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Discipline Manager
Agenda
Overview of Reel Lay Installation method Development programme Installation methodology Current Status
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A combination of Acergy and Subsea 7, two very strong subsea companies, companies that have come together to create a global leader in seabed-to-surface engineering, construction and services.
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S-lay
Reeling
J-lay CDTM
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S b Subsea 7 Asia & Middle ddl East Pipelay l C Capability bl S-lay & J-lay of pipelines in Asia & Middle East is through our Joint Venture Company, Company SapuraAcergy and the Sapura 3000: 240 Tonnes S-lay 400 Tonnes J-lay First deep water project in Malaysia (S-lay) Murphy Kikeh Work ongoing on second deep water project (S-lay and Jlay) Shell Gumusut Kakap lay),
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Driver BuBi Mechanical Lined Pipe is a cost effective solution where CRA materials are required Proven track record for S-lay, Jlay and CDTM Extending the applicability to Reeling will have a positive impact on the economic viability of some offshore ff h development d l t projects j t
R
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Driver
ItemNo.
Production Material
1 2 3 4 5 6
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Carbon Steel outer pipe with a Corrosion Resistant Alloy liner Assembled by Hydraulic process
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Material options
Carbon Steel API X52 API X60 API X65 API X70 Rp 0.2 [MPa] 360 415 450 485 Rm [MPa] 460 520 535 570
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Assembly bl Process
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Development l Programme
Objective: Demonstrate that installation by Reel Lay will not wrinkle the pipe or have an unacceptable impact on the mechanical or corrosion resistance properties required for its intended service. Phase 1 Test a Simulated reeling trials of pipes without internal pressure. Test b Simulated reeling trials of pipes with internal pressure 10i 10ins.Dia, Di X65 outer t pipe15.09 i 15 09 + 3mm 3 Alloy All 825 liner li
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Development l Programme
Simulated reeling test rig. Bend Radius 7.5 mtrs. Herriot Watt University Scotland.
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No wrinkles measured
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Testing of different pipe sizes & liner materials Demonstration for low fatigue applications Enhanced FEA
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Phase 2 2010 Scope ( completed) Simulated Reeling trials with internal pressure 8 ins dia. X65,Alloy 625 & 316l (no girth weld) Depressurisation Test Fatigue Testing Strip & Full scale DNV Qualification DNV RP A203
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Depressurisation Test
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Enhanced h d FEA
BUBI PIPE STAGES SHOWING MECHANICAL GRIP FROM 30 BAR PRESSURE DURING REELING
liner
Start
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Telescoped
Hydroformed
Coated
Installation
Bore measurements taken to record any change during o/a process and provide inputs to FE model. On Manufacture at Butting Prior to simulated reeling Following Simulated reeling Post fatigue testing
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Fatigue test was taken to a stress/no. of cycles as per the DNV 30.2 F1 Curve Stress range, MPa 180 120 60 Design life (F1), cycles 85,740 289,372 2 314 975 2,314,975 Target life (F1), cycles 293,424 990,307 7 922 458 7,922,458
All samples showed no defects which could be attributed to the fatigue testing NDE (AUT (AUT, X-ray X and dD Dye Penetrant P t t testing) t ti ) and d Sectioning S ti i was performed f dt to confirm fi i integrity t it of the clad weld to liner interface
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Testing
Dye- penetrant testing to check for defects on liner longitudinal, overlay and Girth welds. X-ray of longitudinal, seam and girth welds. Tensile test of both materials. Charpy V notched impact tests at -30oC on the carbon steel Hardness testing on X65 and the Alloy 625 Metallographic examination of the seal weld area G48 Corrosion tests carried out at 50oC 50oC, on Alloy 625 liner G28 Intergranular corrosion (Method A)
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Installation ll Methodology h d l
Key objective: Maintaining internal pressure during the stalk reeling onto the vessel and installation.
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Installation Methodology
Pig
End Cap
TIEINSHED
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Installation Methodology
TIEINSHED
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Installation Methodology
TIEINSHED
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Installation Methodology
TIEINSHED
Key procedures:
Straightening Trials Offshore tie ins Offshore Emergency Abandonment
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S f Safety
Risk assessment performed using the Shell software FRED (Fire, Release, E l i Explosion and d Di Dispersion). i )
All personnel l within ithi 10m 10 of f the th reel, l either ith deck d k level l l or at t height, h i ht should h ld wear normal suitable eye protection and safety clothing.
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DnV Qualification Q lf
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Full Scale fatigue testing on 8ins. X65 with Alloy 625 liner. Reeling Trials on 12 ins. X80 with Alloy 625 liner.
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Submerged Buoy
70+ km of BuBi Mechanical Lined Pipe to be installed in approx. 2100 mtrs. Water depth
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C Conclusions l Tests to date demonstrate no wrinkling occurs when reeling is performed with internal pressure. pressure Installation of mechanical lined pipe by Reel Lay is achievable, safe and will offer significant economic advantages. Q DNV Qualified First p project j awarded
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