Subsea Pipeline and Risers

Dasharatha Achani
 MECHOCEAN
Eng. Solutions

Dr. Dasharatha Achani

Phone: +47 92622284
Introduction E-mail: [email protected]

9-Aug-16
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 MECHOCEAN
Course content Eng. Solutions

 Design Overview
 Route Selection
 Pipeline Hydraulics
Structural Design of pipeline
 Fabrication, Welding and ECA
 Stability
 Span assessment and correction
 Upheaval and Lateral Buckling
 Pipeline construction and installation
 Riser Design

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 MECHOCEAN
Course material Eng. Solutions

 Text Book:
• Subsea Pipeline Engineering, by Andrew C. Palmer & Roger A.
King
• Subsea Pipelines and Risers, BY Yong Bai AND Qiang Bai

 Presentation materials will be sent through E-mail

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Typical Deep Water Fields Eng. Solutions

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Eng. Solutions

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Deep Water Concepts Eng. Solutions

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Deep Very deep UltraEng.deep
Solutions

Shallow water
Deep water
Very deep water
Ultra deep water
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 MECHOCEAN
Elements of Subsea Production Systems Eng. Solutions

Process facilities

Risers

Protection structure
Control umbilical X-mas tree
Riser base Flow lines
Template

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TYPICAL FIELD LAYOUT COMPONENTS Eng. Solutions

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Flexible Risers from Floating Production Unit or FPSO
Eng. Solutions

Riser Installation
(Steel/Flexible)

Image courtesy of NKT

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J-Tube Caisson Installation on Fixed Platform Eng. Solutions

J-Tube Installation

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UMBILICALS / POWER CABLES Eng. Solutions

Umbilical

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Eng. Solutions

Reel lay

Flowline
(Steel/Flexible)

Installing Flowlines

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In-line Tee for Future Subsea Tie-in Eng. Solutions

Future Tie-In Tee

Image courtesy of Hereema

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SSIV (Subsea Isolation Valve) Eng. Solutions

Subsea Isolation
Valve (SSIV)
Courtesy of Shell

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Images courtesy of Grenland group /FMC
MANIFOLDS
Eng. Solutions

Manifold

Images
9-Aug-16 courtesy of Acergy Australia
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Subsea Controls and Valves for high reliability Eng. Solutions

Subsea Controls

Courtesy
9-Aug-16 of Cameron valves
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Flowline Jumpers (Tie-in Spools) & Diverless Connectors Eng. Solutions

Flowline Jumper
(Flexible)

Image Courtesy of Vetco Aibel 2004

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Eng. Solutions

Images courtesy of FMC

CHRISTMAS TREES

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SUBSEA TIE-IN SPOOL PROTECTION COVERS Eng. Solutions

Subsea Protection
(Rockdump/Mattresses
etc.)

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Pipeline crossing protection by rock dumping Eng. Solutions

Image courtesy of Van Oord

Pipeline Crossings

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 MECHOCEAN
Subsea technology: many disciplines Eng. Solutions

Drilling and well technology

Intervention Manifold and

Pipeline systems structures
technology Material
technology

Subsea
Concept and
processing systems design, Electric power
supply/distribution
operations/control

Marine
Operations, Multiphase flow
Process technology surveillance,
operations technology
inspection

Environmental technologies

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 MECHOCEAN
Stages of project planning, execution and operation Eng. Solutions

Plan Execute Operate

Project execution plan, PEP Project execution activities

Concept Development

Detail engineering
 Feasibility Study

Commissioning
 Screening Study Operation

Construction
Procurement

Installation
Fabrication
 Concept Stduy Maintenance

Hook-up
Pre-engineering or FEED

Project sanction Ready for operation

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 Objectives for concept & engineering studies
MECHOCEAN
Eng. Solutions

Feasibility study Screening study Concept study FEED Detail eng.

