Infill Liner Pipeline

8/22/2019 New infield pipeline liner offers effective rehab option | Offshore Magazine
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New in eld pipeline liner o ers e ective rehab option

Jul 17th, 2014
The main Samarang

complex offshore
Malaysia, operated by
Petronas Carigali, was
one site where the new
in eld liner was
deployed.
Petronas deploys new system to preserve integrity of subsea lines
Robert Walters
Anticorrosion Protective Systems
A new liner comprised of thermoplastic uoropolymers, polyurethanes, and Kevlar is available to the offshore
pipeline market, and has been successfully deployed by Petronas Carigali (PCSB) on some of its subsea pipelines in
the South China Sea.
https://www.offshore-mag.com/home/article/16804625/new-infield-pipeline-liner-offers-effective-rehab-option 1/12
Adapted from a liner originally developed for the onshore utility pipeline market, the new in eld liner product is
being developed for the offshore pipeline market by Anticorrosion Protective Systems (APS), a pipeline rehabilitation
specialist engineering and contracting company.
Designed for harsh application pipelines, the deployment of these in eld liners has enabled Petronas Carigali to re-
commission several offshore pipelines that were shut down due to corrosion-related deterioration.
Battling internal corrosion
PCSB owns and operates an extensive network of subsea pipelines offshore Malaysia, in the South China Sea. Many
of these pipelines are between several hundred meters to several kilometers in length, are in varying water depths
and run from platform to platform, and from platform to onshore facilities.
Internal corrosion, due largely to sulfate reducing bacteria (SRB), can shorten pipeline life. Historically, this results in
the need to replace such pipelines as often as in four years.
These types of relatively short lifecycles and frequent replacements represent substantial capex for PCSB. To reduce
these costs and to extend pipeline life, the company began to support the development of in-situ corrosion barriers
that could be successfully deployed for use in new and existing pipelines.
Historically, there has not been a viable way to install such a corrosion barrier within a subsea pipeline. But, PCSB's
need to preserve and enhance the integrity of its offshore pipeline network led to the design and development of the
in eld liners (IFL) project.
IFL development project
The project began in April 2011 under the joint management of Petronas and APS. The project team delivered a
market-ready product within two-years.
The goal of the project was to develop materials and technologies necessary to successfully install plastic liners into
existing and new subsea carbon steel pipelines that convey corrosive hydrocarbon media, where SRB is one of the
principal sources of corrosion. The IFL liner protects the internal pipe bore from corrosion and offers a secondary
containment capability in the event of a rupture or damage to the outer steel pipeline.
The project started by testing an existing nominal 8-in. Kevlar reinforced plastic liner product, produced and
manufactured by Raedlinger, Germany, for the utility market. Although this material had not been used to line subsea
pipeline, the general liner matrix demonstrated many of the physical attributes necessary for success in such
applications:
• High tensile and good physical properties
• Moderate chemical resistance
• A high degree of exibility
• Ability to be manufactured and spooled in long lengths.
Liner quali cation and development
The quali cation of the liner was undertaken in accordance with the API Recommended 15S "Quali cation of
Spoolable Reinforced Plastic Line Pipe" ( rst edition March 2006), with further reference to the applicable ASTM test
standards, API 17 series, and NACE standards. Testing and quali cation were done in a number of locations including
Germany, Norway, and the UAE.
The nal enhanced IFL liner matrix is comprised of a Solvay Solexis PVDF (polyvinylidene di uoride) inner liner, a
tightly woven aramid core using Dupont Kevlar fabric, with an outer layer of abrasive-resistant thermoplastic
polyurethane from BASF. Other versions of the liner are available for less aggressive service conditions, such as water
reinjection and gas transmission.
All the principal objectives of the project were ful lled. A new, enhanced version of the IFL liner has been developed.
Performance testing has completely justi ed the use of IFL in aggressive, hot, sour hydrocarbon service conditions of
up to 120 ˚C (248 ˚F), with IFL liners exhibiting a stand-alone burst capability of up to 120 bar (1,740 psi).
Industry motivation
Most subsea pipelines are carbon steel installed by laybarge, during which single or double random joints of steel
pipe are welded together on the deck of the barge and laid onto the seabed. After completion of welding, crews on
the barge can "make-up" the external corrosion protection and "in ll" the missing concrete protection. It is not
possible, however, to "make-up" any damage that may be caused to any internal coating when welding, or "in ll" any
cut-back to the internal coating needed to facilitate the steel weld. As a result, it is common for most subsea
pipelines to be laid without an internal coating and without an additional wall thickness of sacri cial steel, which
could compensate for the calculated rate of corrosion throughout the design life of the pipeline.
(Left) Crew prepares to launch the spooled liner. (Right) Crew

