Pipeline Repair Project Feed 1
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PIPELINE REPAIR AT KP 110 – KP 133 KUALA TUNGKAL TO PANARAN TGI OFFSHORE PIPELINE 18th-June-08
FEED Handover Meeting Agenda 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Project Introduction Problem Definition Design Basis Pipeline Mechanical Design Pipeline Outline Installation Analysis Repair Methodology Cost Estimate and Schedule Valve Skid Design EIA Review HAZID & HAZOP Action Items Prof. Andrew Palmer’s Review Closeout Report Discussion and Close Out
Project Introduction
KP 133.5
KP 110.5
FEED OBJECTIVES
Engineer a feasible repair method that can be executed by available installation contractors in the region
Develop a method based on use of industry proven equipment and procedures
Review the method with potential EPCC contractors to get feedback on their construction risks.
Develop a method which offers no or minimum stoppage of Gas to the consumers
Develop a method which enables restoring the gas flow to the full design pressure as early as possible
Conduct risk work shop and identify risks that should be managed by PMT
Identify long lead items for procurement so that repair work can be executed as early as practically possible
Project Introduction
Details of Damaged Section (KP110.5 to KP133.5) • Total of 19 buckles along the damaged section • Maximum deformation of buckle – 7.59% of OD • Water depth at damaged section – 35m
Project Introduction
Design Basis of Replacement Pipeline DESCRIPTION
UNIT
PARAMETERS
Approximate Length
km
Approximately 23.0
Pipeline OD
mm
711.2 (28”)
Material
-
Carbon Steel
Line Pipe Specification
-
API 5L X65, manufactured to DNV OS-F101
Pipeline Wall Thickness
mm
15.9 (.625”)
Service
-
Dry Sales Gas
Pipeline Corrosion Allowance
mm
0.0
Internal Coating
-
80 micron DFT Epoxy Coating
External Corrosion Coating
-
3 Layer PE
External Corrosion Coating Thickness
mm
2.1
Concrete Weight Coating Thickness
mm
94
Design Pressure
Barg
113.8 (1650 psig)
Operating Temperature
°C
40.6
Hydrotest Pressure
Barg
136.7 (1983 psig)
Maximum Operating Pressure
Barg
103.4 (1500 psig)
Product Density
Kg/m3
63.0
Pressure Rating of Pipeline Components
-
ANSI Class 900
Design Basis of Replacement Pipeline
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Installation Analysis
Pipeline Installation Analysis
Final Repair Method
Repair Method • Zero Downtime Method
Micros oft PowerPoint Presentation
Schematic Diagram
Comparison Between Both Methods
Cost Flange Connections/ KaMos Gaskets
Hot Taps
STOPPLE
Barred Tees
5D Bend
Gate Valve
Shut-down Time
CM – Reduced Downtime
Nil
6 (4 in-place)
4
Nil
Nil
Nil
Zero Downtime Method
6
8 (6 in-place)
4
2
4
2 x 28” 2 x 16”
Note: 2.
CM – Conventional Method
3.
The hardware cost stated above includes 10% for transportation cost.
Hardware Cost
Construction Cost
Total Cost
4 – 6 Wks
US$3.3
US$30M
US$33.3
Nil
US$9.6M
US$40M
US$49.6
Comparison Between Both Methods Reduced Downtime Method Advantages
Disadvantages
•
No flange connections along the pipeline
•
Involves less construction and diving work
• •
Stoppage of gas supply to consumers for 4 to 6 weeks Delay in construction work will result in more stoppage of gas supply to consumers
•
After commissioning sales gas will have some water till complete dryness is achieved
•
Equipment procured does not offer flexibility to switch to zero down time method
•
4 In-place hot-tap clamps
Zero Downtime Method •
Zero Shut-down time and any delay in construction will not disrupt flow to the consumers
•
Restoration of full design pressure before completion of repair
•
Equipment procured offers flexibility to switch to reduced down time method
•
6 flange connections
•
Involves more construction / diving work
•
6 In-place hot-tap clamps
Material Cost
US$3.3M
US$9.6M
Construction Cost
US$30.0M
US$40.0M
Comparisons of Risks Reduced Downtime Method
Zero Downtime Method
1.
Emergency Response Plan required
1.
Emergency Response Plan required
1.
Gas Freeing the abandoned pipeline
1.
Gas Freeing the abandoned pipeline
1.
Potential of buckling the pipeline during above water tie-in
1.
KaMOS gasket failure
1.
Presences of large amount of water and air pockets in the pipeline while restoring the flow
1.
Experienced Hot-tap contractor should be engaged
1.
