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Abu Dhabi, 21st April 2015
Ali Rashed Al Jarwan Chief Executive Officer Abu Dhabi Marine Operating Company
NO ORGANIZATION CAN AFFORD FAILURES
1974
FLIXBOROUGH UK
27 fatalities
1988
PIPER ALPHA
167 fatalities
1984
PEMEX gas explosion
452 fatalities
1989
EXXON VALDEZ
258,000 barrels
1989
PHILIPS PASADENA
23 fatalities
5000+ families
BHOPAL Gas
1984
15 fatalities
Texas City Refinery
2005
Turkey
BTC Pipeline
2005
Listed 21 degrees
Thunder Horse PDQ
2005
Alaska Spills
2006
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Zakum Oil Lines Replacement Project - INITIATION
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Subsea Pipe Lines Inspection, in number of lines
In 2011, following a number of Pin-hole leaks, we decided to replace 25 oil
lines based on QUALITATIVE ASSESSMENT ( Physical inspection program
was not complete).
This was major and complex brownfield project which was solely driven by
“Zero Hydrocarbon Leak Policy”. Hence, ‘Time was of the essence to
minimize Business Impacts‘.
Major challenges were :-
Executing in an operating brown field which is congested, shallow
water and soft soil;
Firm commitment of marine spread and timely availability;
Management of multiple shutdowns (WHTs, Complexes);
Availability of competent / qualified personnel;
Large number of interfaces.
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Zakum Oil Lines Replacement Project - Scope
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Description Quantity
New Pipelines to be Laid 26 Lines (90 km)
Subsea Cable Installation 57 WHTs (202 km)
Permanent Pigging Facilities, Corrosion Inhibitor, Electrical
Equipment, Structural Extension, Piping modification,
Safety Shutdown System.
26 WHTs Topside Modification Works
New Riser Platforms with new Bridges. 2 Nos.
Existing Pipelines to be Demolished. 27 Nos.
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Zakum Oil Lines Replacement Project - Schedule
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ACTIVITIES 2011 2012 2013 2014 2015 2016 2017
Inspection ( By 2 Contractors)
Pipe line FFS / Assessment (qualitative & quantitative)/ Passport
Pipe line Catalog
Pressure protection System
Spares Inventory
FEED (By Technip)
Procurement (By ADMA)
EPC ( Pipeline Replacement
Engineering
EPC Execute ( Subsea Cable)
Deoiling & Demolition
Apr Jun
May Sep
Nov Sep
May Jun
Oct Sep
Oct Feb
Feb Sep
Oct Dec
Nov Nov
Feb Feb
Jan ,Dec
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Zakum Oil Lines Replacement Project - OUTCOME
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1. Development of Execution Strategy for Pipe Lines Replacement
2. Development of Pipeline PASSPORT
3. Development of Integrity Management Database System
4. Development of Integrity Management Planning
5. Development of Safe Operation Process until Replacement
6. Introduction of various New Technologies
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Execution Strategy – Pipe Lines Replacement
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Internal Inspection / Integrity Assessments / Risk Ranking
Engineering started with a list of pipelines to be replaced based on Qualitative Assessment.
In Parallel the Intelligent Pigging (IP) / Quantitative Assessment was in progress.
Number of pipelines were added or removed from the scope as the results of the IP/Quantitative
Assessment (Deterministic and actual condition based) / Risk Ranking.
Parallel Engineering
Early Surveys : Pipeline route surveys and Geo-Technical survey for new structures were carried
out prior to commencement of Engineering.
Laser scanning (WHTs 3D PDMS) : Laser scanning reduced time required for site visit for obtaining
‘As-Built’ information of WHTs.
Standardization : Pipeline sizes & Equipment were standardized to optimize the delivery.
Optimization of Topside Modifications : In parallel, an independent study has been completed by
an In-house Task Force and study outcome findings were incorporated in Engineering.
Structural Integrity of Existing WHTs : In parallel, the adequacy of existing Structure of WHTs
were thoroughly checked and confirmed by a specialist Consultant.
Early procurement of Long Lead Items (LLIs)
Line pipes, bends, Composite Subsea Cables & Accessories and ESDVs were identified as the long
lead items. This eliminates a major risk from the project schedule.
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Execution Strategy – Pipe Lines Replacement
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Leadership
Senior Management : Provide Directives, Timely Approvals, Extensive Supports and Mitigation in
Dynamic Way.
Shareholders : Early approvals on EPC Bidders List / Project Execution Strategy.
Early Engagement of EPC Contractors
Pipeline Early ITT issue while engineering is in progress : ITT was issued early as soon as
majority of the documents were issued as final. Remaining documents and additional scope was
issued as Tender Bulletins. This resulted in reduction in duration of bidding phase.
Alignment Meetings with EPC Bidders : Technical alignment meetings were conducted with
potential EPC Contractors before submission of Technical and Commercial proposal. The objectives
of the meetings were to clarify all technical issues , explain the project objectives, complexity of the
field and to establish a workable base schedule.
Outage Optimization at all Phases
Outage optimization workshops are conducted in order to minimize the production losses during
offshore installation.
Early tie-in packages : Early tie-ins implementation during planned shut down (opportunity)
windows to minimize the loss of production during EPC phase.
Jumper Lines : Installation of temporary bypass lines to continue producing upstream towers.
SIMOP : Topside modification works while wells are producing in order to minimize shutdown
duration.
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Integrity Management Planning
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Safe Operation until Replacement
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Pressure Protection System
Replacement Inhibition
Pipeline Repair
Inspection & Monitoring
Pipeline Catalog
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New Technology – Inspection
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New Technology – Laser Scanning
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Abu Dhabi, 21st April 2015
Ali Rashed Al Jarwan Chief Executive Officer Abu Dhabi Marine Operating Company