Pipeline

OFFSHORE PIPELINE SYSTEMS By

Raj Kumar Sr. Manager

Delivering excellence through people Offshore Pipeline Systems Slide Number - 1 of 70

ENGINEERS INDIA LIMITED EPC and Total Solutions Consultancy Organization Petroleum Refineries f Petrochemicals Pipelines Offshore Platforms Gas Processing Metallurgy Infrastructure Engineers India Ltd – Delivering excellence through people

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OFFSHORE PIPELINE SYSTEMS

Modes of Hydrocarbon Transportation - India 35% 30%

Pipelines R dT Road Tankers k

32%

25%

32%

20%

Pipelines Road Tankers Rail Tankers Water Carriers

15%

Rail Tankers

26%

Water Carriers

10%

10% 5% 0% % Share

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OFFSHORE PIPELINE SYSTEMS

Various Stages ‰ Introduction ‰ Components ‰ Stages of Offshore

Pipeline Project ‰ Construction, Construction Testing & Commissioning ‰ Video deo

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OFFSHORE PIPELINE SYSTEMS

Introduction Why pipelines? „ „ „ „ „ „ „

Safer Environment friendly Least energy gy requirement q Lowest maintenance costs Minimal impact on land use pattern Negligible loss of product in transit High reliability

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OFFSHORE PIPELINE SYSTEMS

Introduction What can be Transported p ? Liquids

Gases

Crude Oil Petroleum Products Petrochemical Products

Natural Gas Any other Gas

Chemicals

Solids(in slurry form) form)

Water LPG

Coal Ores Tailings

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OFFSHORE PIPELINE SYSTEMS

Introduction Onshore pipelines Cross Country Trunk pipelines

Submarine pipelines Trunk lines Infield pipelines

Spur Lines Intra--field pipelines Intra Gathering & Distribution lines

Offshore terminals (SPM and jetties) Effluent outfalls

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OFFSHORE PIPELINE SYSTEMS

Introduction Major Offshore Fields of India • • • • • • •

Bombay High North & South South Bassien Bassien,, Tapti Neelam,, Heera Neelam Heera,, Panna Panna,, Mukta Ravva Cauvery Basin KG Basin Dhirubhai Ambani Field

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OFFSHORE FIELDS OF INDIA (West Coast)

HAZIRA

BOMBAY HIGH FIELD

PANNA FIELD

BASSEIN FIELD NEELAM FIELD

URAN

HEERA FIELDOffshore Pipeline Systems

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OFFSHORE FIELDS OF INDIA (East Coast)

DA FIELD KG BASIN

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OFFSHORE PIPELINE SYSTEMS

Sequence of Flow Well Head Platform

Onshore Gas Terminal

Process cum Living Quarters

T k Tanker Offloading

Sub Sea Pipeline

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OFFSHORE PIPELINE SYSTEMS

Offshore Pipeline Components

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OFFSHORE PIPELINE SYSTEMS

Platform

Jacket

Riser

Pipeline p

Riser b d bend

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OFFSHORE PIPELINE SYSTEMS

Typical Field Layout NLM11

N

NLM10

NLM8 NLM9 NLM6 NLM7 NLM4 NLM5 NLP NLW WN2

NLM3 SBM NLF

LEGEND

NLM2

WN1

NLM1

HOL HUT PIPELINES

HGL

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W I LINES W F LINES GAS /OIL LINES CRUDE OIL LINES PLATFORM SBM EXISTING PIPELINES

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OFFSHORE PIPELINE SYSTEMS

Pipelines for Loading/Unloading Systems ™

Loading/Unloading Jetties

™

Single Point Mooring Systems(SPM)

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OFFSHORE PIPELINE SYSTEMS

Conventional Oil Jetty

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OFFSHORE PIPELINE SYSTEMS

SPM – Crude Offloading

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OFFSHORE PIPELINE SYSTEMS

Schematic – Crude Offloading

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SPM-Hose Configurations

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Hoses

1.

First/ Second Off Off--buoy hose 2. Mainline hose 3. Taper hose 4. Tail hose 5. Rail hose

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1. 2 2.

