main technical solutions for the nord stream 2 gas
TRANSCRIPT
Main Technical Solutions for the Nord Stream 2 Gas Pipeline Offshore SectionEuropean Business Congress Vienna, May 26, 2017. Sergey Serdyukov, Chief Technical Officer of Nord Stream 2 AG
Nord Stream 2 AG 2
Nord Stream 2 gas pipeline is an immediate successor of the first successfully implemented twin pipeline system.> Also, directly connects the major gas reserves of Russia
with the EU gas markets.> Also, ensures reliable and efficient route of supplying
over 12% of the EU cumulative demand in natural gas (478 bln m3 in 2012).
> Also, comprises 2 parallel gas lines 48 inches measuring ca. 1220 km in length each.
> Also, environmentally impeccable both in materials composition and installation method.
> Also, bypasses all known zones of sunk chemical weapons of the 2nd World War.
Improved clone of the Nord Stream gas pipeline system
Nord Stream 2 AG 3
There have been three stages of research work for the Nord Stream 2 project, which began in 2012:> Stage I - Evaluation of the
Corridor to the North of St. Petersburg
> Stage II – Choosing a Landfall on the Southern Coast of the Gulf of Finland
> Stage III – Evaluating Landfall Options in the Kingisepp District
Selecting the route in Russia
Nord Stream 2 AG 4
Nord Stream 2 pipeline: facilities & infrastructure
Pig-Traparea(PipelineServiceFacilities)
CompressorStation
Unified GasSupply System
NEL
GasReceivingTerminal
Nord Stream 2 Pipeline
Associated Facilities
Infrastructure Not Associated with NSP2 Project
FeederLine
EUGAALL
NSP2
Pig-Traparea(PipelineServiceFacilities)
Nord Stream 2 AG 5
Main design factors: max. diameter of the offshore gas pipeline – 48”, length – 1220 km, and maximum pressure 220 bar.Additional conditions:> Both lines are to be constructed in parallel with a completion deadline in 2019.> No compressor station on the German Landfall (recreational area).> Final temperature of Nord Stream 2 – according to 2К criteria (2 degrees less than T of the seabed).> Three-sectional design with operating pressure 220-200-170 bar respectively.> Burying of the pipeline into the seabed in navigation areas at the 1 m depth.> No blasting operations for seabed leveling.> Stability of gas pipelines during wreck of any known type of civil vessels.> Highest reliability criteria SIL 3 with fault level 1х10 to minus 5 cases per 100 km per year shouldbe ensured.> Intra-day supply schedule of 0-50-100 % should beensured.> Internal intelligent pigging with pigs 7 meter long and weight 10 tons should be ensured – in order to guarantee permanent internal diameter of 1153 mm.
What is the basis of the main design solutions?
Nord Stream 2 AG 6
1. Selection of 48” pipeline diameter (Internal diameter = 1153 mm) –max. offshore size – creates strict requirements for pipe material tobe selected.
2. The most critical pipe material parameter – strong resilience, i.e.required steel should have ratio: σ yield strength/ σ tensile strength <0.92.
3. World leading steel manufacturers spent from 10 to 18 months to create such steel (First Alpine, Europipe, Nippon Steel, Sumitomo, JFE, Severstal, NLMK, ММК).
4. Х-80 steel promoted by leading pipe manufacturers can not inprincipal ensure compliance with this requirement.
5. Offshore is an area for Х-70 steel to be used, this is where provensolutions are to be implemented!
Pipe material: why Х70 steel should be used?
Nord Stream 2 AG 7
There are three types of pipe coating:> Internal epoxy antifriction coating with design roughness
less than 6 μm.> External three layer anti-corrosion epoxy-polyethelene
coating (4.2 mm).> Concrete weight coating to ensure stability on the seabed
(60 -110 mm).
