pipeline repair project feed 2
DESCRIPTION
Offshore Pipeline Repair FEED PresentationTRANSCRIPT
18th-June-08
PIPELINE REPAIR AT KP 110 – KP 133 KUALA TUNGKAL TO PANARAN TGI OFFSHORE PIPELINE
FEED Handover Meeting Agenda
1. Project Introduction
2. Project Status
3. MTO
4. Procurement & Installation Specifications
5. MR’s
6. TBE/Table of Compliance
7. Procurement Status
8. Discussion and Close out
Project Introduction
KP 133.5
KP 110.5
Project Introduction
Details of Damaged Section (KP110.5 to KP133.5) • Total of 19 buckles along the damaged section
• Maximum deformation of buckle – 7.59% of OD
• Water depth at damaged section – 35m
Design Basis of Replacement Pipeline
DESCRIPTION UNIT PARAMETERS
Approximate Length km Approximately 23.0
Pipeline OD mm 711.2 (28”)
Material - Carbon Steel
Line Pipe Specification - API 5L X65, manufactured to DNV OS-F101
Pipeline Wall Thickness mm 15.9 (.625”)
Service - Dry Sales Gas
Pipeline Corrosion Allowance mm 0.0
Internal Coating - 80 micron DFT Epoxy Coating
External Corrosion Coating - 3 Layer PE
External Corrosion Coating Thickness mm 2.1
Concrete Weight Coating Thickness mm 94
Design Pressure Barg 113.8 (1650 psig)
Operating Temperature °C 40.6
Hydrotest Pressure Barg 136.7 (1983 psig)
Maximum Operating Pressure Barg 103.4 (1500 psig)
Product Density Kg/m3 63.0
Pressure Rating of Pipeline Components - ANSI Class 900
FEED OBJECTIVES
Engineer a feasible repair method that can be executed by available installation contractors in the region
Develop a method based on use of industry proven equipment and procedures
Review the method with potential EPCC contractors to get feedback on their construction risks.
Develop a method which offers no or minimum stoppage of Gas to the consumers
Develop a method which enables restoring the gas flow to the full design pressure as early as possible
Conduct risk work shop and identify risks that should be managed by PMT
Identify long lead items for procurement so that repair work can be executed as early as practically possible
