SiRCoS Submarine pipeline repair system. Carlo Maria Spinelli - Bratislava, September 2008

Transcription

1 SiRCoS Submarine pipeline repair system Carlo Maria Spinelli - Bratislava, September 2008

2 Outline 1 Introduction to subsea pipelines 2 Deep water projects 3 Pipeline damage & scenarios 4 SiRCoS Repair System 5 Conclusion 2

3 1 Introduction to subsea pipeline Thousand kilometres of marine pipelines have been laid in European seas for 30 years; Since the early 70 s, pipeline industry has constantly improved design, materials and techniques for construction, operation; Offshore pipelines have been scoring a remarkable record of safety and reliability; DELIVERY NETWORK North sea network 400 m w.d m w.d m w.d. Blue Stream Pipeline 2200 m w.d. Trans Mediterranean Pipeline Green Stream Pipeline 3

4 1.1 Introduction to subsea pipeline The offshore challenge Difficulty index(depth x OD 2 ) / ref. case Snam Messina crossing as normalizing reference case : 20" OD x 500 m w.d. Snam Messina crossing Trans Mediterranean Pipeline I & II Blue Stream Amoco Aquaba II Europipe II South Stream Galsi Medgaz Green Stream Ormen Lange North Stream BP Mardì Gras Year 4

5 Outline 1 Introduction to subsea pipelines 2 Deep water projects overview 3 Pipeline damage & scenarios 4 SiRCoS Repair System 5 Conclusion 5

6 2 Deep water projects overview New pipelines are being under costruction / evaluation in deep waters; Installation, inspection, maintenance and repairs methods must be improved to face new challenging situations, as example : J and S laying techniques, pipe steel performance, high wall thickness, roundness, isotropy etc. 24 x 300 km depth 2700m km depth 2200m South Stream Pipeline Medgaz Pipeline North Stream Pipeline Galsi Pipeline 24 x 200 km depth 2150m 48 x lenght 1200 km 6

7 2.1 Deep water projects overview Deeper water Longer path Larger diameter m Up to 48 OD km 7

8 Outline 1 Introduction to subsea pipelines 2 Deep water projects overview 3 Pipeline damage & scenarios 4 SiRCoS Repair System 5 Conclusion 8

9 3 Pipeline damage Offshore pipeline operational reliability is high, but : in shallow water vessels may dent or damage pipelines; in deeper water larger vessels may drag anchors, trawl gear are able to bend or move pipelines; internal and external corrosion are potential threats of leaks; Fishing vessel Trawl gears Pipeline 9

10 3.1 Pipeline damage & scenarios Submarine pipelines are operated in a physically and technically harsh environment: objects dropped from vessels can also damage pipelines. When a pipeline damage occurs, partial or overall transportation disruption over a long period might have severe economical consequences : a need has been recognized to develop and put in place a system to make diverless emergency repairs to the pipelines. The incentive for the oil/gas producers is to minimize the expensive downtime of the production systems. 10

11 Outline 1 Introduction to subsea pipelines 2 Deep water projects overview 3 Pipeline damage & scenarios 4 SiRCoS Repair System 5 Conclusion 11

12 4 SiRCoS Repair System SiRCoS Repair System (stands for Sistema Riparazione Condotte Sottomarine): It s a diver less repair system for deep water pipelines developed by Saipem/Sonsub for Eni. It comprises a suit of: equipment, components, tools ready for intervention in case of damage at subsea trunk lines. SiRCoS permanent repair can be obtained by the: - clamp installation on a local damage; - replacement of a pipe section for longer and more severe damages, 12

13 4.1 SiRCoS Repair System Main SirCoS Operational Specifications: Maximum water depth: 2,200 m Maximum seabed slope: 10 transversal, 15 longitudinal (30 for the repair clamp) Sea bottom visibility: close to zero Pipe size: 20 to 32 (larger diameters may be included, too), Pipe material: steel grade up to API 5L X70 equivalent Pipe coating removal: both anticorrosion coat & concrete coating up to 100 mm thick SirCoS fits the most challenging pipeline operative conditions and after the repair the pipeline will remain piggable. 13

14 4.2 SiRCoS Repair System (Movie) 14

15 4.3 SiRCoS Repair System RPCs (Repaired Pipe Components) specific for each pipeline to be permanently installed: - repair clamp for small local damages, - spool pieces to be used for the replacement of pipe sections, - pipe end connectors,. 15

16 4.4 SiRCoS Repair System Common Intervention Equipment (CIE) is the set of equipment and sub-sea Modules to install the Repair Pipe Components. It can be used on more than one pipeline: 1 x Cutting tool, 1 x Installation Module for the End Connector-Forging Tool, 1 x Coating Removal Tool to remove coating and the concrete coat, 4 x H-Frames and jacking clamps to clamp & lift the pipe sections. 1 x Installation Module for the spool piece, 2 x Docking modules, 1 x Acoustic metrology set, 1 x Installation Module for the repair clamps 2 x Isolated Hydraulic Power Units (IHPU) fed by the WROV to control all the previous modules 16

17 4.5 SiRCoS Repair System Connection system Forging Tool. One Forging Tool is necessary to install the End Connectors on each System of Pipelines. End Connector Pipe Forging Tool End Connector & Forging tool Pipe End after cutting C C Water inlet Metal to metal connection Hydro Forging 17

18 4.5 SiRCoS Testing & Certification The engineering phase of the system and mainly the connection device, is fully compliant with the DNV RP F113 Pipeline Subsea Repair. Most of the tests have been planned to verify the load and seal capability of the metal-tometal connection, by : Laboratory tests; Full scale tests on reduced connectors; Shallow water testing. At the end of these steps, SiRCoS repair system has been certified by DNV for the Type Certification 18

19 4.6 SiRCoS Update Clients RPC s built in 2007 for GreenStream 32 OD pipeline RPC s built in 2008 for Medgaz 24 OD pipeline now under testing Repair Service Contract signed by GreenStream in 2008 Negoziation with other pipeline operators in Far East Improvements Blue & South Stream (Sour Service and high walled pipe > 40 mm.) Nord Stream (larger diameter extension ) 19

20 5.1 Conclusion The long lasting commitment of Eni-Saipem/Sonsub in offshore projects since 70 has allowed to design, test, qualify a diverless pipeline repair system. It consists of a set of modular tools, suitable to operate on a wide range of pipelines (20 up to 32 and over). The system requires the support of conventional work class ROVs and vessels, it s maintained to be promptly available within the shortest mobilisation schedule. Eni owns this unique repair technology, certified by Det Norske Veritas during open water tests, SiRCoS is now available to other operators in the form of repair services carried out by Saipem/Sonsub. SiRCoS provides significant advantages to any subsea pipeline operator for which reliable operation management are vital to guarantee the cost effectiveness of its own transportation network. 20

21 Many thanks to all the Saipem/Sonsub division for its strong support in developing this repair system, mainly Sergio Fabbri, co-author and Roberto Brandi. Thank for Your attention. 21