Reliability of protective coating of the gas pipeline
> Use of state-of-the art chemical technologies forthe Nord Stream project has allowed to achieve 1.8μm roughness
> Use of JCO method for pipe bending has allowedpipe mills to achieve out-of-roundness of less than1 mm
> Use of iron ore supplied from Swedish deposit hascompletely excluded possibility of concrete coatingdefects.
Nord Stream 2 AG 8
Optimal technical design
Task
1 224km – two pipelinesvia the Baltic Sea
Technical design Pressure Achievements
3sections with differentpressure – less steel
consumption
220bar at Landfall
Russia – 102 barLandfall Germany
0intermediate
compressor stations
Nord Stream 2 AG 9
Experience of the Nord Stream operation was taken into consideration during development of technical concept of the Nord Stream 2 project, with several technical changes proposed such as:> 1 x Gate Valve changed (DEGV) to 2 x Ball Valves (PTR and PTG)> 2 x 28” New Ball Valves for Isolation> New Flanged 28” Filter> 28” Flow Meter Flanged> 28” Isolation Joint
Update of technical solutions
Nord Stream 2 AG 10
Considering the standard DNV-OS-F101 (2013), an innovative pre-commissioning concept will be used for the Nord Stream 2 project, i.e. without hydraulic tests of the offshore gas pipeline with the required safety level to be ensured through alternative measures. This concept is applicable only to 48-inch gas pipeline due to its specific characteristics.
Innovative pre-commissioning concept
The battery limit of the pressure test
Nord Stream 2 AG 11
The required safety level is ensured through alternative methods such as:> Highest quality standards and control over their implementation at all stages of the Project (selection of the supplier, selection of the material, control over pipe manufacturing, control over welding and installation, etc.);> Ensuring strength of pipes during manufacturing (double independent automated ultrasonic inspection of weld joints, additional non-destructive test of weld joints, 100% expanding of pipes up to the yield stress throughout the whole length, factory hydraulic test of pipes at pressure corresponding to 96% specified minimum yield strength direction from the center out;> 100% automated 8-beam ultrasonic inspection of cross weld joints and additional methods of non-destructive test when assembling pipes on a pipelaying vessel;> As required, manual ultrasonic inspection and magnetic-particle non-destructive test (MPI NDT) to obtain more detailed information;> Bevel edge to be formed and its geometry for a cross weld joint to be controlled immediately before welding; > Continuous recording of welding parameters; > Continuous control of the curve degree of the pipeline being installed.
Alternative methods of the gas pipeline control and reliabilityassurance
Nord Stream 2 AG 12
Pipelay installation and inspection tool
S-Lay Offshore Pipeline Installation
48” ART Scan™ Tool
Pioneering Spirit
Solitaire
Nord Stream 2 AG 13
Intellectual COMBO pig was developed for Nord Steam project having the following parameters:> Length - 7 m> Weight – over 7 t> Travel speed: 1.5 m/s (moving with gas flow)> Travel time: 1224 km in around 10 days> Memory size: 10 Tbyte of high-resolution data> Powerful system of magnets due to wall thickness 41 mmThe pigs are launched from the Russian landfall and extracted from the pig receiver at the Germany landfall
Internal inspection
Nord Stream 2 AG 14
External inspection of the gas pipeline offshore section
Nord Stream 2 AG 15
No hydraulic testing will allow avoiding such negative consequences as> Significant impact on the environment due to discharge of 2,600,000 m3 of water with
conserving agents and debiotics;
> Rockfilling in the process of hyperbaric welding between sections;
> Additional loads on the offshore pipeline at the clear span sections.
No hydraulic testing will allow significantly reducing the capital investments intoconstruction and ensure the project is implemented as per the schedule.
Use of innovative solutions as a way to optimize the Project
Nord Stream 2 AG 16
Contacts
Nord Stream 2 AG
Baarerstrasse 526300 Zug / SwitzerlandPhone: +41 41 414 54 15www.nord-stream2.com
Sergey G. Serdyukov
Chief Technical [email protected]