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Abstract of Papers:-
The Malampaya Deep Water Gas to Power Project is a development in the Malampaya and
Camago reservoirs that uses deep water subsea wells connected by wet-gas flow lines to a
platform in shallow water, where gas and condensate are processed. Dry gas then travels via
a 504 km subsea Gas Export Pipeline (GEP) to the Malampaya Onshore Gas Plant (MOGP) at
Batangas for final processing and fiscal metering before the gas is dispatched to customers
downstream.
The primary emergency shutdown valve (ESDV) on the GEP riser, having been discovered to
be defective, was unable to provide an acceptable isolation for the platform from the GEP
inventory in the event of an emergency shutdown. This mandated that the ESDV be
removed and replaced, along with its neighbouring manual block valve. This work
necessitated a plant shutdown since gas export is not possible while repairs proceed. A
major shutdown, planned for over a year, was due to take place in February/March 2010. A
range of rejuvenation work was scheduled, including replacement of the aforementioned
valves.
Abstract of Papers (cont’d) :-
Two options presented themselves: i) to bleed down the entire GEP—a protracted and very
costly alternative—and ii) to deploy pressure isolation of the line downstream of the valves.
The latter method was preferred, with isolation using remote-controlled plugging
technology known as the SmartPlug® was provided by TDW. SmartPlug® is a remote-
controlled (umbilical-less) pipeline isolation system effective in isolating oil and gas
pipelines. Designed, manufactured, and tested to withstand MAOP (Maximum Allowable
Operating Pressure), SmartPlug® allows repairs and maintenance to be carried out while
maintaining pipeline pressure.
Several challenges were apparent. As this was the first ever pressure isolation of its kind
undertaken at the Malampaya platform by SPEX, there were understandable concerns
about viability. This paper describes the steps from the site visit and engineering feasibility
study of applying pipeline plugging technology, to offshore mobilization and then to
execution. Fortunately, the operation proceeded according to plan, and was judged a
success by the operator.
www.tdwilliamson.com
By Rolf Gunnar Lie, T.D. Williamson Asia Pacific Pte Ltd, Singapore
7th Asian Pipeline Conference and Exhibition
“Overcoming Challenges in Pipelines”
Malampaya Gas Export Line
Valve Replacement
using
Remote-controlled Plugging Technology
57th Asian Pipeline Conference & Exhibition 2011 5
Agenda
Malampaya pipeline system.
Why valve change out
Gas Export Line – Shut Down activities & Isolation scope
Pipeline Isolation by use of SmartPlug®
Pigging of the SmartPlug®
Actuation System and Communication System
Benefits in using pipeline pressure isolation
Launching, setting, monitoring and retrieval
Results
Safety
67th Asian Pipeline Conference & Exhibition 2011 6
Malampaya Pipeline System
77th Asian Pipeline Conference & Exhibition 2011 7
Malampaya gas Export Line – Isolation scope
Gas Export Line to onshore
processing facility (isolation
location) Defect ESDV and Manual Valve
87th Asian Pipeline Conference & Exhibition 2011
Why Valve Change Outs!
8
A. If the primary emergency shutdown valve (ESDV) or Launcher Valves (MOV) fail to provide an acceptable isolation for the platform from the Gas Export Pipeline inventory in the event of an emergency shutdown it represents a safety risk and the valve therefore has to be removed and replaced.
B. Why? Because even a pin hole leak above the leaking valve can cause a CatastropicEvent at the platform or has too large impact for the operator to accept the risk!
C. The leakage of valves are generally determined by acoustic leak detection.
D. Leakage rate criteria are:
i. MOV’s in H2S lines: >=0,01kg/s
ii. SDV Gas Lines: >=0,1kg/s
iii. SDV Oil lines: >=6kg/min
E. Shell does this globally but have different leakage acceptance criteria.
F. Valve replacement work is generally done during planned shutdowns as gas export will not be possible for the duration of the work.
