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Mechanical Lined Pipe - Installation by Reel-Lay
Wacek LipskiWacek LipskiDiscipline Manager
The New Subsea7
Description of BuBiR
Mechanical Lined Pipe
Overview of Reel Lay Installation method
Development programme
Agenda
Development programme
Installation methodology
Current StatusCurrent Status
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O bOur new beginning
A combination of Acergy and Subsea 7, two very strong subsea companies that have come together to create a subsea companies, that have come together to create a global leader in seabed-to-surface engineering, construction and services.
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S b h d f lSubsea 7 Methods of Pipelay
S-layS-lay
Reeling
J-lay
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CDTM
S b & ddl l C b lSubsea 7 –Asia & Middle East Pipelay Capability
S-lay & J-lay of pipelines in Asia & Middle East is through our Joint Venture Company SapuraAcergy and the Sapura 3000:Joint Venture Company, SapuraAcergy and the Sapura 3000:
– 240 Tonnes S-lay– 400 Tonnes J-lay– First deep water project in Malaysia (S-lay) – Murphy Kikeh– Work ongoing on second deep water project (S-lay and J-
lay) Shell Gumusut Kakaplay), Shell Gumusut Kakap
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Driver
BuBiR
Mechanical Lined Pipe is a BuBi Mechanical Lined Pipe is a cost effective solution where CRA materials are required
Proven track record for S-lay, J-lay and CDTM
Extending the applicability to Extending the applicability to Reeling will have a positive impact on the economic viability of some ff h d l t j toffshore development projects
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Driver
Item No.Production Material
Pipeline DetailsLinepipe price
OD WT
1 22Cr 10" 14.3mm 1.75
2 13Cr 10" 12.7mm 1.5
3 Lined 316L 10" 12.7mm + 3mm liner 1.0
4 Lined 825 10" 12 7mm + 3mm liner 2.254 Lined 825 10 12.7mm + 3mm liner 2.25
5 Clad 316L 10" 11.8mm + 3mm clad 2.25
3 56 Clad 825 10" 11.8mm + 3mm clad 3.5
Material price comparison based on 20 miles length.
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f R h l dDescription of BuBiR Mechanical Lined Pipe
• Carbon Steel outer pipe with a Corrosion with a Corrosion Resistant Alloy liner
• Assembled by Hydraulic process
Carbon Steel Outer PipeCarbon Steel Outer Pipe
Cladding(Alloy 625 typ )
50mmNom 3mm liner
(Alloy 625 typ.)
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f R h l dDescription of BuBiR Mechanical Lined Pipe
Material options
Carbon Steel Rp 0.2 [MPa] Rm [MPa]API X52 360 460API X60 415 520API X65 450 535API X70 485 570
Cladding Rp 0.2 [MPa] Rm [MPa]
Example of material options
2.4858 / 825 240 500 - 7002.4856 / 625 276 690 - 8901.4539 / 904L 220 520 - 7201.4404 / 316L 220 520 - 6701.4404 / 316L 220 520 670
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Description of Mechanical Lined PipeDescription of Mechanical Lined Pipe
• Pipe Sizes and wall thickness options.
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Construction Process for BuBi PipeR
Construction Process for BuBi Pipe
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blAssembly Process
0 10 1
Hydraulic expansion press (Schäferpresse)
32
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Hydraulic expansion press (Schäferpresse)
l llReel Lay Installation
Port Isobel Spool Base – Gulf of Mexico
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lDevelopment Programme
Objective:
Demonstrate that installation by Reel Lay will not wrinkle the pipe or have an unacceptable impact on the mechanical or corrosion resistance properties required for its intended corrosion resistance properties required for its intended service.
Phase 1
Test a – Simulated reeling trials of pipes without internal pressure.
Test b – Simulated reeling trials of pipes with internal pressure
10i Di X65 t i 15 09 + 3 All 825 li
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10ins.Dia, X65 outer pipe15.09 + 3mm Alloy 825 liner
lTest a – No internal pressure
FE Analysis - wrinkle prediction performed on pipe with no internal pressure internal pressure.
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lDevelopment Programme
Simulated reeling test rig.Bend Radius 7.5 mtrs.
