CRA-TUBULARS

CRA-Tubulars | The Corrosion Resistant Alternative is a newly established engineering firm backed by decades of excellence, innovation, and commercialization. The company operates in the energy sector and seeks to help operators solve the issue of well integrity, associated costs, and subsequent loss of oil production. We have developed TCT, and we are in the process of getting API5C certification.

CRA-Tubulars is an initiative by Emile Burnaby Lautier and cooperates with several industry partners to establish the highest quality product and deliver it to market as quickly as possible

CRA-Tubulars aims to help Energy Companies solve the issues of well-integrity, associated costs, and subsequent loss of production with the introduction of an alternative type of tubular TCT – Titanium Composite Tubulars – by making technically superior and affordable down hole completion tubing and connections out of titanium, carbon fibre and aerospace epoxy whilst meeting oilfield standards for easy qualification and implementation.

Mission

To deliver an API 5 certified alternative OCTG solution for the most challenging downhole conditions in Oil
and Gas, CCS and new energy requirements.
To offer an affordable titanium-carbon fibre-epoxy OCTG solution with superior commercial lifecycle
performance
To repurpose and leverage aerospace and deep water technology, employ these for downhole field
requirements and patent and manufacture those development to build company value
To build lasting relationships with technical
partners and customers and join forces to accelerate technical
and commercial implementation.

Goals

CRA-Tubulars aims to become a leading provider of high-performance corrosion resistant OTCG
for Oil and Gas, CCS and alternative energy applications.
We intend to prove in the field that TCT is a superior tubular for demanding corrosive well environments.
Our team’s expertise, personal reputation and relationships with customers, technology partners,
and suppliers in the Energy industry, supporting a step change yet robust technology, CRA-
Tubulars builds a level of trust that is needed for successful adoption of new technology.

Vision

Market Challenge

The annual cost of OCTG tubing in the Energy Industry is estimated to be $91 Billion. The premium alloy market equates to $3.4 Billion for corrosion-resistant tubing in annual capital expenditures related to corrosion.

With around 1800 rigs operating in 2022, Rystad Energy expects around 54,000 wells to be drilled worldwide in 2021, a 12% increase from 2020. In 2022 drilling is set to increase even more, by another 19% year-on-year to about 64,500 wells, though activity will still fall short of the 73,000 wells drilled in 2019.

Drilling-Chart

These direct costs and HSE risks could rise further in coming years. as CCS and alternative energy apphcatlons require high-end alloy solutions and new field discoveries are found in deeper reservoirs with higher temperatures. Pressures and containing greater
concentrations of corrosive medium. It Is widely recognized within the Industry that effective management of corrosion will contribute towards accruing the following benefits.

Service sector spending on carbon capture and storage (CCUS) developments is set to skyrocket this decade, quadrupling from 2022 to 2025, with cumulative global expenditure over the next three years topping $50 billion, Rystad Energy research indicates.
There are 56 commercial CCUS projects already in operation globally, capable of capturing up to 41 million tonnes per annum (tpa) of CO2 across various industries. Based on already announced projects, nearly 140 CCUS plants could be operational by 2025, capturing at
least 150 million tpa of CO2 if all projects move ahead as scheduled. These projects are currently in various stages of development, including feasibility, concept and construction.

shell gamechnager

Shell GameChanger is funding CRA Tubulars with their Titanium Composite Tubular technology to get API 5C5 certification for CCUS and Hydrogen OCTG applications.

North Sea brownfields are currently under planning, with some major integrated projects going through the conceptual design phase with major players involved. Examples are L10, Acorn, and Porthos.

Players in the European CCUS sectors are Exxon Mobil, Shell, Wintershall, Total, and BP, with the support of government authorities. Dedicated project and subject matter teams in the traditional technical disciplines, reinforced with additional expertise, have recently been set up for forwarding project planning and investment. Schlumberger is one of the leading players in North America and is currently in various stages of planning on 60 CCUS projects. In several projects, Schlumberger acts as an operator.