G. Thinking is preventive planned maintenance rather then emergency response.
97th Asian Pipeline Conference & Exhibition 2011 9
Possible solutions to the problem
Live with a defective ESDV at the platform – NO, because of
safety
Replace the ESDV relying solely on a single SSIV flapper
type valve for isolation from the Gas Export Line (single
isolation) – NO, because of safety
Depressurise and purge the entire GEP, then replace ESDV
– NO, because of Cost
Using of high pressure Isolation Plugs - YES
107th Asian Pipeline Conference & Exhibition 2011 10
Benefits in using SmartPlug®
FEATURE BENEFIT
Eliminates
displacement of
product
• No bleed-down
• Reduced chemicals to
treat water
• Reduced nitrogen to
purge
Eliminates re-
commissioning of
pipelines
• No disposal of hydrates
• No disposal of chemicals
or contaminated water
• No full line drying
Eliminate
shutdown
completely
• Production can continue
during maintenance
Allows phased de-
commissioning, or
start-up of new
facilities
Production continues, or
starts while construction
work is on going
THE REAL BENEFIT
• Reduces pipeline
down time
• Saves money
• Increases
production & profits
117th Asian Pipeline Conference & Exhibition 2011 11
Isolation by use of SmartPlug®
The TDW SmartPlug® is a remotely controlled and
operated (umbilical-less) pipeline isolation system used
for isolation of oil and gas pipelines.
127th Asian Pipeline Conference & Exhibition 2011 12
Pigging of the SmartPlug®
SmartPlug is a bi –directional piggable tool.
Travels with the flow in the pipeline.
Negotiate 3D bend , sometimes as small as 1.5D bends.
Negotiate valves, T’s.
Pre –engineering always include piggability study.
Onboard tracking and positioningsystem.
137th Asian Pipeline Conference & Exhibition 2011 13
SmartPlug® Actuation System
147th Asian Pipeline Conference & Exhibition 2011 14
SmartPlug® Communication System
157th Asian Pipeline Conference & Exhibition 2011 15
Project Execution
Steps to be achieved:
1. Engineering
2. Equipment and personnel mobilization
3. Launching of the SmartPlug® & pigging
4. Setting of the SmartPlug®
5. Monitoring while ESDV replacement is ongoing.
6. Un-setting and retrieval
167th Asian Pipeline Conference & Exhibition 2011 16
Setting and Monitoring
Manual valve
ESDV
SmartPlug® Set location
177th Asian Pipeline Conference & Exhibition 2011 17
Results
The defective ESDV and manual block valve were
successfully removed and replaced and the integrity safety
barrier in the GAS Export Line re-established.
The SmartPlug® offered a quick and effective solution to an
otherwise costly and complicated problem.
187th Asian Pipeline Conference & Exhibition 2011 18
Safety
197th Asian Pipeline Conference & Exhibition 2011 19
Acknowledgements
Co-Author: Gerald Mr. Gerald Misajon, Maintenance Engineer, Shell Philippines Exploration and Production, Manila
Nathan Roberts, Discipline Lead - Mechanical Engineering, Shell Philippines Exploration, Manila
Nathan Stephenson, Project Manager, Sarawak Shell Sdn Berhad /Sabah Shell Petroleum Co Ltd, Kuala Lumpur
Bård Kloster, Offshore Supervisor SmartPlug® operation, TDW Offshore Services AS, Stavanger, Norway
207th Asian Pipeline Conference & Exhibition 2011 20
Contact details:
Rolf Gunnar Lie
T.D. Williamson Asia Pacific Pte Ltd
4 Tech Park Crescent
SINGAPORE 638128
Phone: +65 96651 3837
E-mail: [email protected]
® Registered trademarks of T.D. Williamson, Inc. in the United States and in foreign countries. ™ Trademarks of T.D. Williamson, Inc. in
the United States and in foreign countries.
Thank you for your
attention!