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SUBSEA PIPELINES DESIGN CHALLENGES
Presenters: Mr. Gbenga Suleiman (Lead Pipeline Engineer)Mr. A. K. Sangal (Pipeline Engineering Manager)Mr. Oussama Takieddine (Vice President Engineering)
PRESENTATION TO IPLOCA BOARD MEMBERS (21st APRIL, 2015)
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Beyond the Possible
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Beyond the Possible
Wednesday, May 06, 2015
NPCC ENGINEERING CAPABILITIES
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NPCC ENGINEERING CAPABILITIESBeyond the Possible
ONE STOP SHOP
Conceptual Engineering
FEED and Basic Engineering
Detailed Engineering
Constructability Engineering Review
Construction Engineering
Installation Engineering
Naval Engineering
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NPCC ENGINEERING CAPABILITIESBeyond the Possible
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Offshore / Onshore upstream facilities
• Well Fluid Gathering
• Separation System
• Gas Compression
• Gas Dehydration
• Fuel Gas Treatment
• Produced Water Treatment and
Disposal
• Sand Treatment / Separation
• Water and Gas Injection Facilities
• Crude / Products Storage
• Flare, Vent and Drain Systems
• Utilities (Inst. Air / Cooling Water / Hot Water etc.)
• Power System
• Telecom
• Control Systems
• Buildings: Accommodation and Technical Building
NPCC ENGINEERING EXPERIENCE
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NPCC ENGINEERING CAPABILITIESBeyond the Possible
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Our offshore capabilities includes subsea pipelines, cables and flexible engineering design, as well as onshore pipeline design capability.
NPCC ENGINEERING EXPERIENCE
OFFSHORE PIPELINE AND FLEXIBLES ONSHORE PIPELINE DESIGN
Route Selection Right-of-way selection
Wall Thickness Calculation Wall Thickness Calculation
Stability / Expansion Analysis Anti-Buoyancy Measures
Riser Stress Analysis Piping / Pipeline Stress Analysis
Global Buckling (Lateral & Upheaval) Road and River crossing
Other Detailed Engineering Activities Cathodic Protection (ICCP)
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Beyond the Possible
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ENGINEERING STRENGTH
NPCC ENGINEERING CAPABILITIES
NPCC Engineering – India (NEL)NPCC Engineering - Abu Dhabi Base
We also have about 275 staff in other engineering support center – India
VP ‐ E ED PEMPROCESS & SAFETY
E&I
MECHANICAL
PIPINGPIPELINE
STRUCTURAL
CIVIL
NAVAL
SERVICES & PL/QA
TECH SUPPORT
121
2230
66 91
13
35
47
PEM PROCESS & SAFETY
E&I
MECHANICAL
PIPINGPIPELINE
STRUCTURAL
CIVILNAVAL
SERVICES TECH SUPPORT
0 11 4
30
6
5928
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340490 465 430 470
626 75070
100 115 120 160
209250
0
200
400
600
800
1000
1200NPCC NEL
Engi
neer
ing
Man
pow
er Forecast
835
630550580590
410
1,000
ENGINEERING MANPOWER HISTOGRAM
Over 95% of our workforce are permanent staff
NPCC ENGINEERING CAPABILITIES
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TECHNICAL PRESENTATION
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CONTENTS
1. PIPELINES/CABLES ROUTE SELECTION
General Route Selection Criteria
Route Selection Challenges
New Approach to Route Selection
2. PIPELINES/CABLES STABILITY ON SEABED
Concept of Stability Design
Conventional Approach to Stability Design & Mitigation Method
New Approach to Stability Design & Mitigation Method
3. SOME EMERGING TECHNOLOGIES IN SUBSEA PIPELINES
Materials selection
Design / Analysis
Pipeline Integrity
Beyond the Possible
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Beyond the Possible
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1. PIPELINES/CABLES ROUTE SELECTION
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PIPELINES/CABLES ROUTE SELECTION
Minimize route length as much as possible.
