Intelligent Pigging Inspection of SNEPCO’s - MCEDDmcedd.com/wp-content/uploads/Mehran Moini - Shell.pdf · Shell Nigeria Exploration & Production Co. Intelligent Pigging Inspection

Shell Nigeria Exploration & Production Co.

Intelligent Pigging Inspection of SNEPCO’s Deepwater Production Loop – Bonga, Nigeria


Introduction to SNEPCO

Shell Nigeria Exploration and Production Company (SNEPCO), based in Lagos carries out deepwater projects and operations in Nigeria

SNEPCO operates Bonga; Nigeria’s first deepwater development which has been on stream since Nov 2005

SNEPCO operates Bonga on behalf of The Nigerian National Petroleum Corporation (NNPC) who represent the Nigerian government,

Other co-venturers are ExxonMobil, Total and Eni (Affiliates)

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Introduction to Bonga Field

Bonga is Shell’s first and only operated Deepwater asset in Nigeria

Located South West of Warri,120 KM offshore in water depths1000 meters plus

Developed using subsea wells tied to a series of manifolds and tied back to a moored FPSO located centrally in the field

Production is via 4 Production Loops with 8 Steel Catenary Risers (SCR)

Water injection (for pressure maintenance) is via 3 flowlines with 2 SCR’s

Associated Gas is exported via a 90 KM subsea pipeline

Oil is loaded to visiting tankers via a Single Point Mooring located approx 3 KM from the FPSO

Bonga FPSO has capacity >200 kbopd of oil, 100 kbwpd of produced water, 330 kbwpd of injection water and 150 mmscf/d of gas

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Bonga Production Manifold (PM) 05 Overview

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East

PM5

Production Flowline - 02

Production Flowline - 01

N

Bo

ng

a F

PS

O

Launchers

& Receivers

West

Wells

Wells

Pigging Loop


Case for Pigging of Bonga Flowlines

Intelligent Pigging is the only available technology for complete inspection of pipelines from launcher to receiver

Shell as a prudent operator uses IP to confirm integrity status of pipelines

Intelligent pigging of pipelines is a Statutory Requirement in Nigeria

Corrosion Inhibitor availability in Bonga was interrupted for short periods due to umbilical blockage

Bonga Asset expects positive assurance with proof that Bonga flowlines have “Technical Integrity”

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Bonga Production Flowline Loops – Pigging Challenges

Bonga has three 10” and one 12” Production Loops; (with outer pipe diameters of 12” and 14” respectively)

For flow assurance purposes Bonga Production Loops are Pipe-In-Pipe design

Inner pipe has non-standard wall thicknesses up to 28mm

Bonga Production Loops are designed for pigging

MFL Intelligent Pigging tools are not suitable for Pipe-In-Pipe design

Ultrasonic (UT) and Eddy Current tools can be used, but because of extra wall thickness and high operating pressures they are on the edge of technical limits

Pigging uses cargo oil & wells in the loop must be shut-in; i.e. deferment

Pigging is not possible during tanker off takes

The longest loop (PM5) approx 20 KM, was selected for inspection

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Bonga PM5 Loop Intelligent Pigging – Preparation

Simple technical requirements for required technology and cleanliness in ITT; strict specs for defect detection (e.g. pits 15% of thickness)

Contract awarded to a Nigerian service provider – Aug 2012

Tool engineering – Nov/Dec 2012

Tool modifications, Pull and Pump tests completed – Dec 2012 / Jan 2013

Tool and Personnel mobilisation – Jan 2013

Site survey, Pigging Procedures, HAZID/HAZOP/JHA, tool tests – Jan/Feb 2013

Pigging Procedures signed and approved – Feb 2013

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Intelligent Pigging – Execution

09/02/13, Low Density Foam Pig launched; received shattered

10/02/13, Medeium Density Foam Pig launched; received no damage

11/02/13, one Cup Pig followed by two Bi-Di Pig launched, all received without damage

12 and 13 Feb Tanker off take (no pigging activity)

14/02/13, 1st Gauge Pig launched; received dented

15/02/13, 2nd Gauge Pig launched; received slight damage, PM5 confirmed clean and ovality acceptable for Intelligent tools

