bundles subsea uk lunch and learn 2012
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27.1.11 1Page
Bundle Pipeline Systems
& Shell FRAM DevelopmentIain Watson & Peter Walker
March 21st, 2012
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Bundle Technologies
Advantages of Bundle Systems
Agenda
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2Page27.1.11
Shell Fram Bundle FEED
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Bundle Technologies
Agenda
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3Page27.1.11
Shell Fram FEED
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What is a Bundle / Towed Pipeline Solution? A Pipeline Bundle is a carrier pipe within which any combination of
individual pipelines and umbilical components is carried.
The individual components terminate in Towheads within which
manifolding may take place. A Towed Pipeline Solution provides a low stress installation method
where-by a pipeline bundle is towed and installed using the ControlledDepth Tow Method.
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Subsea 7 Installed Bundles
sgard
Heidrun
NorwayNorway
Osprey
Cormorant
Frigg East
Murchison
GullfaksBruce
65 bundles in 33 years
Up to 7.6km length
Up to 28.7km in series
Up to 320m water depth
Shallowest 42m
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Claymore
PiperSaltire Thelma
Cyrus, FarragonScapa
Alba
Gannet
Embla
Dan DenmarkDenmark
WickWick
ScotlandScotland
Buckland Leadon
Skene
Longest tow 1000 km Up to 49.5 carrier
Up to 545 te towhead
Heaviest bundle 9154 te
Up to 3 PiP flowlines
U-value
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Bundle Components
Flowlines
Insulation
Sleeve Pipe
Control/Chemical Tubes
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, ,
Main Spacer
Centraliser Pipe-in-Pipe Spacer
Bulkheads
Ballast Chains
Anodes
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What exactly is a Pipeline Bundle?
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Typical Bundle Layout
BP Machar
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BP Andrew
Kerr McGee Leadon
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Materials
Flowline Materials
Carbon steel - X52, X65, X70 with SS or
Alloy Liners
Corrosion Resistant Alloys - 13% 22% & 25%
Cr Steels
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Plastic (HDPE) Liners for Water Injection Lines
Controls
Hard Pipe Hydraulic and Chemical Systems -
316 SS, 25% Cr Duplex to Carbon Steel
Electrical & Fibre Optic Control Systems
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The Long Trek West
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Wester Fabrication Facility
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Hastigrow Fabrication Facility
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Welding Firing Lines
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Inner Bundle Fabrication
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Insulation Type
Passive Insulation System
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Pipe-in-Pipe System
Electrical Active/Trace Heating
Indirect Hot Water Heating
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Production Line Insulation
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Applying ITP Izoflex Insulation
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Applying ITP Izoflex Insulation
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Spot Welding Steel Sheet Over ITP Izoflex
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Spot Welding Steel Sheet Over ITP Izoflex
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Bundle System Applicability
1500
2000
m)
Wet Insulation
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0
500
1000
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
WaterDep
th(
U-Value (W/m2K)
Pipe-in-Pipe
Bundles - Towed Pipeline Systems
Flexibles
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Flow Assurance Geometry of Pipelines
The environment within the carrier pipe provides an ideal opportunity forinnovative solutions in Flow Assurance.
The pipelines can be arranged to facilitate heat transfer between product linesor from dedicated heating lines.
Heat transfer analysis confirmed by experimental results.
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Active Heating Systems
Warm-up before Start-up
Increase Temperatures for Low Production Rates
Keep System Temperature High during Shutdowns
Reduce Chemical Injection
Six Active Heating Systems installed in the North Sea
Hot Water Circulation over distances of 15 km
Electric Heat Transfer
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Carrier Sheathing
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27m lengths welded into 500-1000m trains All production operations on line
Trains sheathed to final location
Final field joint tie-ins
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Towheads
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Jura Manifold Beach Landing
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Jura Manifold Beach Landing
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Bulkheads
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Bulkheads
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Towhead Tie-In
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Bundle Launch
Structures greater than 500Te
Tidal currents monitored & tug
locations altered accordingly
Tug bollard pull up to 400Te
Capstan winch providing
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o ac tens on up to e
A99 road bridge opens to allow
large structures to pass through
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Launch
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Control Depth Tow Method Chains attached at regular intervals along the
bundle.