  • Statutory / Corporate compliance with Safety, Health and Environmental (HSE) policies reduction in leaks
  • Increased well availability and a reduction in unplanned maintenance / integrity breaches
  • Reduction in shut-in well costs
  • Improved production and performance of the wells
  • Assets in the upstream oil and gas environment needing protection from corrosion may include wells, risers, drilling rigs, offshore platforms, pipeline connectors, and more.

THE CRA-TUBULARS PRODUCT

TITANIUM LINED

  • No H2S or chloride induced SCC (stress cracking corrosion)
  • Liner prevents microcracks of the composite body

PREMIUM CONNECTIONS

  • API-5CT compliant traditional sizes ID / OD including connections
  • Off the shelve accessories, no change to operations

CARBON FIBER & AEROSPACE GRADE EPOXY

  • Weight is 1/2 of metallic CRA (low completion stresses and forces)
  • Temperature coefficient is 1/3 of metallic CRA (low completion stresses and forces)
  • Matches and exceeds metallic CRA tubing with 18,000 PSI burst, 240,000 lbs tensile load and max operating temperature at 180C (350F)
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Market Volume

Worldwide 812,000 wells are affected by integrity issues. Approximately 9% are permanently shut-in and 10% are temporarily shut-in. Globally there are approximately 2,000 active drilling rigs, considering that an average rig will drill a new well every 6-8 weeks, this amounts to 14,000 newly drilled wells per annum. With 812,000 affected by corrosion and an average well depth of 9,000 ft, the total market consists of 6 million feet of pipe. One CRA-Tubular’s production facility can produce approx. 800,000 ft of pipe per year generating an annual turnover of $90MM USD. One facility equates to a cure for 0.025% of the corrosion affected wells.

Market volum dotted bg img

Pricing of TCT Compared with
Carbon Steel and Inconel

The sales price of TCT will depend on the field location, the complexity of the wellbore, well depth and other parameters.
TCT tubing is a premium product and is competitively priced on par with CR22 tubulars; however, an important distinction is the fact
that TCT outperforms even higher-grade pipe like Super Duplex and Inconel delivering life of the well service. This makes TCT a budget bargain.

Pricing of TCT

DUPLEX

INCONEL

TITANIUM COMPOSITE TUBING

Lifetime of product in comparable corrosive environment

+

+++

++++++

Downtime due to shut-in well

++++++

++

+

Minimum installation footprint

Rig

Rig

HWU

Lead time for installation equipment

6-12 Months

6-12 Months

1 Months 28

Lead time of product

6-12 Months

12-18 Months

± 2 Months

Comparable Cost

$$$

$$$$$$$

13CR < TCT < Duplex

ROADMAP | Route-to-Market

Upon Approval and Funding, 2 Quarters Lead-Time to Trial Deployment

  • From idea to company 2010-2019.
  • Company founded in November 2019.
  • Prototype in Q1-2020.
  • Proprietary connection final design stage.
  • The CAL II testing (API-5C) process ongoing.
  • Currently in final stage of trial negotiations.
  • Targeting commercial operation in Q3 of 2023.

TCT Operational Advantages: Producer

Titanium Composite Tubing (or “TCT”) is Truly a Superior Solution

Frequently Asked Questions

We currently provide 2 3/8”, 2 7/8”, 3 ½’, 4 ½” and shortly in 5” tubing. These tubing sizes have standard API ID’s. Dimensions and tubing weight are as follows:  

API Size:

OD Tubing

API Size:

ID

Weight

Thread Type

Inch

mm

ID Inch

ID mm

LBS/ft

2.375″

60.325

1.995

49

~ 3.1

any

2.875″

73.025

2.244

57

~ 3.1

any

3.5″

88.9

2.795

71

~ 3.1

any

4.5″

114.3

3.724

94.6

~ 3.1

any

5″

127.0

4.408

111.96

~ 3.1

any

TCT is composed of a corrosion-resistant liner made of Titanium ASTM Grade-2. The liner is then covered with several layers of Aerospace grade carbon fiber and high-grade epoxy resin. The Ti. liner gives corrosion resistance and prevents permeation of any hydrocarbons into the CF layer. The CF layer provides strength in the axial and radial direction.

