usan deepwater manifold engineering project

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Point Engineering LimitedCorporate Presentation for Provision of Engineering Support Services for

GE Oil & Gas

Technical Presentation to GE Oil & GasPresentation by Engr. Oseghale Lucas Okohue, B.ENG., MSc., CIPMP

Subsea Production Systems (SPSs) Specialist

16 January 2017

UgandaNigeria

Kenya

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Usan Deepwater Manifold Engineering ProjectExperience

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Usan Deepwater Manifold

EngineeringProject

Project: Deep Water Development Projects - Detailed Engineering Design of USAN – SUBSEA

PRODUCTION SYSTEMClient: Cameron / Total, LagosProject Man-hours: 57,154Client Contact: John Hellums ([email protected])

Description:Point Engineering is proud to be part of the group that executed the Detailed Design of Subsea Manifold in Nigeria for the first time.

POINT’S Scope of Work: detailed design of manifolds, suction piles and jumpers including elements of:

Structural Engineering Piping engineering Interface engineering Geotechnical (soils analysis etc) QA/QC procedures Test regime procedures Assistance at fabrication site Installation procedures Documentation control Misc (coatings, preservation, storage etc)

POINT completed this work in December 2009 in its Lagos office which was the Project Office

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EngineeringProject

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EngineeringProject

MANIFOLD Identifier: ManDC01 – ManDC02Total no of Manifold: 8No of Slots: 4Each manifold comprises of:

Manifold Module (MM) Support Structure and Foundations (Piles)

MANIFOLD EQUIPMENT MATRIX

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EngineeringProject

Each manifold comprises of cont.. Four multiphase flow meters (one per well slot). 12.5” OD production headers (X65-Carbon Steel). All headers and branch lines for connection to the subsea trees terminate (Cameron Horizontal Connector) hubs.

Note:

All well tie-in production pipe work was fabricated from 22 Cr Duplex Pipe.

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EngineeringProject

The Manifold Module (MM) consist of: CHC Hubs; Valve Assemblies and Actuators Subsea Control Modules, Multiphase Flowmeters and Controls tubing.

Note:

All this were provided by the company (CAMERON)

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Total no of Suction Pile : 8Pile can dimension:

Diameter: 6m Length: 11m

SUCTION PILE EQUIPMENT MATRIX

Note:The top section provided the interface / connectionto the manifold support frame.

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PRODUCTION JUMPERS EQUIPMENT MATRIX

Note:Hardpipe production well jumpers constructed of22 Cr Duplex pipe link Production Manifolds to X-Tree.

Jumper Identifiers: PJ01 – PJ22Total Qty: 22Nominal bore diameter: 6 in

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EngineeringProject

The following aspect was considered in the engineering of USAN deepwater manifold engineering project :

Systems Design & Analysis Load Design & Analysis Piping Design & Analysis Structural Design & Analysis Suction Pile Foundation Design & Analysis Manifold Components

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EngineeringProject

Systems Design & Analysis

The manifold was designed to provide sufficient amount of piping, valves, and flow controls to collect produced fluids or distribute injection fluids such as gas, water, or chemicals in a safe manner.

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EngineeringProject

The following information were fully considered in the system design and analysis of USAN Manifold Engineering:

Number of Wells; Well Spacing;

clear access space,

retrievable components,

Height above seabed,

fault detection

General maintenance of the manifold structure i.e.

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Barrier Philosophy Safety

External Corrosion Protection Design

Other considerations were as follows:

Templates Design i.e. integrated or modular

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EngineeringProject

Loads Design & Analysis External Loads; i.e.:

Applicable Loads such as fabrication, storing,

testing, transportation, installation, operation etc.

Accidental loads such as dropped object,

environmental loads, snag loads etc.Note:

ISO 13628-1 and NORSOK U-001 was adapted for

protection against trawl load and dropped object.

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EngineeringProject

Other loads considered includes:

Thermal Effects – specified and approved by

Cameroon

Note:

All loads were addressed based on ISO 13628 - 1.

Load on Templates i.e.

Thermal expansion of casing

Tie-in loads and flowline expansion

Environmental Impact

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EngineeringProject

Piping Design & Analysis Applicable Piping Codes:

ASME B31.8, ASME B31.4, ASME 31.3, ASME

VIII, DNV-OS-F101, DNV-RP-F112 and API Spec.

Erosion Critical flow velocity was calculated based on

ANSI / API RP 14 E to validate critical

production rate and required erosion

allowance.

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EngineeringProject

Flow Assurance issues such as: Low points, dead ends and possible location

of water accumulations were minimized as

much as possible to prevent hydrate formation.

ISO 13628 - 1: 2005 was used for validation.

Note:

The manifold piping loop was designed to allow

passage of pigs through the main headers to provide

round-trip pigging of the flowlines from the production

platform.

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EngineeringProject

Structural Design & Analysis ISO 19900, ISO 19902, APIRP 2A was strictly

adhered to.

material selection,

joint design,

welding requirements and also

types of inspection

Classification of structural components and welds

joint were used to determine :

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EngineeringProject

Bottom Frame , Guide Base and Support Structure

Loads from soil condition, well system, bottom

frame against vertical deflection, structure / well

interface design, casing thermal expansion

were also considered.

All design loads transferred by the structure from

interfacing system and equipments to the

foundation system were strictly considered.

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alignment capability for interface between

subsystems such as (wellhead, tree, etc) and piping

systems, PLET, and installation aids was also

considered.