Minimize health and safety risk and ensure marine life sustainability.
Consider environmental and regulatory factors.
Optimise flow assurance (minimize pressure losses).
Minimize pipeline free spans and amount of intervention work.
Consider the piggability philosophy of the pipeline.
Avoid Flare Heat Affected Zone (HAZ), dropped object areas, etc.
Beyond the Possible
GENERAL ROUTE SELECTION CRITERIA
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PIPELINES/CABLES ROUTE SELECTION
Avoid boulders, pockmarks, submarine exercise area, dredging, wrecks, fishing areas, etc.
Avoid Sabkha areas (Onshore)
Avoid pre-defined areas due to existing infrastructure and geo-technically unstable areas
Minimize local slide risk (avoiding the steepest slopes)
Minimize and/or avoid crossings on curves and within proximity of existing crossings, wherever possible.
Ensure crossing angle, if required, is not less than 30°
Beyond the Possible
ROUTE SELECTION CRITERIA CONT’D.
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PIPELINES/CABLES ROUTE SELECTION
Seabed features e.g. Boulders, Rocks, Rough bottom, and Steep slope which are susceptible to landslide.
Seabed obstructions from existing structures e.g. wrecks, PLEM, PLET, e.t.c.
Construction limitations e.g. shore/platform approaches, bend radius, laybarge draft, etc.
Other seabed, users, e.g. shipping lanes, fishing, dredging, exclusion zones, etc.
Beyond the Possible
ROUTE SELECTION CHALLENGES
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NEW APPROACH TO ROUTE SELECTION - Geographical Information System (GIS)
Application used is called ArcGIS
It is a real-time method of pipeline and cable route selection.
It integrates data from different sources into a centralized database
used for modeling and analysis based on spatial component
It has better precision capability in optimizing route
It saves time and cost as compared to the convectional system of
route selection
Beyond the Possible
PIPELINES/CABLES ROUTE SELECTION
Good Geophysical /
Geotechnical knowledge
however, is required.
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Beyond the Possible
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2. PIPELINES/CABLES STABILITY ON SEABED
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Installed subsea pipelines/cables are likely to become unstable under the influence ofhydrodynamic forces and buoyancy effects.
Stability of such pipelines/cables are checked by analysis at the onset of the project design.
Adequate solutions are then considered to prevent the undesired condition.
Beyond the Possible
PIPELINES/CABLES STABILITY ON SEABEDCONCEPT OF STABILITY DESIGN
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Analysis is usually carried out to determine pipelines/cables stability requirement using softwareapplications such as:
o AGA software, DNV Stablelines, Plus-one software, etc..
CONVENTIONAL MITIGATION METHOD
Typical mitigation usually recommended for subsea pipelines/cables stability correction are:
o Increase system weight by adding concrete weight coating
o Addition of concrete mattresses
o Use on Anchor blocks / Screw Anchors
Beyond the Possible
CONVENTIONAL APPROACH TO STABILITY DESIGN
PIPELINES/CABLES STABILITY ON SEABED
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CONVENTIONAL MITIGATION METHOD (CONT’D.)
other mitigation methods are:
o Rock-dumping on the installed pipeline
o Grout bag installation
Beyond the Possible
PIPELINES/CABLES STABILITY ON SEABED
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NEW APPROACH TO STABILITY DESIGNo ORCAFLEX - developed for dynamic simulation of subsea cables stability.
o ABAQUS - a finite element based software used for optimal pipeline /cables stability analysis .