15/02/13, Eddy Current tool launched; received undamaged and data quality confirmed

16/02/13, UT tool launched; received undamaged and data quality confirmed – End of PM5 pigging campaign

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Bonga Intelligent Pigging - Findings

Selected loop has the highest water cut and was suspected to have internal corrosion defects

Tools were selected for detection of metal loss including shallow internal corrosion

Detailed analysis of data confirmed that PM5 did not have internal corrosion defects

Only 9 incidents of minor milling defects and 6 minor external corrosion defect were detected

Data was verified by using two tools with different technologies

Intelligent pigging enabled the Pipeline Team to provide Bonga Asset with the assurance that PM5 has Technical Integrity

W-PIMS estimated remaining life of PM5 over 40 years

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Bonga Intelligent Pigging of PM5 Loop - Summary

Approx 1000 man-hours worked without Lost Time Incident

Campaign completed in 10 days, (originally planned for 21 days)

Total of 7 pig runs using foam, cup, scraper pigs completed to clean the loop and confirm safe passage

Two IP runs successfully completed using the latest available technology

The FIRST deepwater pipe-in-pipe inspection, in Shell, in Nigeria and possibly in the world

Pigging successfully completed by SNEPCO staff and Nigerian Contractor

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Bonga Intelligent Pigging – Foam Pigs to confirm passage

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1- Low Density Foam arrives shattered, this

is not unexpected

2- Medium Density Foam arrives intact; safe

to launch cup pig


Bonga Intelligent Pigging – Cup & Bi Di Scraper Pigs used for cleaning

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3- Cup Pig received slight damage to sizing

plate.

4- Two Bi Di pigs with brush received in good

condition. Total debris only 4.5 kg, line is very

clean !


Bonga Intelligent Pigging – Gauge Pigs confirm ovality and “no obstructions”

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5- The first gauge pig with noticeable dent to

plates, pipeline data logger attached to the back

of the pig (not seen in photo). For reassurance

a second gauge pig is launched.

6- The second gauge pig received with minimal

damage, line ovality and safe passage for intelligent

tools confirmed


Bonga Intelligent Pigging – XGP/SIC and UT Intelligent Pigs

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8- At 23.30 Sat 16th Feb, the UT tool arrives back.

Job completed LTI free

7- Intelligent tool ready for launch


Bonga Intelligent Pigging – The Team

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Bonga pigging Crew – Feb 2013


List of Abbreviations

FPSO Floating Production Storage and Offloading

kbopd 1000 Barrels of Oil Per Day

kpwbd 1000 Barrels of Water Per Day

mmscf/d Million Standard Cubic Feet Per Day

JHA Job Hazard Analysis

HAZID Hazard Identification

HAZOP Hazards in Operation

MFL Magnetic Flux Leakage

Bi-Di Bi Directional

W-PIMS Web Pipeline Integrity Management System

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Disclaimer

The companies in which Royal Dutch Shell plc directly and indirectly owns investments are separate entities. In this presentation, “Shell”, “Shell group” and “Royal Dutch Shell” are sometimes used for convenience where references are made to Royal Dutch Shell plc and its subsidiaries in general. Likewise, the words “we”, “us” and “our” are also used to refer to subsidiaries in general or to those who work for them. These expressions are also used where no useful purpose is served by identifying the particular company or companies.

Shell Companies in Nigeria have their own separate identities but on this presentation we may sometimes use "Shell", "we" or "us" when we refer to Shell Companies in Nigeria in general or where no useful purpose is served by identifying any particular Shell Nigeria Company.

All information or advice provided as part of this presentation is intended to be general in nature and you should not rely on it in connection with the making of any decision. SNEPCo tries to ensure that all information provided as part of this presentation is correct at the time of inclusion on the presentation but does not guarantee the accuracy of such information.

SNEPCo is not liable for any action you may take as a result of relying on such information or advice or for any loss or damage suffered by you as a result of you taking this action.

Information is provided with the consent of NNPC, the Licence Holder

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Intelligent Pigging Inspection of SNEPCO’s - MCEDDmcedd.com/wp-content/uploads/Mehran Moini - Shell.pdf · Shell Nigeria Exploration & Production Co. Intelligent Pigging Inspection