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  • Challenges of Installing El t i ll H t d Li d PiElectrically Heated Lined Pipe

    Wacek Lipski

    seabed-to-surface

    4th June 2008

  • Contents

    Who are Acergy

    hTyrihans project overview

    Key installation challenges

    Acergy Piper overview

    Integration of Cable Lay spread

    Welding of Bubi Pipe

    NDT of Bubi Pipe

    Cable Strapping

    Summaryy

    seabed-to-surfaceprivate and confidential06 June 2008slide 2

  • Who are Acergy?

    We are a seabed-to-surface engineering and construction contractor for the offshore oil and gas industry contractor for the offshore oil and gas industry worldwide. We plan, design and deliver complex, integrated projects in harsh and challenging offshore environmentsenvironments.

    Our Vision:Acergys vision is to be the acknowledged leader in seabed to surface engineering and constructionseabed-to-surface engineering and construction.

    seabed-to-surfaceprivate and confidential06 June 2008slide 3

  • Tyrihans Project Overview

    seabed-to-surfaceprivate and confidential06 June 2008slide 4

  • Kristin A sgard BAcergy Falcon Scandi Acergy

    Acergy Piper

    seabed-to-surfaceprivate and confidential06 June 2008slide 5

  • Tyrihans Project Overview

    Acergy 2007 Scope:Installation of 16/18 Production pipeline from Kristin to p pTyrihans South, complete with piggy backed Direct Electrical Heating (DEH) cableInstallation of 10 Gas Injection line from sgard to Tyrihans Installation of 10 Gas Injection line from sgard to Tyrihans South

    Challenges imposed by the field:Product from Tyrihans field and possible future tie-ins required either complete CRA or CRA lined production pipeHydrate control evaluated to be most economical using an Hydrate control evaluated to be most economical using an electrical heating systemLongest/largest diameter pipeline installed with DEH systemDue to long, previously untried cable length, risks of spark-over which is difficult to detect. Requires high quality cable installation

    seabed-to-surfaceprivate and confidential06 June 2008slide 6

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  • Tyrihans Project Overview System Components

    seabed-to-surfaceprivate and confidential06 June 2008slide 7

  • 16/18 Production Pipeline Specifications

    43 km total length 0.4 km 16->28.3 km 18 ->14 km 1623 9 WT DNV GR 450 SAWL IFD ith 3 316 L 23.9 mm WT, DNV GR 450 SAWL IFD with 3 mm 316 L mechanically bonded liner43 km of DEH cable, 15.5 kg/m, 85 mm OD, 700 tonnes in , g/ , ,total500 m of AFC cable, 52 kg/m, 135 mm OD, temporarily strapped to the pipestrapped to the pipe700 Tonnes of MPSWater depth 320 mpSoft silty clays15 curves, radius 2000 m

    seabed-to-surfaceprivate and confidential06 June 2008slide 8

  • Contents

    Who are Acergy

    hTyrihans project overview

    Key installation challenges

    Acergy Piper overview

    Integration of Cable Lay spread

    Welding of Bubi Pipe

    NDT of Bubi Pipe

    Cable Strapping

    Summaryy

    seabed-to-surfaceprivate and confidential06 June 2008slide 9

  • Key Installation ChallengesD i i t ll ti d i t ti f b d bl l Design, installation and integration of brand new cable lay spread onto Acergy PiperWelding and NDT of mechanically bonded lined pipeg y p pDesign and qualification of strapping system to hold heating cable onto the pipelineM i t i i t ti t l th ti tMaintaining a rotation tolerance over the entire route

    seabed-to-surfaceprivate and confidential06 June 2008slide 10

  • Key Installation ChallengesAlsoAlso...

    Initiation with anchored barge in a congested seabedCurve layabilityy ySystem Behaviour (interaction effects)PP injection SystemMPS/Cable handling

    Fundamental factor in solving these is a large, robust working platform.Acergy Piperplatform.Acergy Piper

    seabed-to-surfaceprivate and confidential06 June 2008slide 11

  • Contents

    Who are Acergy

    hTyrihans project overview

    Key installation challenges

    Acergy Piper overview

    Integration of Cable Lay spread

    Welding of Bubi Pipe

    NDT of Bubi Pipe

    Cable Strapping

    Summaryy

    seabed-to-surfaceprivate and confidential06 June 2008slide 12

  • Acergy Piper - Overviewd3rd generation, anchor positioned lay barge

    One of the most efficient semi-submersible pipelay bargesbarges

    Outstanding track record of achievement in the challenging environmental conditions of the UK and Norwegian sectors of the North Sea

    Also successfully carried out significant pipe lay and trunkline operations in West Africa the Mediterranean trunkline operations in West Africa, the Mediterranean and the Gulf of Mexico