Gas supply shut down time can increase due to construction delays
1.
Experienced Hot-tap contractor should be engaged
Shut-Down Time for Reduce Downtime Method
Overall Schedule for Zero Downtime Method – Best Scenario
Overall Schedule for Zero Downtime Method - Realistic
Potential EPCC Contractors Pipelay
Subsea
Cal Dive
Saipem
Global
Acergy
Technip Subsea 7
Valve Skid Design
Valve Skid Design
Valve Skid Design
Valve Skid Design
EIA Action Plan
EIA Action Plan
EIA Action Plan
HAZID & HAZOP Action Items
HAZID Action Items –
HAZOP Action Items –
Adobe Acrobat 7.0 Document
Adobe Acrobat 7.0 Document
Dr Andrew Palmer’s Review and Actions Required
Dr Andrew Palmer’s Review and Actions Required
Dr Andrew Palmer’s Review and Actions Required
Project Status – Engineering S/N
Pipeline Mechanical Design Activities
Status
Further Actions
1.
28” Pipe WT and Concrete Thickness
Done
-
2.
16” Pipe WT and Stability
Done
EPC Contractor to check suitability of the available 16” pipe from Stockist. For a !6” dia 11.1 mm thick a 40mm concrete is required. EPC Contractor to proposed method to ensure stability of pipeline if 16” pipe is not concrete coated.
3.
Small Diameter Pipings, WT and Stability
Done
EPC Contractor to check suitability of the available 6” pipe from Stockist. EPC Contractor to ensure stability of piping during operation.
4.
Cathodic Protection Design
Done
No CP is proposed for the temporary piping as it is exposed to sea water for a short period only. There is enough margin on the anodes provided on the permanent facilities to take care of the temporary piping.
5.
Pipelay Analysis
Done
EPC Contractor to perform detailed dynamic lay analysis based on their proposed pipe laybarge
6.
Bottom Roughness
Done
EPC Contractor to perform pre-engineering survey and update the Bottom Roughness Analysis. Span rectification if required.
7.
Overall Schematic
Done
EPC Contractor to perform final HAZOP and HAZID and update overall schematic.
Project Status – Engineering S/N
Installation Methodologies Activities
Status
Further Actions
1.
Zero Downtime Method
Done
EPC Contractor to develop a detailed execution plan and procedures for this method
2.
Reduced Downtime Method
Done
-
3.
Comparisons between Methods
Done
-
4.
HAZID and HAZOP
Done
EPC Contractor to perform HAZID and HAZOP based on the execution plan and procedures developed by EPC Contractor
Project Status – Engineering
Valve Skid Design
S/N 1.
Activities
Statue
Piping Analysis - Caesar II Model
Done
2.
Structural Analysis - SACS Model
Done
3.
Drawings
Done
Further Actions EPC
Contractor to carry out detailed design of Valve Skids .
EPC
Contractor to re-check installation analysis and design installation aids based on the final skid design and equipment / vessel proposed for installation. EPC
Contractor to develop detailed fabrication drawings.
Project Status – Engineering S/N
Material Specifications Activities
Status
Further Actions
1.
Flanges, Bolts, Nuts, Gaskets and Fittings
Done
-
2.
Subsea DBB Expandable Gate Valves / Gate Valves
Done
-
3.
5D Induction Bends
Done
4.
Subsea Mechanical Connectors & Hot Tap Assembly
Done
EPC
Contractor to attend all FAT testing for both mechanical connectors and hot tap assemblies EPC
Contractor to perform mock testing before the actual installation works 5.
Field Welding and NDT
Done
6.
Construction Materials
Not Done
EPC Contractor to prepare welding and NDT procedures All non-long lead and construction materials to be procured by EPC Contractor
Project Status – Engineering S/N
Installation Specifications Activities
Status
Further Actions
1.
Pipeline Installation
Done
EPC Contractor to develop all necessary installation procedures
2.
Survey and Monitoring
Done
EPC Contractor to develop detail survey and monitoring procedures.
3.
Pipeline Cleaning, Gauging, Pigging and Hydrotest
Done
EPC Contractor develop detail pre-commissioning procedures. Final HAZOP and HAZID need to be performed
Project Status – Engineering S/N
Drawings Activities
Status
Further Actions
1.
Pipeline Alignment
Done
EPC Contractor to update based on pre-engineering survey and identify locations where span rectification is required
2.
Tie-in Arrangements
Done
EPC Contractor to update based on final arrangement proposed and approved by PMT / TGI
EPC Contractor to perform HAZOP and HAZID based on the final arrangement and make necessary adjustments 3.
