Subsea Challenges in Deep Panuke

14th September 2009

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Agenda

 Overview of Acergy Scope in Deep Panuke project

 Challenges and Solutions
 Environmental conditions
 Highly Corrosive Produced Fluids
 Offshore welding
 Insulation requirements
 Operational Challenges
 SSIV Structure Installation Conditions
 Tie in spool arrangements
 Q&A

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Deep Panuke – Overview and Acergy Scope of Work
Production Field Centre
Production Wells
Disposal Well
8” Clad 825 Flowlines
3” CRA 625 Flowline
22” SSIV & Spools PFC
Control Umbilicals

22” SSIV
8”
8”

8”

8”

3”

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Environmental Conditions

 Environmental conditions

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Environmental Conditions

Water Depth
35-45m
Max Wave
1yr = 18m
10yr = 21m
100yr = 25m

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Environmental Conditions
 Pipeline Stability
 Pipelines are unstable on the
seabed when empty (due to pipe
weight).
 Pipelines shall be flooded during
or immediately after laydown
and trenched thereafter.
 Rock shall be placed on trench
transitions and any areas
requiring buckling mitigation.

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Environmental Conditions
 Spool Stability
 Spools are stabilised by using
concrete mattresses, typically
around 150mm thick for
protection.
 On Deep Panuke, mats have
been proposed as thick as
450mm to increase weight for
stability.
 Expansion spools must be
allowed to expand and are
stabilised by shielding from
environmental loads.

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Highly Corrosive Fluids
 Production fluids
 H2S – 3000ppm
 CO2 – 3.5%
 Design Pressure – 306Barg
 Design Temperature -30degC to 115DegC

 Outwith the capability range for duplex and super-duplex

stainless steels
 Nickel based alloys 825 and 625 selected
 Clad pipe selected to reduce cost
 Metallurgically bonded due to installation method

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Highly Corrosive Fluids
 Disposal fluids
 H2S – 14%
 CO2 – 86%
 Design Pressure – 240Barg
 Design Temperature -20degC to 45DegC

 Outwith the capability range for duplex and super-duplex

stainless steels
 Nickel based alloy 625 selected
 Clad pipe not an option for lower than 4” due to
manufacturing techniques

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Highly Corrosive Fluids

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Offshore Welding

Firing Line, Inspection and Field Joint Coating

Deck Radius Controller
Ramp radius Controller and straightener

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Offshore Welding and ECA

Fully bonded clad required due to

bending process. Unbonded (lined)
pipe would likely wrinkle.

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Offshore Welding
 “Standard” clad pipe design ignores the clad layer for strength
calculations.

 Restricted availability to purchase metallurgically bonded clad

pipe. Only two companies worldwide were identified.

 Due to schedule, JSW in Japan were selected to manufacture

the pipe, but could not supply the required wall thickness.

 Acergy proposed using results from an ongoing DNV study to

use the strength of the clad layer of pipe. This required further
testing and verification of the clad properties and the bond to the
parent metal.

 Positive results from these tests were crucial to the success of

the project.

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Insulation Requirements

 Insulation Requirements
 Pipeline – 4.22 W/m2K
 Spools – 4.05 W/m2K
Clad Layer
• Spools – Alloy 825/625
• Pipeline – Alloy 825

Backing Layer
• Spools - DNV 450 (X65)
• Pipeline – DNV 415 (X60)

Insulation Coating
• Spools – SPU
• Pipeline – 4LPP

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Insulation Requirements
Polyurethane coatings
used for insulation
purposes on tie-in
spools.

This system consists of:

Fusion Bonded Epoxy
300 Microns
Multi layer SPU/GSPU
“unlimited”

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Insulation Requirements

4LPP coating used for pipelines

 Fusion Bonded Epoxy 120 Microns
 Adhesive (Co-polymer) 150 micron
 PP Foam layer < 50 mm
 PP outer layer < 5 mm

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Insulation Requirements

IMPU used for field joint coating

 FBE layer
 IMPU Fill

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Insulation Requirements
 Since the whole pipeline system must meet the minimum
requirements for insulation, all components, including flanges,
must be insulated.

 Flange insulation covers similar to the one below are

proposed.

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SSIV and Structure

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Tie in Arrangement at PFC

 Tie-In Arrangement at PFC is congested

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Tie in Arrangement at PFC

PFC Heading +/- 5 Degrees

+
PFC Tolerance +/- 3m
+
Pipeline Tolerance +/- 3m

Up to 10m variance in some spools

Resolved by increasing leg lengths and green length

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Q&A

 Questions...

… and answers?

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