•Document that a •Identify all relevant •Develop and mature •Further mature and •Further develop,
business opportunity alternative facilities the selected ultimately freeze the detail and specify
or a hydrocarbon & concepts and assess concepts. selected concept for technical solutions
discovery is relevant new •Evaluate and select project sanction established in the
profitable, and that technologies commercially available •Negotiate potential FEED to the level of
technically feasible •Evaluate facility processes (relevant technology purchase detail required for:
facilities concepts do alternatives and for onshore) agreements purchasing
exist establish shortlist of •Select concept and (relevant for onshore) fabrication
•Document that the concepts provide a firm design construction
appraisal status and basis for FEED installation/hook-up
subsurface data are
adequate for start of commissioning
concept studies operation
•Establish a realistic
schedule for the
project planning phase

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 MECHOCEAN
Eng. Solutions
Management Operating

contractors company

Engineering Procurement

contractors contractors

Fabrication Construction Installation

Equipment

contractors contractors contractors

Materials
Hook-up Commissioning
Services

contractors contractors
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 MECHOCEAN
Types of pipelines Eng. Solutions

 Trunk pipelines
• Crude export
• Gas export
• Usually large diameter pipelines
 Infield pipelines
• Production
• Gas Injection
• Water Injection

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 MECHOCEAN
Pipeline design issues Eng. Solutions

 Pipeline route
 Pipeline design
• Flow issues – Pipe size
• Pressure & temperature – Wall thickness
• Corrosion protection
• Coatings – Corrosion protection, thermal insulations and
impact protection
 Linepipe selection
 Installation issues
 On-bottom stability
 Upheaval and lateral buckling
 Freespan and correction

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Eng. Solutions

Routing Design

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EXPECTATION Eng. Solutions

 Understand the ’rules’ for routing

 Know about seabed features and what to expect from

surveys

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CHOOSING THE BEST ROUTE Eng. Solutions

Ideally the straight line between two points

 Minimum cost
 Minimum pressure drop

However seldom the case

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WHAT AFFECTS ROUTING? Eng. Solutions

 Seabed obstructions

 Seabed features

 Other users of the sea

 Construction limitations

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SEABED OBSTRUCTIONS Eng. Solutions

Platforms
Wells
Wrecks
Pipelines
Cables

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SEABED OBSTRUCTIONS Eng. Solutions

 Fixed items
• Minimum clearances
 DNV 2000 - 500 m (1640 ft)
 API 1111 - 91 m (300 ft) (guidance)
 FPSO & semi-sub drill rig
 Anchor spread typically
 ~2 km (1.2 mile) radius

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PIPELINES AND CABLES Eng. Solutions

 Corridor with other lines

• If existing pipeline
 Typical separation 50 m to 100 m (160 ft to 330 ft)
• If constructed together
 Typical separation 20 m to 30 m (65ft to 100 ft)

 Minimum number of crossings

• Protect existing and new pipelines at crossings

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OTHER USERS OF SEABED Eng. Solutions

 Other countries
 Exclusion zones
 Dredging areas
 Shipping lanes
 Other companies’ acreage
 Fishing grounds
 SAC ( Special areas of conservation)

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OTHER COUNTRIES Eng. Solutions

 Multiple code compliance

 Multiple reporting requirements
 Both design and operation

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SEABED FEATURES Eng. Solutions

 Rocks
 Sandwaves
 Pock marks
 Mud slides
 Mud volcanoes
 Iceberg scars

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 MECHOCEAN
SANDWAVES Eng. Solutions

Mobile sandwaves
Route along troughs
Lower pipeline to trough level - pre-sweep

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CONSTRUCTION LIMITATIONS Eng. Solutions

 Shore approach
 Platform approach
 Pipeline crossing
 Bend radius
 Trenching

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SHORE APPROACH Eng. Solutions

Why not the shortest route?

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SHORE APPROACH Eng. Solutions

 Laybarge draught
• 3rd generation typically 12 m (40 ft)
 Perpendicular usually gives shortest beach pull
 Environmental wave loading is minimised

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SHORE APPROACH Eng. Solutions

 Beach pull
• Trenching is preferred
 Tunnel pull
• Expensive option
 Horizontal drilling

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PLATFORM APPROACH Eng. Solutions

 Lay past platform

 Minimum clearance of vessel
to platform
 Sufficient dog-leg on spool
to take-up pipeline expansion
 Connect to riser
 Avoid dropped object and
anchoring zones
 Corridor

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 MECHOCEAN
PLATFORM APPROACH Eng. Solutions

 J-tube riser
 Pipeline pulled directly into platform
 Vessel does not pass platform
 No dog-leg spool

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PIPELINE CROSSING Eng. Solutions

 Minimum 30˚ approach angle

 Size of crossing – length elevated off seabed
 Quantity of rock dump to protect pipelines
 Handling of anchors over the new and existing pipeline

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LAYING IN CURVES Eng. Solutions

 Bend must be of sufficient radius to ensure seabed friction

can hold it
 Typically
• 168.3 mm (6 in) – 1000 m (0.6 miles)
• 323.9 mm (12 in) – 1500 m (0.9 miles)
• 609.6 mm (24 in) – 2000 m (1.2 miles)
• 914.4 mm (36 in) – 2500 m (1.6 miles)
 Flexibles – low radius

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RULES OF ROUTING - SUMMARY Eng. Solutions

Route can rarely be a straight line.