Ensures accurate weight control to
approximately 0.5%.
Weight of chain links on seabed is submergedweight of bundle.
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for tow if required.
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CDTM in Practice
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A data highway runs thelength of the bundle andallows acoustic commandsmade at one end of thebundle to be implemented atthe other, for example forvalve actuation or acousticspool metrology.
Towmasters real-time display of bundle shape and water depth
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What We Can Do
Field Concept Development, FEED Studies
Tender Engineering
Detailed Design & Fabrication Launch, Tow & Installation Analysis
Dynamic & Fatigue Analysis
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Regional Support (Bundles), Norway & Asia Pacific
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Bundle Technologies
Advantages of Bundle Systems
Agenda
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Shell Fram Bundle FEED
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Why Bundles? - Advantages
Eliminate the requirement for heavy lift vessels by incorporating Subsea Structures within a
Towed Production System (Maximum to date 545te).
Testing and commissioning of complete system onshore therefore reducing offshore time: -
Hydro testing, dewatering, drying, control fluid flushing, valve operations etc.
Fast hook up and commissioning for early first oil dates.
Installation under existing or temporary floating assets.
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Reduced number of subsea tie-ins and spool installations.
Seabed stability using Gravity Based or Piled design.
Protection incorporated in structure design.
Improved Flow Assurance / thermal Management (Heated Hot Water, Trace Heating).
Leak mitigation in case of internal flowline failure (maintain leaked oil within Carrier Annulus) -
Flowline safety class can be reduced when using DNV-OS-F101 Design Code.
Use of CRA Lined pipe in place of Clad pipe or solid CRA pipe.
High Temperature Flowline Design (up to 160C curre ntly).
Turn out cost more predictable (reduced exposure to weather/soils risk).
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Fram Field Location
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Fram Field Location
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Fram Development Proposed Field Concept
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Fram Development Proposed Field Layout (Xodus)
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Fram Infield Layout
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Fram FPSO Approaches (Xodus)
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Fram Drill Centre East Towhead & Well Tie-ins (Xodus)
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Fram Drill Centre West Towhead & Well Tie-ins (Xodus)
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Fram Bundle FEED - Principal Design Assumptions
Principal Design Data / Assumptions for Fram FEED:
8 Slot towhead manifold at DCE (5 wells initially).
6 Slot towhead manifold at DCW (3 wells initially).
2 midline SSIV structures required at FPSO (out with swing circle).
14 NB Gas Export SSIV located in Midline Towhead (East).
Shared services between drill centres sin le test riser as lift riser & riser umbilical .
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Mixture of Oil & Gas Wells at both drill centres. 345 Barg Design Pressure / 110C Design Temperature (Production/Test).
Max CO2 content ~1.1 mol.% in produced fluids.
Max. H2S ~6 ppmv in produced fluids.
~47,000 mg/l Chlorides in produced water.
Water depth infield ~ 95 m (wrt LAT).
20 year system design life
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Fram Bundle Cross Section Designs
DCE & DCW Bundle Cross Sections
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Midline Bundle Cross Section (Shared Services)
Fram Bundle Cross Section Designs
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Fram Bundle Cross Section Designs
Pipe-in-pipe Insulation System Performance (both options)
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CRA Lined Pipe (Butting) Mechanically Bonded (BuBi)
Fram Bundle Production & Test Line Linepipe Design
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The Mechanically bonded Butting Bimetal Pipe (BuBi Linepipe)
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Fram Bundle Simplified Configuration (P&ID)
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Fram Bundle - DCE Towhead Pipework (General Assembly)
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Fram Bundle - DCW Towhead (General Assembly)
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Fram Bundle - Midline Structure East (GA)
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Fram Bundle - Midline Structure West (GA)
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Bundle Launch at Subsea 7s Wester Site
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Bundle Tow Route
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Bundle Tow Configuration
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Bundle Tow Route
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Control Depth Tow Method
Chains attached at regular intervals along thebundle.
Ensures accurate weight control toapproximately 0.5%.
Weight of chain links on seabed is submergedweight of bundle.
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for tow if required.
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Questions?
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seabed-to-surface
www.subsea7.com