TCT is economical from a lifecycle cost perspective. It outlasts any high alloy metallic tubing. Considering the cost of several workovers, new tubing, chemical treatment, and cashflow impact resulting from shut-in periods, the price is very competitive. TCT is more economical than 13Cr tubing and certainly a lot less expensive than Duplex or Inconel tubing. TCT is priced slightly above CR13 tubing but will last many times longer.

CRA-Tubulars plans to manufacture tubing in-country or certainly within the region. In this model we expect to deliver a spool of TCT in under 1 month, combined with HWOU installation, our process can have your well back on production within 2 months. This is much faster than traditional jointed metal CRA completions. Delivery times of Duplex or Inconel are typically over 18 months.

TCT is provided in two grades: Burst and collapse 10KSI and the high grade >15KSI. Temperature is 180 degrees Celsius; this puts our non-metallic CRA comfortably in the HPHT range of applications. We have a high grade under development aiming to approach 200C.

No, to achieve the highest possible temperature resistance we are using highly crosslinked thus brittle resins. Our combination of resin, fiber, and the liner however is not brittle. Microcracks do occur in the outer layer (none in the inner-liner) as soon as the pipe is spooled on a reel this is normal and does not affect its performance in any way.

Since TCT is as strong as metal, the behavior is expected to be similar. During such conditions steel tubing, drill pipe, and collars have been seen expelled from the well. That will likely happen with TCT too. Will it happen sooner? Not sure, but even if the event fully escalates 50% faster than with metal, the consequences will not be different, only instead of say an hour, it might happen in 30 minutes. Nothing to avert the consequence of such an event can be done in that time frame. Steel pipe, casing, and tubing have been sand-cut in minutes resulting from the extreme velocities of the two mediums together. Similar expectations for TCT.

There is no reason, when looking at other Industries, to believe non-metallic composite is less strong than metallic are. Airplanes are made of carbon fiber (CF), F1 cars are accident impact strengthened with CF. They are all much stronger than metal equivalent material. The unique and extreme forces in an uncontrolled well flow cannot be counteracted by metal or non-metallic composites, they will perform similarly.

Yes, there is sufficient safety on the collapse performance (radial hoop strength) to allow for safe installation and operation. Calculations have shown that with a tubing full of gas, zero pressure at surface, an annulus with packer fluid and max design pressure at surface (ie MDASP) there is no risk of collapse. Category: General Properties and Dimensions

In most of the corrosive well-operating environments, the expected life exceeds 20 to 30 years. Titanium is very durable, corrosion-resistant, and in other industries like seawater coolers in nuclear power plants and chemical industries, it is the metal of choice for high corrosion resistance.

Carbon fiber is strong and nearly inert to corrosion bar wet/temperature degradation over time. CRA-tubulars apply a safety factor to the operating envelope. The (initial) operating limits are the limits CF would have after degradation.

We use a propriety cross-over design from carbon-fiber composite to any metal CRA alloy matching any type of premium or non-premium thread required by the client.

As mentioned, we can provide any available thread type. TCT can be connected to any off-the-shelf completion accessory.

Our product is a reeled endless tubing and is delivered in this configuration. The maximum length depends on the number of completion accessories installed. It can be one length from hanger to the packer, or it can be in segments for instance, from hanger to SCSSV and then next to the packer.

Tubing stress analysis indicates that well depths over 6,000 meters are still well within the operating envelope of the tubing.

TCT will in general be used in wells requiring a metal CRA tubing completion. However, the corrosive film on the Titanium liner is much harder than metal CRA alloy. Therefore, it will be much more difficult to damage that film contrary to Duplex or Inconel alloys. However, it is recommended to design and execute interventions similar to high Chrome, Nickel, or Inconel tubing. Carbon steel intervention tools can chip off steel splinters which could be embedded in the metal CRA tubing and give access to corrosion. If it is necessary to perform Interventions, non-metallic centralizers should be deployed, reduced running speed, especially in dry completions, like gas-wells. Intervention tools shall be selected new, burrs filed off. Plastic coated wire is a distinct advantage in both types of CRA tubing.

