Fit-Up Solutions – Latest PracticeDenise Smiles

SummaryGood fit-up of pipes – what is it and why it is necessary?

Defining terms – pipe end geometry

Methods for achieving better fit up

Application to SCR and fatigue senstive pipes

Application to flowlines

Conclusions

Pipe end geometry

Pipe End Geometry

Example CalliperMeasurements

(no common datum)

2-D Geometry in Laser

Measurement Data

Choice – Vernier Calliper

If you want this

Use this

Don’t expect to know the pipe shape!

No Diameter

1 193.4

2 193.9

3 194.1

4 193.8

Choice – Laser ToolIf you want to fit pipes together

Use this

Pipe shape is known

Platform Geometry

Riser factsRisers are:

Dynamic structures and hence fatigue sensitiveOne of the most challenging aspects of deepwater developmentFailure would cause pollution problems

Issues the riser has to deal with:WavesCurrents more than 1 knotWinds Hurricane Katrina decreased the expected life of risers that were affected

Critical regions:Flexjoint attachment to floating vesselTouchdown region as riser connects with sea bed

Automatic WeldingAutomatic Welding is used routinely

Better control over parameters improves welding reliablity

HiLo is one of the key factors

Cut-outs are a significant expense

Internal Pipe Joint Mismatch (HiLo)

Internal HiLo mismatch must be less than 0.5 mm

4

End Matching – pick pipe and rotate to fit

Rotate to fitDefinition of the

Rotation Mark location with respect to the Free Pipe (right)

RotationIf pipes are not rotated exactly right

HiLo increases dramatically

Rotation

HiL

o Sweetspot

Examples of pipe fit up software

Bad fit up, shapes do not match

Good fit up, shapes match

Graphical Explanation of reordering requirements

020406080

100

1.5 1 0.7 0.5

Pipe

s Re

quir

ing

Reor

deri

ng (%

)

HiLo Requirement (mm)

OMS Software “Best Possible” FitOMS Fit Up Software provides users with a “best possible” fit up based on a perfect rotation and alignment of a pipe

Perfect alignment and perfect rotation will not be achieved all of the time

The next slide shows how alignment and rotation will affect the HiLo achieved

Flowline SolutionsOMS has created solutions for Flowlines

HiLo tolerances are relaxed compared to SCR’s

Fabrications efficiencies can be highly cost effective

Solutions are designed to be as easy to implement as possible

Results are faster and cheaper production

What to expectA typical flowline project will have fit up requirements of:

Internal HiLo = 1 mm

External HiLo = 2 mm

Such a HiLo requirement would be expected to result in fit up problems in around 5 – 10% of the pipes

Any problem pipes would be recycled back into the firing line sequence at any time

Obtaining a better fit-upIf the HiLo requirement are lowered – i.e. for a more accurate fit up then some changes to the fit up procedure will have to be made

Achieving a lower HiLo becomes harder the lower the HiLo requirement

Even small HiLo reductions can result in many more pipes that need reordering

Larger reductions will result in all pipes needing to be reordered

Implementation

Loader - empty

Pipe Yard

Pipe stacks contain measured pipes awaiting welding

Software used here

Unloading rack

Firing Line

Beveling shed

Ready rack

Welding Stations and AUT etc

Sorting rack or ‘buffer area’ in the pipe yard

Software used when pipes are pulled from stack

Pipes are rolled out on the sorting rack and checked

All pipes delivered to firing line can be usedin sequence

Loader - full

Sorting rack / buffer area

SummaryManagement of fit up can be achieved for any HiLo ID (0.5 mm to 1.0 mm) or OD (1-3 mm)

Problem fit-ups that would normally slow production can be managed so that they rarely occur

Cost savings generally pay for the solution

OMS have a range of solutions that enable any firing line fit up scenario to be improved

Case Study No 1. 20” UOE SCR for Gulf of Mexico, SLAY – Shell Amberjack/Allseas

Critical pipe lay for project

0.5 mm HiLo requirements

UOE pipe with significant peaking, shape and size variations

Failed attempt by calliper measurements

Requirement to develop solution with Shell

1 SCR, 1 Spare SCR and contingency planning

Measurement of pipes

Pipes measured in New Iberia

Marks on pipe from failed attempt to measure using calipers

UOE Shape problems

UOE pipes often have peaking problems near long seam

This makes it difficult for these pipes to be fitted together

MethodologyArrange pipes in sequence provided by OMS

Mark one end of each pipe with the rotation datum mark

When welding pipes rotate new pipe to align datum with long seam of the existing pipe

Spacer to align

Check HiLo is within specification and weld

Small 20 mm sections allowed to have 0.7 mm HiLo

Marking datum and rotating to fit

System proven during pipe layPipes were welded into double joints then put into Main Line for SLaying

All HiLo’s were found to be in specified tolerance of 0.5 mm for fatigue critical sections and 0.7 mm for small regions around the girth of the pipe

