical state. First of all, it is due to the fact that the accident rate of the oil-field equipment is the most significant factor of tecnogenic impact of oil production on the environment. The results of the oil-field equipment diagnostics serve as a basis for preparation of justified programs for scheduled maintenance, which allow prevention of different accidents.
The purposeful work for improvement of the oil-filed equipment reliability and reduction of its accident rate is being performed in OAO TATNEFT on the continuous basis.
832 km of polymer-coated and 539 km of reinforced plastic pipes is were produced in 2007; anticorrosion protection of vertical steel tanks and horizontal settlers was performed with application of the paint/varnish coating materials covering the total area of 22,700 m2; 730 wells were equipped with cathodic protection.
For the purpose of gas lines protection against corrosion, the works for introduction of active electromechanical protection, corrosion inhibitors injection, and worn out sections overhaul (replacement) were performed. The amount of 6,366 tons of corrosion inhibitors was produced and used for treatment of highly corrosive media.
Particular attention was paid in 2007 to reduction of expenses for overhauls of casing strings due to their corrosive destruction. In order to protect the downhole equipment and production strings of wells against high pressure and corrosion, the М1-Х packers were installed in injection wells.
Actions for improvement of oil-field equipment reliability
| Actions | 2005 | 2006 | 2007 |
| Production of corrosion inhibitors, tons | 4,863 | 6,052 | 6,366 |
| Production of reinforced plastic pipes + polymer-coated pipes (w/o tubing), km | 1,012 | 1,291 | 1,371 |
| Anticorrosion protection of vertical stainless steel tanks and horizontal settlers with paint materials, m2 | 21,269 | 9,312 | 22,700 |
| Cathodic protection of casing strings, pcs | 590 | 550 | 730 |
Volumes of PE pipes used in construction of gas pipelines, km
| 2005 | 2006 | 2007 | |
| PE gas pipelines | 12.9 | 21.1 | 30.8 |
The design of a non-flanged mechanical dielectric connection of pipelines, which is more reliable and cheaper in comparison with its analogs, was developed.
A program for introduction of polymer-coated tubing and fiber-glass tubing introduction was put on the way. Currently, the protection of the active injection well stock using waste water is 64.6%.
The well MTBF value reached 873 days. The increase versus the previous year made over 60 days.
The oil pipeline rapture level decreased by 8% in comparison with the previous year.
Due to organization and control over implementation of anticorrosion measures, the total amount of the reservoir pressure maintenance pipelines leaks decreased by 15.8%, while in case of the waste water lines — by 21.1%.
82 km of gas lines were replaced; with the pipe leak level for gas lines reduced by 31% in comparison with 2006 due to optimum selection of sections for replacement.
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