Selasa, 03 Februari 2015

DNV invites industry to participate in pipeline integrity management JIP

 Det Norske Veritas is preparing a new recommended practice for offshore pipeline integrity management and is inviting upstream producers and pipeline operators to participate in this joint industry project.
There are over 20,000 mi of pipeline infrastructure in the Gulf of Mexico servicing and transporting about 30% of US domestically produced oil and gas. The challenge is that some lines remain in operation after 40 years of service, and many beyond their originally anticipated service life. Recent hurricane events in the Gulf of Mexico demonstrated the vulnerability of this supply network and the consequences of disruptions.
While some potential leaks or failures might be attributable to events such as subsea mudslides or hurricanes, most are a result of the condition of the pipeline itself. It is imperative to manage and maintain the integrity of the subsea pipelines, DNV says.
DNV, in cooperation with the industry, is preparing a new Recommended Practice (RP) for offshore pipeline integrity management. The RP will address in-service issues from the early design phase through to the operational phase. The objective is for the RP to be a state-of-the-art document, developed in close cooperation with the industry and reflecting industry practices and sound engineering practices for establishing and maintaining the integrity of subsea pipeline systems, DNV says.
The RP will identify the components of a subsea pipeline integrity management program and will provide a highly detailed framework that producers or pipeline operators can use when preparing the integrity management programs for their own pipeline systems. It will also include a detailed framework for a direct assessment methodology, which would be applicable to the subsea pipelines and would be submitted to the National Association of Corrosion Engineers, International (NACE) for review and approval.
This project is a follow-up to a 2006 project for the US Department of the Interior (DOI) Minerals Management Service (MMS), in which DNV assessed the integrity practices used by operators in the GoM.
DNV encourages upstream producers and pipeline operators to participate in the development of this JIP, which is intended to be practical and cost effective, while maintaining a commitment to system integrity, safety, and the protection of the environment, the company says.
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Pipeline Ending Manifold (PLEM) /PLET

Subsea manifold is a flow-routing subsea hardware (subsea flow router) that connects between subsea trees and flowlines. It is used to optimize the subsea layout arrangement and reduce the quantity of risers connected to the platform. If connected to dual flowlines, the manifold can typically accommodate pigging and have the capability of routing production from a particular tree to a particular flowline.
Pipeline End Manifold (PLEM)

It a simpler version of a cluster manifold generally designed to direct fluids for only one or two subsea Christmas trees. A PLEM generally connects directly to a subsea flow line without the use of a pipeline end termination (PLET).
Manifold Compenents

Four well manifold P&ID.
A manifold is typically composed of the following major components:
  • Pipework and valves – contains and controls the production and injection fluids.
  • Structure framework – protects and supports the pipework and valves.
  • Subsea connection equipment – allows subsea tie-in of multiple pieces of equipment. Types include vertical, horizontal and stab-and-hinge-over connections.
  • Foundation – interface between the manifold structure and seabed.
  • Controls Equipment – allows the remote control of any hydraulically actuated subsea manifold valves and the monitoring of production and injection fluids. Control pods may be either internal or external to the manifold.
Valves
Valves on the manifold are essential for directing and controlling the flows. They can be either manual or hydraulically actuated. Sometimes chemical injection valves are placed on the manifold as well.
  • Branch valves are generally slab type gate valves (similar to tree valves). Their sizes are based on the production/injection tree size.
  • Flowline header valves are also gate type, but ball valves have been used previously. Their sizes are based on the flowline size.
  • Materials are chosen for compatibility with production and injection fluids. Most of time, it is CRA-clad.
  • Double barrier philosophy generally used against production fluids.
    • Two valves in series
    • One valve and one pressure cap
    • Primary seal is generally a metal-to-metal seal
Pipework
A wide range of pipework configurations is possible. Each header connects to an individual flowline. the pipework sizing is based on the tree piping size and the flowline diameters. The main circuit is designed to accommodate pigging operations. The material of construction needs to be compatible with production and injection fluids.
  • Test headers can be incorporated to test individual or groups of trees
    • Test headers can be a second or even third header isolated in the manifold
  • Insulation may be required for unscheduled or emergency shutdowns
Control System
Control system for the manifolds is the same as the control system for the trees. Multiple options for the control system have been used in the manifold design
  • No controls on the manifold. The manifold is controlled by tree subsea control modules (SCMs).
  • SCMs on the manifold.
  • Manifold with control system distribution units with flying leads going to trees.
Framework Structure
The framework is a welded structure to provide support for the pipework and valves and contain the foundation interface structure. The pipework is allowed to float inside the framework within limits and it is not rigidly attached to the frame. The frame can also be used for lifting and landing of the jumper tie-in tools.
Foundation
  • Mud mats – a simple foundation resting directly on the seabed, generally with a short skirt around the perimeter to resist lateral loads.
  • Piles – long cylindrical structures embedded into the soil intended to hold a subsea structure above the seabed. Foundations may utilize one or more individual piles.
  • Intermediate Structures – an intermediate structure can be used to interface a subsea manifold with a pile foundation to reduce weight of the manifold structure or to ease retrieval of the manifold. Intermediate structures can be either retrievable or permanent structures.
Tie-ins to wells and flowlines
The tie-in hubs placed on the outer edge of the manifold, which are used to tie-in jumpers that bring in fluid from the production wells and export fluid into the flowlines (production manifold). The tie-in sizing is based on the tree piping size and the flowline diameters. and the loads applied from the flowlines
Insulations
Generally gas manifolds are not insulated and oil manifolds are insulated. For oil production, insulation is necessary to allow adequate cool-down time to treat or remove trapped production water. Gas production is generally treated continuously with chemicals to prevent hydrates.
Deployment method
The following vessels are typically used for manifold deployment:
  • Drill Rig: through moon pool or keel-hauled on drill string
  • Heavy Lift vessels (Derrick Barges): through moon pool or over side
  • Work-class vessels: over side on crane or winch
The following equipments are typically required:
  • Manifold hydraulic installation tool
  • Sling sets, either wire rope or synthetic fiber
Applicable API Specs
  • API Spec 17P – Templates and Manifolds
  • API Spec 17D – Specifications for subsea wellhead and Christmas tree equipments
  • API Spec 17A – Recommended practice for design and operation of subsea production systems
  • API Spec 17H, ISO 13628-8 – ROV Interfaces
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Pig Launchers & Receivers

