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Mechanical Lined Pipe - Installation by Reel-Lay Wacek Lipski

Discipline Manager

The New Subsea7 Description of BuBi Mechanical Lined Pipe


R

Agenda

Overview of Reel Lay Installation method Development programme Installation methodology Current Status

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O new b Our beginning

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 b Subsea 7 Methods h d of f Pipelay l

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
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Driver

ItemNo.

Production Material

PipelineDetails Linepipe price OD WT

1 2 3 4 5 6

22Cr 13Cr Lined316L Lined825 Clad316L Clad825

10" 10" 10" 10" 10 10" 10"

14.3mm 12.7mm 12.7mm+3mmliner 12 7mm+3mmliner 12.7mm 11.8mm+3mmclad 11.8mm+3mmclad

1.75 1.5 1.0 2.25 2.25 35 3.5

Material price comparison based on 20 miles length.

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Description of f BuBi Mechanical h l Lined d Pipe

Carbon Steel outer pipe with a Corrosion Resistant Alloy liner Assembled by Hydraulic process

Carbon Steel Outer Pipe

Cladding (Alloy 625 typ.) typ ) Nom 3mm liner


50mm

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Description of f BuBi Mechanical h l Lined d Pipe

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

Example of material options


Cladding 2.4858 / 825 2.4856 / 625 1.4539 / 904L 1.4404 / 316L Rp 0.2 [MPa] 240 276 220 220 Rm [MPa] 500 - 700 690 - 890 520 - 720 520 - 670

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Description of Mechanical Lined Pipe


Pipe Sizes and wall thickness options.

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Construction Process for BuBi Pipe

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Assembly bl Process

Hydraulic expansion press (Schferpresse)


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Reel l Lay Installation ll

Port Isobel Spool Base Gulf of Mexico

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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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Test a No internal l pressure

FE Analysis - wrinkle prediction performed on pipe with no internal pressure. pressure

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Development l Programme

Simulated reeling test rig. Bend Radius 7.5 mtrs. Herriot Watt University Scotland.
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Test a No Internal l Pressure

Wrinkles recorded in line with FE Analysis. y

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Test b With h internal l pressure

FE Analysis - wrinkle prediction performed on pipe with i internal l pressure

No wrinkles measured
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Further h Development l Phase h 2

Testing of different pipe sizes & liner materials Demonstration for low fatigue applications Enhanced FEA

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Testing of fd different ff pipe sizes & liner l materials l

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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Testing of fd different ff pipe sizes & liner l materials l

Depressurisation Test

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Enhanced h d FEA
BUBI PIPE STAGES SHOWING MECHANICAL GRIP FROM 30 BAR PRESSURE DURING REELING

Car rbon steel

Shot blasted carbon steel

Liner Li inserted 6mm gap

liner

Liner expansion at 1200 bar

Coating C i at 240C ~ 40 gap

30 bar for Reeling

Start
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Telescoped

Hydroformed

Coated

Installation

Pipeline Inspection 2000 readings every 20mm along the pipe

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 Testing Strip Test

40M cycles and no failure at 60MPa on 2 post reeled sample.

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Fatigue Testing Full ll S Scale l Resonance Test

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 MANIFOLD ENDCAP

Pig

End Cap

TIEINSHED

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Installation Methodology

PIG MANIFOLD ENDCAP

TIEINSHED

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Installation Methodology

PIG MANIFOLD ENDCAP

TIEINSHED

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Installation Methodology

PIG MANIFOLD ENDCAP

TIEINSHED

Key procedures:
Straightening Trials Offshore tie ins Offshore Emergency Abandonment
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High h Friction Pig Tests


The tests performed to date demonstrated that the high friction pig could be pumped into position and located accurately to the desired position in the pipeline. Leak proof at 4 bar differential pressure (tested over 12 hrs). Consistent launch, running & reversal pressures recorded. p

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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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Development l S Scope 20 2011


Reeling Trials on 12 ins. X65 with Alloy 625 liner. Reeling Trials on 8ins. 8ins X65 with 316l liner

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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Pre Salt S l - Guar G and d Lula l

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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