subsea corrosion experiences - marine renewables … corrosion experiences . ... introduction 2. dnv...
TRANSCRIPT
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Material durability of Cables and Moorings
Jan Kenkhuis – Principal Engineer Mooring & Subsea
Subsea Corrosion Experiences
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Workshop Front End Engineering
Agenda of this Presentation
1. Introduction 2. DNV code
Subsea Facilities 3. Umbilical's Oil & Gas 4. Moorings Oil & Gas 5. Bluetec Texel practice 6. Engineering 7. Conclusion 8. Questions
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Story of the US Navy Littoral Combat Ship
Aim Easy to Maintain over their lifespan
http://www.nace.org/CORROSION-FAILURE-LCS-2-USS-Independence-Naval-Ship-Engine-Corrosion.aspx
Introduction- World known Example of 2002
Ships were made of Aluminium with • First ship suffered galvanic corrosion (2003) • Second ship crack through the hull (2013)
Cause of Failure ---Design Flaws (2014) • Corrosion concentrated in the ships propulsion system
where steel impeller housing came in contact with the aluminium vessel (Nov 2013)
• The specification lacked the requirement for a Cathodic protection system
• 2 dissimilar metals come into electrical contact • Electrical continuity not established
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DNV-GL code – Subsea Facilities( 2014)
Oil & Gas Technology Developments ; Incidents and Future Trends
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• Technology - Historical trends, future trends and developments
• Integrity management (from design to operation). • Degradation mechanisms and failure modes. • Inspection, maintenance and monitoring
methodologies. • Recommendations for improvements and knowledge
sharing.
The threat of corrosion corrosion is a material degradation; depends on the exposed environment and the material or a combination of materials in question
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DNV-GL code – Degradation mechanism
The threat “material degradation” mechanism occurs either: Abrupt degradation
brittle facture of ceramics; glass; fasteners
Slow over time
CO2-corrosion of alloy steel and fatigue;
ageing of elastomers;
loss of spring capacity
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Bluewater SPM System (2008)
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Umbilical SUTU example
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At time of installation in 2008 At time of repair in 2009
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SUTU after recovering
Open SUTU Hydraulic connectors
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Cause of the rapid corrosion
• No electrical continuity guaranteed between connectors and bulkhead plate.
• Connectors supplied from 1.4418 stainless grade. Equals to 304 grade
• The specification asked for 316L grade • Concerns raised about the uncertainty
of the isolation between SUTU and PLEM
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2nd example Bluewater Haewene Brim
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Non Sheathed Spiral Strand Wire
Bird cage detection close up picture
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Cathodic Protection on Sockets
Anode after 5 years
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Anode new
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Cathodic protection of chain stopper
Orkot bushes to achieve electrical discontinuity
chain stoppers with CP system
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Bluewater Texel Project Experiences
Water depth= 30m
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BTT in Operation
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BTT platform Oct 2015
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1. Position joining shackle nylon - chain
2. Umbilical bottom frame
3. Shape free spanning umbilical
Side view mooring system
5. Umbilical routing bottom connector - shore
4. Position chain routing and anchors (4x)
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Visual Inspections
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Mooring Lines: after 0.5 years Mooring Lines: prior installation
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BTT underwater, non-coated
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BTT floater out of the water
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Before cleaning
After cleaning
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BTT Cathodic Protection
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Lifecycle of a Development Project
Operate
Detailed Design
Fab / Cons. Documents
Procurement
Proposal &
Tender Preparation
Concept Developmen
t
<---- -------------------------------Project Initiation [FEED]----------------------------->
Conceptual and partly detailed Floater Layout
Contract Award
Project Definition
Operation & maintenance
Definition
Engineering Design
Site Preparation, anchoring, erection or hook-up,
Instrument, Electrical Installation
Assembly & Offshore Installation
Material Acquisitio
n
Fabrication
Fabrication
Start-up Commissionin
g Handover
Checkout and Pre-Commissioning
Commissioning & Handover
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Development Risk Assessment
• The first step in assessing feasibility is the risk assessment review result for:
• Manufacturing • Assembly on site • Foundation Installation • Mooring spread pay-out • Hook-up • Cable Installation • Operation • Day to Day maintenance
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Integrity Management of Subsea Systems
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ESTABLISH INTEGRITY MAINTAIN INTEGRITY Concept, design and Construction (incl. pre-commissioning)
Operations (incl. Commissioning)
INTEGRITY MANAGEMENT PROCESS Risk Assessment and Integrity Management (IM) Planning
Inspection Monitoring and Testing
Integrity Assessment
Mitigation, intervention and repair
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Based on sound engineering practice the following can be concluded: 1. The mooring or cable design spec should included external coating protection
combined with CP systems.// electrical continuity etc. 2. Request verification of a corrosion expert as part of risk assessment program 3. The materials provided by supplier should be traceable [MRB] 4. Acceptance test of batches of components could be included
to check on suitability for subsea applications 5. Often if the proposed components are mature and proven this has an advantage 6. Avoid damage to the coating ( sheathing) as much as possible in installation stage. 7. Execute electrical continuity checks prior lowering overboard. 8. Use sheathed steel wires only ( offers an extra of 5-8 years of service life) 9. Develop in engineering stage an Subsea Integrity management plan.
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Thank you! Questions?