subsea uk lunch and learn 2012
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Subsea Uk Lunch and Learn 2012TRANSCRIPT
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Bundle Pipeline Systems
& Shell FRAM Development
Iain Watson & Peter Walker
March 21st, 2012
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Bundle Technologies
Advantages of Bundle Systems
Shell Fram Bundle FEED
Agenda
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Shell Fram Bundle FEED
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Bundle Technologies
Advantages of Bundle Systems
Agenda
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Advantages of Bundle Systems
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 ofindividual pipelines and umbilical components is carried.
• The individual components terminate in “Towheads” within whichmanifolding may take place.
• A Towed Pipeline Solution provides a low stress installation methodwhere-by a pipeline bundle is towed and installed using the ControlledDepth Tow Method.
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Subsea 7 Installed Bundles
Åsgard
Heidrun
NorwayNorway
Osprey
Cormorant
Frigg East
Murchison
GullfaksBruce
Keith
• 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
DanDenmarkDenmark
WickWick
ScotlandScotland
Buckland
Keith
LeadonSkene
• 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 <0.7 W/m2K
• 3 Ongoing Projects
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Bundle Components
• Flowlines
• Insulation
• Sleeve Pipe
• Control/Chemical Tubes
• Power, Signal, & Data Highway cables
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• Power, Signal, & Data Highway cables
• 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
Pipe-in-Pipe System
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
Wat
er D
epth
(m)
Pipe-in -Pipe
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
Wat
er D
epth
(m)
U-Value (W/m 2K)
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
holdback tension up to 70Te
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holdback tension up to 70Te
• 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 submerged weight of bundle.
• Chains can be easily cut by ROV to trim bundle
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• Chains can be easily cut by ROV to trim bundle 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.
Towmaster’s 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
• Failure Investigation Support
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• Failure Investigation Support
• Regional Support (Bundles), Norway & Asia Pacific
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Bundle Technologies
Advantages of Bundle Systems
Shell Fram Bundle FEED
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 160°C curre ntly).
• Turn out cost more predictable (reduced exposure to weather/soils risk).
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Bundle Technologies
Advantages of Bundle Systems
Shell Fram Bundle FEED
Agenda
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Shell Fram Bundle FEED
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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 (single test riser, gas lift riser & riser umbilical).
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• Shared services between drill centres (single test riser, gas lift riser & riser umbilical).
• Mixture of Oil & Gas Wells at both drill centres.
• 345 Barg Design Pressure / 110°C 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 7’s 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 the bundle.
• Ensures accurate weight control to approximately 0.5%.
• Weight of chain links on seabed is submerged weight of bundle.
• Chains can be easily cut by ROV to trim bundle
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• Chains can be easily cut by ROV to trim bundle for tow if required.
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Questions?
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seabed-to-surface
www.subsea7.com