Pig launchers and pig receivers are installed on pipelines to launch and receive pipeline pigs, pipeline spheres and pipeline inspection tools. Pig launchers & pig receivers offer a safe and effective means of inserting and removing pipeline pigs to and from pipelines. Pipeline Engineering fabricates pig launchers and pig receivers to meet the specific requirements of a pipeline.
Our in-house design, engineering, fabrication and testing capability is used to produce all types of pig and sphere launching and receiving systems.
The pig launchers and pig receivers we fabricate range from simple barrel pig launchers and receivers through to complete skid mounted units with associated equipment including actuated valves, quick opening closures, instrumentation, pig signallers and control systems.
The pig launchers and receivers we fabricate are suitable for onshore, offshore and subsea pipelines. All units are designed and fabricated to relevant required pipeline and vessel design codes including:
Pig Launchers & Receivers
  • ASME U Stamp Division 1 & 2
  • ASME VIII
  • NACE
  • BS 5500
  • ASME B31.3, B31.4, B31.8
We fabricate pig launchers and pig receivers from 2" to 60" designed with operating pressures up to 400 bar. Pig launchers and pig receivers are produced in a range of materials, from low strength carbon steel, to high strength carbon steel, and where specified, stainless steel, duplex stainless steel and carbon steel internally clad with corrosion resistant inconel materials.
Pig Launchers & Receivers
Multiple pig launchers are designed to allow the sequential launching of pigs and spheres. Using our automatic multiple pig launching system a series of pigs can be launched into a pipeline without having to repeatedly depressurise and re-pressurise after each pig launch. The process can also be controlled from a remote location. This is particularly relevant on unmanned platforms such as offshore platforms and sour service applications.
Sphere release fingers on sphere launchers are used to control the release of a series of spheres into a pipeline.
Pig Launchers & ReceiversPipeline Engineering will design pig launcher and receiver systems which are 'tailor-made' to meet specific operational requirements. This can include:
  • Multiple valve operation
  • Automatic or manually operated pig and sphere release systems
  • Integrated skid mounted packages
In addition to the supply of newly manufactured pig launchers and pig receivers, Pipeline Engineering provides an inspection, maintenance and refurbishment service to existing in service pig launchers and receivers.
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Vortex Induced Vibration of Offshore Pipeline

In fluid dynamics, vortex-induced vibrations (VIV) are motions induced on bodies interacting with an external fluid flow, produced by – or the motion producing – periodical irregularities on this flow.
A classical example is the VIV of an underwater cylinder. You can see how this happens by putting a cylinder into the water (a swimming-pool or even a bucket) and moving it through the water in the direction perpendicular to its axis. Since real fluids always present some viscosity, the flow around the cylinder will be slowed down while in contact with its surface, forming the so called boundary layer. At some point, however, this boundary layer can separate from the body because of its excessive curvature. Vortices are then formed changing the pressure distribution along the surface. 

