otc asia 2014 petronas

OTC-24721-MS

A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow

Line in the East Malaysia Samarang Field

John R Wright Jr. Polyflow LLC, Khairul Anuar Karim, PETRONAS Carigali and Steve

Kennedy, SCG Oil and Gas

Agenda

1) Background 2) Steps and Analysis for Successful Rehabilitation 3) Details of the Installation 4) Benefits Analysis 5) Areas for Improvement 6) Q & A

Slide 2

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Background

• PL-112 Pipeline • 52 Km off Labuan in Samarang Field • 8-10 Meters of Water • 6” API -5L X-42 Steel Pipe Installed in 1977 • Approximately 1Kilometer

• Anchor Hooked Pipe Causing a Kink in 2009 • Repairs Made with Misalignment Flanges • Difficulty in Maintenance and Loss of Wall Thickness

Concluded Repairs as Temporary • Current Infield Drilling

• Required New Pipeline for Next 25 Years • New Steel Pipeline Replacement and Reinforced Thermoplastic

Pipe Rehabilitation were Evaluated • Future Flowing Conditions

• 1,800bbl – 5,000bbl/day Depending upon Field Requirements • Concern with SRB’s in Future • Low Formation Pressure

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Analysis and Planning Steps for RTP Rehab

• Sizing of the New Flow Line • Material Selection • Pull Force Analysis • Selection of Pulling Equipment • Detailed Layout of Project

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Proper Sizing of Pipe Slide 5

• Sized for Desired Production Fits Inside of Existing Steel Acceptable Pressure Drop

for Formation Ideally Fits Through Existing

Risers • Design for Maintaining

Minimum Velocities 0.61m/s will Carry Solids in

Liquids Reduces Ongoing

Maintenance (Pigging) • Selected 3.5” RTP (2.95” ID)

Acceptable Pressure Drops Minimal Velocities for Range

of Flow Risers Have to be Modified

Modified Riser with 12D Bend

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Existing Riser with 5D Bend

Pressure Drops and Critical Velocities for 3.5” RTP

Velocity at 1,800bbl/day is 2 ft./sec (0.61 m/sec)

Typical Production Volume Pressure Drop of 15.3 psi @ 1,800bbl/day

Maximum Production Pressure drop 96.4 psi @ 5,000bbl/day

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Material Selection

• RTP Components Inner Liner- Fluid Compatibility Reinforcement- Strength Jacket- Protects Reinforcement

• Liner- PPS/Fortron Hydrocarbon CO2, H2S, Brine

Resistance (Norsok 710 Testing) Low Permeation

• Reinforcement - Aramid/Twaron Static/Cyclic Strength Resistance to the Environment

• Outer Jacket- Nylon Abrasion Resistance Hydrocarbon Resistance

Aramid Reinforcement

PPS Liner

Volume (%) Composition 30 3% CO2, 2% H2S, 95% CH4 10 Distilled water (conductivity < 5 µS) 60 70% heptane, 20% cyclohexane, 10% toluene

Composition of NORSOK M710 Solution

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Nylon Jacket

RTP Components

Chemical Resistance and Permeation of PPS/Fortron

30

35

40

45

50

55

60

0 20 40 60 80 100 120

190C170C160C150C

Tensile Strength of Fortron PPS (MPa) as a function of Ageing (Days) from 140-190C

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Pre-Planning Project Layout

Spool off Location

Riser Termination

Project Pre-planning

• Gauging Pig for Existing Line • Pull Force Analysis

• Wet vs. Dry • 1,818 Kg Pull Force Wet • Synthetic Rope (5X Safety Factor)

• Project Layout • Platform Space vs. Boat • Individual Steps • Responsible Party • Underwater Work

• Riser Bottom Bend Modifications • Subsea Bend Modification

• Top Side Spools Modifications • Project Scheduling • Capabilities of Platform Equipment

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Platform A Platform B Existing Pipeline Plastic Insert Pipe Messenger Pig

Cross-section

Messenger pig

Winch Spool Reel

Installation Method: Planning

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Installation Method: Planning