oversees placement of liner on offshore vessel. (Below) Liner is
received at wellhead.
Unfortunately, corrosion is rarely a linear phenomenon, and certain types of corrosion can cause damage to the pipe
wall faster than is predicted in the design. Pitting, grooving, cracking, or crevicing to the interior pipeline wall can
occur in a remarkably short period of time. For instance, a pipeline installed with a 20-year design life may
experience failure after as little as four years in service.
IFL offers a fast, economical option to new-lay pipeline replacement. It can be used to rehabilitate an existing subsea
pipeline where:
• It is desirable to extend the service life of the pipeline beyond the period of operation on the original design
• Unforeseen operational parameters, such as CO2 or SRB corrosion, have caused the pipeline to reach the end of its
useful life ahead of schedule. The pipeline may or may not have at that point already been shut-down and abandoned
for safety and/or environmental reasons
• Routine inspection of the pipeline has shown greater than anticipated corrosion. Unless corrosion is arrested, the
pipeline will fail at a predictable point in the future earlier than the design life
• In instances where pipelines have been decommissioned or abandoned due to integrity related issues.
Overall, pipeline liner lengths depend on the pipeline diameter, con guration, and number of short radius bends.
However, trials indicate that the rehabilitation of a typical 6- or 8-in. diameter hydrocarbon owlines could be
feasible over distances of up to 10 km (6.2 mi).
Crew in ates liner after

installation.
Replacing a pipeline and abandoning/removing the old one usually represents a major engineering, procurement
and installation campaign, and an equally major capital expense.
The insertion of an IFL liner into a defective pipeline is a process of lesser magnitude in terms of planning,
implementation, and expense. In terms of project turn-around, IFL might be able to achieve in weeks what may
otherwise take years with conventional pipelay replacement, especially if the necessary pipelay barges for
conventional laybarge are not available in the region.
IFL installation procedure
A thorough inspection of the existing subsea pipeline prior to the detailed planning of any IFL liner rehabilitation
project is mandatory, as is the collation of all data relative to the prevailing operating parameters and conditions.
Inspections can be by intelligent pigs or other external remote inspection tools such as the MTM Aqua.
This data is used to assess the general condition and remaining wall thickness of the pipeline, and to verify the IFL
liner size requirements in the event that an enhanced tight- t, high-pressure liner is required.
Prior to offshore deployment of the marine spread, the host pipeline must be decommissioned, cleaned, and gauged
ready for the liner insertion.
The IFL liner material, although manufactured in a circular pro le, can be temporarily attened for transportation,
and reeled onto a transportation drums sized to t a conventional shipping containers. Each drum can be loaded
with up to 5 km (3 mi) of IFL liner, depending on the liner diameter. These drums are then shipped to an onshore
location within the destination country, usually a marine supply base, where they are further processed into a folded
liner format prior to being sent offshore for installation.
The IFL liner installation is fast, reaching speeds of approximately 10 m/min (32.8 ft/min), inserting a typical 2-km
(1.2-mi) liner in no more than 3.5 hrs.
The IFL liner drum is, wherever practical, positioned on the offshore platform structure, or when necessary, on the
deck of a work boat so the liner can be unspooled.
A feeder cable is red through the pipeline during the nal cleaning and gauging procedure, and this is used to pull
back an installation winch cable through liner for connection to a towing head, which is located on the leading end of
the liner.
During the engineering phase of a rehabilitation project, the speci c winching loads necessary for the liner insertion
are analyzed using the proprietary predictive IFL software. The winch packs used for the actual installation process
are equipped with load cells and over-ride devices so in the event of greater than predicted load during the
winching, the operator is alerted. In such a case, the devices can automatically cut out at a given load if the
engineered safety factor relative to the liner yield strength is approached. In reality, for most liner insertion
situations in the 0.5- to 5-km (0.3 to 3.1 mi) range, the insertion forces are no more than one-tenth of the liner
tensile yield strength.
Prior to the liner installation, the IFL end termination coupling devices are installed at the riser ange locations.
Once the IFL liner is drawn through the entire pipeline length, it is re-rounded by lling with either air or water. The
liner, manufactured to the same diameter as the host pipeline bore, then expands to form an intimate t with the
inner wall of the host pipe.
With the liner fully re-rounded against the wall of the host pipeline, the last task is to install the end termination
inserts. These ensure reliable compression seals and restraint at the liner ends. The re-lined pipeline can then be
hydrotested conventionally and all topsides pipe work can be reconnected. After that, the pipeline is ready for re-
commissioning and for its new, extended life of operation.
The future
The IFL development project has delivered to Petronas a viable alternative way to replace deteriorated offshore
pipelines.
Following the successful conclusion of the IFL development, APS has installed several in eld liners for the Petronas
subsea pipeline network in Malaysia, whereby re-commissioning of previously shut-down pipelines was enabled in
summer 2013.
Petronas favors the option of pipeline rehabilitation over that of new-lay pipeline replacement, and in so doing, will
drastically reduce its offshore opex.
The author
Robert Walters is the IFL Global Project Director and Chairman of APS.
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8/22/2019 New infield pipeline liner offers effective rehab option | Offshore Magazine

New in eld pipeline liner o ers e ective rehab option

The main Samarang

Petronas deploys new system to preserve integrity of subsea lines

Battling internal corrosion

IFL development project

• High tensile and good physical properties

• Moderate chemical resistance

• A high degree of exibility

• Ability to be manufactured and spooled in long lengths.

Liner quali cation and development

(Left) Crew prepares to launch the spooled liner. (Right) Crew

Crew in ates liner after

IFL installation procedure

Drilling & Completion

Drilling & Completion

Drilling & Completion

Drilling & Completion

Drilling & Completion

Drilling & Completion

Drilling & Completion

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© 2019 Endeavor Business Media, LLC. All rights reserved.

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