When the vortices are not formed symmetrically around the body (with respect to its midplane), different lift forces develop on each side of the body, thus leading to motion transverse to the flow. This motion changes the nature of the vortex formation in such a way as to lead to a limited motion amplitude (differently, then, from what would be expected in a typical case of resonance).

VIV manifests itself on many different branches of engineering, from cables to heat exchanger tube arrays. It is also a major consideration in the design of ocean structures. Thus study of VIV is a part of a number of disciplines, incorporating fluid mechanics, structural mechanics, vibrations, computational fluid dynamics (CFD), acoustics, statistics, and smart materials.

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Pipelines at the bottom of the sea are susceptible to ocean currents. Even relatively calm currents can induce turbulences in the wake of the pipeline, which results in the pipeline to start 'dancing'. Pipe vibrations can trigger fatigue, with catastrophic fracture as a result. Consequently, when designing submarine pipelines, caution is being paid to avoid such vibrations. Our research engineers use powerful software to predict submarine pipeline stability.


“Dancing at Great Depth”

Even relatively calm currents can induce turbulences in the wake of the pipeline, resulting in pipeline oscillations. The pipeline vibrations can trigger fatigue, causing accelerated damage. Since fatigue damage can give rise to complete fracture with catastrophic consequences, extreme caution is being paid in order to avoid such vibrations when designing submarine pipelines. Flow patterns around submarine pipelines greatly depend on the velocity of the sea currents and on the tube diameter. 

When the current becomes too strong, turbulences show up in the wake of the pipeline. This vortex shedding exerts an alternating force on the pipeline. Consequently, the pipeline is being subjected to cyclic loading. The pipeline starts to dance, following a characteristic ‘number-eight’ path. Under cyclic loading, the pipe is being exposed to fatigue, which could cause the pipe to fail under surprisingly modest stresses.
Vortex induced vibrations

Current State of Art

Much progress has been made during the past decade, both numerically and experimentally, toward the understanding of the kinematics (dynamics) of VIV, albeit in the low-Reynolds number regime. The fundamental reason for this is that VIV is not a small perturbation superimposed on a mean steady motion. It is an inherently nonlinear, self-governed or self-regulated, multi-degree-of-freedom phenomenon. It presents unsteady flow characteristics manifested by the existence of two unsteady shear layers and large-scale structures.

There is much that is known and understood and much that remains in the empirical/descriptive realm of knowledge: what is the dominant response frequency, the range of normalized velocity, the variation of the phase angle (by which the force leads the displacement), and the response amplitude in the synchronization range as a function of the controlling and influencing parameters? Industrial applications highlight our inability to predict the dynamic response of fluid–structure interactions. 

They continue to require the input of the in-phase and out-of-phase components of the lift coefficients (or the transverse force), in-line drag coefficients, correlation lengths, damping coefficients, relative roughness, shear, waves, and currents, among other governing and influencing parameters, and thus also require the input of relatively large safety factors. Fundamental studies as well as large-scale experiments (when these results are disseminated in the open literature) will provide the necessary understanding for the quantification of the relationships between the response of a structure and the governing and influencing parameters.

It cannot be emphasized strongly enough that the current state of the laboratory art concerns the interaction of a rigid body (mostly and most importantly for a circular cylinder) whose degrees of freedom have been reduced from six to often one (i.e., transverse motion) with a three-dimensional separated flow, dominated by large-scale vortical structures.

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Energy sector to drive demand for spiral welded pipes and tubes, according to new report by global industry analysts, inc.

GIA announces the release of a comprehensive global report on the Spiral Welded Pipes and Tubes markets. Global market for Spiral Welded Pipes and Tubes is projected to reach 24.6 million tons by 2018, driven by economic recovery, level of activity in the energy sector, and intensifying pipeline construction activity.

