challanges with subsea pipeline integrity management in
TRANSCRIPT
February 2015
McDermott International, Inc.
© 2014 McDermott International, Inc. All rights reserved.
Challenges with Subsea Pipeline Integrity Management in the
Middle EastManoj Kulshrestha
Contents
Middle East on World Hydrocarbon Map Peculiarities of Middle East Fields Threats to Pipelines Operators Preparedness Emergency Pipeline Repair System (EPRS) EPRS Manual ‐ Limitations EPRS – Why McDermott? Beyond EPRS Manual Conclusions References
World Oil –Middle East Share
Rest of World 68%
Bahrain
Iran
Iraq
Israel
Jordan
Kuwait
Oman
Qatar
Saudi Arabia
Syria
United Arab Emirates
Yemen
Middle East Contribution32%
[ Source : Reference # 3, 4 ]
“Five Middle East oil producing countries are among top ten oil producers in the world”
Worldwide Natural Gas Production
Rest of World83%
Other Middle East8%
Qatar4%
Iran5%
[ Source : Reference # 11]
Iran, Qatar & Saudi Arabia are among top ten producer of natural gas in the world
Regional Pipelines Distribution
Americas69%
Asia14%
Europe8%
South America
3%
Africa3%
Middle East2% Australia's
1%
0
500,000
1,000,000
1,500,000
2,000,000
2,500,000 2,369,082
474,449
287,395110,585 87,381 82,134 34,469
Tota
l Pip
elin
e Le
ngth
(km
)
Total pipeline length Worldwide : 3,445,495 km Middle East : 82,134 km
[ Source : Reference # 5]
Peculiarities of Middle East Fields
Middle East has one of the largest oil and gas producingoffshore fields
Shallow water depths – increases probability of damage Hard seabed – burial is not economical Unplanned field developments – spaghetti of pipelines,cables and umbilical
Multiple operators – no common design operating andmaintenance philosophy
No statutory guidelines – pipelines, vessel anchorageand loading areas
[ Source : Reference # 2 & 12]
Peculiarities of Middle East Fields
No defined protection philosophy – unburied pipelines,sometimes without concrete coating
Uncontrolled fishing activities – fish traps found onpipelines
No abandonment plans – non‐operational pipelines notremoved or preserved
Environmental guidelines – still immature
21%
30%26%
7%
6%
5%
1% 1%1% 1%
1%
AnchoringImpactCorrosionStructuralMaterialNatural HazardConstructionMaintenanceHuman ErrorOperational ProblemsOther
[ Source : Reference # 7]
Offshore Steel Pipeline Incidents
Threats to Pipelines
Continuous field developmental activities: damages by Construction barges/anchor handling tugs Drilling rigs Accommodation barges
Heavy oil and LNG tanker traffic Fishing activities – mainly cable/umbilical damages Possibility of intrusions
Operators Preparedness
Preventive measures Security shields around offshore assets Satellite surveillance for vessels movement Information sharing among various operators
Emergency preparedness Pursue Emergency Pipelines Repair System (EPRS) studies Maintain repair apparatuses inventory Share resources – EPRS club Secure long‐term contracts with vessel owners
[ Source : Reference # 1]
INSTALLATION ENGINEERINGPROCEDURES
EPRSTEAM REPAIR SPREAD
REPAIR MATERIALMANUAL
EPRS – Components
Rapid, organized, response toidentify, assess, stabilize andreinstate mechanical andoperating integrity ofdamaged section of pipelineswhile maintaining high safetystandards and mitigationagainst environmental impact
No industry code or standardexists
[ Source : Reference # 1]
EPRS ‐ Studies
McDermott performed EPRS studies for North Field, Qatar operators
North Field 3rd largest non‐ associated gas reservoir in world, Discovered 1971 Proven gas reserves of 885 tcf Reserve to production ratio – 160 Integrated mega projects Operated by leading companies
Pipelines are life lines to uphold Qatar as: Meeting 30% of energy need of UAE Operating world’s largest GTL facility Largest LNG exporter – 85% of produced natural gas
[ Source : Reference # 10]
EPRS‐ 9 Step Damage Repair Approach
REPORTING
PRESSURE REDUCTION
INSPECTION ASSESSMENT
CATEGORY
REPAIR METHOD TIME FRAME
INTERVENTION PROCEDURE
INVENTORY
EPRS‐ Assessment of Credible Damages
Non‐Corrosive Damages Gouge Gouge on weld Dent Gouge in dent Dent on weld Abrasion Anchor drag (Displacement) Displacement with dent and gouge Crack and crack like flaws
EPRS Manual
Assessment performed forpossible credible damagescenarios for all distinctivesections of pipelines
Acceptable limit for gougesand dents were computed
Anchor dragging simulatedusing Finite Element Tools
All results knit into thedecision making processthrough flow chart
0.0
5.0
10.0
15.0
20.0
25.0
0.0 200.0 400.0 600.0 800.0 1000.0 1200.0
defe
ct d
epth
(d),
mm
defect length (L or 2c), mm
Failure at 182 bar
failure at 100 percent SMYS
Red
Amber
Yellow
Gouge
Pipeline Diameter
30 inch 28 inch24 inch 18 inch
Concrete Thickness
90 mm
60 mm110 mm
45 mm
Lateral Displacement for Yield
(m)
4.2 5.7 3 7.1 5.6 7.3
Local Angle for Yield (°)
0.8 3.9 0.8 0.7 0.4 1.5
Global Angle for Yield (°)
9.1 8.5 3.1 9.1 11.2 10.5
Length of displaced section (m)
350 350 240 390 390 480
EPRS – Decision Making Tree
Decision making tree aids operators in Swift decision on intervention or to continue operation Time frame for repair & Reduce loss in production
EPRS Manual Limitations
Assessment performed for possible credible damagescenarios – provides quick guidelines
Assessment based on generalized parameters Each damage is unique and sensitivity to locationspecific parameters can affect recommendations
Certain damages at transition limits require sensitivitychecks
Explicit analysis are always recommended prior to anyintervention
Any further analysis require skilled team and softwareincluding Finite Element (FE) tools
EPRS – Why McDermott?
