Critical Pipeline Replacement in Dehydration Plant with Operational Continuity

Record-time intervention that avoided operational losses in a dehydration plant.

Estudo de Caso Nº

192 Cliente

Petróleos Sudamericanos

Argentina

2025

Condições de Trabalho

Temperature: 20°C / 68°F | Pressure: 3 kg/cm² | Fluid components: Water with hydrocarbon content (>2% HC)

Solução Pexgol

Pexgol 250 mm, Class 15

Aplicação

Water transport to dehydration plant (injection for secondary recovery)

Comprimento

10 m / 3.28 ft

Categorias

Petróleo e Gás, Água

The Challenge

Petróleos Sudamericanos is an Argentine company dedicated to the exploration and production of hydrocarbons, operating key assets in the Catriel Oeste region.

In this project, the dehydration plant plays a critical role: treated water is used for injection in secondary recovery processes, while oil is conditioned for delivery to reﬁneries. The operation required the continuous transport of a ﬂuid composed mostly of water (98%) with the presence of hydrocarbons (>2%), creating highly aggressive conditions for pipeline materials.

The existing GRP pipeline suffered recurrent failures due to constant corrosion, forcing shutdowns of both the plant and the oilﬁeld for repairs. These stoppages resulted in signiﬁcant production losses, increased operational costs, and disruptions across the entire transport and dispatch chain.

Additionally, since this was a critical line within the process, any intervention involved high operational and economic risk, as downtime needed to be minimized.

The Solution

To deﬁnitively solve the problem, a solution using 250 mm (Class 15) Pexgol pipes was implemented, designed to operate at a pressure of 3 kg/cm² and a temperature of 20°C, with excellent performance in ﬂuids containing hydrocarbons.

The pipeline replacement was executed as a critical operation completed in just two working days. Thanks to the material’s ﬂexibility, availability in long lengths, and ease of installation using electrofusion ﬁttings, intervention time was signiﬁcantly reduced.

As a result, the oilﬁeld was shut down for only 8 hours, avoiding production losses, idle equipment and labor costs, and the need to reschedule ﬁeld operations.

The chemical resistance of PE-Xa to hydrocarbons and its immunity to corrosion eliminated the root cause of the problem, ensuring reliable long-term operation. Additionally, the material’s light weight and fast installation enabled efﬁcient execution even in a sensitive operational environment.

This solution not only resolved the immediate issue but also optimized system operational continuity, reducing risks and costs associated with future interventions.