End connection M i li h Mainline hose

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OFFSHORE PIPELINE SYSTEMS

Process Platform Complex

Crude Oil Well Fluids N t lG Natural Gas I j ti W Injection Water t

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OFFSHORE PIPELINE SYSTEMS

Major Components ‰ Platform Structure z z z z

Lower Deck Cellar Deck Top Deck Heli Deck

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OFFSHORE PIPELINE SYSTEMS Stages of an Offshore Pipeline Project

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OFFSHORE PIPELINE SYSTEMS

Codes &Standards DnV OS-F101 ASME B 31.8 ASME B 31.4

API 1104 API 1110 NACE MR 0175

IP 6

Det Norske Veritas, Rules for Submarine Pipeline p Systems y Gas Transmission and Distribution Piping Systems Liquid Transportation Systems for Hydrocarbons, LPG and Anhydrous Ammonia and Alcohols Standard for Welding Pipelines and Related Facilities Pressure Testing of Liquid Petroleum Pipelines p Material Requirements – Sulphide Stress Cracking Resistant Materials for Oil Field Equipment IInstitute tit t off Petroleum P t l – Pipeline Safety Code

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OFFSHORE PIPELINE SYSTEMS

Stages of a Project Conceptual Study Feasibility y Study y Basic Engineering Detailed Engineering Construction Testing & Commissioning Engineers India Ltd – Delivering excellence through people

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OFFSHORE PIPELINE SYSTEMS

Conceptual Study ˆ ˆ ˆ ˆ ˆ ˆ

Establish System Requirement Evaluate Constraints on System Design Identify Interface With Other Systems Develop Design Data Requirements Assess Construction Methodology Finalize the Concept

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OFFSHORE PIPELINE SYSTEMS

Feasibility Study

ˆ ˆ ˆ ˆ ˆ ˆ

Evaluate Technical Options Eliminate Unviable Options Firming up of Process Facilities Develop Broad System Specifications Establish Project Cost Plan Project j Implementation p Scheme

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OFFSHORE PIPELINE SYSTEMS

Basic Engineering ˆ ˆ ˆ ˆ

Finalise Process Scheme & Equipments Environmental & Process Data Review Pipeline Routing & Size Optimization Establish Requirements for z z z z

ˆ

Surveys and Investigations Material of Construction Preliminary Analysis Construction, Construction Testing and Commissioning

Develop Implementation Schedule

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OFFSHORE PIPELINE SYSTEMS

Safety Aspects E i Environmental t l Parameter P t and d Soil S il Data D t Pipeline Stability Shore Approaches Trenching and Burial Safety of Existing Facilities

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OFFSHORE PIPELINE SYSTEMS

Detailed Design & Engineering ‰ Engineering Design Basis ‰ Route Engineering & Surveys ‰ Engineering analysis and Calculations ‰ Specification and Job Standards ‰ Engineering for Procurement ‰ Drawings for Construction ‰ Installation analysis and Procedures Engineers India Ltd – Delivering excellence through people

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OFFSHORE PIPELINE SYSTEMS

Design Basis ‰ Basic Data ‰ Design Codes and Standards ‰ Design Philosophy ‰ Operation and maintenance philosophy ‰ Environmental Criteria z

Installation

z

Operation

‰ Criteria for engineering analysis Engineers India Ltd – Delivering excellence through people

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OFFSHORE PIPELINE SYSTEMS

Route Selection ‰ Routing Considerations z Pipeline length z Sensitive areas z Ob t ti Obstructions z Installation Limitations z Crossings z Drilling Rig Movement / Access ‰ Surveys z Geo--physical & Geo Geo Geo--technical Surveys z Platform Approach / Riser Face Survey Engineers India Ltd – Delivering excellence through people

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OFFSHORE PIPELINE SYSTEMS

Pipeline Wall Thickness Selection

‰ Analysis / Calculations z z z z z

Hoop Stress Buckle Initialtion B kl P Buckle Propagation ti Collapse Bucking Local Buckling

