Download - Pipeline Repair Project FEED 1
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18th-June-08
PIPELINE REPAIR AT KP 110 – KP 133 KUALA TUNGKAL TO PANARAN TGI OFFSHORE PIPELINE
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FEED Handover Meeting Agenda
1. Project Introduction
2. Problem Definition
3. Design Basis
4. Pipeline Mechanical Design
5. Pipeline Outline Installation Analysis
6. Repair Methodology
7. Cost Estimate and Schedule
8. Valve Skid Design
9. EIA Review
10. HAZID & HAZOP Action Items
11. Prof. Andrew Palmer’s Review
12. Closeout Report
13. Discussion and Close Out
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Project Introduction
KP 133.5
KP 110.5
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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
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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
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Project Introduction
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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
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Design Basis of Replacement Pipeline
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Pipeline Mechanical Design
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Pipeline Mechanical Design
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Pipeline Mechanical Design
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Pipeline Mechanical Design
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Pipeline Mechanical Design
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Pipeline Mechanical Design
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Pipeline Mechanical Design
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Pipeline Installation Analysis
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Pipeline Installation Analysis
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Final Repair Method
Repair Method
• Zero Downtime Method Microsoft PowerPoint Presentation
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Schematic Diagram
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Comparison Between Both Methods
Flange Connections/
KaMos GasketsHot Taps STOPPLE
BarredTees
5D Bend
GateValve
Shut-down Time
Cost
HardwareCost
ConstructionCost
TotalCost
CM – ReducedDowntime
Nil6
(4 in-place)4 Nil Nil Nil 4 – 6 Wks US$3.3 US$30M US$33.3
ZeroDowntime
Method6
8(6 in-place)
4 2 42 x 28”2 x 16”
Nil US$9.6M US$40M US$49.6
Note:
1. CM – Conventional Method
2. The hardware cost stated above includes 10% for transportation cost.
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Comparison Between Both MethodsReduced Downtime Method Zero Downtime Method
Advantages • No flange connections along the pipeline
• Involves less construction and diving work
• 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
Disadvantages • 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
• 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
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Comparisons of Risks
Reduced Downtime Method Zero Downtime Method
1. Emergency Response Plan required 1. Emergency Response Plan required
2. Gas Freeing the abandoned pipeline 2. Gas Freeing the abandoned pipeline
3. Potential of buckling the pipeline during above water tie-in
3. KaMOS gasket failure
4. Presences of large amount of water and air pockets in the pipeline while restoring the flow
4. Experienced Hot-tap contractor should be engaged
5. Gas supply shut down time can increase due to construction delays
6. Experienced Hot-tap contractor should be engaged
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Shut-Down Time for Reduce Downtime Method
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Overall Schedule for Zero Downtime Method – Best Scenario
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Overall Schedule for Zero Downtime Method - Realistic
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Potential EPCC Contractors
Pipelay Subsea
Cal Dive
Saipem
Global
Acergy
Technip Subsea 7
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Valve Skid Design
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Valve Skid Design
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Valve Skid Design
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Valve Skid Design
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EIA Action Plan
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EIA Action Plan
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EIA Action Plan
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HAZID & HAZOP Action Items
HAZID Action Items –
HAZOP Action Items – Adobe Acrobat 7.0
Document
Adobe Acrobat 7.0 Document
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Dr Andrew Palmer’s Review and Actions Required
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Dr Andrew Palmer’s Review and Actions Required
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Dr Andrew Palmer’s Review and Actions Required
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Project Status – Engineering
Pipeline Mechanical Design
S/N 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.
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Project Status – Engineering
Installation Methodologies
S/N 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
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Project Status – Engineering
Valve Skid Design
S/N Activities Statue Further Actions
1. Piping Analysis - Caesar II Model
DoneEPC 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.
2. Structural Analysis - SACS Model
Done
3. Drawings Done
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Project Status – Engineering
Material Specifications
S/N 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 assembliesEPC Contractor to perform mock testing before the actual installation works
5. Field Welding and NDT Done EPC Contractor to prepare welding and NDT procedures
6. Construction Materials Not Done All non-long lead and construction materials to be procured by EPC Contractor
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Project Status – Engineering
Installation Specifications
S/N 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
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Project Status – Engineering
Drawings
S/N 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.
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Discussion and Close Out