Spiral welded pipes market, though encountering overcapacity conditions particularly in North America, is expected to witness steady growth in the upcoming years driven by the implementation of new pipeline projects. Investments in oil and gas exploration and production, which are influenced by prevailing crude oil & gas prices, have a considerable impact on the demand for spiral welded pipes and tubes. Resurgent world economy and consequent increase in the demand for industrial natural gas is expected to drive up momentum of the spiral welded pipes market.
Global demand for spiral welded pipes, which are primarily used in the transportation of oil and gas and in water transportation projects, is closely linked to the investments in the energy sector. The energy sector makes use of spiral welded pipes with diameters of up to 60” and up to 80 feet in length. Another factor that is expected to fuel demand for spiral pipes and tubes is new pipeline construction activity due to the shift of population from traditional centers that would necessitate development of infrastructure for delivering oil and natural gas to the new locations. Demand for spiral welded pipes is also expected from the replacement market, as most of the existing pipeline infrastructure, particularly in developed regions, has reached their end of useful life. Structural applications of spiral welded pipes are also gaining momentum, specifically with additional activity occurring in port, offshore loading and infrastructure improvement sectors.
As stated by the new market research report on Spiral Welded Pipes and Tubes, Asia-Pacific represents the largest market worldwide, driven primarily by increased use in transporting natural gas. Besides Asia-Pacific, Latin America ranks among the fastest growing regional markets with compounded annual growth rate ranging between 7.5% and 9.0% over the review period. North American market, on the other hand, is encountering testing times owing to weak demand and overcapacity conditions. Oversupply is the major concern for spiral welded pipes market particularly with regard to large diameter double submerged arc welded or DSAW line pipes, which finds use in transmitting oil, natural gas liquids, and natural gas to consumers from drilling locations.
Despite the prevailing conditions, potential opportunities are expected primarily from the implementation of new pipeline projects in the upcoming years, resurgent growth of the US economy, and increased demand from natural gas exploration operations. Also, overcapacity conditions are expected to fade away in the coming years, as several megaprojects are set to be taken up across the world, particularly in regions such as Southeast Asia, Australia, Middle East, Africa, and West Asia.
Replacement of aging infrastructure offers huge potential for pipe manufacturers. The need to replace old pipelines is particular high in the US and Russia, where pipeline networks were mostly installed during the 60s and 70s. With the average lifespan of oil and gas transportation pipes ranging between 25 and 30 years, opportunities in the replacement market are huge, particularly for HSAW pipes. In the US, replacement demand holds enormous potential as a result of the recent enactment of the legislation that necessitates more inspections to be carried out, which could increase the likelihood of pipeline replacements. The Act is likely to play a critical role in enabling manufacturers of large diameter line pipes to survive the tough economic and overcapacity conditions.
Major players profiled in the report include American SpiralWeld Pipe Company LLC, ArcelorMittal SA, Borusan Mannesmann Boru Sanayi ve Ticaret A.S., Europipe GmbH, EVRAZ North America, JFE Steel Corporation, Jindal SAW Ltd., Man Industries Ltd., National Pipe Company Ltd., Nippon Steel & Sumitomo Metal Corporation, PSL Limited, Shengli Oil & Gas Pipe Holdings Limited, Stupp Corporation, Volzhsky Pipe Plant, UMW Group, and Welspun Corp Ltd.
The research report titled “Spiral Welded Pipes and Tubes: A Global Strategic Business Report” announced by Global Industry Analysts Inc., provides a comprehensive review of market trends, issues, drivers, company profiles, mergers, acquisitions and other strategic industry activities. The report provides market estimates and projections for all major geographic markets including the US, Canada, Japan, Europe (France, Germany, Italy, UK, Spain, Russia and Rest of Europe), Asia-Pacific (China and Rest of Asia-Pacific), Middle East, and Latin America.
For more details about this comprehensive market research report, please visit –
http://www.strategyr.com/Spiral_Welded_Pipes_and_Tubes_Market_Report.asp
About Global Industry Analysts, Inc.
Global Industry Analysts, Inc., (GIA) is a leading publisher of off-the-shelf market research. Founded in 1987, the company currently employs over 800 people worldwide. Annually, GIA publishes more than 1300 full-scale research reports and analyzes 40,000+ market and technology trends while monitoring more than 126,000 Companies worldwide. Serving over 9500 clients in 27 countries, GIA is recognized today, as one of the world’s largest and reputed market research firms.
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STOPAQ - Offshore Corrosion Prevention and Insulation Systems

When Frans Nooren founded STOPAQ in 1988, he started a waterproofing contracting company aimed at solving many civil structure water problems, a major concern in a country like the Netherlands. Drawing on his practical experience, he set out to improve sealing technology products and developed an innovative product, which he demonstrated to great success by sealing leaks in the harbour walls at Rotterdam.
Due to erosion of the soil behind the dock wall pilings, corrosion had taken place and corroded the sheet from the rear, leading to perforations. These had to be sealed from the harbour side using novel technology involving a sealing compound applied and cured under water. This product was the start of a new generation of sealants and coatings.

Polyisobutene resin sealants for the offshore industry

The polyisobutene resin technology STOPAQ's product range is based on make it ideal for field joint coating of pipelines. The company's latest innovation of visco-elastic coatings – which are patented innovative polymer technology and available worldwide – can provide pipeline owners and operators with reliable, long-lasting anti-corrosion coatings for field joints and for the repair of damaged areas on the main pipeline coatings.
As the coatings are 100% self-healing, chemical and temperature-resistant, and less likely to damage in service, they can be easily and quickly applied without the need of special equipment or highly skilled operators. This, in turn, means there are fewer application and through life costs.

