OTC-24721-MS A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field John R Wright Jr. Polyflow LLC, Khairul Anuar Karim, PETRONAS Carigali and Steve Kennedy, SCG Oil and Gas
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OTC-24721-MS
A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow
Line in the East Malaysia Samarang Field
John R Wright Jr. Polyflow LLC, Khairul Anuar Karim, PETRONAS Carigali and Steve
Kennedy, SCG Oil and Gas
Agenda
1) Background 2) Steps and Analysis for Successful Rehabilitation 3) Details of the Installation 4) Benefits Analysis 5) Areas for Improvement 6) Q & A
Slide 2
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
Background
• PL-112 Pipeline • 52 Km off Labuan in Samarang Field • 8-10 Meters of Water • 6” API -5L X-42 Steel Pipe Installed in 1977 • Approximately 1Kilometer
• Anchor Hooked Pipe Causing a Kink in 2009 • Repairs Made with Misalignment Flanges • Difficulty in Maintenance and Loss of Wall Thickness
Concluded Repairs as Temporary • Current Infield Drilling
• Required New Pipeline for Next 25 Years • New Steel Pipeline Replacement and Reinforced Thermoplastic
Pipe Rehabilitation were Evaluated • Future Flowing Conditions
• 1,800bbl – 5,000bbl/day Depending upon Field Requirements • Concern with SRB’s in Future • Low Formation Pressure
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
Analysis and Planning Steps for RTP Rehab
• Sizing of the New Flow Line • Material Selection • Pull Force Analysis • Selection of Pulling Equipment • Detailed Layout of Project
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
Proper Sizing of Pipe Slide 5
• Sized for Desired Production Fits Inside of Existing Steel Acceptable Pressure Drop
Acceptable Pressure Drops Minimal Velocities for Range
of Flow Risers Have to be Modified
Modified Riser with 12D Bend
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
Existing Riser with 5D Bend
Pressure Drops and Critical Velocities for 3.5” RTP
Velocity at 1,800bbl/day is 2 ft./sec (0.61 m/sec)
Typical Production Volume Pressure Drop of 15.3 psi @ 1,800bbl/day
Maximum Production Pressure drop 96.4 psi @ 5,000bbl/day
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
Nylon Jacket
RTP Components
Chemical Resistance and Permeation of PPS/Fortron
30
35
40
45
50
55
60
0 20 40 60 80 100 120
190C170C160C150C
Tensile Strength of Fortron PPS (MPa) as a function of Ageing (Days) from 140-190C
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
Pre-Planning Project Layout
Spool off Location
Riser Termination
Project Pre-planning
• Gauging Pig for Existing Line • Pull Force Analysis
• Wet vs. Dry • 1,818 Kg Pull Force Wet • Synthetic Rope (5X Safety Factor)
• Project Layout • Platform Space vs. Boat • Individual Steps • Responsible Party • Underwater Work
• Riser Bottom Bend Modifications • Subsea Bend Modification
• Top Side Spools Modifications • Project Scheduling • Capabilities of Platform Equipment
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
Platform A Platform B Existing Pipeline Plastic Insert Pipe Messenger Pig
Cross-section
Messenger pig
Winch Spool Reel
Installation Method: Planning
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
Installation Method: Actual
Spool Reel
Vessel
Plastic Insert Pipe
Installing the RTP
• Cleaning the Line – Scrape Both Directions
• Erect Scaffolding to Align Pipe from Boat
• Foam Pig Synthetic Rope Through Pipeline
• Set up Winch for Pulling • Align Pulleys over Flange Opening • Attach Pulling Cone to Pipe and
Cable
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
Erecting Scaffolding
Cleaning Activity for Existing Line RTP Pull Thru Activity
• End Connections • Double Faced RTJ Flanged • Seal off Annular Space • Port on Annulus with Pressure Gage
Boat to Scaffold
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
RTP Pulling Activity
Jointing between two portions of RTP pipe Splice Coupling
Inspection of the RTP After Pull Through • Inspect Pulled RTP
• Inspect for Gouges & Jacket Breaches
• Deformation in Pipe • Cut to Length & Install
Termination • Hydro- Test at 2X MAOP for 24
Hours (360PSI) • Design Pressure – 1,440PSI
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
Final Pull Out of RTP
Final Spool Make-up Hydrotest Pressure Chart
Analysis of Benefits
• After One Year of Operation Flowing 1,800bb – 7,000bbl/day
• 7,000bbl/day Causing Excessive Back Pressure
No Chemical Treatment No Pigging/ Cleanout
• CAPEX 67% Lower than New Steel Line Eliminating Riser Modifications &
Pulling from Boat Creates 80+ % Savings
• Benefit to Environment compared to conventional steel replacement Minimum disturbance to seafloor &
marine life Reused of existing steel pipeline
• Existing Steel Line Remains Part of the System and is not Abandoned
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
Lessons Learned – Areas for Improvement
• Improvement in Planning • Changed from Platform to Platform vs Boat to Platform • Platform Deck Space Availability • Crane on Platform Inoperable
• Making Sure Continuous Back Tension on Pipe During Pulling • Sharp Changes in Tension can Kink Pipe
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
Kink Portion Observed During Pulling Activity
Lessons Learned – Areas for Improvement cont.
• Better Pulling Rope Design to Minimize Damage During Pulling • Nylon Jacket on Rope too Thin • Tore As Pulled Through Riser
• Rub on Sharp Flange • Wrinkling Create Hang-up • No Issue with Pipe
• Rope Broke 1 Meter from End of Pull – Finish with Cable
• Jacket Tears Hung Up in Load Cell
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
Final Pull Out of RTP
Wrinkling of Pulling Rope When Bent Damage layer of Pulling Rope
Lessons Learned – Areas for Improvement cont.
• Alternative Rope Designs • Heavier Nylon Jacket • Braided Jacket • Braided Jacket with Nylon Jacket
• Testing Ongoing
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy
Acknowledgements
Slide 22
Special thanks to: a) P&E Management, PCSB b) SBO Management, PCSB - Maintenance & Operation, SBO c) Samarang Operations d) Technology Provider - Polyflow Inc. e) Contractors