february 2014 - z-subsea capability summary.pdf · start-up and shutdown operating guidelines ......

© Copyright Z-Subsea Lt. 1© Copyright Z-Subsea Ltd.

© Copyright Z-Subsea Ltd.

February 2014


www.Z-Subsea.comExcellence in Engineering© Copyright Z-Subsea Ltd.

© Copyright Z-Subsea Ltd. © Copyright Z-Subsea Ltd.

Introduction to Z-Subsea

Mission Statement

Worldwide projects track records

Key differentiators

Subsea design services

Materials and Integrity services

Capability Summary




Z-Subsea is an independent, Subsea Design and Integrity Engineering consultancy

established in 2011.

We provide integrated full life cycle solutions to the oil and gas industry worldwide.

Our current clients include Tullow Oil, TAQA, DNV ME, Neptune Marine Services,

Theon, FairLead Maritime, Petro Vietnam, etc.

Our full cycle services commence with conceptual definition and continue with

detailed design, construction move into operational support and up to end of life.

Safe Operation beyond the original design life (life extension) is also of high interest

to us.

We employ innovative and cost effective approaches to maximise our client’s safe

design and operation at a minimised unnecessary shutdowns.

Z-Subsea is an official member of Oil and Gas UK and Subsea UK and in the

process of registration with FPAL.




To be a world class multi-disciplinary, integrated and

impartial Subsea, Materials and Integrity consultancy.




Delivery driven by integrated approach throughout the project life cycle

(Design to end of life) and beyond (Life extension)

Quality of Personnel; national/International reputation and vast amount of

experience

Employing experienced personnel; worked for Contractors, Engineering

Consultancies, Verification bodies and Operators

Reasonable rates, high quality delivery and quick turn around

Specialisation in hot topics; such as Deepwater, HP/HT, Sour-service and

strain-based condition




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TAQA-UK: Consultancy services to TAQA on inspection, monitoring and integrity management of

12 J-Tubes within concrete caissons and suggesting mitigation measures.

Tullow Oil -UK: Materials/Welding and integrity consultancy supports to T.E.N project in Ghana

FairLead Maritime: Dynamic Nonlinear FEM of semi-sub impact to jacket

Neptune Marine Services (Neptune) - Australia: Verification and Development of Free-Span

and VIV analysis tool

DNV/GL - Middle East: Design verification of topside modification of Bukha-A Platform including

piping, process and material disciplines - Oman Oil Company Exploration & Production LLC

(OOCEP)

DNV/GL- Middle East: Design verification of subsea pipeline of Musandam Gas Plant Project -

Oman Oil Company Exploration & Production LLC (OOCEP)

DNV/GL - Middle East: Preparation of design Performance Standards for onshore pipeline,

structures and facilities - PDO




Z-Subsea Technical Capability Overview Subsea Design

Field Development Options

Field Layout and Route Selection

Design of Subsea Pipelines and Risers

Design of Flexible Risers and Umbilicals

Design of Subsea Structures and Pipe

Works

Advanced Pipeline/Riser Design (HPHT,

Strain Based Design, Low Cycle Fatigue,

Pipe-in-Pipe)

Component Design (Bulkhead, Flange, Y-

Piece,…)

Materials/Integrity Engineering Materials Selection

Corrosion Protection and CP Design

Welding and NDT

Fracture Mechanics Based Integrity (Fatigue/

Fracture) Assessments (ECA)

Corrosion Assessment of Existing Assets

(Fitness for service assessments)

Life Extension Studies

Advanced Analysis HPHT Pipelines Upheaval and Lateral

Buckling Advanced Analysis and Design

Design by Analysis for Flanges and

Bulkheads

Free Span and VIV Assessment for Pipelines

and Risers

Ship-Jacket Impact Advanced FE Analysis

and Assessment

Specialised Services to

Subsea Projects Flow Assurance

Subsea Process

Subsea Controls

Safety Engineering

Cost and Schedule Estimate

Contract Management

Specialised Training Courses


www.Z-Subsea.comExcellence in Engineering


Overview of Subsea Design Services

(Conceptual, Pre-FEED, FEED and Detail Design)

Field Development Options;

Field Layout and Route Selection;

Subsea Pipelines and Risers;

Flexible Risers and Umbilicals;

Installation Analysis;

Subsea Structures and Pipeworks

Materials and Coating Selection;

Corrosion Protection Philosophy and CP Design

Components Design (Bulkheads, Y-Pieces,…);

Subsea Controls;

Subsea Process;

Flow Assurance

Safety Engineering;

Cost And Schedule Estimate;




Field Development Options

Stand-alone;

Tied-back;

Phased Development;

How is it done?

