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Introduction to Z-Subsea
Mission Statement
Worldwide projects track records
Key differentiators
Subsea design services
Materials and Integrity services
Capability Summary
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Z-Subsea is an independent, Subsea Design and Integrity Engineering consultancy
established in 2011.
We provide integrated full life cycle solutions to the oil and gas industry worldwide.
Our current clients include Tullow Oil, TAQA, DNV ME, Neptune Marine Services,
Theon, FairLead Maritime, Petro Vietnam, etc.
Our full cycle services commence with conceptual definition and continue with
detailed design, construction move into operational support and up to end of life.
Safe Operation beyond the original design life (life extension) is also of high interest
to us.
We employ innovative and cost effective approaches to maximise our client’s safe
design and operation at a minimised unnecessary shutdowns.
Z-Subsea is an official member of Oil and Gas UK and Subsea UK and in the
process of registration with FPAL.
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To be a world class multi-disciplinary, integrated and
impartial Subsea, Materials and Integrity consultancy.
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Delivery driven by integrated approach throughout the project life cycle
(Design to end of life) and beyond (Life extension)
Quality of Personnel; national/International reputation and vast amount of
experience
Employing experienced personnel; worked for Contractors, Engineering
Consultancies, Verification bodies and Operators
Reasonable rates, high quality delivery and quick turn around
Specialisation in hot topics; such as Deepwater, HP/HT, Sour-service and
strain-based condition
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TAQA-UK: Consultancy services to TAQA on inspection, monitoring and integrity management of
12 J-Tubes within concrete caissons and suggesting mitigation measures.
Tullow Oil -UK: Materials/Welding and integrity consultancy supports to T.E.N project in Ghana
FairLead Maritime: Dynamic Nonlinear FEM of semi-sub impact to jacket
Neptune Marine Services (Neptune) - Australia: Verification and Development of Free-Span
and VIV analysis tool
DNV/GL - Middle East: Design verification of topside modification of Bukha-A Platform including
piping, process and material disciplines - Oman Oil Company Exploration & Production LLC
(OOCEP)
DNV/GL- Middle East: Design verification of subsea pipeline of Musandam Gas Plant Project -
Oman Oil Company Exploration & Production LLC (OOCEP)
DNV/GL - Middle East: Preparation of design Performance Standards for onshore pipeline,
structures and facilities - PDO
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Z-Subsea Technical Capability Overview Subsea Design
Field Development Options
Field Layout and Route Selection
Design of Subsea Pipelines and Risers
Design of Flexible Risers and Umbilicals
Design of Subsea Structures and Pipe
Works
Advanced Pipeline/Riser Design (HPHT,
Strain Based Design, Low Cycle Fatigue,
Pipe-in-Pipe)
Component Design (Bulkhead, Flange, Y-
Piece,…)
Materials/Integrity Engineering Materials Selection
Corrosion Protection and CP Design
Welding and NDT
Fracture Mechanics Based Integrity (Fatigue/
Fracture) Assessments (ECA)
Corrosion Assessment of Existing Assets
(Fitness for service assessments)
Life Extension Studies
Advanced Analysis HPHT Pipelines Upheaval and Lateral
Buckling Advanced Analysis and Design
Design by Analysis for Flanges and
Bulkheads
Free Span and VIV Assessment for Pipelines
and Risers
Ship-Jacket Impact Advanced FE Analysis
and Assessment
Specialised Services to
Subsea Projects Flow Assurance
Subsea Process
Subsea Controls
Safety Engineering
Cost and Schedule Estimate
Contract Management
Specialised Training Courses
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Overview of Subsea Design Services
(Conceptual, Pre-FEED, FEED and Detail Design)
Field Development Options;
Field Layout and Route Selection;
Subsea Pipelines and Risers;
Flexible Risers and Umbilicals;
Installation Analysis;
Subsea Structures and Pipeworks
Materials and Coating Selection;
Corrosion Protection Philosophy and CP Design
Components Design (Bulkheads, Y-Pieces,…);
Subsea Controls;
Subsea Process;
Flow Assurance
Safety Engineering;
Cost And Schedule Estimate;
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Field Development Options
Stand-alone;
Tied-back;
Phased Development;
How is it done?