Valve Skid Details
Done
EPC Contractor to include details of installation aids and prepare fabrication drawings.
Discussion and Close Out
FEED Handover Meeting Agenda 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Project Introduction Problem Definition Design Basis Pipeline Mechanical Design Pipeline Outline Installation Analysis Repair Methodology Cost Estimate and Schedule Valve Skid Design EIA Review HAZID & HAZOP Action Items Prof. Andrew Palmer’s Review Closeout Report Discussion and Close Out
Project Introduction
KP 133.5
KP 110.5
FEED OBJECTIVES
Engineer a feasible repair method that can be executed by available installation contractors in the region
Develop a method based on use of industry proven equipment and procedures
Review the method with potential EPCC contractors to get feedback on their construction risks.
Develop a method which offers no or minimum stoppage of Gas to the consumers
Develop a method which enables restoring the gas flow to the full design pressure as early as possible
Conduct risk work shop and identify risks that should be managed by PMT
Identify long lead items for procurement so that repair work can be executed as early as practically possible
Project Introduction
Details of Damaged Section (KP110.5 to KP133.5) • Total of 19 buckles along the damaged section • Maximum deformation of buckle – 7.59% of OD • Water depth at damaged section – 35m
Project Introduction
Design Basis of Replacement Pipeline DESCRIPTION
UNIT
PARAMETERS
Approximate Length
km
Approximately 23.0
Pipeline OD
mm
711.2 (28”)
Material
-
Carbon Steel
Line Pipe Specification
-
API 5L X65, manufactured to DNV OS-F101
Pipeline Wall Thickness
mm
15.9 (.625”)
Service
-
Dry Sales Gas
Pipeline Corrosion Allowance
mm
0.0
Internal Coating
-
80 micron DFT Epoxy Coating
External Corrosion Coating
-
3 Layer PE
External Corrosion Coating Thickness
mm
2.1
Concrete Weight Coating Thickness
mm
94
Design Pressure
Barg
113.8 (1650 psig)
Operating Temperature
°C
40.6
Hydrotest Pressure
Barg
136.7 (1983 psig)
Maximum Operating Pressure
Barg
103.4 (1500 psig)
Product Density
Kg/m3
63.0
Pressure Rating of Pipeline Components
-
ANSI Class 900
Design Basis of Replacement Pipeline
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Installation Analysis
Pipeline Installation Analysis
Final Repair Method
Repair Method • Zero Downtime Method
Micros oft PowerPoint Presentation
Schematic Diagram
Comparison Between Both Methods
Cost Flange Connections/ KaMos Gaskets
Hot Taps
STOPPLE
Barred Tees
5D Bend
Gate Valve
Shut-down Time
CM – Reduced Downtime
Nil
6 (4 in-place)
4
Nil
Nil
Nil
Zero Downtime Method
6
8 (6 in-place)
4
2
4
2 x 28” 2 x 16”
Note: 2.
CM – Conventional Method
3.
The hardware cost stated above includes 10% for transportation cost.
Hardware Cost
Construction Cost
Total Cost
4 – 6 Wks
US$3.3
US$30M
US$33.3
Nil
US$9.6M
US$40M
US$49.6
Comparison Between Both Methods Reduced Downtime Method Advantages
Disadvantages
•
No flange connections along the pipeline
•
Involves less construction and diving work
• •
Stoppage of gas supply to consumers for 4 to 6 weeks Delay in construction work will result in more stoppage of gas supply to consumers
•
After commissioning sales gas will have some water till complete dryness is achieved
•
Equipment procured does not offer flexibility to switch to zero down time method
•
4 In-place hot-tap clamps
Zero Downtime Method •
Zero Shut-down time and any delay in construction will not disrupt flow to the consumers
•
Restoration of full design pressure before completion of repair
•
Equipment procured offers flexibility to switch to reduced down time method
•
6 flange connections
•
Involves more construction / diving work
•
6 In-place hot-tap clamps
Material Cost
US$3.3M
US$9.6M
Construction Cost
US$30.0M
US$40.0M
Comparisons of Risks Reduced Downtime Method
Zero Downtime Method
1.
Emergency Response Plan required
1.
Emergency Response Plan required
1.
Gas Freeing the abandoned pipeline
1.
Gas Freeing the abandoned pipeline
1.
Potential of buckling the pipeline during above water tie-in
1.
KaMOS gasket failure
1.
Presences of large amount of water and air pockets in the pipeline while restoring the flow
1.
Experienced Hot-tap contractor should be engaged
1.
Gas supply shut down time can increase due to construction delays
1.
