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Airborne Oil & Gas An introduction to TCP 20-09-2017
Airborne Oil & Gas
An introduction to TCP
20-09-2017
Thermoplastic Composite Pipe (TCP): Concept
• Solid pipe structure: bonded
• Fit for purpose polymer: liner, matrix & coating
• Glass or carbon fibres fully embedded (true composite)
• Optional weight coating for on-bottom stability
No corrosion
Flexible
Light weight
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A plastic liner is over-wound with polymer impregnated fibre tapes and melt fused using Airborne Oil & Gas propriety production technology to form a single walled structureMonolithic wall reduces permeation and allows for high pressure applications including gas service
Coating
Laminate
Liner
Weight coating
(optional)
Thermoplastic Composite Pipe (TCP): Concept
• Terminated within hours
• Fully qualified and field proven
• Can be fitted with bend restrictors, bend stiffeners and
clump weights (TCP Downline)
• Various flange options available (API, ANSI, etc)
• Various material options available (carbon steel, CRA etc)
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The TCP can be terminated in the field, both onshore and offshore. This allows for flexibility in tie-in as well as pulling through J-tubes without end-fittingThe liner is reamed prior to stem insert, maximising bore dimensionsCRA options include weld inlays
Seals
Wedges
Sleeve
Stem & flange
Riser (SURF), Downline (SWI)• Fibres in all load directions• High internal and external pressure strength• High tensile strength• Larger MBR: D/d 50• Fully elastic
Thermoplastic Composite Pipe (TCP): Concept
Flowline & Jumper Spool (SURF), Hose & Jumper (SWI)
• Flexible fibre angle design
• High internal and external pressure strength
• Lower tensile strength
• Small MBR: D/d 30
• Flexible
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Tensile layers
Pressure balanced layers
Hoop layers
Subsea Umbilicals Risers Flowlines (SURF) Subsea Well Intervention (SWI)
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TCP Products that bring value to the industry
Key Proposition
Key Applications
• No corrosion
• Lower total installed cost
• Lowest total cost of ownership
• 50% weight reduction
• Lower riser cost
• Lower installation cost
Flowlines & Spools Risers
• In-field flowlines
• Spools & well jumpers
• Gas, water & HC service
• Deepwater
• Corrosive environments
• Gas, water & HC service
• Collapse resistant 3000 m
• Smooth bore
• Flexible
• High flowrates
• Lower cost per intervention
• Long service life
Dynamic Jumpers & Hoses Downlines
• Light well intervention
• Plug & Abandonment
• Pipeline pre-commissioning
• Light well intervention
• Plug & Abandonment
• Pipeline pre-commissioning
Key Proposition
Key Applications
Staircase Key completed and ongoing projects
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Building Field Track Record: Staircase approach
Downline
Jumper
Flowline / spool
Other
Headquarters
Regional office1. CCT – Composite Coiled Tubing
Dynamic riser
Time
Co
mp
lexi
ty
2017
CCT1
Downline
Hose &dynamic jumper
Flowline,jumper, spool
2007
Track Record
Delivery TCP Description Application Client End user / project
2010 2 x 600m umbilicals Seismic (airgun) Cortland Fibron
2011 2 x 4.5” downlines, 800m Trenching AGR, Flexlife Chevron
2012 3” downline, 2500m + reeler Pipeline pre-comm Saipem Guara & Lula and Sapinhoa
2015 2.5” downline, 1600m Pipeline pre-comm IKM /Subsea7 Statoil Astaa Hansteen
2015* 6” flowline, 550m Hydrocarbon production Petronas Carigali SKO West Lutong
2015 2x 2”, 10ksi dynamic jumpers P&A Wild Well Control Marubeni
2015 1“ static high pressure spools Methanol injection Chevron Alder
2016 2.5”, 10 ksi dynamic jumpers Acid stimulation OneSubsea Various
2016 3“ downline, 1500m + spread Acid stimulation Shell SNEPCo Bonga
2016 Deepwater riser design Water alternating Gas Petrobras Libra
2017* 6” spool qualification Spool, water injection Total Zinia
2017* 5.2” 10 ksi jumper spool qualification Spool, water injection Shell Perdido
2017 2” 10 ksi dynamic jumpers Acid stimulation Enpro / GE Oil & Gas Tullow Oil Ghana
2017 2” 5 ksi gas lift jumper Gas lift Anasuria Anasuria
*: in progress
Generic
• Airborne Oil & Gas is the world’s first company
qualified in accordance with DNV RP F119
• Materials: E-glass PE (others in progress)
• Design: TCP & End-fitting
• Production
Product
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TCP: Qualification
Constituent level – Polymer & Fibre
Ply level
Laminate level
Representative pipes
Fullscale
Dynamic jumpers Downlines
Jumper Spools Flowlines
*
*: In progress
Product
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Airborne’s TCP is fully qualified
Standard
Fully qualified
Development
• Airborne initiated the creation
of an industry standard for TCP:
• DNVGL-RP F119
• Airborne is the world’s first and
only company that has fully
qualified its first products
• Airborne continues to qualify its
new products and materials, e.g:
• Carbon / PVDF
• Risers
Temperature: fit for purpose TCP offering
• Glass – HDPE:• Fully qualified to 60 Degrees C,
option to 65 Degrees C (150 F)• Track record in permanent
application• Medium pressure (5 ksi)• Low permeation• High chemical resistance