Winch

Existing Pipeline Plastic Insert Pipe Messenger Pig

Spool Reel

Cross-section

Plastic Insert Pipe

Platform A Platform B

Messenger wire

Winch

Platform A Platform B

Cross-section

Existing PL 112 Plastic Insert Pipe Messenger Wire

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Installation Method: Actual

Winch

Platform A Platform B

Cross-section

Existing PL 112 Plastic Insert Pipe Messenger Wire

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Installation Method: Actual

Spool Reel

Vessel

Plastic Insert Pipe

Installing the RTP

• Cleaning the Line – Scrape Both Directions

• Erect Scaffolding to Align Pipe from Boat

• Foam Pig Synthetic Rope Through Pipeline

• Set up Winch for Pulling • Align Pulleys over Flange Opening • Attach Pulling Cone to Pipe and

Cable

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Erecting Scaffolding

Cleaning Activity for Existing Line RTP Pull Thru Activity

Pulling the RTP and Splice Joints

• Pull Rate – 20m/min • Cable Passed Through Load Cell

• Pull Force At Expected Value • Indicator for Hang-ups

• Spliced Couplings • 300 Meters Per Pipe Length • Duplex 2205 Joint Splices

• End Connections • Double Faced RTJ Flanged • Seal off Annular Space • Port on Annulus with Pressure Gage

Boat to Scaffold

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

RTP Pulling Activity

Jointing between two portions of RTP pipe Splice Coupling

Inspection of the RTP After Pull Through • Inspect Pulled RTP

• Inspect for Gouges & Jacket Breaches

• Deformation in Pipe • Cut to Length & Install

Termination • Hydro- Test at 2X MAOP for 24

Hours (360PSI) • Design Pressure – 1,440PSI

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Final Pull Out of RTP

Final Spool Make-up Hydrotest Pressure Chart

Analysis of Benefits

• After One Year of Operation Flowing 1,800bb – 7,000bbl/day

• 7,000bbl/day Causing Excessive Back Pressure

No Chemical Treatment No Pigging/ Cleanout

• CAPEX 67% Lower than New Steel Line Eliminating Riser Modifications &

Pulling from Boat Creates 80+ % Savings

• Benefit to Environment compared to conventional steel replacement Minimum disturbance to seafloor &

marine life Reused of existing steel pipeline

• Existing Steel Line Remains Part of the System and is not Abandoned

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Lessons Learned – Areas for Improvement

• Improvement in Planning • Changed from Platform to Platform vs Boat to Platform • Platform Deck Space Availability • Crane on Platform Inoperable

• Making Sure Continuous Back Tension on Pipe During Pulling • Sharp Changes in Tension can Kink Pipe

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Kink Portion Observed During Pulling Activity

Lessons Learned – Areas for Improvement cont.

• Better Pulling Rope Design to Minimize Damage During Pulling • Nylon Jacket on Rope too Thin • Tore As Pulled Through Riser

• Rub on Sharp Flange • Wrinkling Create Hang-up • No Issue with Pipe

• Rope Broke 1 Meter from End of Pull – Finish with Cable

• Jacket Tears Hung Up in Load Cell

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Final Pull Out of RTP

Wrinkling of Pulling Rope When Bent Damage layer of Pulling Rope

Lessons Learned – Areas for Improvement cont.

• Alternative Rope Designs • Heavier Nylon Jacket • Braided Jacket • Braided Jacket with Nylon Jacket

• Testing Ongoing

OTC-24721-MS- A Case Study Detailing the Design, Planning, Installation and Cost and Environmental Benefit Analysis of a Reinforced Thermoplastic Pipe Pulled Through the Inside of an Existing Offshore Steel Flow Line in the East Malaysia Samarang Field- Wright, Karim,

Kennedy

Acknowledgements

Slide 22

Special thanks to: a) P&E Management, PCSB b) SBO Management, PCSB - Maintenance & Operation, SBO c) Samarang Operations d) Technology Provider - Polyflow Inc. e) Contractors

Acknowledgements / Thank You / Questions

Slide 23

Appendix