Experienced Hot-tap contractor should be engaged
Shut-Down Time for Reduce Downtime Method
Overall Schedule for Zero Downtime Method – Best Scenario
Overall Schedule for Zero Downtime Method - Realistic
Potential EPCC Contractors Pipelay
Subsea
Cal Dive
Saipem
Global
Acergy
Technip Subsea 7
Valve Skid Design
Valve Skid Design
Valve Skid Design
Valve Skid Design
EIA Action Plan
EIA Action Plan
EIA Action Plan
HAZID & HAZOP Action Items
HAZID Action Items –
HAZOP Action Items –
Adobe Acrobat 7.0 Document
Adobe Acrobat 7.0 Document
Dr Andrew Palmer’s Review and Actions Required
Dr Andrew Palmer’s Review and Actions Required
Dr Andrew Palmer’s Review and Actions Required
Project Status – Engineering S/N
Pipeline Mechanical Design Activities
Status
Further Actions
1.
28” Pipe WT and Concrete Thickness
Done
-
2.
16” Pipe WT and Stability
Done
EPC Contractor to check suitability of the available 16” pipe from Stockist. For a !6” dia 11.1 mm thick a 40mm concrete is required. EPC Contractor to proposed method to ensure stability of pipeline if 16” pipe is not concrete coated.
3.
Small Diameter Pipings, WT and Stability
Done
EPC Contractor to check suitability of the available 6” pipe from Stockist. EPC Contractor to ensure stability of piping during operation.
4.
Cathodic Protection Design
Done
No CP is proposed for the temporary piping as it is exposed to sea water for a short period only. There is enough margin on the anodes provided on the permanent facilities to take care of the temporary piping.
5.
Pipelay Analysis
Done
EPC Contractor to perform detailed dynamic lay analysis based on their proposed pipe laybarge
6.
Bottom Roughness
Done
EPC Contractor to perform pre-engineering survey and update the Bottom Roughness Analysis. Span rectification if required.
7.
Overall Schematic
Done
EPC Contractor to perform final HAZOP and HAZID and update overall schematic.
Project Status – Engineering S/N
Installation Methodologies Activities
Status
Further Actions
1.
Zero Downtime Method
Done
EPC Contractor to develop a detailed execution plan and procedures for this method
2.
Reduced Downtime Method
Done
-
3.
Comparisons between Methods
Done
-
4.
HAZID and HAZOP
Done
EPC Contractor to perform HAZID and HAZOP based on the execution plan and procedures developed by EPC Contractor
Project Status – Engineering
Valve Skid Design
S/N 1.
Activities
Statue
Piping Analysis - Caesar II Model
Done
2.
Structural Analysis - SACS Model
Done
3.
Drawings
Done
Further Actions EPC
Contractor to carry out detailed design of Valve Skids .
EPC
Contractor to re-check installation analysis and design installation aids based on the final skid design and equipment / vessel proposed for installation. EPC
Contractor to develop detailed fabrication drawings.
Project Status – Engineering S/N
Material Specifications Activities
Status
Further Actions
1.
Flanges, Bolts, Nuts, Gaskets and Fittings
Done
-
2.
Subsea DBB Expandable Gate Valves / Gate Valves
Done
-
3.
5D Induction Bends
Done
4.
Subsea Mechanical Connectors & Hot Tap Assembly
Done
EPC
Contractor to attend all FAT testing for both mechanical connectors and hot tap assemblies EPC
Contractor to perform mock testing before the actual installation works 5.
Field Welding and NDT
Done
6.
Construction Materials
Not Done
EPC Contractor to prepare welding and NDT procedures All non-long lead and construction materials to be procured by EPC Contractor
Project Status – Engineering S/N
Installation Specifications Activities
Status
Further Actions
1.
Pipeline Installation
Done
EPC Contractor to develop all necessary installation procedures
2.
Survey and Monitoring
Done
EPC Contractor to develop detail survey and monitoring procedures.
3.
Pipeline Cleaning, Gauging, Pigging and Hydrotest
Done
EPC Contractor develop detail pre-commissioning procedures. Final HAZOP and HAZID need to be performed
Project Status – Engineering S/N
Drawings Activities
Status
Further Actions
1.
Pipeline Alignment
Done
EPC Contractor to update based on pre-engineering survey and identify locations where span rectification is required
2.
Tie-in Arrangements
Done
EPC Contractor to update based on final arrangement proposed and approved by PMT / TGI
EPC Contractor to perform HAZOP and HAZID based on the final arrangement and make necessary adjustments 3.
Valve Skid Details
Done
EPC Contractor to include details of installation aids and prepare fabrication drawings.
Discussion and Close Out
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