canusa-cps offshore evolution & lessons learned … · offshore evolution & lessons learned...
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Canusa-CPS
Offshore Evolution & Lessons Learned
Upstream Conference & Exhibition
Bucharest
Thursday 23rd April, 2015
Dan Pearson – Area Manager Onshore Western & Central Europe
Ten Business Units
2
Bredero Shaw Coatings
- corrosion protection - insulation - weight / protective - internal flow efficiency
Desert NDT
Flexpipe Flexible composite
pipe for: - oil and natural gas
gathering lines - oilfield water and
fluids
PIPELINE & PIPE SERVICES
DSG-Canusa
Heat shrink tubing for sealing and protection
ShawFlex
Control, instrumentation cable
PETROCHEMICAL & INDUSTRIAL
Canusa-CPS
Weld inspection - Radiographic - Ultrasonic - Offshore and
onshore
Shaw Pipeline Services
Joint protection Pipe coating
materials
Socotherm Coatings
- corrosion protection - weight / protective - thermal insulation
Guardian • Drill pipe/tubular
inspection • Inventory
management services
Integrity Management
Weld inspection - Radiographic - Ultrasonic
Evolution of offshore pipeline projects
Offshore Innovations
2001-2: Blue Stream Project 10-24" OD x 15,000 joints Introduction of GTS-PP Onshore Sections & Compressor Station
Blue Stream
GTS-PP Heat Shrink Sleeve System
Offshore Innovations
2001-2: Blue Stream Project 10-24" OD x 15,000 joints Introduction of GTS-PP Onshore Sections & Compressor Station
2002-3: Green Stream Project > 600 km x 32" OD GTS-PP in S-Lay Saipem Castoro Sei
Green Stream
Offshore Innovations
2001-2: Blue Stream Project 10-24" OD x 15,000 joints Introduction of GTS-PP Onshore Sections & Compressor Station
2002-3: Green Stream Project > 600 km x 32" OD GTS-PP in S-Lay Saipem Castoro Sei
2004-6: Langeled Project 1,200 km x 42-44" OD Acergy Piper & Allseas Solitaire
Offshore Innovations
2001-2: Blue Stream Project 10-24" OD x 15,000 joints Introduction of GTS-PP Onshore Sections & Compressor Station
2002-3: Green Stream Project > 600 km x 32" OD GTS-PP in S-Lay Saipem Castoro Sei
2004-6: Langeled Project 1,200 km x 42-44" OD Acergy Piper & Allseas Solitaire
2006-8: Dolphin Project 160 km x 36" & 480 km x 48" OD Induction Heating Saipem Castoro Sei and Castoro 2
Dolphin
Induction Heating Generators & Coils
Offshore Innovations
2001-2: Blue Stream Project 10-24" OD x 15,000 joints Introduction of GTS-PP Onshore Sections & Compressor Station
2002-3: Green Stream Project > 600 km x 32" OD GTS-PP in S-Lay Saipem Castoro Sei
2004-6: Langeled Project 1,200 km x 42-44" OD Acergy Piper & Allseas Solitaire
2006-8: Dolphin Project 160 km x 36" & 480 km x 48" OD Induction Heating Saipem Castoro Sei and Castoro 2
2007-9: Medgaz Project 207 km x 24" OD Semi-Automated GTS-PP (6.0 mm Thickness) Saipem Castoro Sei & S-7000
Medgaz
Custom edge-reduced sleeve design
Chamfered overlap and underlap seams
Thick central sleeve area
Medgaz
Automated Sleeve Welders
Manual Sleeve Welders
Conditioning Ovens
Sleeve Spacer Tools
Offshore Innovations
2001-2: Blue Stream Project 10-24" OD x 15,000 joints Introduction of GTS-PP Onshore Sections & Compressor Station
2002-3: Green Stream Project > 600 km x 32" OD GTS-PP in S-Lay Saipem Castoro Sei
2004-6: Langeled Project 1,200 km x 42-44" OD Acergy Piper & Allseas Solitaire
2006-8: Dolphin Project 160 km x 36" & 480 km x 48" OD Induction Heating Saipem Castoro Sei and Castoro 2
2007-9: Medgaz Project 207 km x 24" OD Semi-Automated GTS-PP (6.0 mm Thickness) Saipem Castoro Sei & S-7000
2009-11: Nord Stream Project 2,400 km x 48" OD Saipem Castoro Sei & Allseas Solitaire
Nord Stream
Offshore Innovations
2001-2: Blue Stream Project 10-24" OD x 15,000 joints Introduction of GTS-PP Onshore Sections & Compressor Station
2002-3: Green Stream Project > 600 km x 32" OD GTS-PP in S-Lay Saipem Castoro Sei
2004-6: Langeled Project 1,200 km x 42-44" OD Acergy Piper & Allseas Solitaire
2006-8: Dolphin Project 160 km x 36" & 480 km x 48" OD Induction Heating Saipem Castoro Sei and Castoro 2
2007-9: Medgaz Project 207 km x 24" OD Semi-Automated GTS-PP (6.0 mm Thickness) Saipem Castoro Sei & S-7000
2009-11: Nord Stream Project 2,400 km x 48" OD Saipem Castoro Sei & Allseas Solitaire
South Stream Project
*Adapted from Peritus International Ltd. Engineering Paper, February 23-24, 2011
Difficulty Index for Deepwater Pipelay Projects
Tupi (2,130 m - S)Medgaz (2,152 m - J/S)
Galsi (2,822 m - J/S)
Blue Stream(2,150 m - J/S)
South Stream(2,000 m - J/S)
Walker Ridge (2,175 m - J/S)
Urugua (1,360 m - J/S)
USAN (850 m - S)
Greater Plutonio(1,500 m - J)
Langeled (400 m - S) Nord Stream (210 m - S)
Green Stream(1,200 m - S)
Liwan (1,500 m - J/S)
0
500
1000
1500
2000
2500
3000
1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 2025Year
Wat
er D
epth
x Pi
pe D
iamet
er
Offshore Pipeline Trend
Lessons Learned
General FJC Design
3 layer systems for 3 layer mainline coatings
FJC Selected to Match Performance, Temperature, Service Selected for MLC – PP HSS for 3LPP – PE HSS for 3LPE – Liquid Epoxy for FBE
{Mirrors the mainline coating
PE/PP Mainline Coating Sealant
FBE Primer
Steel Pipe
Weld Bead
Cross Linked PE/PP Backing
3 mm thick Adhesive
Epoxy Primer
General FJC Design
Force cured liquid epoxy – Same properties and thickness required as for the FBE layer of the mainline
3LPE / 3LPP coating – Uniform coating thickness, always > 100 μm, and 200-300 μm recommended
for maximum resistance to cathodic disbondment (especially at high temperatures)
