How To Repair A Pipeline

Transcription

1 Emergency Pipeline Repair System London Presentation Lloyds OPERA Group by George Lim Business Development Manager, T.D. Williamson London, April 24,

2 1 Who is T.D.Williamson? 2 What is EPRS? 3 Onshore EPRS 4 Offshore EPRS

3 CONFIDENTIAL T.D. Williamson Inc Specialized equipment, tools, technologies, products and services Internal inspection, maintenance and intervention of live lines For oil & gas and process industries, water and industrial businesses * Pioneers in Hot Tapping & Plugging * Pioneers in Pigging * 90 years old * * Onshore and Offshore * Global presence * HQ in Tulsa, Oklahoma, USA * 3

4 1 Who is T.D.Williamson? 2 What is EPRS? 3 Onshore EPRS 4 Offshore EPRS 4

5 EPRS? Emergency Pipeline Repair Catastrophic Failure ASSESS PROCURE MOBILIZE EXECUTE Make safe Damage identification & evaluation Repair scenarios Materials Equipment Spreads Resources Technology Base location Service contracts Organization Extended Downtime Business Interruption Exposure of people, asset, environment High reactive costs Regulator intervention Insurance issues Share value impact CNN Repair Recommission Restore flow 5

6 ASSESS PROCURE MOBILIZE EXECUTE Damage identification & evaluation Repair scenarios Materials Equipment Spreads Resources Technology Base location Service contracts Organization Repair Recommission Restore flow How To Minimize Downtime? Do the Assessment, Procurement and Mobilization before any emergency arises 6

7 Emergency Pipeline Repair System EPRS Emergency ASSESS PROCURE MOBILIZE Catastrophic Failure EXECUTE Damage identification & evaluation Repair scenarios Materials Equipment Spreads Resources Technology Base location Service contracts Organization Make safe Repair Recommission Restore flow Short downtime EPRS results in operational readiness Capacity to swiftly restore flow in an emergency 7

8 1 Who is T.D.Williamson? 2 What is EPRS? 3 Onshore EPRS 4 Offshore EPRS 8

9 ONSHORE Damage Mechanism Corrosion Impact - accidental, malicious Natural Hazards - earthquakes, landslides Structural Intervention illegal taps Damage Consequence Catastrophic failure: o Unexpected damage requiring immediate response o Pipeline normally in shutdown condition Integrity risk: o o Monitored risk and a planned repair Pipeline normally in operating condition 9

10 ONSHORE Repair Scenarios Repair Composites Technologies such as Res-Q Welded Sleeves or Leak Repair Clamps Hot Tap and STOPPLE / By- Pass Methods Cold Cutting and Pipe Replacement Tie-In of New Tested Pipe 10

11 ONSHORE What Do You Need? Equipment, Materials, Resources? Equipment: Aligned & Maintained? Technicians: Trained & Certified? Response Time & Geographic Locations? Repair & Rehabilitation Methods Local Inventory vs. Needs Health / Safety / Environmental Applications Engineering Support 11

12 TDW Emergency Response Concept Gap Analysis Current EPRS Capacity vs. Actual Needs Planning Equipment Fittings / Clamps / Composites Technicians Establishing Optimal Capacity 12