Inspector observed that fit-ups were so good that the pipes were brought together and needed no adjustment before welding

Conclusion – Case study 1

Difficult SCR was built to specification

All pipes welded in sequence without requirement for any contingency pipe to be used

All fit ups within the HiLo requirement

Project manager stated that he would repeat the methodology the next time

Case Study No 2. 8” and 10” Seamless Pipe for spoolbase welding

1 x 8” SCR

1 x 10” SCR

Cold end sized pipes

No counterboring

HiLo to be achieved by:Specific architecture (matching ends)

Rotation of pipes (to best fit angle)

Specific Pipe OrderingPipes are put together in a specificorder to create the SCR architecture

A significant improvement in FitUp is achieved by this specific odering of the pipes

Client reported excellent fit up of pipes for this project

Fit up table provided to client

Joint Num

ber

Weld N

umber

Pipe Fixed (m

m)

Pipe Free (mm

)

ID M

ax Hi/Lo

(mm

)

SCR ID M

in H

i/Lo (mm

)

ID Rotation (m

m)

OD

Max H

i/Lo (m

m)

OD

Min H

i/Lo (m

m)

Negative

Rotation Tolerance (m

m)

Positive Rotation

Tolerance (mm

)

1 ATP-GR3.01 03025_A 03023_A 0.76 0.21 106 0.93 0.39 -26 332 ATP-GR3.02 03023_B 01022_B 0.37 0.37 118 0.86 0.53 N/A N/A3 ATP-GR3.03 01022_A 01005_A 0.57 0.15 -267 0.61 0.37 -37 294 ATP-GR3.04 01005_B 01148_B 0.61 0.13 172 0.64 0.38 -30 365 ATP-GR3.05 01148_A 01064_A 0.89 0.15 -87 0.74 0.18 -23 166 ATP-GR3.06 01064_B 01204_A 0.78 0.14 -154 0.53 0.36 -24 167 ATP-GR3.07 01204_B 01207_A 0.68 0.17 -236 0.71 0.30 -13 108 ATP-GR3.08 01207_B 01239_B 0.75 0.18 158 0.76 0.40 -21 159 ATP-GR3.09 01239_A 01303_B 0.98 0.18 -249 0.84 0.46 -26 17

10 ATP-GR3.10 01303_A 01224_A 0.82 0.16 314 1.05 0.44 -15 911 ATP-GR3.11 01224_B 01234_A 0.93 0.16 -186 0.64 0.22 -13 1012 ATP-GR3.12 01234_B 01231_B 0.87 0.20 172 0.85 0.43 -10 1313 ATP-GR3.13 01231_A 01320_B 0.99 0.16 156 0.67 0.26 -14 914 ATP-GR3.14 01320_A 01449_A 0.75 0.16 192 0.73 0.38 -20 1415 ATP-GR3.15 01449_B 01297_A 0.89 0.13 -7 0.53 0.30 -10 14

Conclusions – Case Study 2Efficient measurement of pipes

Cold end sized pipes give good fit up but not good enough for SCR

Rotation gave better fit but still not good enough

Unique string build gave best result

SCR build successfully and efficiently

Case Study No 3. Seamless pipe in Brasil, Spoolbase BC10/TU/P56 – Petrobras/Subsea7

Requirement for ID HiLo of 1.0 mm and OD HiLo of 2.0 mm

Pipes measured offline

Pipes loaded onto sorting rack

Sequencing of pipes in software

Pipes put into ready rack for firing line in sequence and with rotation datums marked

Measurement

Pipes are delivered to racks for OMS to measure

Operating the system on the spoolbase

Pipe sorting Sequenced pipes

OMS Tried and Tested SolutionRotation of pipes to find the best ID and OD fit provides a huge benefit in the firing line

The majority of pipes can be used directly

Problem pipes are identified before fit-up at the welding station

A method of dealing with problem fit ups can be implemented in various locations (examples are provided below)

The impact on logistics/pipe handling is minimal

Benefits are very significant, due to avoidance of fit-up issues and avoiding disruption due to removal of bad pipes at a welding station or underaking remedial work in the firing line

Conclusions – Case study 3Most pipes can be welded directly (using rotation)

A small proportion need to be held back or diverted

There are several schemes to achieve this

OMS will endeavour to find the optimal solution for client in terms of:

Minimised Logistics

Ease of implementation in a given yard/spoolbase scenario

Lowest cost/effort in fabricating the strings/stalks overall

Overall ConclusionsDeliver solutions that achieve the best possible fit-up of pipes for client – flowline or SCR

Philosophy:

Measure + Analysis or Visualisation Software = Best Fit-up via End Matching or Counterboring

Solution can be tailored to meet client needs

Best fit-up solution using true pipe geometry

Minimise overall logistics to achieve best result

Up-front management of problems

Packages includes operators or operator training