Airborne Oil & Gas. An introduction to TCP

Transcription

1 Airborne Oil & Gas An introduction to TCP

2 Thermoplastic Composite Pipe (TCP): Concept Coating Weight coating (optional) Laminate Liner 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 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 structure Monolithic wall reduces permeation and allows for high pressure applications including gas service 2

3 Thermoplastic Composite Pipe (TCP): Concept Seals Wedges Sleeve Stem & flange 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) 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 endfitting The liner is reamed prior to stem insert, maximising bore dimensions CRA options include weld inlays 3

4 Thermoplastic Composite Pipe (TCP): Concept Pressure balanced layers 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 Hoop layers Tensile layers 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 4

5 5 TCP Products that bring value to the industry Subsea Umbilicals Risers Flowlines (SURF) Subsea Well Intervention (SWI) Flowlines & Spools Risers Dynamic Jumpers & Hoses Downlines Key Proposition Key Proposition No corrosion Lower total installed cost Lowest total cost of ownership 50% weight reduction Lower riser cost Lower installation cost Collapse resistant 3000 m Smooth bore Flexible High flowrates Lower cost per intervention Long service life Key Applications Key Applications In-field flowlines Spools & well jumpers Gas, water & HC service Deepwater Corrosive environments Gas, water & HC service Light well intervention Plug & Abandonment Pipeline pre-commissioning Light well intervention Plug & Abandonment Pipeline pre-commissioning

6 Complexity Building Field Track Record: Staircase approach Staircase Key completed and ongoing projects Dynamic riser Flowline, jumper, spool Hose & dynamic jumper Downline CCT Time Downline Flowline / spool Headquarters 1. CCT Composite Coiled Tubing Jumper Other Regional office 6

7 Track Record Delivery TCP Description Application Client End user / project x 600m umbilicals Seismic (airgun) Cortland Fibron x 4.5 downlines, 800m Trenching AGR, Flexlife Chevron downline, 2500m + reeler Pipeline pre-comm Saipem Guara & Lula and Sapinhoa downline, 1600m Pipeline pre-comm IKM /Subsea7 Statoil Astaa Hansteen 2015* 6 flowline, 550m Hydrocarbon production Petronas Carigali SKO West Lutong x 2, 10ksi dynamic jumpers P&A Wild Well Control Marubeni static high pressure spools Methanol injection Chevron Alder , 10 ksi dynamic jumpers Acid stimulation OneSubsea Various 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* ksi jumper spool qualification Spool, water injection Shell Perdido ksi dynamic jumpers Acid stimulation Enpro / GE Oil & Gas Tullow Oil Ghana ksi gas lift jumper Gas lift Anasuria Anasuria *: in progress

8 TCP: Qualification Generic Product 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 Full scale Jumper Spools * Flowlines Representative pipes Dynamic jumpers Downlines Laminate level Ply level Constituent level Polymer & Fibre *: In progress 8

9 Airborne s TCP is fully qualified Product Standard Airborne initiated the creation of an industry standard for TCP: DNVGL-RP F119 Fully qualified Airborne is the world s first and only company that has fully qualified its first products Development Airborne continues to qualify its new products and materials, e.g: Carbon / PVDF Risers 9

10 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 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 C 80 C 121 C 10

11 Internal Pressure [bar] Allowable External Pressure [bar] TCP Flowline and Jumper Spools: Envelope 1, , Carbon fiber/pa12 Glass fiber/pe Internal Diameter [inch] CF/PA12 - Water Injection CF/PA12 - Production EGF/PE Internal Diameter [inch] 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 11

12 SURF products: TCP Flowline TCP Jumper Spool TCP Riser

13 TCP Flowline Up to 7.5 inch ID Up to 690 bar/10ksi m 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 13

14 TCP Flowlines: Life Cycle Cost 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 cost Rigid Steel - TCP -30% Lower Operating Cost (OPEX) No corrosion, no corrosion mitigation Smooth bore, better flow Less inspection, less pigging Long design life 14

15 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 15

16 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) 16

17 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 17

18 TCP Jumpers Spools: Total Installed Cost Lower Total Installed Cost with TCP 60% cost reduction compared to steel* 40% cost reduction compared to unbonded flexibles* Steel vs. TCP -60% -40% Steel * Overall as-installed cost based on 5 well jumpers TCP 18

19 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) 19

20 Proud of our Track Record

21 Project case 1: Chevron Alder Jumper Spool Project case 2: Petronas Flowline Alder field: Gas condensate,high Pressure High Temp (HPHT) Single subsea well at 152m WD Methanol injection within the tree and wellhead tie-in spool downstream of tree. The TCP jumper connecting the manifold with the tree Key system characteristics Specifications 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 Inner Diameter: 1 Pressure rating: 12,500 psi Water depth: 150 m Length: 100 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 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 bar Water depth: 50 m Length: 500 m 21

22 Project case 3: Subsea 7 & IKM Testing Downline Project case 4: Enpro Subsea Acid Stimulation Jumpers Statoil s Astaa Hansteen.:On this project, the TCP Downline is used for the precommissioning 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 Africa Key element in this project was ultra-fast (12 wks) delivery First successful scale squeeze was completed in July Key system characteristics Specifications Key system characteristics Specifications 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 Inner Diameter: 2.5 Pressure rating: 345 bar Water depth: 1300 m Length: 1500 m Qualified # deployment: 180 Completed to date: 19 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 Inner Diameter: 2 Pressure rating: 689 bar Water depth: 1500 m Quantity: 3 pcs Qualified # deployment:: 100+ Completed to date: 1 22

23 Project case 5: SNEPCo Downline, Jumpers & Deployment System Project case 6: Saipem Guara & Lula Downline Shell Nigeria Exploration & Production Company (SNEPCo): Supply TCP Downline, Jumpers and deployment system (Reeler and Tensioner system, as well as a bespoke overboarding chute design) to be used for stimulation purposes. The TCP Downline and Jumper will connect to a subsea tree injection cap, ready for deployment in 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 bar Water depth: 1500 m Length: 1600 m Qualified # deployment: 225 Completed to date: 0 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 bar Water depth: 2140 m Length: 2500 m Qualified # of deployments: 45 Completed: 45 23

24 NL Head Office Monnickendamkade EC IJmuiden The Netherlands Tel: More information info@airborneoilandgas.com Sales Frits Kronenburg Area Sales Manager Europe f.kronenburg@airborneoilandgas.com Taylor Enze Area Sales Manager North America t.enze@airborneoilandgas.com Wouter Spruijt Area Sales Manager Africa, Middle East, Asia & Australia w.spruijt@airborneoilandgas.com Business Development Jan van der Graaf Business Development Manager Brazil j.vandergraaf@airborneoilandgas.com Peter Aarts Business Development Manager West Africa p.aarts@airborneoilandgas.com

25 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 meters per spool Strategically located in Amsterdam Port Area 25