13 Master Document: Gap Analysis of Current Capacity T.D. WILLIAMSON MASTER PIPELINE INTERVENTION GAP ANALYSIS CUSTOMER PDVSA SAN TOME OPERATING UNIT ING. MANTENIMIENTO Sealing Elements Equipment Spares CONTACT FRANKLIN MATA (Cel)/ (Of) Fittings Technicians Repair & Rehabiliation DATE 06/14/2006 REVISION Pipe Location Pipe Description Operating Condtions Pipe Contents Equipment Sealing Elements Equipment Spares Fittings Technicians Repair & Rehabiliation Start Nominal Pipe Size Inches Wall Thick Inches Max Op Max Op Temp Press. (Psi) (F) Daily Production BBD / mfcm Crude Oil Natrl Gas H2S % Hot Tap SINGLE Stopple DOUBLE Stopple PER WALL THICKNESS (*) Cutters, Pilots, Etc. (**) Hot Tap Stopple Hot Tap Stopple Repair Clamps Welded Sleeves Composite Wraps ARE.ED 3 LATERAL ARECUNA 16" N/A 450.LBS 100 F 1714 x N/A N/A YES YES YES YES YES NO YES YES YES YES N/A NO ARE.ED 4 LATERAL ARECUNA 16" N/A 550.LBS 100 F x N/A N/A YES YES YES YES YES NO YES YES YES YES N/A NO OED- 16 LATERAL ARECUNA 6" N/A 440.LBS 440 F 3335 x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO OED- 20 LATERAL MEREY 6" N/A 500.LBS 500 F 258 x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO LED-13 LATERAL ADAS 10" N/A 600.LBS x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO MED-20 LATERAL MEREY 20" N/A 500.LBS x N/A N/A YES YES YES NO NO NO NO YES YES NO N/A NO MED-20 LATERAL MEREY 12" N/A 550.LBS 126 DOS LINEAS x N/A N/A YES YES YES NO YES NO NO YES YES YES N/A NO OED-27 LATERAL MEREY 12" N/A 400.LBS x N/A N/A YES YES YES NO YES NO NO YES YES YES N/A NO MED-15 LATERAL BARE 12" N/A 700.LBS x N/A N/A YES YES YES NO YES NO NO YES YES YES N/A NO MED -4 LATERAL MEREY 6" N/A 400.LBS x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO MED-18 LATERAL MEREY 6" N/A 600.LBS x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO LATERAL DE GUARA P. T. O 24" N/A 200 LBS x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO OED-11 P. T. O 4" N/A 120.LBS x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO COB P. T. O 36" 36" N/A 500 LBS ,000 x N/A N/A NO NO NO NO NO NO NO YES YES NO NO NO PTO KM 127 (T-51) 30" N/A 710 LBS ,000 x N/A N/A YES YES YES NO NO NO NO YES YES YES N/A NO

14 Example of Equipment Needed TDW STOPPLE Equipment to perform 3 Double STOPPLE position operations on # steel pipes with 36" bypass Equipment for Tapping Equipment for Bypass Consumables 1 Tapping Machine TM 2400 complete 1 SANDWICH Valve adapter 48" 600# 1 Cutter holder 46" 2 STOPPLE Cutter 46" 2 Pilot drill 46" 2 SANDWICH Valve 48" 600# Equipment for Plugging 2 STOPPLE Hydraulic cylinder 2 STOPPLE Housing 48" 600# 2 STOPPLE Plugging head 46" Equipment for Completion 1 LOCK-O-RING Plug holder 1 LOCK-O-RING Bypass gauge 1 Tapping Machine TM 2400 complete 1 SANDWICH Valve adapter 36" 600# 1 Cutter holder 12" to 30" 2 Standard Cutter 36" 2 Pilot drill 36" 2 SANDWICH Valve 36" 600# 1 LOCK-O-RING Plug holder 12" to 36" 1 LOCK-O-RING Bypass gauge Equipment for equalization 1 Drilling Machine T Carrying case for T Drive socket 1 Air motor for T Threaded valve adapter 2" 2 Drill 1 7/16" 2 Full bore valve 2" 1 Plug holder 6 STOPPLE Fitting 46X48" 600 RF 6 LOCK-O-RING Plug 48" 6 Blind flange set 48" 600 RF 12 STOPPLE Sealing element 46" 6 Coupon reinforcement 46" 6 LOCK-O-RING Fitting 46" x 36" 600 RF 6 LOCK-O-RING Plug 36" 6 Blind flange set 36" 600 RF 6 THREAD-O-RING Fitting 2" complete You need to know what to buy 14

15 Technician Skills Inventory: Gap Analysis TECHNICIAN KNOWLEDGE AND SKILLS INVENTORY T.D. WILLIAMSON PIPELINE INTERVENTION GAP ANALYSIS CUSTOMER PDVSA SAN TOMÉ OPERATING UNIT ING. MANTENIMIENTO CONTACT FRANKLIN MATA (Cel)/ (Of) DATE 06/14/2006 JUAN BRONT (TECHNICIAN: 6 YEARS, MECHANIC: 6 YEARS) IDENTIFICATION NUMBER: C.I.: , AGE 39 EXPERIENCE: YES / NO EQUIPMENT KNOWLEDGE OPERATION & PROCEDURE KNOWLEDGE FACTORY TRAINED FIELD AUDIT DATE CERTIFICATION DATE HOT TAP & STOPPLE EQUIPMENT T-101 Drilling Machine YES YES YES NO NO NO 360 Tapping Machine YES YES YES NO NO NO 660/760 Tapping Machine YES YES YES NO NO NO 1200 Tapping Machine YES YES YES NO NO NO SHORTSTOPP 60 Plugging Machine YES YES YES NO NO NO SHORTSTOPP 60 Plugging Machine YES YES YES NO NO NO STOPPLE Plugging (less than 500 psi) YES YES YES NO NO NO Hydraulic Cilinder 6" - 12" YES YES YES NO NO NO Hydraulic Cilinder 14" - 22" YES YES YES NO NO NO Hydraulic Cilinder 24" - 36" YES YES YES NO NO NO Pipeline Medium Pressure Temp Gas: Liquid: Sour Water 80 PSI 140 F Crude oil 650 PSI 140 F LPG: 600 PSI 80 F Hi-Flow: Gasoline 80 PSI 80 F Diesel

