27.1.11 1Page

Bundle Pipeline Systems

& Shell FRAM Development

Iain Watson & Peter Walker

March 21st, 2012

Bundle Technologies

Advantages of Bundle Systems

Shell Fram Bundle FEED

Agenda

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Shell Fram Bundle FEED

Bundle Technologies

Advantages of Bundle Systems

Agenda

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Advantages of Bundle Systems

Shell Fram FEED

What is a Bundle / Towed Pipeline Solution?

• A Pipeline Bundle is a carrier pipe within which any combination ofindividual pipelines and umbilical components is carried.

• The individual components terminate in “Towheads” within whichmanifolding may take place.

• A Towed Pipeline Solution provides a low stress installation methodwhere-by a pipeline bundle is towed and installed using the ControlledDepth Tow Method.

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Subsea 7 Installed Bundles

Åsgard

Heidrun

NorwayNorway

Osprey

Cormorant

Frigg East

Murchison

GullfaksBruce

Keith

• 65 bundles in 33 years

• Up to 7.6km length

• Up to 28.7km in series

• Up to 320m water depth

• Shallowest 42m

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Claymore

PiperSaltire Thelma

Cyrus, FarragonScapa

Alba

Gannet

Embla

DanDenmarkDenmark

WickWick

ScotlandScotland

Buckland

Keith

LeadonSkene

• Longest tow 1000 km

• Up to 49.5” carrier

• Up to 545 te towhead

• Heaviest bundle 9154 te

• Up to 3 PiP flowlines

• U-value <0.7 W/m2K

• 3 Ongoing Projects

Bundle Components

• Flowlines

• Insulation

• Sleeve Pipe

• Control/Chemical Tubes

• Power, Signal, & Data Highway cables

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• Power, Signal, & Data Highway cables

• Main Spacer

• Centraliser – Pipe-in-Pipe Spacer

• Bulkheads

• Ballast Chains

• Anodes

What exactly is a “Pipeline Bundle?”

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Typical Bundle Layout

BP Machar

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BP Andrew

Kerr McGee Leadon

Materials

Flowline Materials

• Carbon steel - X52, X65, X70 with SS or

Alloy Liners

• Corrosion Resistant Alloys - 13% 22% & 25%

Cr Steels

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• Plastic (HDPE) Liners for Water Injection Lines

Controls

• Hard Pipe Hydraulic and Chemical Systems -

316 SS, 25% Cr Duplex to Carbon Steel

• Electrical & Fibre Optic Control Systems

The Long Trek West

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Wester Fabrication Facility

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Hastigrow Fabrication Facility

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Welding Firing Lines

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Inner Bundle Fabrication

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Insulation Type

Pipe-in-Pipe System

Passive Insulation System

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Pipe-in-Pipe System

Electrical Active/Trace Heating

Indirect Hot Water Heating

Production Line Insulation

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Applying ITP Izoflex Insulation

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Applying ITP Izoflex Insulation

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Spot Welding Steel Sheet Over ITP Izoflex

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Spot Welding Steel Sheet Over ITP Izoflex

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Bundle System Applicability

1500

2000

Wat

er D

epth

(m)

Pipe-in -Pipe

Wet Insulation

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0

500

1000

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5

Wat

er D

epth

(m)

U-Value (W/m 2K)

Pipe-in -Pipe

Bundles - Towed Pipeline Systems

Flexibles

Flow Assurance – Geometry of Pipelines

• The environment within the carrier pipe provides an ideal opportunity forinnovative solutions in Flow Assurance.

• The pipelines can be arranged to facilitate heat transfer between product linesor from dedicated heating lines.

• Heat transfer analysis confirmed by experimental results.

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Active Heating Systems

� Warm-up before Start-up

� Increase Temperatures for Low Production Rates

� Keep System Temperature High during Shutdowns

� Reduce Chemical Injection

Six Active Heating Systems installed in the North Sea

Hot Water Circulation over distances of 15 km

Electric Heat Transfer

Carrier Sheathing

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• 27m lengths welded into 500-1000m trains

• All production operations on line

• Trains sheathed to final location

• Final field joint tie-ins

Towheads

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Jura Manifold Beach Landing

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Jura Manifold Beach Landing

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Bulkheads

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Bulkheads

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Towhead Tie-In

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Bundle Launch

• Structures greater than 500Te

• Tidal currents monitored & tug

locations altered accordingly

• Tug bollard pull up to 400Te

• Capstan winch providing

holdback tension up to 70Te

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holdback tension up to 70Te

• A99 road bridge opens to allow

large structures to pass through

Launch

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Control Depth Tow Method

• Chains attached at regular intervals along the bundle.

• Ensures accurate weight control to approximately 0.5%.