‰ Pipeline Stress Checks z Hoop Stress z Equivalent Stress † Analysis Tools z PC Based Software ‘‘Pipecalc Pipecalc’’ Engineers India Ltd – Delivering excellence through people

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OFFSHORE PIPELINE SYSTEMS

Wall Thickness Calculation F r Offshore For Off h r Pipelines Pip lin t=

PD + co corrosion os o allowance ow ce 2.SMYS.a where P is the internal design pressure in psig. psig S is the specified minimum yield strength D is the pipe outside diameter in inches. t is the nominal wall thickness in inches. a is the design factor (0.72 for pipeline and 0.5 for riser) Engineers India Ltd – Delivering excellence through people

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OFFSHORE PIPELINE SYSTEMS

Allowable Stress Limits Design Condition Installation : 1 year Environmental Loading

Stress Classification

Allowable Stress (% SMYS) Zone 1 ((Pipeline) p )

Zone 2 ((Riser))

Equivalent Stress

85

85

Functional

Hoop Stress Equivalent Stress

72 72

50 50

Functional + 100 year Environmental Loading

Hoop Stress

72

50

Equivalent Stress

85

67

Hydrotest + 1 year Environmental Loading

Hoop Stress

90

90

Equivalent Stress

90

90

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OFFSHORE PIPELINE SYSTEMS

Types of Linepipes „

Seamless up to 16” 16”

„

LSAW 18” and above

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OFFSHORE PIPELINE SYSTEMS

Engineering Analysis ‰ Pipeline Stability (Lateral & Vertical) ‰ Pipeline Expansion ‰ Pipeline Spans ‰ Riser † Analysis y Tools z PC Based Software ‘‘Pipecalc Pipecalc’’

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OFFSHORE PIPELINE SYSTEMS

Anti Corrosion Coatings Anti-Corrosion ‰

Coating Types z z

‰

Coal Tar Enamel Fusion Bonded Epoxy

Selection Criteria z z z z z

Service Conditions Performance Record Ease of Repair Cost Effectiveness Compatibility with Concrete Coating

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OFFSHORE PIPELINE SYSTEMS

Pipeline Crossing ‰

Type z z

Exposed Pipelines (Single / Multiple) Buried Pipelines (Single / Multiple)

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OFFSHORE PIPELINE SYSTEMS

Pipeline Crossing ‰ Analysis z Permissible Spans (Static & Dynamic) z Stress Analysis z Stability of Supports ‰ Analysis Tools z PC Based InIn-house Software ‘Pipe Cross’

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OFFSHORE PIPELINE SYSTEMS

Pipeline Engineering Design Tools PIPECALC PRISE REGIS

Sub sea Pipeline Calculations – J P Kenny Riser Analysis – J P Kenny

SPAN

Alignmentt Sh Ali Sheett G Generation ti & D Drawing i Management – J P Kenny Pipeline/Riser Installation Analysis – Robert b J. Malahy l h Jr. Riser Span Evaluation - EIL

PIPECROSS

Pipeline Crossing Analysis - EIL

CAESER II

Piping Stress Analysis - COADE

OFFPIPE

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OFFSHORE PIPELINE SYSTEMS

Major Deliverables Design Reports

Drawings

Procurement/ Tenders

Design Basis

Field Layout

Route Selection

Alignment Sheets

Material Specifications Material Requisitions

Wall Thickness

Platform Approaches

Technical Evaluation

Stability

Crossing Details

Vendor Data Review

Pipeline/Riser Spans

Riser Location

Survey Tenders

Crossings

Riser make-up

Risers/Flexibility

Clamp Details

Installation Bid Package Contractor’s Installation Procedure R i Review

In-situ stress analysis PLEM/ Lateral/ Spool Details Cathodic Protection

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OFFSHORE PIPELINE SYSTEM LAYOUT Engineers India Ltd – Delivering excellence through people

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OFFSHORE PIPELINE SYSTEMS

Components of Offshore Pipeline Risers Laterals Main Pipeline Pipeline End Manifolds (PLEMs) Shore Approaches & Terminal Facilities Electrical & Instrumentation System Engineers India Ltd – Delivering excellence through people