16 Technicians Training & Certification by TDW Hot Tapping & Plugging Equipment Selection of Equipment Mix: Size, Pressure, Etc. Basic Maintenance of Key Components Trouble Shooting Application engineering HSE Training Written Exams 16

17 ONSHORE Service Centre Set Up o Customer owned o TDW premises Fire Station 17

18 Equipment Maintenance by TDW Restoration & Certification of Original TDW Equipment by Factory Standards (OEM) Detailed Diagnostics Validation of Equipment Performance with Written Test Protocols 1-Year Guarantee: Labor & Parts Maintenance Records 18

19 TDW Emergency Response Services Operational : 24 hour x 365 day emergency cover Mobilisation within an agreed time Agreed repair methodologies Detailed work plans for each emergency TDW Trained and Certified Technicians Full Personnel Safety Compliance Job Safety Analysis OEM Maintained equipment Fully auditable service Commercial : Multi-year contract for operation and maintenance Agreement based on 24 hour availability Agreed rates for retention, per operation and / or maintenance activities 19

20 Long Term Partnerships Scope of EPRS Services: In-Country Equipment & Personnel Site assessment Project Management Training & drills Comprehensive scope Excavation and civil acivities, including site reinstatement HT&P Equipment & Fittings, Welding, NDT and cold cutting Coating removal and re-coating Pressure testing SmartPlug TM Res-Q Wrap Repair clamps Pigging & In-line Inspection 20

21 TDW Current Emergency Response Contracts Asia Pacific Turkey Botas o Customer owned equipment, TDW operated o TDW personnel & local subcontractors o Fixed annual fee for Maintaining Readiness o Call-off services per incident on reimbursable basis Variety of Contract Types Singapore Exxon Mobil o TDW is Fire Station for a process industry customer o Service Centre at 15 minutes driving distance from the refineries o 5-year Frame Agreement for call-off services Australia consortium of pipeline operators o Partnering by 5 local Transmission companies o Pooling of equipment owned by the customers o TDW provides ER services, operates and maintains the equipment 21

22 TDW Current Emergency Response Contracts South America Venezuela PDVSA o Customer owned equipment, TDW supplied o Customer owned service centres, Technicians o TDW provides maintenance, Technician training & certification USA Alaska Alyeska o Customer owned equipment, TDW operated Europe France o General call-off support 22

23 Case Study Onshore EPRS 23

24 BTC Pipeline Key features From Baku Tiblisi Ceyhan Consortium of 11 operators 1768 km long and 42, 34 and 12 diameters Crossing 3 countries, mountain ranges up to 2,830 metres Traverses 3000 roads, railways, utility lines above/below ground Crosses 1500 water courses up to 500 metres wide 1million b/d 24

25 Purpose of EPRS Contract Put in place a system for response and repair under unpredictable circumstances and emergency situations Damage Scenarios Loss of containment by Corrosion Malicious damage Illegal fittings Earthquakes Landslides TDW Services Supply of equipment & materials Call-off services per incident Maintain Readiness In-country point of contact Initial mobilization 4 hours 24 hours working year contract (Owner to supply specified material) 25

26 Key Events Day 1 : Fire at BVS 26km of 42 pipe affected Assessment team arrived 11 hours after first notification Equipment & manpower within 24 hours of instruction Specialists from Europe within 60 hours of instruction Determined the strategy and time frame with customer Identified single point contact Ensured back-up/contingency plans Damage successfully repaired Pipeline shutdown for 15 days 26

27 Integrity Risks 25 Illegal taps removed Pipe preparations Manageable associated hazards Low / medium risk Predictable location Known quantity (generally) Easier planning Recovery of illegal feature Welded fitting prior to hot tap

28 Site activities normal operations 42 double STOPPLE Job with bypass Valve condition assessment 8 bypass for temporary capping Coating removal and re-coating Pre-heating and welding 28

29 Key Lessons Learned Single point contact at each base One-step-ahead strategy very effective Range of repair procedures Sub-contractor base needs strengthening Strategic placement of equipment along pipeline Dedicated EPRS packages at critical stations Increased inventory across the board Formalise maintenance activities 29

