OTC Asia 2014 Petronas

OTC-24721-MS
A Case Study Detailing the Design, Planning, Installation and Cost
and Environmental Benefit Analysis of a Reinforced Thermoplastic
Pipe Pulled Through the Inside of an Existing Offshore Steel Flow
Line in the East Malaysia Samarang Field
John R Wright Jr. Polyflow LLC, Khairul Anuar Karim, PETRONAS Carigali and Steve
Kennedy, SCG Oil and Gas

Agenda
1) Background
2) Steps and Analysis for Successful Rehabilitation
3) Details of the Installation
4) Benefits Analysis
5) Areas for Improvement
6) Q & A
Slide 2
OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced
Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,
Kennedy

Background
• PL-112 Pipeline
• 52 Km off Labuan in Samarang Field
• 8-10 Meters of Water
• 6” API -5L X-42 Steel Pipe Installed in 1977
• Approximately 1Kilometer
• Anchor Hooked Pipe Causing a Kink in 2009
• Repairs Made with Misalignment Flanges
• Difficulty in Maintenance and Loss of Wall Thickness
Concluded Repairs as Temporary
• Current Infield Drilling
• Required New Pipeline for Next 25 Years
• New Steel Pipeline Replacement and Reinforced Thermoplastic
Pipe Rehabilitation were Evaluated
• Future Flowing Conditions
• 1,800bbl – 5,000bbl/day Depending upon Field Requirements
• Concern with SRB’s in Future
• Low Formation Pressure
Kennedy

Analysis and Planning Steps for RTP Rehab
• Sizing of the New Flow Line
• Material Selection
• Pull Force Analysis
• Selection of Pulling Equipment
• Detailed Layout of Project
Kennedy

Proper Sizing of Pipe
Slide 5
• Sized for Desired Production
 Fits Inside of Existing Steel
 Acceptable Pressure Drop
for Formation
 Ideally Fits Through Existing
Risers
• Design for Maintaining
Minimum Velocities
 0.61m/s will Carry Solids in
Liquids
 Reduces Ongoing
Maintenance (Pigging)
• Selected 3.5” RTP (2.95” ID)
 Acceptable Pressure Drops
 Minimal Velocities for Range
of Flow
 Risers Have to be Modified Modified Riser with 12D Bend
Kennedy
Existing Riser with 5D Bend

Pressure Drops and Critical Velocities for 3.5” RTP
Velocity at
1,800bbl/day is
2 ft./sec (0.61 m/sec)
Typical Production
Volume Pressure
Drop of 15.3 psi @
1,800bbl/day
Maximum Production
Pressure drop 96.4 psi @
5,000bbl/day
Kennedy

Material Selection
• RTP Components
 Inner Liner- Fluid Compatibility
 Reinforcement- Strength
 Jacket- Protects Reinforcement
• Liner- PPS/Fortron
 Hydrocarbon CO2, H2S, Brine
Resistance (Norsok 710 Testing)
 Low Permeation
• Reinforcement - Aramid/Twaron
 Static/Cyclic Strength
 Resistance to the Environment
• Outer Jacket- Nylon
 Abrasion Resistance
 Hydrocarbon Resistance
Aramid Reinforcement
PPS Liner
Volume (%) Composition
30 3% CO2, 2% H2S, 95% CH4
10 Distilled water (conductivity < 5 µS)
60 70% heptane, 20% cyclohexane, 10% toluene
Composition of NORSOK M710 Solution
Kennedy
Nylon Jacket
RTP Components

Chemical Resistance and Permeation of PPS/Fortron
30
35
40
45
50
55
60
0 20 40 60 80 100 120
190
C
170
C
160
C
150
C
Tensile Strength of Fortron PPS (MPa) as a function of Ageing
(Days) from 140-190C
Kennedy

Kennedy
Pre-Planning Project Layout
Spool off Location
Riser Termination

Project Pre-planning
• Gauging Pig for Existing Line
• Pull Force Analysis
• Wet vs. Dry
• 1,818 Kg Pull Force Wet
• Synthetic Rope (5X Safety Factor)
• Project Layout
• Platform Space vs. Boat
• Individual Steps
• Responsible Party
• Underwater Work
• Riser Bottom Bend Modifications
• Subsea Bend Modification
• Top Side Spools Modifications
• Project Scheduling
• Capabilities of Platform Equipment
Kennedy