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80˚C60-65˚C
121˚C
• Carbon – PA12:• Up to 80 Degrees C (180 F)• High pressure (10 ksi)• Low permeation• First client track record 2017• DNV qualification complete end
2018
• Carbon – PVDF:• Highest temperature up to 121
Degrees C (250 F)• High pressure (10 ksi)• Lowest permeation• Highest chemical resistance• DNV qualification complete 1H 2019
Fully qualified and track record 2017 Commercially available 2018 Pilot potential
TCP Flowline and Jumper Spools: Envelope
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0
200
400
600
800
1,000
1,200
1 2 3 4 5 6 7 8
Inte
rnal
Pres
sure
[bar
]
Internal Diameter [inch]Carbon fiber/PA12 Glass fiber/PE
0
50
100
150
200
250
300
350
400
450
500
1 2 3 4 5 6 7 8
Allo
wab
leEx
tern
alPr
essu
re[b
ar]
Internal Diameter [inch]CF/PA12 - Water Injection CF/PA12 - Production EGF/PE
Notes: • Manufacturing limitations based on current equipment. Dotted lines indicate capability
without manufacturing limitations. • EGF/PE Flowlines qualified for use up to 60°C. • Qualification ongoing for CF/PA12 up to 80°C and CF/PVDF up to 120°C (envelope not shown
for PVDF).
Notes: • Assumed pipe wall temperature for collapse calculations: 40°C• Allowable external pressure includes safety factors as per DNV safety class high
SURF products:
TCP Flowline
TCP Jumper Spool
TCP Riser
TCP Flowline
• Up to 7.5 inch ID
• Up to 690 bar/10ksi
• 2500-5000m in one length
• Integrated weight coating
• Fit-for-purpose material selection
• No corrosion
• Flexible
• Simplifying configuration
• Simplifying installation
• Allowing reel lay
Lower Total Installed Cost
Lower Total Cost of Ownership
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Comparison with steel:
• Lower Total Installed cost (CAPEX)
• Less seabed intervention works
• No PLET, no spools, no metrology
• No diving
• Direct pull-in to topsides
• Low installation vessel day rates
• Installation with additional weight and burial in one pass
Comparison total installed costRigid Steel - TCP
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TCP Flowlines: Life Cycle Cost
-30%
• Lower Operating Cost (OPEX)
• No corrosion, no corrosion mitigation
• Smooth bore, better flow
• Less inspection, less pigging
• Long design life
Fit for purpose On Bottom Stability solutions
Requirements different for each project and region
1. Integrated weight coating:
• Supplied ex-works
• Providing additional protection
2. Wire rope or chain:
• Clamped to pipe at regular interval
• Can be combined with weight coating
3. Seamless in combination with regulatory requirements:
• Burial (trenching/rock dump)
• Combined insulation/weight shells
• Mattresses
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Integrity Management
• Implementation based on existing and proven
methods:
• Internal pressure, temperature and fluid
composition monitoring
• Visual Inspection - internal/external
• Calliper pig – detecting liner deformation, excessive
abrasion
• Coupon monitoring
• Sonar tracking for buried pipelines (with weight
coating / wire rope)
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TCP Jumper Spools
• Up to 7.5 inch ID
• Up to 690 bar/10ksi
• No metrology
• Flexible
Lowest Total Installed Cost
Lowest Total Cost of Ownership
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Lower Total Installed Cost with TCP
• 60% cost reduction compared to steel*
• 40% cost reduction compared to unbonded flexibles*
Steel vs. TCP
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TCP Jumpers Spools: Total Installed Cost
* Overall as-installed cost based on 5 well jumpers
TCP
Steel-60%
-40%
TCP Riser
• Developing the building blocks
• CF/PA12 and CF/PVDF material qualification
• Global configuration analysis capability
• IM/real time monitoring
• Working with various EPC contractors on cost effective concepts (e.g. Libra)
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Proud of our Track
Record
Specifications
Inner Diameter: 1”Pressure rating: 12,500 psiWater depth: 150 mLength: 100 m
Project case 1: Chevron Alder Jumper Spool Project case 2: Petronas Flowline
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Key system characteristics
Project schedule advantages• Manufactured in advance, terminated
prior to installation on site• Significantly more tolerance in length
than rigid pipe• No metrology required
Lower cost• Reduced fabrication cost• Reduced buoyancy cost• Reduced transport costs• Reduced Installation costs
Alder field: Gas condensate ,High Pressure High Temp (HPHT)Single subsea well at 152m WDMethanol injection within the tree and wellhead tie-in spool downstream of tree.The TCP jumper connecting the manifold with the tree
Key system characteristics
Lower total installed cost• Fast installation• Terminated offshore• Single operation platform tie-in• No divers
Lower total cost of ownership• No corrosion• Less pigging• No inhibitors, biocides pumping
Specifications
Inner Diameter: 6”Pressure rating: 345 barWater depth: 50 mLength: 500 m
Petronas Carigali: HC flowline to replace a corroding flowline suffering from MIC. The qualification program included, besides a variety of lab and prototype testing, full scale offshore installation testing. With successful completion of the whole program, a pilot flowline is now to be installed in Oct 2017.