30 1 Who is T.D.Williamson? 2 What is EPRS? 3 Onshore EPRS 4 Offshore EPRS Main difference Offshore vs. Onshore pipelines: Difficult Accessibility 30

31 Trends in Offshore Pipelines 0 Diver limit Shallow Deep Water Ultra Deep Water Water Depth [m] ,000 1,100 1,200 1,300 1,400 1,500 1,600 1,700 1,800 1,900 2,000 2,100 2,200 Shell EUROPA 32 km 1,158 m Example of a pipeline profile Texaco GEMINI 45 km 1,063 m ExxonMobil MICA 47 km 1,326 m Enterprise CORRIB 97 km 350 m British Gas SCARAB/SAFFRON 90 km 650 m Reliance KG D6 100 km 1000 m British Gas SIMIAN/SIENNA 105 km 1,040 m Norsk Hydro ORMEN LANGE 120 km 1,100 m Shell MENSA 109 km 1,615 m TOTAL CANYON EXPRESS 92 km 2,198 m Longer pipelines Statoil SNØHVIT 170 km 350 m Deeper water Nord stream 1000 km 210 m Tie-back Distance [km] Gas development Oil development 31

32 OFFSHORE Damage Assessment Occurrence Index Incidents of Offshore Pipelines/Risers Gulf of Mexico to Corrosion (Internal) Natural Hazards Impact Unknown Corrosion (External) Structural (Design) Material Defect Line Pluggage Anchoring Construction Erosion Failure Cause 32 Number of Incidents total 1842

33 Failure Mechanisms & Damage types Corrosion Dry Buckle Paraffin Scale Hydrate Plugs Impact Damage Anchor Drags 33

34 Anchor Damage Example BP CATS Anchor Drag Transmed Anchor Drag Kvitebjorn Anchor Drag RECENT ANCHOR DRAGS High (difficult) Detection Index Damage not seen in 2006 Damage detected in

35 OFFSHORE Risk Priority Index = Occurrence x Severity x Detection Risk Priority Index (Operational) GoM High Risk Priority Index Highest index of 350 to 450: Anchor snag Others with high RPI : Buckling; Dropped objects Corrosion nowhere to be seen Dropped Object Near Platform (Wet) Dropped Object Away From Platform (Wet) Thermal Buckling (Wet) Dropped Object Near Platform (Dry) Mudslide Break (Mississipi Canyon) Paraffin Accumulation Dropped Object Away From Platform (Dry) Inline Equipment Failure: valves, flanges etc Dropped Object Near Platform (Dent) Dropped Object Away From Platform (Dent) Hydrate Formation Source: Deep Water RUPE Report 35 Anchor Snag (Wet Buckle) Anchor Snag (Dry Buckle) Thermal Buckling (Dry)

36 Find the Damage Damage Finding / Locating System Damage Minor Major Internal Blockage Assessment Pin hole leak; Piggable dent Non-piggable dent; Rupture Wax or Hydrates NO Rupture? YES Pipe content Continue Flow (Shallow water) Suspend Flow Controlled DECOM Uncontrolled Flooding Suspend Flow management Bypass Hot Tap Stopple Pipeline Isolation No Cut out Cut out No Cut out Replace pipe Fabr/ Lay Short - by DSV Long - by Laybarge Repair Leak Repair Clamp Structural Clamp Flanges In-Line Connectors Hyperbaric Weld Surface Lift&Tie-in Chem Injection System (+ Hot Tap) Re-commissioning Re-commissioning

37 Repair Scenario Damage Limitation SmartPlug Isolation Preventive Measure Temporary Isolation to preserve inventory Operated by Total 24 SmartPlug in new line being laid 36 SmartPlug in existing export line 37

38 Repair Scenario Minor Damage Repair Clamp TDW Remotely Operated Clamp Installation Tool 38

39 Repair Scenario Major Damage Bypass with Hot Tap & STOPPLE isolation Required Material & Equipment: Leak Cut-Out with SmartPlug isolation Hot Tap & Plugging Fittings Clamps Isolation Technology Marine spread 39

40 Surface Tie-in Repair Scenario Major Damage Cut out damaged section Recover each end onto laybarge Re-lay with overlap Lift both ends & weld Lay over Required Material & Equipment: Isolation technologies Marine spread 40