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OFFSHORE PIPELINE SYSTEMS

Schematic of Offshore Pipeline System

BPB PLATFORM

42" SBHT PIPELINE

SBHL-3 24"

24"

30"

24"

24"

24"

24"

POINT

A SBHL-1 BPA PLATFORM

SBHL-2

30" 30

SBHL-4 PLEM

A

LEGEND HYDRAULIC ACTUATED BALL VALVE GAS ACTUATED BALL VALVE GAS ACTUATED PLUG VALVE CHECK VALVE INSULATING JOINT

SBHL-7

SBHL-6

SBHL-5

LANDFALL POINT

14"

14" SV-1 OFFSHORE SECTION

14"

14"

14"

SV-2 ONSHORE SECTION

HAZIRA RECIEVING TERMINAL

14" SV-3

MINDHOLA RIVER

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TAPI RIVER Offshore Pipeline Systems Slide Number - 45 of 70

Alignment Sheet Sample Alignment Sheets (Offshore)

I

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Sample Riser Drawings (Riser GAD)

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Offshore Pipeline Systems

Riser Drgs.

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Sample Riser Drawings (Riser Approach Drawing)

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Offshore Pipeline Systems

Riser Drgs.

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OFFSHORE PIPELINE SYSTEM

INSTALLATION Delivering excellence through people Offshore Pipeline Systems Slide Number - 49 of 70

OFFSHORE PIPELINE SYSTEMS

Construction Testing & Commissioning Construction, z z z z z z z

Pipe Corrosion & Concrete Coating Welding and Joint Coating Pipeline Laying Specialty Items Installation Riser Installation Pipeline Crossing Installation Testing Dewatering, Testing, Dewatering Drying and Commissioning

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OFFSHORE PIPELINE SYSTEMS

Installation Techniques q

ƒ ƒ ƒ ƒ

Conventional Installation by Laybarge Installation by J Lay Tow Techniques Installation by Reelship

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OFFSHORE PIPELINE SYSTEMS

Pipelay p y Barge g

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OFFSHORE PIPELINE SYSTEMS

Drill Rig g

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OFFSHORE PIPELINE SYSTEMS Submarine Pipeline Laying ‰

Pipeline laying operation done by Lay Barge by SS-lay method

‰

Pipelay Analysis done using OFFPIPE software for Pipe Stress Control at different depths p and environmental conditions

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OFFSHORE PIPELINE SYSTEMS

Lay y Vessel Requirements q

ƒ ƒ ƒ ƒ ƒ ƒ ƒ

Material Handling Conveyors Line--up Station Line Welding Stations Pipe Tensioners A/R Winch X-Ray Inspection

ƒ ƒ ƒ ƒ ƒ

Field Joint Coating Pipe p Davits Pipe Roller Supports Stinger g System y Mooring System

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OFFSHORE PIPELINE SYSTEMS

Pipe p Tensioner

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OFFSHORE PIPELINE SYSTEMS

Lay y Vessel Requirements q - Stinger g

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OFFSHORE PIPELINE SYSTEMS

Installation – Pipe p Lay y Procedures ‰ Pipelay Initiation ‰ Continuous Pipelay ‰ Pipelay Down

(Abandonment) ‰ Riser Installation

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OFFSHORE PIPELINE SYSTEMS

Landfall Point (LFP) ( )

Landfall

Shore--Pulling Shore

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OFFSHORE PIPELINE SYSTEMS

CCWC for Stability y

Concrete Coating g

Pipe p Weighing g g

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OFFSHORE PIPELINE SYSTEMS

Riser installation

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OFFSHORE PIPELINE SYSTEMS

Pipeline p Protection by y Trenching g ‰ To Enhance/Improve Stability ‰ To Provide Protection Against Offshore

Operations ‰ To Avoid Span Correction

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Lay barge VMGL Regina 250

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Stinger

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Pipeline Laying

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Field Joint Coating

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Fit – up for installation

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Lifting operations in Lay barge

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Pipeline Laying Video

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LSAW PIPE MANUFACTURING

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Thank You

www.engineersindia.com

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