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Suction Pile Foundation Design & Analysis Suction piles were designed based on soil condition

and load considerations with regards to aspect

ratio of piles.

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EngineeringProject

The foundation design was selected based on

site-specific soil conditions.

Foundation design considerations are as follows:

Seabed slopes

Suction loads

Well-supporting structures

Arrangements for air escape

Skirt foundation for self-penetration

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Note:

We also considered impact from heat as a result of

produced hydrocarbons, if gas are present (in soil). Foundation was design to withstand loads from:

tie-in of flowlines,

spool-pieces,

pipelines,

umbilicals and

other flowlines.

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EngineeringProject

Industry standards for manifold components

(i.e. i.e. valves, controls, and connectors) were

adhered to.

Components

Chemical Injection:

Layout and arrangement of the chemical

injection piping and valves was evaluated.

Location of injection points in the manifold

header was approved.

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EngineeringProject

Consideration of Fluid Characteristics

Produced hydrocarbon, formation water,

completion fluids, injection chemicals, water and

gases, were all considered.

Pour point, Pressure, Temperature, Composition,

Viscosity, Gas / Oil / Water ratio, Sand / Paraffin /

Hydrate, Corrosivity were also made referenced

to.

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In House Detailed Design Engineering Scope

Load Analysis;

Tolerance Analysis;

Analysis of Structural Strength of Equipment;

Soil Stability Analysis;

Load out, Sea Fastening, Transportation, Lifting &

Installation Outline Analysis.

ROV Access Analysis and

Production cutting lists, fabrication, drawings and

test procedures etc.

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In House Software Utilized

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FEA Analysis for USAN HIP Fitting (Dual Cross & Elbows) Hydrogen Induced Stress Cracking Analysis

for Manifold

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EngineeringProject

FEA Analysis for USAN HIP Fitting (Dual Cross & Elbows) Hydrogen Induced Stress Cracking Analysis

for Manifold

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EngineeringProject

Fabrication Details

Structural Steel Work;

Sea Fastening;

Lifting Points;

Manifold Pipe work;

Control Pipe work and

Cathodic Protection.

Detailed design was created to support fabrication of

the following:

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EngineeringProject

Lessons Learned

The challenges faced in completing the Usan

Deepwater Manifold Engineering Project on time

were successfully met and overcome.

Adequate planning time and resources must be

allowed for a project of this complexity.

All fulltime planning team, including service

company personnel, is required.

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EngineeringProject

Lessons Learned Cont..

Having a planning team who can focus on subsea

production systems is essential.

The manifold engineering team must be familiar

with each other's responsibilities to provide

adequate onshore and offshore support.

The adoption of a positive safety culture by all

personnel was critical to achieving the project‘s

safety performance.

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EngineeringProject

Lessons Learned Cont..

In summary; over all project success depends on

attention to details on all manifold engineering

design and procedures, not just "high-tech“

aspect.

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Project HSE

The following processes were in place to ensure goal

zero:

Induction of all personnel upon arrival.

Medical examination of personnel.

Work Competency was strictly adhered to.

Daily tool box was held.

HSE weekly meeting held.

Constant inspection of equipment and facilities.

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Project HSE Cont..

Carried out job safety audit.

Daily JHA

Ensure adequate compliance to company's policy.

Improving on the job by training and re-training.

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Project QA / QC

Quality Assurance and Quality control during the

project was planned and addressed to fulfill

conformance of the project detailed engineering

scope in accordance to international standards and

industry acceptance specifications.

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EngineeringProject

Summary

Usan Deepwater Manifold Engineering Project took

about 16 months.

Usan Deepwater Manifold Engineering Project had a

total Man-hours of 57,154.

Mobilization of equipment and point engineering

crew to site was swift.

Goal zero achieved.

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EngineeringProject

Our Engineering Teams are familiar with:

ISO 13628 Petroleum and natural gas industries —

Design and operation of subsea production systems

BS EN / ISO 13628 part 6 – Subsea production

control systems

BS EN / ISO 13628 part 5 – Subsea umbilicals

BS EN / ISO 13628 part 4 – Subsea wellhead and

tree equipment

ANSI/API Specification 6A – Specification for

Wellhead and Christmas Tree Equipment

.

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ANSI/API Specification 17D – Specification for Subsea

Wellhead and Christmas Tree Equipment

SAE AS4059 – Aerospace Fluid Power – Cleanliness

Classification for Hydraulic Fluid Client Specific

Requirements

BS EN / ISO 61511 – Functional Safety – Safety

instrumented systems for the process industry sector

.

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EngineeringProject

Our Engineering Teams are familiar with: BS EN / ISO 61508 – Functional Safety of electrical/

electronic/programmable electronic safety related

systems

BS EN / ISO 20815 – Petroleum petrochemical and

natural gas industries – Production assurance and

reliability management

API RP 17O – Recommended Practice for Subsea High

Integrity Pressure Protection System (HIPPS)

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API RP 17N – Subsea Production System Reliability

and Technical Risk Management

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Failure Mode Identification and Risk Ranking – FMIRR

Failure Modes and Effects Analysis – FMEA

Reliability Availability Maintainability – RAM

Safety Analysis Report – SAR

Safety Requirements Specification – SAR

Failure Modes and Effects Criticality Analysis – FMECA

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Safety Integrity Level – SIL

Reliability Block Diagram – RBD instead of Fault Tree

Analysis – FTA

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Thank You

usan deepwater manifold engineering project

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