– Allows pre-inspection of primary anti-corrosion layer prior to HSS application – Ensures DFT is maintained after application with no displacement during
application of outer coating layer – Ensures full cure of LE layer in applied FJC system prior to leaving the vessel
Pre-manufactured materials produced in ISO certified factories – no field chemistry
Specialized formulations to match mainline coating specifications
General FJC Design
Single wrap products in mainline coating thicknesses
Profiled / customized FJC solutions allowing for reduced FJC thickness at overlaps onto mainline coating – Faster installation times / faster contact with pre-heated mainline coating to promote
optimal conditions for fusion – Reduce potential for mainline coating disbondment at cutback edges by overheating
Custom edge-
reduced sleeve design
Chamfered overlap
and underlap
seams
Thick central sleeve area
Design of FJC Specifications
Differences between Industry, Project & Company Specifications
ISO 21809-3 is only a starting point – not a replacement for a Project or End-User specification – Not enough to simply state in a spec that Field Joint Coatings must comply with ISO
21809-3 – As stated in Clause 6.1,
– “designer needs to select the appropriate field joint coating from those available in the Standard based on parent coating compatibility, line pipe construction, location and operating conditions.”
– Goal should always be to create joint coating with equivalent performance (and with full compatibility) to the factory applied coating to avoid any compromise in pipeline integrity
– End Users must be active in defining the standard they require – End Users must take responsibility to define required standard and open up or
narrow down the choice available as appropriate to the circumstances – The Standard can be used as a tool to bring the various elements of the supply
chain together
Design of FJC Specifications
Mainline coating, temperature, mechanical properties, anti-corrosion properties, design life, service conditions, construction conditions, special performance criteria, track record, total installed cost, etc. should all be considered
FJC should be selected to match performance of mainline pipe coating – No need to downgrade coating specifications at the field joint – Products/systems now available from numerous suppliers
Design of FJC Specifications
Coordination required between mainline coating and FJC specifications
PQT’s / PPT’s performed with production intent products and equipment – Project pipe OD(s) – Production cycle times – Specialized testing for pipeline construction – bending, roller box,
friction clamps – Simulated service testing – now more readily available
– Include in deepwater qualification programs as mandatory to demonstrate suitability of coatings for the intended deepwater service at design conditions
Design of FJC Specifications
Example of Pre-Qualification Testing involving; - Application of materials onto project pipe using project equipment
- Simulation of quenching and roller box testing within same process
Advanced Products
3LPP Coating Requirements
Test / Property Factory Coating NFA 49-711
Factory Coating DIN 30678
GTS-PP System Specifications
Adhesion to Steel @ Ambient Temperature ≥ 250N/cm ≥ 100N/cm
@ 50°C > 250N/cm
Adhesion to Steel @ Max. Operating Temperature
≥ 80N/cm @ 110°C
≥ 80N/cm @ 90°C
> 80N/cm @ 110°C
Adhesion to 3LPP @ Ambient Temperature N/A N/A Fused
Impact Resistance (Pass Holiday Test) ≥ 10J/mm ≥ 5J/mm
30 Impacts > 10J/mm
Indentation Resistance ≤ 0.1mm @ 23°C ≤ 0.4mm @ 110°C ≤ 0.3mm @ 90°C < 0.1mm @ 23°C
< 0.4mm @ 110°C
Industry Best Practices – Application
Surface preparation – abrasive blasting (mandatory) – Ensure clean, well prepared surface for optimal coating adhesion & performance
Induction heating (mandatory) – Uniform heating across width & around circumference of joint – Penetrating heat for lasting effect – Controlled & repeatable heating process with faster heating times – Indirect heating of MLC overlap area prevents damage & bonding issues
Industry Best Practices – Application
Cycle time optimization – Conditioning ovens
– Pre-heat FJC materials prior to application
– Ensures consistent starting point for application
– Reduces application time
– Tube welding – Enables the production of tubular
field joint coating system prior to application on the joint, during other application steps
– Potential to save 45-60 s from the critical FJC application path
Field Joint Coating Services
Field services / supervision / support should be supplied by FJC materials manufacturer as a condition of supply – Operator training & accreditation
– Training completed with same products, application equipment and for project specific conditions
– Validity of training limited to project or 1 year from issue – Equipment set-up
– Ensure optimal set-up of coating stations and equipment for coating quality, health and safety and application speed
– Process optimization – Supervision during construction
– Higher expectations to ensure quality and achievement of intended design life
– Support Contractor QA programs
Approach is next best alternative to automation
Industry Best Practices – Application
Automated application – Automated systems now available for partial / full application of the field
joint coating – Faster and more consistent installation times producing best-in-class
application quality with guaranteed productivity
- 36”OD System