Not all cutting tools are advisable. Obviously, chemical cutters will not work, similarly, they do not work on metallic CRA tubing. The electric pipe cutting tool from Sondex wireline has been successfully tested on these materials.

Category: Intervention Activities

Yes, it can be milled but requires modified tools and reduced milling rates/conditions, bit type rpm, etc. The cuttings from milling the tubing are very light, and even lightweight, low viscosity brine will carry it to the surface.

Category: Intervention Activities

In the case of severed tubing, the fishing operation is similar to metal tubing. The TOF can be dressed, fished internally, or externally. A grapple overshot with slips engaging on the outside of the tubing and possibly a spear inside could work equally well as with traditional metal tubing fishing.

In the unlikely event that after a bit and scraper run the well is not fully accessible, the impact of TCT tubing weighing one-third of its metal competitor is low. Furthermore, TCT is as strong as metal, no issues.

Yes, TCT tubing can be made-up to any standard, any manufacturer’s accessory, as well as to nipples for plugs, standing valves, beam-pump seating nipples, etc. Any conventional completion design can incorporate TCT tubing.

At the moment this has not been tested, however, looking at a large number of available alternative options, mechanical or explosive, it should be possible.

Yes, a hydraulic control-line can be incorporated into the outer layer. Using available SCSSV’s and packer with integrated control-line options, it can be supplied. Similarly, fiber optic cable can be integrated. Existing technology allows for the cable to exit the tubing, bypass the accessory, and connect to the optic cable below again.

Power cable for ESP can be “wrapped” in the out layer, providing a sturdy and protected alternative to traditionally banding to the outside of the tubing.

Yes, there is sufficient safety on the collapse performance (radial hoop strength) to allow for safe installation and operation. Calculations have shown that with a tubing full of gas, zero pressure at surface, an annulus with packer fluid and max design pressure at surface (ie MDASP) there is no risk of collapse. Category: General Properties and Dimensions

In conventional metal CRA completion, monitoring of corrosion during the production life of the well is desired.

Can we inspect, and is that needed, in non-metallic CRA tubing?

Pulsed Eddy is a technology that could be tried on this new development. It makes non-magnetic elements slightly magnetic showing wall thickness reduction. It is a proven technology in measuring riser wall thickness and airplane structure inspection.

Downhole Video is a visual option to investigate the condition of the inside of the tubing.

CRA tubulars intends to further develop this requirement for those clients needing to comply with this requirement.

Carbon Capture and Storage requires captured CO2 to be pumped as a liquid down old oil and gas wells. Pumping the liquid CO2 into an empty reservoir below hydrostatic pressures a well would allow the liquid to “evaporate” at the top of the well, resulting in a large temperature drop. This Joule Thompson cooling effect varies with the effective remaining reservoir pressure. Over time this evaporation will reduce as reservoir
pressure increases. TCT is designed with two unique components suited for this purpose, Titanium-Ti and Carbon Fiber-CF. Titanium has a track record as a storage vessel for liquid Helium and CF was used on NASA’s Space Shuttle liquid Oxygen and Hydrogen tanks. These proven track records in extreme cold environments, exhibit fit for purpose application of  TCT components. Kobe steel puts the minimum temperature limit of Titanium at minus -269 degrees Celsius (4 degrees Kelvin). Carbon fiber in the grade used in TCT can safely be applied to minus -40 degrees Celsius without losing its strength.
In comparison, (metallic-CRA-alloys) like Duplex or Super Duplex are limited at around minus -50 C and minus -100 degrees C respectively.
Additionally, prices of these (metallic-CRA-alloys) are much higher than TCT, making it a very interesting economical alternative in these applications.

The thermal resistance of carbon fiber (through-thickness) =0.8W/m-K.

The TCT total thermal resistance per length (1 meter) R=0.0339K/W

Carbon fiber has a negative Coefficient of Thermal Expansion (CTE) and since it is so much stiffer than the surrounding epoxy, the combined effect is dominated by the CF. Therefore, the Temperature Coefficient is between 1/3 and 1/2 of that of metal tubing.