Route influenced by
 Obstructions
• e.g. platforms, wells, shipwrecks, cables, pipelines
 Seabed features
• e.g. rocks, sandwaves, mud slides
 Other users of seabed
• e.g. exclusion zones, dredging, shipping lanes, fishing, SSSIs
 Limitations of construction equipment
• e.g. shore and platform approach, crossings, trenching

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Eng. Solutions

Route survey

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DESIGN SEQUENCE Eng. Solutions

Desk Study Select preliminary route options using

existing data

Route survey specification

On-board data review – modify

Route survey
Survey requirements as appropriate

Finalise route Select final route based on survey data

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 MECHOCEAN
SEQUENCE OF EVENTS Eng. Solutions

Feasibility Study
Desk Study

Conceptual design
SANCTION
Offshore survey

FEED

Detail design
Pre-lay As-built

Construction

Time

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 MECHOCEAN
DESK STUDY Eng. Solutions

At conceptual design stage, do a desk study

 Initial view of profile and geology
 Block ownership
 Existing pipelines, wells, wrecks etc

Cost effective
 One day offshore = 8 weeks for an engineer

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GEOPHYSICAL SURVEY Eng. Solutions

 Reconnaissance of potential hazards

 Seabed bathymetry
 Sub-bottom profile

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 MECHOCEAN
GEOTECHNICAL SURVEYS Eng. Solutions

 Performed to obtain information on the physical properties of

soil and rock around a site to design earthworks and
foundations for proposed structures

Include surface exploration and subsurface exploration of a

site, usually involves soil sampling, and In-situ tests (like CPT)
and laboratory tests of the soil samples retrieved.

Use cone penetrometer (CPT) and/or vibrocores or gravity

corers

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CPT Eng. Solutions

Reports:
 Types of soil or rock at or below seabed
 Thickness of layers
 Engineering characteristics
• Density
• Porosity
• Strength

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Eng. Solutions

ALIGNMENT SHEETS

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 MECHOCEAN
ALIGNMENT SHEETS Eng. Solutions

Definition:
 A drawing which illustrates a length of pipeline – typically 2 km to 3 km
(1.2 miles to 1.9 miles) – and which indicates key features
Purpose:
 Provides the information required to produce the material take-off (MTO)
 Summarises key information required to installation contractor

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EXAMPLE ALIGNMENT SHEETS Eng. Solutions

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KEY FEATURES ON ALIGNMENT SHEETS Eng. Solutions

Seabed features
 Boulders / shipwrecks
 Survey data ( soils information etc.)
Installation data
 Pipelay tolerance
 Lay tension
 Crossings
 Backfill requirements
Pipeline properties
 Curvatures and tangent points (TP)
 Concrete and / or corrosion coating
 Wall thickness
 Buckle arrestor spacing
 Field joint details
 Anode spacing
 Fittings
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 MECHOCEAN
ALIGNMENT SHEETS - SUMMARY Eng. Solutions

Alignment sheets illustrate a length of pipeline and indicate key

features
Document useful information for:
 Route selection process
 MTO production
 Installation process

Content and level of detail dependent on required use of sheet

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 MECHOCEAN
ROUTE SELECTION - SUMMARY Eng. Solutions

• Understanding of the ‘rules’ for routing

• Know about seabed features and what to expect from surveys

• Understand the main features of alignment sheets

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Route example Eng. Solutions

Routing Design

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 MECHOCEAN
Examples of Routing Design Considerations Eng. Solutions

Curve Stability

Geohazard: Iceberg Scar

Close lay: optimise routing and

minimise seabed intervetion

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 MECHOCEAN
Experience from past project Eng. Solutions

Pipeline routed along flank of

iceberg scars

Pipeline buckling under hydro-

test conditions at Scar
shoulder

Rock berm failure on slope

during installation

Total rectification work approx.

Euro 2mil / 50 000 Te rock

Captured lessons learned and

implemented

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Questions Eng. Solutions

1. Name the different stages involved in project planning and

execution
2. What are the factors influencing the pipeline route ? Give
examples
3. What are the design sequences of route Survey?
4. What is alignment sheet and what is its purpose?

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