EPIC schedule estimate;

Cost estimate;

Income estimate;

Cash flow generation;

Extracting economic indicators such as NPV, IRR and UTC.




Field Layout and Route Selection◦ Geotechnical and geophysical surveys;◦ Manifolds and structures locations;◦ Pipeline routes;◦ Pipeline system (single, piggybacked, PIP or

bundle);◦ Controls (EHC, distribution centres);

Subsea Pipelines◦ Material Selection◦ Wall Thicknesses◦ On-bottom stability ◦ On-bottom roughness and Free span◦ Pipeline protection◦ Fatigue◦ Lateral and upheaval buckling◦ Expansion and Walking◦ Crossing design◦ Pipe-in-pipe

◦ Tie-in spools (conventional, vertical)◦ Pipe-soil interaction models◦ Alignment sheets◦ High Pressure/High Temperature (HPHT)

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Risers and Umbilicals◦ Single rigid risers◦ Pipe-in-Pipe Risers◦ Caisson risers◦ Retrofit risers◦ J-tubes◦ Flexible risers◦ Umbilicals◦ SCRs

Subsea Structures and Pipework◦ SSIV◦ Manifold◦ PLEM, PLET, UTA◦ Foundation (Mud mat, Suction pile)

Component design and Advanced FE◦ Flanges◦ Bulkheads ◦ Tee-pieces◦ Y-Pieces

Reliability Based Design




Corrosion protection philosophy and CP design◦ CP selection◦ CP interference◦ CP and anode weight calculation

Subsea Controls◦ EPU: Electrical Power Unit◦ HPU: Hydraulic Power Unit◦ TUTU: Topside Umbilical Termination Unit◦ SDU: Subsea Distribution Unit◦ UTA: Umbilical Termination Assembly◦ SCM: Subsea Control Module◦ MCM: Manifold Control Module

Material and Coating Selection◦ Sour service (CRA, inhibitor, chemical injection)◦ External corrosion◦ U value

Cost and schedule estimate




Subsea Process◦ Subsea Process drawing development e.g. P&ID, PFD, C&E diagrams◦ Design pressure & temperature philosophy ◦ Choke valve sizing◦ Start-up and Shutdown operating guidelines ◦ Hydrate remediation strategy◦ HIPPS system operational test procedures◦ HAZID & HAZOP, LOPA participation◦ Equipment duty specification/datasheet◦ Technical evaluation of vendor proposals

Flow assurance◦ Fluid property calculations using PVTSIM◦ Steady State analysis using PIPESIM (including pipeline sizing optimisation,

pressure and temperature profiles, turndown, erosional velocity ratio, slugging etc.)

◦ Hydrate and Wax management strategy ◦ Insulation selection (U-value optimisation)◦ Liquid management and slug catcher optimisation ◦ Transient analysis using OLGA (including Pipeline cool-down, restarts, ramp-

up, packing, blowdown analysis)◦ HIPPS response time evaluation◦ Pigging simulation and optimisation




Engineering management◦ Conceptual

◦ Pre-FEED

◦ FEED

◦ Detailed Design

Procurement Management◦ Market study and assessment of suppliers

◦ Procurement management




Quantitative/Qualitative Risk Assessment

Life cycle integrity management:◦ Concept/Design/Fabrication

◦ Operation (Remaining Life calculation)

◦ End of life and beyond (Life extension-HSE KP4 programme)

◦ Decommissioning or Re-Use

◦ Abandonment

Developing and managing project-specific Inspection, Monitoring and Testing philosophies.