Kennedy
Platform A Platform B
Existing Pipeline
Plastic Insert Pipe
Messenger Pig
Cross-section
Messenger pig
Winch Spool Reel
Installation Method: Planning

Kennedy
Installation Method: Planning
Winch
Existing Pipeline
Plastic Insert Pipe
Messenger Pig
Spool Reel
Cross-section
Plastic Insert Pipe

Messenger wire
Winch
Cross-section
Existing PL 112
Plastic Insert Pipe
Messenger Wire
Kennedy
Installation Method: Actual

Winch
Cross-section
Existing PL 112
Plastic Insert Pipe
Messenger Wire
Kennedy
Installation Method: Actual
Spool
Reel
Vessel
Plastic Insert Pipe

Installing the RTP
• Cleaning the Line – Scrape Both
Directions
• Erect Scaffolding to Align Pipe from
Boat
• Foam Pig Synthetic Rope Through
Pipeline
• Set up Winch for Pulling
• Align Pulleys over Flange Opening
• Attach Pulling Cone to Pipe and
Cable
Kennedy
Erecting Scaffolding
Cleaning Activity for Existing LineRTP Pull Thru Activity

Pulling the RTP and Splice Joints
• Pull Rate – 20m/min
• Cable Passed Through Load Cell
• Pull Force At Expected Value
• Indicator for Hang-ups
• Spliced Couplings
• 300 Meters Per Pipe Length
• Duplex 2205 Joint Splices
• End Connections
• Double Faced RTJ Flanged
• Seal off Annular Space
• Port on Annulus with Pressure Gage
Boat to Scaffold
Kennedy
RTP Pulling Activity
Jointing between two portions of RTP pipe
Splice Coupling

Inspection of the RTP After Pull Through
• Inspect Pulled RTP
• Inspect for Gouges & Jacket
Breaches
• Deformation in Pipe
• Cut to Length & Install
Termination
• Hydro- Test at 2X MAOP for 24
Hours (360PSI)
• Design Pressure – 1,440PSI
Kennedy
Final Pull Out of RTP
Final Spool Make-up
Hydrotest Pressure Chart

Analysis of Benefits
• After One Year of Operation
 Flowing 1,800bb – 7,000bbl/day
• 7,000bbl/day Causing Excessive
Back Pressure
 No Chemical Treatment
 No Pigging/ Cleanout
• CAPEX 67% Lower than New Steel Line
 Eliminating Riser Modifications &
Pulling from Boat Creates 80+ %
Savings
• Benefit to Environment compared to
conventional steel replacement
 Minimum disturbance to seafloor &
marine life
 Reused of existing steel pipeline
• Existing Steel Line Remains Part of the
System and is not Abandoned
Kennedy

Lessons Learned – Areas for Improvement
• Improvement in Planning
• Changed from Platform to Platform vs Boat to Platform
• Platform Deck Space Availability
• Crane on Platform Inoperable
• Making Sure Continuous Back Tension on Pipe During Pulling
• Sharp Changes in Tension can Kink Pipe
Kennedy
Kink Portion Observed During Pulling Activity

Lessons Learned – Areas for Improvement cont.
• Better Pulling Rope Design to
Minimize Damage During Pulling
• Nylon Jacket on Rope too Thin
• Tore As Pulled Through Riser
• Rub on Sharp Flange
• Wrinkling Create Hang-up
• No Issue with Pipe
• Rope Broke 1 Meter from End of
Pull – Finish with Cable
• Jacket Tears Hung Up in Load
Cell
Kennedy
Final Pull Out of RTP
Wrinkling of Pulling Rope When Bent Damage layer of Pulling Rope

Lessons Learned – Areas for Improvement cont.
• Alternative Rope Designs
• Heavier Nylon Jacket
• Braided Jacket
• Braided Jacket with Nylon Jacket
• Testing Ongoing
Kennedy

Acknowledgements
Slide 22
Special thanks to:
a) P&E Management, PCSB
b) SBO Management, PCSB
- Maintenance & Operation, SBO
c) Samarang Operations
d) Technology Provider
- Polyflow Inc.
e) Contractors

Acknowledgements / Thank You / Questions
Slide 23

OTC Asia 2014 Petronas

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