Schematic Diagram
MTO for Zero Downtime Method
Hot Tap Tees
Size Material Quantities
28 x 6” ASTM A 694 F65 2
28 x 16” ASTM A 694 F65 2
28 x 28” ASTM A 694 F65 4
28” 5D Hot Induction Bends
28”, 90ºBends API 5L X65 4+1spare 2 for Test bend and WPQT
Mechanical Connectors
28” ASTM A 694 F65 2
Flanges
6” Pressurizing line ASTM A 694 F65 4+1 Swivel type
16” Branch Line ASTM A 694 F65 2+1 WN Flange
4+1 Swivel flange
8+1 Blind flange
Misalignment flange
28” Pipeline ASTM A 694 F65 4+1 WN Flange
6+1 Swivel flange
10+1 Blind flange
2+1 Misalignment flange
28” Pig Launcher/Receiver ASTM A 694 F65 2 Swivel flange
MTO for Zero Downtime Method
Testable Gaskets
Size Material Quantities
28” SS 316 Octagonal 4+1 Kamos Gasket
16” SS 316 Octagonal 4+1 Kamos Gasket
Test Kit SS316 2 Kamos
Weldolets
28 x 4 “ ASTM A 694 F65 / WPHY65 2+1 80XS
28 x 2” ASTM A 694 F65 / WPHY65 2+1 80XS
16 x 4” ASTM A 694 F65 / WPHY65 2+1 80XS
16 x 6” ASTM A 694 F65 / WPHY65 2+1 80XS
Barred Tee
28” x 16” ASTM A 694 F65 / WPHY65 2 Reducing Tee
Elbow
16” ASTM A 694 F65 / WPHY65 4 90º
Subsea Ball Valves
2" Body: A350-LF-2 / A352 LCC
Ball & Seat: A182-F55 with WC coating
Seat Spring: Inconel X750
2 Full Bore, RTJ x Welded End
4" 4 Full Bore, RTJ x Welded End
6” 2 Full Bore, RTJ x Welded End
MTO for Zero Downtime Method
Expanding Gate Valves
Size Material Quantities
16” Body: A350-LF-2 / A352 LCC
Gate & Seat: A182-F55 with WC coating
Seat Spring: Inconel X750
2 Reduced Bore, Welded end.
Through conduit Double Block and Bleed
28” 2 Full Bore, Piggable and welded end
Through conduit Double Block and Bleed
Subsea Globe Valve
6” Body: A350-LF-2 / A352 LCC
Trim : A182-F55 with WC coating
Stem packing : Flexible Graphite
2 RTJ X RTJ
Welded bonnet
Material Specifications
S/N Activities Status Further Actions
1. Line Pipe TGI Specification Done -
2. Flanges, Bolts, Nuts, Gaskets and Fittings
29780-00-SU-SPC-001
Done -
3. Subsea DBB Expandable Gate Valves / Gate Valves
29780-00-SU-SPC-003
Done -
4. 5D Induction Bends 29780-00-SU-SPC-004
Done
5. Subsea Mechanical Connectors & Hot Tap Assembly
29780-00-SU-SPC-005
Done EPC Contractor to attend all FAT testing for both mechanical connectors and hot tap assembliesEPC Contractor to perform mock testing at the works followed by full mock up before the actual installation works
6. Field Welding and NDT 29780-00-SU-SPC-002
Done EPC Contractor to prepare welding and NDT procedures
7. Installation 29780-00-SU-SPC-007
Done EPC Contractor to develop installation procedures.
8. Survey and Monitoring 29780-00-SU-SPC-008
Done -
9. Hydrotest, Gauging and Pigging
29780-00-SU-SPC-009
Done EPC to develop site procedures. Final HAZOP and HAZID need to be performed.
10. Construction Materials ---- Not Done All non-long lead and construction materials to be procured by EPC Contractor
Material Requisitions
S/N Activities Status Further Actions
1. Line Pipe TGI Done -
2. Flanges, Bolts, Nuts, Gaskets and Fittings
29780-00-SU-RFQ-0003 Done -
3. Subsea DBB Expandable Gate Valves / Ball Valves
29780-00-SU-RFQ-0002 Done -
4. 5D Induction Bends 29780-00-SU-RFQ-0001 Done -
5. Subsea Mechanical Connectors & Hot Tap Assembly
29780-00-SU-RFQ-0004 Done -
TBE/Table of Complinace
S/N Activities Status Further Actions
1. Line Pipe TGI -- -
2. 5D Induction Bends TGI -- -
3. Flanges, Bolts, Nuts, Gaskets and Fittings
TGI Done -
4. Subsea DBB Expandable Gate Valves / Ball Valves
TGI Done -
5. Subsea Mechanical Connectors & Hot Tap Assembly
TGI Done -
Project Status – Procurement
Steel Plate and Line Pipe Manufacturing Inspection
• AnYang Steel Plate Mill audit – Done
• Line Pipe Manufacture Kick-off meeting and Mill audit – ????
All non-long lead items & consumables to be supplied by EPC Contractor and subjected to PMT’s approval – status ????
Specifications and MRs for Long Lead Items Preparation – Done
• Long lead items are identified in the MTO Report
Project Status – Procurement
Procurement Assistance
S/N Activities Status Further Actions
Float MR TBE
1. Flanges, Bolts, Nuts, Gaskets and Fittings
Done Done -
2. Subsea Double Expandable Gate Valves / Gate Valves
Done Done -
3. 5D Induction Bends - - Specifications and MRs issued to TGI. TGI to send out for quotations – Status unknown ???
4. Subsea Mechanical Connectors & Hot Tap Assembly
Done Done PMT to ensure EPC Contractor attend all FAT testing and perform mock testing before actual repair works
Project Status – Procurement
Procurement Assistance
S/N Activities Selected Vendor Further Actions
1. Line Pipe PT Bakrie 28” Line Production status to be updated by TGI.
Status of 16” pipe to be informed by TGI ????
2. 5D Induction Bends - - Specifications and MRs issued to TGI. Awaiting TGI to send out for quotations. TGI to update the status ????
3. Coating & Anodes BrederoShaw -Batam TGI to update the status ?????
4. Flanges, Bolts, Nuts, Gaskets and Fittings
Oceanering TGI to update the staus
5. Subsea Double Expandable Gate Valves / Globe/Ball Valves
BEL Valves -
6. Subsea Mechanical Connectors & Hot Tap Assembly
OCEANERING PMT to ensure EPC Contractor attend all FAT testing and perform mock testing before actual repair works
Project Status – Procurement
Balance Procurement Items
S/N Activities
1. Line Pipe Small bore pipes like 6”,4”, 2” etc to be procured by EPC contractor
2. Small Bore valves ¾” 2 “
3. Flanges, Bolts, Nuts, Gaskets and Fittings
Small bore and miscellaneous items to be procured by EPC contractor
5. Barred Tee To be confirmed by TGI ?????
6. Structurals for Skid assembly
To be Procured by EPC contractor
Discussion and Close Out