Producing and maintaining up-to-date asset register documents e.g., MAPD, IMR, DFI suite of documents

EstablishIntegrity

(Concept/Design)

Maintain Integrity

(Operation)

De-commissioning

or Re-Use

Abandonment

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Performing Integrity Assessment/Engineering Criticality

Assessment (ECA) to DNV OS-F101/RP-F108, BS

7910, API 579-1/ASME FFS-1 and API 1104 with main

speciality on assessment of:

◦ Operation in Sour-service.

◦ Installation and operation under high plastic strain

conditions (e.g., Reeling), HP/HT and Deepwater

◦ Clad and Lined pipelines

Material

StressFlaw

ECA

Tensile properties

Fracture toughness

High temperature properties

Fatigue crack growth data

Geometry

Size

Location

Orientation

Profile

Primary

Secondary (residual)

Defect Acceptance

Curve




Fatigue assessment (S-N and crack growth) to DNV

RP-C203, BS7910 and BS7608.

Fitness for Service assessment (FFS) of corroded

subsea assets according to DNV RP-F101, API579-

1/ASME FFS-1, BS 7910 or ASME B31G procedures

covering areas such as:

◦ Interpretation and comparison of the past and current

intelligent pigging data

◦ Highlighting most critical corrosion features

◦ Determination of the safe working pressure at

presence of the most critical corrosion features

◦ Calculation of corrosion rate using models such as

Cassandra, NORSOK, De-waard, etc.

◦ Calculation of remaining life to failure for the most

critical features

Fitness for service assessment (FFS) of Dents,

Blisters, Pits, Laminations, Buckles, etc. using API579-

1/ASME FFS-1 and procedures the Pipeline Defect

Assessment Manual (PDAM).




Management of mechanical testing programmes in air

or corrosive environments on behalf of our clients

(using our testing partners, e.g., TWI, Exova, Corus,

DNV, etc.) including:

◦ Tensile testing of standard or sub-size Round/Flat

specimens under static and/or cyclic loading (Reeling

simulation)

◦ Fracture mechanics testing (CTOD/J) on SENT/SENB/CT

specimens to determine single value of fracture toughness

or R-Curve.

◦ Fatigue crack growth testing using SENB/CT specimens

and determination crack growth curves.

◦ Pipe full-scale testing, Wide-plate and segment tests, Pipe

burst tests.




Numerical modelling (FEA) of cracked/un-cracked

subsea facilities, pipelines, risers, platform structures,

pressure vessels and piping.

Managing Inspection, Monitoring, Mitigation,

Intervention and Repair activities on behalf of our

clients based on the project specific IM philosophy

Managing failure investigations (IM and Materials

Group joint effort)

Running specialised/tailor-made training courses,

workshops, seminars, etc.

FEA of a cracked pipe

Riser stress analysis (Global)

Global analysis




Welding

Screening appropriate welding procedures at the conceptual phase (high level screening)

Qualifying nominated procedures at the Design stage for application in Fabrication, Construction, Installation

and operation (Repair) phases.

Independent/impartial review, audit, and upgrade of existing welding procedure specifications.

Non-Destructive Testing (NDT)

on-site and/or laboratory based NDT inspections during the procurement, Fabrication, Construction,

Installation and operational phases employing qualified NDT personnel.

Developing defect acceptance criteria (Tolerable flaw size) for pipeline girth welds for EPC contractors and

operators.

Materials Selection/Corrosion

Selection, procurement, managing the fabrication and manufacturing of appropriate material specific to every

project.

Fit for purpose of the selected materials in terms of the operational condition, resistivity against wear, fatigue,

corrosion and protecting requirements (coating and CP systems, etc.).

Provision of Materials Engineering expertise via high level materials screening/selection (conceptual phase),

provision of procurement specifications especially for the long lead components (Corrosion Resistance

Alloys, Clad/lined materials, etc.), support (operation until the end of the design life and beyond (asset life

extension) with aiming at reducing the total life cycle cost.

Provision of support on procurement specifications, Component fabrication, Vendor assessment and

qualification, etc.




Designing of CP systems for CRA materials

Design and operation of Deepwater CP systems

Performing CP current interaction modelling

Performing remedial activities on CP systems

(onshore and offshore)

Reviewing of annual CP survey reports




Thank you

www.z-subsea.com

february 2014 - z-subsea capability summary.pdf · start-up and shutdown operating guidelines ......

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