41 Repair Scenario Deep Water Deep Water Pipeline Repair DW RUPE Source: Deep Water RUPE Report 41

42 Repair Scenario Deep Water Deep Water Flowline Repair DW RUPE 42

43 Offshore Typical EPRS Pre-investments EPRS Study : - Establish Risk Priority - Establish overall EPRS scenarios and needs Saving Time : - Establish Framework Agreement for aerial / subsea surveys - Pre-invest in critical Long Lead materials, e.g. line pipe; clamps; fittings. Impact Anchors, Dropped objects Leak study rupture, water ingress Decomm/Re-comm Repair options isolation, cut-outs Procurement materials, spreads Project organization Critical Saving Costs : - Framework Agreement for marine spread & equipment - - Develop Repair Scenarios for rapid execution (SmartPlug Tool) Saving Pipe Inventory : - Pre-invest in Isolation, Bypass, Hot Tap equipment - Pre-invest in Decommissioning/Re-commissioning needs 43

44 Case Study Offshore EPRS 44

45 Mini Case Study: Malaysia Midline Repair An operator in Malaysia identified a leaking clamp on a 24-inch subsea gas pipeline operating at 750 psi in 70 metres water depth. TDW launched two SmartPlug isolation tools separated by inhibited seawater to straddle the defect to allow it to be cut and replaced. After the cut, each end of the pipeline which was isolated at 750 psi was lifted to the surface in order to weld a flange onto the pipeline, because the operator did not want to install gripped flanges. After lowering the ends, a spool piece was inserted and bolted to the flanges. 45

46 Case Study: TransMed Anchor Drag Mazara 46

47 Damage Consequence TransMed Pipeline System Line 3S completely severed Line 2S dented and lifted out of trench 1 S 2 S 3 S 4 S Blue : Pipelines before the incident Red : Pipelines after the anchor drag 47

48 Damage Consequence Cut out sections of the damaged 26 gas line Compelling evidence of the severe consequences of anchor drags 48

49 Repair Scenario This was an emergency repair, no EPRS was in place POST-EVENT SCENARIO ANALYSIS Damage Type Characterization Physical Characterization Pipeline Operating Condition Expected Downtime Range Downtime Mitigation Measures Pigable Dent < 10% reduction Pipe remains dry None initially, 4 (Buckle) in P/L I.D. and pressurized weeks during repair and RTO Temporary Repair clamp Unpiggable Dent (Buckle) 20 Line > 10% reduction in P/L I.D. Pipeline remains dry and pressurized 2 weeks initially during damage assessment, then 6 weeks during repair and RTO Temporary repair clamp Rupture 26 Line Unpigable inline, penetration of pipeline wall Release of gas, possible localized flooding of pipeline Immediate shutdown, 10 weeks to repair and RTO 49

50 Repair Option selected Surface Tie-In Surface Tie-in Prepare pipeline Cut out damaged section Recover each end onto laybarge Re-lay with overlap Lift both ends & weld Lay over Equipment delivery was requested to be in 6 weeks The company chose a totally diverless repair 50

51 Isolation Option to manage pipeline inventory TDW SmartLift Customised SmartLift TM Pipeline Recovery Tools. Inserted at the cut end Functions: - Isolation tool - Pig launcher/receiver - Lifting head 51

52 Summary Repair Sequence 52

53 Details of 20 Isolation sequence Dent Run & set Barrier pigs Pipeline cut PRT inserted Pigs running into PRT catcher PRT ready for lifting operation 53

54 Specialized 20 Barrier Pig Estimated 14% Reduction at dent location. Pig designed for 20% reduction. (16 ID) TDW SmartTrack TM system - critical to the isolation: ATEX approved transponder mounted in pig body Two-way through-wall communication Electromagnetic signals Wireless communication - transponder & transceiver +/- 5cm accuracy. Data provided through-wall on internal pressures Remote transceiver Topside Transceiver & PDA Eexd 54

55 SmartLift TM Pipeline Recovery Tools Diverless Installation 55

56 Pigging Activity On-board Pig Detection Screen Recovery of Barrier Pig & PRT Pigging distances 150km in dry gas Zero on-site safety incidents 56

57 Decommissioning / Recommissioning Spread 700t of Equipment 2 x Air/N 2 Spreads capable of delivering 6000 scf/m 70 bar and dewpoint of - 40 o C 57

58 Overall Conclusions Onshore & Offshore Growing trend among operators to develop an EPRS Planning and essential investments must be made in advance Differences in approach between Onshore & Offshore EPRS: o Focus for Onshore on: Investment in equipment, inventory, resources o Focus for Offshore on: EPRS Study complex scenarios Realistic emergency cases ranked by Risk Priority Index Frame Agreements to cut long response times Management of pipeline inventory: isolation & bypass vs. DECOMM/RECOMM Common point between Onshore & Offshore EPRS: Think Ahead 58