EPIC schedule estimate;
Cost estimate;
Income estimate;
Cash flow generation;
Extracting economic indicators such as NPV, IRR and UTC.
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Field Layout and Route Selection◦ Geotechnical and geophysical surveys;◦ Manifolds and structures locations;◦ Pipeline routes;◦ Pipeline system (single, piggybacked, PIP or
bundle);◦ Controls (EHC, distribution centres);
Subsea Pipelines◦ Material Selection◦ Wall Thicknesses◦ On-bottom stability ◦ On-bottom roughness and Free span◦ Pipeline protection◦ Fatigue◦ Lateral and upheaval buckling◦ Expansion and Walking◦ Crossing design◦ Pipe-in-pipe
◦ Tie-in spools (conventional, vertical)◦ Pipe-soil interaction models◦ Alignment sheets◦ High Pressure/High Temperature (HPHT)
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Risers and Umbilicals◦ Single rigid risers◦ Pipe-in-Pipe Risers◦ Caisson risers◦ Retrofit risers◦ J-tubes◦ Flexible risers◦ Umbilicals◦ SCRs
Subsea Structures and Pipework◦ SSIV◦ Manifold◦ PLEM, PLET, UTA◦ Foundation (Mud mat, Suction pile)
Component design and Advanced FE◦ Flanges◦ Bulkheads ◦ Tee-pieces◦ Y-Pieces
Reliability Based Design
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Corrosion protection philosophy and CP design◦ CP selection◦ CP interference◦ CP and anode weight calculation
Subsea Controls◦ EPU: Electrical Power Unit◦ HPU: Hydraulic Power Unit◦ TUTU: Topside Umbilical Termination Unit◦ SDU: Subsea Distribution Unit◦ UTA: Umbilical Termination Assembly◦ SCM: Subsea Control Module◦ MCM: Manifold Control Module
Material and Coating Selection◦ Sour service (CRA, inhibitor, chemical injection)◦ External corrosion◦ U value
Cost and schedule estimate
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Subsea Process◦ Subsea Process drawing development e.g. P&ID, PFD, C&E diagrams◦ Design pressure & temperature philosophy ◦ Choke valve sizing◦ Start-up and Shutdown operating guidelines ◦ Hydrate remediation strategy◦ HIPPS system operational test procedures◦ HAZID & HAZOP, LOPA participation◦ Equipment duty specification/datasheet◦ Technical evaluation of vendor proposals
Flow assurance◦ Fluid property calculations using PVTSIM◦ Steady State analysis using PIPESIM (including pipeline sizing optimisation,
pressure and temperature profiles, turndown, erosional velocity ratio, slugging etc.)
◦ Hydrate and Wax management strategy ◦ Insulation selection (U-value optimisation)◦ Liquid management and slug catcher optimisation ◦ Transient analysis using OLGA (including Pipeline cool-down, restarts, ramp-
up, packing, blowdown analysis)◦ HIPPS response time evaluation◦ Pigging simulation and optimisation
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Engineering management◦ Conceptual
◦ Pre-FEED
◦ FEED
◦ Detailed Design
Procurement Management◦ Market study and assessment of suppliers
◦ Procurement management
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Quantitative/Qualitative Risk Assessment
Life cycle integrity management:◦ Concept/Design/Fabrication
◦ Operation (Remaining Life calculation)
◦ End of life and beyond (Life extension-HSE KP4 programme)
◦ Decommissioning or Re-Use
◦ Abandonment
Developing and managing project-specific Inspection, Monitoring and Testing philosophies.
Producing and maintaining up-to-date asset register documents e.g., MAPD, IMR, DFI suite of documents
EstablishIntegrity
(Concept/Design)
Maintain Integrity
(Operation)
De-commissioning
or Re-Use
Abandonment
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Performing Integrity Assessment/Engineering Criticality
Assessment (ECA) to DNV OS-F101/RP-F108, BS
7910, API 579-1/ASME FFS-1 and API 1104 with main
speciality on assessment of:
◦ Operation in Sour-service.