MITIGATION METHODUse of leaded Uraduct and ballasting module for subsea cable stability.
o It has been used by NPCC in previous projectso Currently in use by NPCC in ongoing projecto Installation is done on the barge,o Divers assistance is not requiredo No degradation of rope like in concrete mattresso Accurate and efficient
Use of Artificial seaweed mattresseso Reduce the effect of seawater current on the installed pipelines/cables.o Restores disturbed marine habitat.o Not commonly used in this region due to smooth seabed and relatively low current speed
Beyond the Possible
PIPELINES/CABLES STABILITY ON SEABED
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Beyond the Possible
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3. EMERGING TECHNOLOGIES IN OFFSHORE/SUBSEA PIPELINES
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DEVELOPMENT OF CORROSION RESISTANT ALLOYS (CRA) CLADDING IN STEEL PIPES
ADVANTAGES
Elimination of Corrosion Allowance (CA)
It allows pipe wall thickness optimization
Prevents pipeline internal corrosion
EMERGING TECHNOLOGIES - MATERIALS SELECTIONBeyond the Possible
LIMITATIONS
Not cost effective
Diameter limitation due to cladding
Selection is based on highly corrosive content
only e.g. wet sour gas service
Cost is only justified in highly corrosive service
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3LPE / 3LPP (FBE + ADHESIVE + PE/PP) COATING
It has replaced banned Coal Tar Enamel coating due to its environmentally friendly property.
Better resistance to high temperature system
Better bonding properties and
Ease of Cathodic Protection system installation
Beyond the Possible
EMERGING TECHNOLOGIES - MATERIALS SELECTION
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EMERGING TECHNOLOGIES - PIPELINE ENGINEERING DESIGNFINITE ELEMENT METHOD IN PIPELINE DESIGN (GLOBAL BUCKLING – LATERAL / UPHEAVAL)
Advent of Finite Element Method approach has:
Introduced the system of discretization of pipeline system for
effective and efficient design
(Discretization: breaking down into distinct elements)
It enhances the non-linear finite simulation of global behavior
of pipeline system such as Lateral Buckling and Walking
Beyond the Possible
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ENGINEERING CRITICAL ANALYSIS (ECA)
Based on Fracture Mechanics
(Fracture Mechanics – study of crack propagation in materials)
Introduces the development of Weld Imperfection Acceptance Criteria
Preferred method for field girth weld inspection and quality control for long pipeline projects.
Used in Crack Tip Open Displacement (CTOD) test in Line pipe
It has been extensively applied by NPCC in previous projects
Beyond the Possible
EMERGING TECHNOLOGIES - PIPELINE ENGINEERING DESIGN
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SOIL LIQUEFACTION AND SEABED SCOURING
Soil liquefaction causes seabed subsidence along the pipeline
route.
Scouring induces unwanted span along the pipeline route.
These phenomena has necessitated the need for
further seabed study at the onset of pipeline design.
Its becoming a concern at crossing locations / touch-down
points.
Advantages includes:
Reduces risk of pipeline failure .
Reduces intervention / maintenance cost
Beyond the Possible
EMERGING TECHNOLOGIES - PIPELINE ENGINEERING DESIGN
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PIM APPROACH AT DESIGN STAGE
Pipeline cathodic protection system
Pipeline external corrosion coating
Pipeline internal corrosion lining
Design of anti-corrosive injection system, e.t.c.
PIM APPROACH AT OPERATION STAGE
Pipeline In-Line Inspection by introduction of intelligent Pigging
Routine Ultrasonic Thickness Measurement (UTM)
Introduction of Corrosion Coupon monitoring system
Injection of anti-corrosive compound e.g. Biocides for internal corrosion prevention, e.t.c.
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EMERGING TECHNOLOGIES - PIPELINE INTEGRITY MANAGEMENT
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The global recognition of Integrity Management has created ample brown field project
opportunities,
As the IOCs and NOCs focuses more on Integrity Management for sustainability, PIM
opportunity is bound to grow.
WAY FORWARD
Invest in R & D to provide pipeline design
Lifetime Extension (LTE) solution to our client /operators.
Improve on existing pipeline design/integrity technologies currently available.
Embark on drastic, but sustainable cost cutting measures to remain competitive
Beyond the Possible
EMERGING TECHNOLOGIES - PIPELINE INTEGRITY MANAGEMENT
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THANK YOU
Beyond the Possible
Questions please
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