This number will be derived from that of Titanium and carbon fiber and gives a thermal pipe resistance of R=0.0339K/W per unit length of 1 meter.

Titanium on its own is used for Helium storage vessels because of its extreme low-temperature capabilities. Carbon fiber on its own was used on the Space Shuttle liquid Oxygen and Hydrogen tanks. Both applications are low-temperature environments. The difference in the operating envelope in CCS wells and the aforementioned applications are the forces and stresses experienced in wells. However, Titanium shows an increase in tensile strength when cooled down (Source Kobe Steel).

Low Temperature Characteristics
Neither commercially pure titanium nor titanium alloys become brittle even at extremely low temperatures. In particular, commercially pure titanium and Ti-5AI-2.5Sn ELI can be used even at 4.2 K (-269°C)

Carbon fiber has a negative Coefficient of Temperature Expansion (CTE), reducing thermal effects and forces resulting from temperature fluctuations. Our resin used in TCT can safely be exposed to minus -40 degrees Celsius. As can be seen from this temperature profile simulation illustrated, it would make TCT perfectly suitable for the large majority of CCS wells. It will only go below minus -20C in exceptional cases. At a price around 13Cr tubing, the Operator will get superior service to duplex or Inconel properties, low-temperature coefficient, and low tubing weight.

Carbon Capture and Storage requires captured CO2 to be pumped as a liquid down old oil and gas wells. Pumping the liquid CO2 into an empty reservoir below hydrostatic pressures a well would allow the liquid to “evaporate” at the top of the well, resulting in a large temperature drop. This Joule Thompson cooling effect varies with the effective remaining reservoir pressure. Over time this evaporation will reduce as reservoir
pressure increases. TCT is designed with two unique components suited for this purpose, Titanium-Ti and Carbon Fiber-CF. Titanium has a track record as a storage vessel for liquid Helium and CF was used on NASA’s Space Shuttle liquid Oxygen and Hydrogen tanks. These proven track records in extreme cold environments, exhibit fit for purpose application of TCT components. Kobe steel puts the minimum temperature limit of Titanium at minus -269 degrees Celsius (4 degrees Kelvin). Carbon fiber in the grade used in TCT can safely be applied to minus -40 degrees Celsius without losing its strength.
In comparison, (metallic-CRA-alloys) like Duplex or Super Duplex are limited at around minus -50 C and minus -100 degrees C respectively.
Additionally, prices of these (metallic-CRA-alloys) are much higher than TCT, making it a very interesting economical alternative in these applications.

The thermal resistance of carbon fiber (through-thickness) =0.8W/m-K.

The TCT total thermal resistance per length (1 meter) R=0.0339K/W

Carbon fiber has a negative Coefficient of Thermal Expansion (CTE) and since it is so much stiffer than the surrounding epoxy, the combined effect is dominated by the CF. Therefore, the Temperature Coefficient is between 1/3 and 1/2 of that of metal tubing.

INTRODUCING THE TEAM

150+ Years experience in delivering shareholder returns

Emile-img

EMILE BURNABY LAUTIER

Founder

JOOST DE BAKKER

CEO

Rein-img

REIN MAATJES

CTO

RODERICK VAN SEVENTER

CFO
FLORIS-DEGENER

FLORIS DEGENER

Well Engineer

FRED NILSON

CCO
Hermen img

HARMEN KLEIN WOOLTHUIS

Equipment Engineer

JEROEN VAN BUSSEL

Composites Specialist

ARJAN-LOK--LLM

ARJAN LOK -LLM

Legal Councel
KEVIN-COX--PhD

KEVIN COX -PhD

Head Of Design

Technical Partners

Evonik 1
Voith 1
Toray 1
GMC 1
HRM 1
XX 1
Additional 1
OliaSoft 1

Commercial Partners

Almansoori 1
R&D 1

Contact Us

Feel free to get in touch with us

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RODERICK VAN SEVENTER

Legal Matters

ARJAN LOK

Write Us

    +1 (661) 472-0581

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    JOOST DE BAKKER

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    REIN MAATJES