EPC Advantage ‐ Single Window Solution Competent Engineering Team with FEA expertise Specialized Construction Support Engineering Team Proficient Marine Operations and Diving Team Marine Vessels Procurement Expertise Proven Track Record EPRS Studies for RasGAS and QatarGas Emergency Repairs for Dubai Petroleum
Establishment Damage Assessment for DuGAS, Dubai
Beyond EPRS Manual
Tow Analysis for Replacement Sections Identification/ Procurement of other
installation aids – Buoyancy bags, Bear Clamp, Rollers, Pulling Heads etc.
Independent FEA review for Mechanical Connector
Gripping Pressure Simulation
In addition, McDermott performed the following to have TOTAL READINESS
Conclusions
Apart from Damage Assessment Expertize, contributionof Installation Contractors is equally imperative forRobust EPRS.
EPC Contractors with integrity expertize can provide asingle source solution to operators via long termcontracts
Industry needs to develop codes and practices for EPRS
Q & A
EPRS IS NOT ONLY A MATTER OF PREPAREDNESSBUT
TOTAL PREPAREDNESS
At McDermott – we have Total Preparedness
References
1. Developing a Robust Emergency Pipeline Repair System in Nigeria [Conference] / auth. Iyede Efemena and Akinola Mobolaji // 38th Nigeria Annual International Conference & Exhibition. ‐ Lagos : SPE, 2014. ‐ Vols. Paper No. SPE‐172394‐MS.
2. Guidelines for Pipeline Operators on Pipeline Hazards [Report] / auth. Health & Safety Executive. ‐ Aberdeen : www.hse.gov.uk/pipelines, 2009.
3. International Energy Statistics [Online] / auth. US Department of Energy. ‐ January 13, 2015. ‐http://www.eia.gov/cfapps/ipdbproject/iedindex3.cfm?tid=5&pid=57&aid=1&cid=regions&syid=2009&eyid=2013&unit=TBPD.
4. List of Countries by Oil Production [Online] / auth. Wikipedia. ‐ January 12, 2015. ‐http://en.wikipedia.org/wiki/List_of_countries_by_oil_production.
5. List of countries by total length of pipelines [Online] / auth. Wikipedia. ‐ January 12, 2015. ‐ http://en.wikipedia.org/wiki/List_of_countries_by_total_length_of_pipelines.
6. Performance of European cross‐country oil pipelines ‐ Statistical summary of reported spillages in 2012 and since 1971 [Report] / auth. CONCAWE ‐ Conservation of clean air and water in Europe. ‐ Brussels : CONCAWE, 2013.
References
7. Probability Analysis of Damage to Offshore Pipeline by Ship Factors [Report] / auth. Liu Yutao, HU Hao and Zhang Di. ‐ Shanghai : TRB 92th Annual Meeting, 2011.
8. Risk Assessment Data Directory ‐Major Accidents ‐ Report No. 434‐17 [Report] / auth. International Association of Oil and Gas Producer. ‐ England & Wales : http://www.ogp.org.uk/, 2010.
9. The Update of Loss of Containment Data for Offshore Pipelines ‐ PARLOC 2001 [Report] / auth. Mott MacDonald Ltd.. ‐ Croydon : www.hse.gov.uk/pipelines, 2003.
10. www.eia.gov [Online] / auth. US Energy Information Administration (EIA) // Energy Information. ‐ January 12, 2015. ‐ http://www.eia.gov/countries/cab.cfm?fips=qa.
11. www.eia.gov [Online] / auth. US Department of Energy // International Energy Statistics ‐Gross Natural Gas. ‐ January 6, 2015. ‐http://www.eia.gov/cfapps/ipdbproject/IEDIndex3.cfm?tid=3&pid=3&aid=1.
12. www.offshore‐mag.com [Online]. ‐ 1 10, 2008. ‐ January 13, 2015. ‐ http://www.offshore‐mag.com/articles/print/volume‐68/issue‐10/middle‐east/middle‐east‐to‐be‐worldrsquos‐largest‐offshore‐producer.html.
13. www.subsea7.com [Online] / auth. Subsea. ‐ Saipem Dolphin Emergency Pipeline Repair System (EPRS). ‐ January 8, 2015. ‐http://www.subsea7.com/content/dam/subsea7/documents/whatwedo/projects/northseaandcanada/Saipem%20Dolphin%20(EPRS).pdf.