Project case 3: Subsea 7 & IKM Testing Downline Project case 4: Enpro Subsea Acid Stimulation Jumpers
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Key system characteristics
• Fully field proven • Lower cost per intervention• High flowrates• One single, continuous length downline • Simple end fittings• Strong and durable protective coating • Collapse resistant to up to 3,000 meters
water depth with vacuum capability
Specifications
Inner Diameter: 2.5”Pressure rating: 345 barWater depth: 1300 mLength: 1500 mQualified # deployment: 180Completed to date: 19
Statoil’s Astaa Hansteen.:On this project, the TCP Downline is used for the pre-commissioning of risers and pipelines, pumping various fluids at pressure into subsea pipelines and risers. The project was completed in close cooperation with Subsea 7, who initially selected the downline for this operation. The TCP Downline is used for both pipeline pre-commissioning as well as subsea light well intervention services
Enpro Subsea is a provider of riserless, subsea stimulation services include scale squeeze and acid stimulation services. Enpro supplied 3 TCP jumpers to Ghana, West AfricaKey element in this project was ultra-fast (12 wks) delivery First successful scale squeeze was completed in July 2017.
Key system characteristics
• Fully field proven • Lower cost per intervention• High flowrates• Simple end fittings• Strong and durable protective coating • Collapse resistant to up to 3,000 meters
water depth with vacuum capability• Can be terminated in the field
Specifications
Inner Diameter: 2”Pressure rating: 689 barWater depth: 1500 mQuantity: 3 pcsQualified # deployment:: 100+Completed to date: 1
Project case 5: SNEPCo Downline, Jumpers Project case 6: Saipem Guara & Lula Downline& Deployment System
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Key system characteristics
• Fully field proven • Lower cost per intervention• High flowrates• One single, continuous length downline • Simple end fittings• Strong and durable protective coating • Collapse resistant to up to 3,000 meters
water depth with vacuum capability
Specifications
Inner Diameter: 3”Pressure rating: 345 barWater depth: 1500 mLength: 1600 mQualified # deployment: 225Completed to date: 0
Shell Nigeria Exploration & Production Company (SNEPCo): Supply TCP Downline, Jumpers and deployment system (Reeler and Tensioner system, as well as a bespoke overboardingchute design) to be used for stimulation purposes. The TCP Downline and Jumper will connect to a subsea tree injection cap, ready for deployment in 2017.
Saipem SA – TCP Downline for the pre-commissioning of the Sapinhoá pipeline in Brazil, part of the Guara & Lula field. The TCP Downline was used for pressure testing, cleaning and de-watering of the pipeline, pumping methanol, dyed seawater, nitrogen and high pressure air. In total, the TCP Downline completed 45 deployments to 2140 meters water depth. This TCP Downline has set the world depth record for a composite pipe.
Key system characteristics
• Fully field proven • Lower cost per intervention• High flowrates• One single, continuous length downline • Simple end fittings• Strong and durable protective coating • Collapse resistant to up to 3,000 meters
water depth with vacuum capability
Specifications
Inner Diameter: 3”Pressure rating: 345 barWater depth: 2140 mLength: 2500 mQualified # of deployments: 45Completed: 45
NL Sales
Head Office
Monnickendamkade 11976 EC IJmuidenThe NetherlandsTel: +31 255 763 500
Frits KronenburgArea Sales Manager [email protected]
Taylor EnzeArea Sales Manager North [email protected]
Wouter SpruijtArea Sales Manager Africa, Middle East, Asia & [email protected]
More information
Business DevelopmentJan van der Graaf Business Development Manager [email protected]
Peter AartsBusiness Development Manager West [email protected]
Thermoplastic Composite Pipe (TCP):Manufacturing
Airborne Manufacturing plant
• World’s first full scale thermoplastic composite pipe plant
• Sizes from 1 to 7.5 inch ID (equiv. to 8” nominal pipe size)
• Continuous length - 3000+ meters per spool
• Strategically located in Amsterdam Port Area
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