    Renowned for high speed lay of large diameter, concrete e o ed o g speed ay o a ge d a ete , co c etecoated, carbon steel pipe, but now also a world leader in specialised complex pipeline installation.

    seabed-to-surfaceprivate and confidential06 June 2008slide 13

  • Acergy Piper - Specifications

    340 tonne top tension capacity53,500 Tonnes displacement at 20 m working draft, p gDimensions: 167.5 m x 58.5 m x 33.2 mAccommodation for 400+ personnel2000 Tonne pipe storage capacity14 point mooring systemWater depths up to 450 m + depending on pipe Water depths up to 450 m + depending on pipe characteristics8 main line work stations plus double jointing stationsUsually supported by 3 anchor handlers & supply boatsExcellent lay accuracySt bl l tf bl t t ti l ti d Stable platform, able to operate continue lay operations and maintain position in harsh conditions

    seabed-to-surfaceprivate and confidential06 June 2008slide 14

  • Acergy Piper The Challenge

    The challenge was to The challenge was to convert Piper from a high speed carbon steel pipe l b t l ti l lay barge to a relatively low speed, high quality production base for a relatively short piggybacked pipelineThis required many This required many physical changes, but also cultural changes onboardonboard

    seabed-to-surfaceprivate and confidential06 June 2008slide 15

  • Contents

    Who are Acergy

    hTyrihans project overview

    Key installation challenges

    Acergy Piper overview

    Integration of Cable Lay spread

    Welding of Bubi Pipe

    NDT of Bubi Pipe

    Cable Strapping

    Summaryy

    seabed-to-surfaceprivate and confidential06 June 2008slide 16

  • Integration of Cable Lay Spread The Challenge

    Up to now, Acergy Piper had only been used for lay of generally long and relatively large concrete coated pipesgenerally long and relatively large concrete coated pipesPiper had never before installed a piggy backed cable so a new customised system had to be developed to suit the specific needs of the projectFundamental system requirements were:

    DEH cable stored on board in one lengthDEH cable stored on board in one lengthTemporary system to install a second cable (Armoured feeder cable) for the first 450 m of layDue to the weight of the cable (700 tonne +) payout of pipe needed to be de-coupled from movement of cable storage unitstorage unitStore/handle/install 700 tonnes of MPS

    seabed-to-surfaceprivate and confidential06 June 2008slide 17

  • Integration of Cable Lay Spread The Solution

    AFC Reel

    Cable Repair Shack Location

    Accumulator

    Spooling Tower

    Carousel

    Spooling Tower

    Carousel

    Cable Touchdown on Pipe

    seabed-to-surfaceprivate and confidential06 June 2008slide 18

  • Integration of Cable Lay Spread The Solution

    DEH Cable

    Cable Tensioners

    AFC AFC Cable

    seabed-to-surfaceprivate and confidential06 June 2008slide 19

  • Integration of Cable Lay Spread In Action

    seabed-to-surfaceprivate and confidential06 June 2008slide 20

  • Contents

    Who are Acergy

    hTyrihans project overview

    Key installation challenges

    Acergy Piper overview

    Integration of Cable Lay spread

    Welding of Bubi Pipe

    NDT of Bubi Pipe

    Cable Strapping

    Summaryy

    seabed-to-surfaceprivate and confidential06 June 2008slide 21

  • Welding of BuBi Pipe What is Bubi?

    Trade name for Buttings Bi-Metal PipeMechanically bonded pipe fabricated by expanding a 316L liner inside a carbon steel parent pipeliner inside a carbon steel parent pipeSeal welded at ends to prevent contamination and moisture ingress between the liner and parent pipe

    seabed-to-surfaceprivate and confidential06 June 2008slide 22

  • Welding of BuBi Pipe The Challenge

    Acceptance Criteria allowable defect size less than 1 mm in Root and Hot passContamination prevention no contact Contamination prevention no contact between CRA liner and carbon steelWelding speed to achieve required qualityConsequences of a cut-out Cold cut required and seal weld must be reinstatedCold cutting is slow and seal weld is manual so Cold cutting is slow and seal weld is manual so very time consumingChallenge is to define a welding process and material that is very reliable but not overly slow

    seabed-to-surfaceprivate and confidential06 June 2008slide 23

  • Welding of BuBi Pipe - The Solution

    Undertook extensive trials of a large number of welding processes and fill materials

    d b l dGTAW proved to be extremely sensitive to pipe geometry and thus not suited to this project given the pipe manufacturing and bevel tolerancesGMAW with Duplex resulted in generally higher than permissible porosityTherefore final process utilised GMAW with Inconel for the Therefore, final process utilised GMAW, with Inconel for the Root and hot pass and Incoweld 686 for the fillIncoweld 686 for the fill gave superior strength to 6

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