Advanced corrosion prevention and insulation systems

The offshore world requires advanced corrosion prevention and insulation systems. Corrosion processes can sever offshore equipment and pipe rupture may occur. Hard and tough coatings may break. Very low PH (2-3) electrolyte solutions can cause CUI. Other chemical reactions and or moisture / water penetration must be prevented at great depths.
In response to the offshore industry's demands, STOPAQ and BASF have joined forces. The result of combining STOPAQ's visco-elastic corrosion prevention layer with BASF's PU is a cost-effective solution delivering long-term protection against corrosion by locking out negative influences. We see stopping corrosion as our common mission now. Via our system, we can offer you more control in all process steps from preparation, application and control beyond design life.

Corrosion prevention systems for offshore pipelines and platforms

Pipelines and platforms need to be safe constructions – for people and for the environment. STOPAQ / BASF Offshore can seal spools, under insulation, under fireproofing, J-tube filling, flanges, risers, christmas trees, pp-coating repair, pipe joints, subsea repair, and piles (splash zone). STOPAQ / BASF applications can be found on many important offshore installations worldwide and on offshore pipeline joints.
STOPAQ / BASF offers fully integrated solutions, including service preparation on-board of lay barge vessels. The joint system offers a simple, safe and fast-turnaround job, guaranteeing 100% adhesion. Mechanical protection is ensured by using tapes, shrinkable sleeves or PU infill.

Tailor-made corrosion-resistant coating systems

STOPAQ / BASF's coating system can be tailor-made for each project, and easily applied. Furthermore, it also allows a quicker preparation of steel and adjacent factory applied coating by at least St2/3 brushing method, cold application of the visco-elastic anti-corrosion layer, and immediate and permanent attachment of the impermeable visco-elastic layer to steel, concrete, polypropylene, polyurethanes and polyethylene. There is no risk of osmosis.
Some of the system advantages are:
  • Increasing the speed of application
  • Eliminating the need of flame torch
  • No need for primers
  • Cost-effective: reduces inventory requirements eliminating diameter specific solutions
  • Outstanding impact resistance
  • Cold flow; providing corrosion protection by penetrating into the finest pores of the substrate
  • Very surface tolerant; no grit blasting, only wire brushing or hand tool cleaning required
  • Higher temperatures resistance
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Pipeline Material Grade Selection

General PrincipleThe steels applied in the offshore oil and gas industry vary from carbon steels (taken from American Petroleum Institute standards- Grade B to Grade X 70 and higher) to exotic steels (i.e. duplex). The following factors are to be considered in the selection of material grades:
  • Cost;
  • Resistance to corrosion effects;
  • Weight requirement;
  • Weldability
The higher the grade of steel (up to exotic steels) the more expensive per volume (weight). However, as the cost of producing high grade steels has reduced, the general trend in the industry is to use these steel of higher grades.
Fabrication, Installation, and Operating Cost Considerations
The choice of material grade used for the pipelines will have cost implications on:
  • Fabrication of pipeline;
  • Installation;
  • Operation.
Fabrication
The cost of steels increases for the higher grades. However, the increase in grade may permit a reduction of pipeline wall thickness. This results in the overall reduction of fabrication cost when using a high grade steel compared with a lower grade steel.
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abrication
Installation
It is difficult to weld high grade steels, and consequently lay rate is lower compared to laying the lower grade steels. However, should the pipeline be laid in very deep water and a vessel is laying at its maximum lay tension, then the use of high grade steel may be more suitable, as the reduction in pipe weight would result in lower lay tension. In general, from an installation aspect, the lower grade steel pipelines cost less to install.
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Pipeline Installation
Operation
Depending on the product being transported in the pipeline, the pipeline may be subjected to:
– Corrosion (internal)
– Internal erosion;
– H2S induced corrosion.
Designing for no corrosion defect may be performed by either material selection or modifying operation procedures (i.e. through use of chemical corrosion inhibitors).
Material Grade OptimizationOptimization of material grade is rigorously applied today based on experience gained from the past 20 years of pipeline design, and the technical advances in linepipe manufacturing and welding. The optimization is based on minimization of fabrication and installation cost while meeting operating requirements. As the selection of material grade will have a significant impact on the operating life of the pipeline, the operator is normally involved in the final selection of material grade.
Source:Bai, Yong and Bai, Qiang. Subsea Pipelines And Risers. USA: Elsevier Inc. 2005.