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Herriot Watt University Scotland.
lTest a – No Internal Pressure
Wrinkles recorded in line with FE Analysis.y
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b h lTest b – With internal pressure
FE Analysis - wrinkle prediction performed on pipe with i l internal pressure
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No wrinkles measured
h l h 2Further Development – Phase 2
• Testing of different pipe sizes & liner materials
• Demonstration for low fatigue applications
• Enhanced FEA
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f d ff & l lTesting of different pipe sizes & liner materials
Phase 2
2010 Scope ( completed)
Simulated Reeling trials with internal pressure
8 ins dia. X65,Alloy 625 & 316l (no girth weld)
Depressurisation Test
Fatigue Testing – Strip & Full scale
DNV Qualification – DNV RP – A203
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f d ff & l lTesting of different pipe sizes & liner materials
Depressurisation Test
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h d
BUBI PIPE STAGES SHOWING MECHANICAL GRIP FROM 30 BAR PRESSURE DURING REELING
Enhanced FEArb
on s
teel
liner
Car
Li C iShot blasted carbon steel
Liner inserted
6mmgap
Liner expansion at
1200 bar
Coating at 240°C
~ 40µ gap
30 bar for
Reeling
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Start Telescoped Hydroformed Coated Installation
Pipeline Inspection 2000 readings every 20mm along the pipePipeline Inspection – 2000 readings every 20mm along the pipe
Bore measurements taken to record any change during o/a process and provide inputs to FE model.
On Manufacture at ButtingOn Manufacture at Butting
Prior to simulated reeling
Following Simulated reeling
Post fatigue testing
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Fatigue Testing Strip TestFatigue Testing – Strip Test
40M cycles and no failure at
60MPa on 2 post reeled sample. 60MPa on 2 post reeled sample.
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ll S lFatigue Testing – Full Scale Resonance Test
Fatigue test was taken to a stress/no. of cycles as per the DNV 30.2 F1 Curve
Stress range, MPa Design life (F1), cycles Target life (F1), cycles180 85,740 293,424120 289,372 990,30760 2 314 975 7 922 45860 2,314,975 7,922,458
All samples showed no defects which could be attributed to the fatigue testing
NDE (AUT X d D P t t t ti ) d S ti i f d t fi i t it
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NDE (AUT, X-ray and Dye Penetrant testing) and Sectioning was performed to confirm integrity of the clad weld to liner interface
TestingTesting
Dye- penetrant testing to check for defects on linerDye- penetrant testing to check for defects on liner
longitudinal, overlay and Girth welds.
X-ray of longitudinal, seam and girth welds.
Tensile test of both materials.
Charpy V notched impact tests at -30oC on the carbon steel
Hardness testing on X65 and the Alloy 625
Metallographic examination of the seal weld area
G48 Corrosion tests carried out at 50oC on Alloy 625 linerG48 Corrosion tests carried out at 50oC, on Alloy 625 liner
G28 Intergranular corrosion (Method A)
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ll h d lInstallation Methodology
Key objective:
Maintaining internal pressure
during the stalk reeling onto
the vessel and installation.
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Installation Methodology
PIG
MANIFOLD
Pig End Cap
END CAP
TIE IN SHED
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Installation Methodology
PIG
MANIFOLD
END CAPEND CAP
TIE IN SHED
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Installation Methodology
PIG
MANIFOLD
END CAPEND CAP
TIE IN SHED
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Installation Methodology
PIG
MANIFOLD
END CAPEND CAP
TIE IN SHED
Key procedures:Straightening TrialsOffshore tie – ins
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Offshore tie insOffshore Emergency Abandonment
hHigh Friction Pig Tests
The tests performed to date demonstrated
that the high friction pig could be pumped
into position and located accurately to the
desired position in the pipeline.
Leak proof at 4 bar differential pressure Leak proof at 4 bar differential pressure –
(tested over 12 hrs).
Consistent launch, running & reversal
pressures recorded.p
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S fSafety
Risk assessment performed using the Shell software FRED (Fire, Release, E l i d Di i ) Explosion and Dispersion).
All l ithi 10 f th l ith d k l l t h i ht h ld
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All personnel within 10m of the reel, either deck level or at height, should wear normal suitable eye protection and safety clothing.
Q l fDnV Qualification
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l S 20Development Scope 2011
Reeling Trials on 12 ins. X65 with Alloy 625 liner.
Reeling Trials on 8ins X65 with 316l linerReeling Trials on 8ins. X65 with 316l liner
Full Scale fatigue testing on 8ins. X65 with Alloy 625 liner.Full Scale fatigue testing on 8ins. X65 with Alloy 625 liner.
Reeling Trials on 12 ins. X80 with Alloy 625 liner.
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S l G á d lPre Salt - Guará and Lula
Submerged Buoy
70+ km of BuBi Mechanical Lined Pipe to be installed in approx. 2100 mtrs. Water depth
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C lConclusions
• Tests to date demonstrate no Tests to date demonstrate no wrinkling occurs when reeling is performed with internal pressurepressure.
• Installation of mechanical • Installation of mechanical lined pipe by Reel Lay is achievable, safe and will offer significant economic significant economic advantages.
• DNV QualifiedQ
• First project awarded
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