• Weight of chain links on seabed is submerged weight of bundle.

• Chains can be easily cut by ROV to trim bundle

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• Chains can be easily cut by ROV to trim bundle for tow if required.

CDTM – in Practice

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A data highway runs thelength of the bundle andallows acoustic commandsmade at one end of thebundle to be implemented atthe other, for example forvalve actuation or acousticspool metrology.

Towmaster’s real-time display of bundle shape and water depth

What We Can Do

• Field Concept Development, FEED Studies

• Tender Engineering

• Detailed Design & Fabrication

• Launch, Tow & Installation Analysis

• Dynamic & Fatigue Analysis

• Failure Investigation Support

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• Failure Investigation Support

• Regional Support (Bundles), Norway & Asia Pacific

Bundle Technologies

Advantages of Bundle Systems

Shell Fram Bundle FEED

Agenda

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Shell Fram Bundle FEED

Why Bundles? - Advantages

• Eliminate the requirement for heavy lift vessels by incorporating Subsea Structures within a

Towed Production System (Maximum to date 545te).

• Testing and commissioning of complete system onshore therefore reducing offshore time: -

Hydro testing, dewatering, drying, control fluid flushing, valve operations etc.

• Fast hook up and commissioning for early first oil dates.

• Installation under existing or temporary floating assets.

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• Reduced number of subsea tie-ins and spool installations.

• Seabed stability using Gravity Based or Piled design.

• Protection incorporated in structure design.

• Improved Flow Assurance / thermal Management (Heated – Hot Water, Trace Heating).

• Leak mitigation in case of internal flowline failure (maintain leaked oil within Carrier Annulus) -

Flowline safety class can be reduced when using DNV-OS-F101 Design Code.

• Use of CRA Lined pipe in place of Clad pipe or solid CRA pipe.

• High Temperature Flowline Design (up to 160°C curre ntly).

• Turn out cost more predictable (reduced exposure to weather/soils risk).

Bundle Technologies

Advantages of Bundle Systems

Shell Fram Bundle FEED

Agenda

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Shell Fram Bundle FEED

Fram Field Location

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Fram Field Location

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Fram Development Proposed Field Concept

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Fram Development – Proposed Field Layout (Xodus)

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Fram Infield Layout

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Fram FPSO Approaches (Xodus)

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Fram Drill Centre East Towhead & Well Tie-ins (Xodus)

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Fram Drill Centre West Towhead & Well Tie-ins (Xodus)

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Fram Bundle FEED - Principal Design Assumptions

Principal Design Data / Assumptions for Fram FEED:

• 8 Slot towhead manifold at DCE (5 wells initially).

• 6 Slot towhead manifold at DCW (3 wells initially).

• 2 midline SSIV structures required at FPSO (out with swing circle).

• 14” NB Gas Export SSIV located in Midline Towhead (East).

• Shared services between drill centres (single test riser, gas lift riser & riser umbilical).

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• Shared services between drill centres (single test riser, gas lift riser & riser umbilical).

• Mixture of Oil & Gas Wells at both drill centres.

• 345 Barg Design Pressure / 110°C Design Temperature (Production/Test).

• Max CO2 content ~1.1 mol.% in produced fluids.

• Max. H2S ~6 ppmv in produced fluids.

• ~47,000 mg/l Chlorides in produced water.

• Water depth infield ~ 95 m (wrt LAT).

• 20 year system design life

Fram Bundle Cross Section Designs

DCE & DCW Bundle Cross Sections

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Midline Bundle Cross Section (Shared Services)

Fram Bundle Cross Section Designs

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Fram Bundle Cross Section Designs

Pipe-in-pipe Insulation System Performance (both options)

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CRA Lined Pipe (Butting) – Mechanically Bonded (BuBi)

Fram Bundle Production & Test Line Linepipe Design

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The Mechanically bonded Butting Bimetal Pipe (BuBi Linepipe)

Fram Bundle Simplified Configuration (P&ID)

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Fram Bundle - DCE Towhead Pipework (General Assembly)

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Fram Bundle - DCW Towhead (General Assembly)

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Fram Bundle - Midline Structure East (GA)

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Fram Bundle - Midline Structure West (GA)

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Bundle Launch at Subsea 7’s Wester Site

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Bundle Tow Route

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Bundle Tow Configuration

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Bundle Tow Route

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Control Depth Tow Method

• Chains attached at regular intervals along the bundle.

• Ensures accurate weight control to approximately 0.5%.

• Weight of chain links on seabed is submerged weight of bundle.

• Chains can be easily cut by ROV to trim bundle

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• Chains can be easily cut by ROV to trim bundle for tow if required.

Questions?

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seabed-to-surface

www.subsea7.com