◦ Installation and operation under high plastic strain
conditions (e.g., Reeling), HP/HT and Deepwater
◦ Clad and Lined pipelines
Material
StressFlaw
ECA
Tensile properties
Fracture toughness
High temperature properties
Fatigue crack growth data
Geometry
Size
Location
Orientation
Profile
Primary
Secondary (residual)
Defect Acceptance
Curve
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Fatigue assessment (S-N and crack growth) to DNV
RP-C203, BS7910 and BS7608.
Fitness for Service assessment (FFS) of corroded
subsea assets according to DNV RP-F101, API579-
1/ASME FFS-1, BS 7910 or ASME B31G procedures
covering areas such as:
◦ Interpretation and comparison of the past and current
intelligent pigging data
◦ Highlighting most critical corrosion features
◦ Determination of the safe working pressure at
presence of the most critical corrosion features
◦ Calculation of corrosion rate using models such as
Cassandra, NORSOK, De-waard, etc.
◦ Calculation of remaining life to failure for the most
critical features
Fitness for service assessment (FFS) of Dents,
Blisters, Pits, Laminations, Buckles, etc. using API579-
1/ASME FFS-1 and procedures the Pipeline Defect
Assessment Manual (PDAM).
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Management of mechanical testing programmes in air
or corrosive environments on behalf of our clients
(using our testing partners, e.g., TWI, Exova, Corus,
DNV, etc.) including:
◦ Tensile testing of standard or sub-size Round/Flat
specimens under static and/or cyclic loading (Reeling
simulation)
◦ Fracture mechanics testing (CTOD/J) on SENT/SENB/CT
specimens to determine single value of fracture toughness
or R-Curve.
◦ Fatigue crack growth testing using SENB/CT specimens
and determination crack growth curves.
◦ Pipe full-scale testing, Wide-plate and segment tests, Pipe
burst tests.
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Numerical modelling (FEA) of cracked/un-cracked
subsea facilities, pipelines, risers, platform structures,
pressure vessels and piping.
Managing Inspection, Monitoring, Mitigation,
Intervention and Repair activities on behalf of our
clients based on the project specific IM philosophy
Managing failure investigations (IM and Materials
Group joint effort)
Running specialised/tailor-made training courses,
workshops, seminars, etc.
FEA of a cracked pipe
Riser stress analysis (Global)
Global analysis
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Welding
Screening appropriate welding procedures at the conceptual phase (high level screening)
Qualifying nominated procedures at the Design stage for application in Fabrication, Construction, Installation
and operation (Repair) phases.
Independent/impartial review, audit, and upgrade of existing welding procedure specifications.
Non-Destructive Testing (NDT)
on-site and/or laboratory based NDT inspections during the procurement, Fabrication, Construction,
Installation and operational phases employing qualified NDT personnel.
Developing defect acceptance criteria (Tolerable flaw size) for pipeline girth welds for EPC contractors and
operators.
Materials Selection/Corrosion
Selection, procurement, managing the fabrication and manufacturing of appropriate material specific to every
project.
Fit for purpose of the selected materials in terms of the operational condition, resistivity against wear, fatigue,
corrosion and protecting requirements (coating and CP systems, etc.).
Provision of Materials Engineering expertise via high level materials screening/selection (conceptual phase),
provision of procurement specifications especially for the long lead components (Corrosion Resistance
Alloys, Clad/lined materials, etc.), support (operation until the end of the design life and beyond (asset life
extension) with aiming at reducing the total life cycle cost.
Provision of support on procurement specifications, Component fabrication, Vendor assessment and
qualification, etc.
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Designing of CP systems for CRA materials
Design and operation of Deepwater CP systems
Performing CP current interaction modelling
Performing remedial activities on CP systems
(onshore and offshore)
Reviewing of annual CP survey reports