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C O N F I D E N T I A L Emergency Pipeline Repair System London Presentation Lloyds OPERA Group 1 Lloyds OPERA Group by George Lim Business Development Manager, T.D. Williamson London, April 24, 2012

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Page 1: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Emergency Pipeline Repair System

London Presentation Lloyds OPERA Group

1

Lloyds OPERA Group

by George Lim

Business Development Manager, T.D. Williamson

London, April 24, 2012

Page 2: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

1 Who is T.D.Williamson?

2 What is EPRS?

3 Onshore EPRS3 Onshore EPRS

4 Offshore EPRS

Page 3: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

* Pioneers in Hot Tapping & Plugging * Pioneers in Pigging * 90 years old ** Onshore and Offshore * Global presence * HQ in Tu lsa, Oklahoma, USA *

T.D. Williamson Inc� Specialized equipment, tools, technologies, products and services� Internal inspection, maintenance and intervention of “live” lines � For oil & gas and process industries, water and industrial businesses

3

Page 4: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

1 Who is T.D.Williamson?

2 What is EPRS?

3 Onshore EPRS3 Onshore EPRS

4 Offshore EPRS

4

Page 5: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

CatastrophicFailure ASSESS EXECUTEMOBILIZEPROCURE

• Repair• Base location• Materials• Damage

Emergency Pipeline Repair

EPRS ?

Make safe• Repair• Recommission• Restore flow

• Base location• Service contracts• Organization

• Materials• Equipment

Spreads• Resources• Technology

• Damage identification & evaluation

• Repair scenarios

• Business Interruption• Exposure of people, asset, environment

• High reactive costs• Regulator intervention

• Insurance issues• Share value impact

• CNN

• Business Interruption• Exposure of people, asset, environment

• High reactive costs• Regulator intervention

• Insurance issues• Share value impact

• CNN

Extended Downtime

5

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C O N F I D E N T I A L

EXECUTE

• Repair• Base location

ASSESS MOBILIZEPROCURE

• Materials• Damage • Repair• Recommission• Restore flow

• Base location• Service contracts• Organization

• Materials• Equipment

Spreads• Resources• Technology

• Damage identification & evaluation

• Repair scenarios

How To Minimize Downtime?Do the Assessment, Procurement and Mobilization

before any emergency arises

6

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C O N F I D E N T I A L

CatastrophicFailureASSESS MOBILIZEPROCURE

• Base location• Materials• Damage

EXECUTE

• Repair

Emergency

Emergency Pipeline Repair SystemEPRS

Make safe• Base location• Service contracts• Organization

• Materials• Equipment

Spreads• Resources• Technology

• Damage identification & evaluation

• Repair scenarios

• Repair• Recommission• Restore flow

EPRS results in operational readiness

Capacity to swiftly restore flow in an emergency

Short downtime

7

Page 8: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

1 Who is T.D.Williamson?

2 What is EPRS?

3 Onshore EPRS3 Onshore EPRS

4 Offshore EPRS

8

Page 9: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

ONSHORE

• Corrosion• Impact - accidental, malicious• Natural Hazards - earthquakes, landslides• Structural• Intervention – illegal taps

Damage Mechanism

• Intervention – illegal taps

• Catastrophic failure: o Unexpected damage requiring immediate response o Pipeline normally in shutdown condition

• Integrity risk:o Monitored risk and a planned repairo Pipeline normally in operating condition

Damage Consequence

9

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C O N F I D E N T I A L

� Repair Composites Technologies – such as Res-Q®

� Welded Sleeves or Leak Repair Clamps

� Hot Tap and STOPPLE® / By-Pass Methods

Repair ScenariosONSHORE

Pass Methods

� Cold Cutting and Pipe Replacement

� Tie-In of New Tested Pipe

10

Page 11: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

� Equipment: Aligned & Maintained?

� Technicians: Trained & Certified?

Equipment, Materials, Resources ?

ONSHORE What Do You Need?

� Technicians: Trained & Certified?

� Response Time & Geographic Locations ?

� Repair & Rehabilitation Methods

� Local Inventory vs. Needs

� Health / Safety / Environmental

� Applications Engineering Support11

Page 12: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Current EPRS Capacity vs. Actual Needs

Gap Analysis

TDW Emergency Response Concept

Equipment TechniciansFittings / Clamps / Composites

Planning

Establishing Optimal Capacity12

Page 13: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Master Document: Gap Analysis of Current Capacity

T.D. WILLIAMSON MASTER PIPELINE INTERVENTION GAP ANALYSIS

CUSTOMER PDVSA SAN TOMEOPERATING UNIT ING. MANTENIMIENTO Sealing Elements Equipment Spares

CONTACT FRANKLIN MATA58-414-190655 (Cel)/ 58-283-2301698 (Of)

DATE 06/14/2006REVISION

Sealing Elements Equipment Spares

ARE.ED 3LATERAL ARECUNA

16" N/A 450.LBS 100° F 1714 x N/A N/A YES YES YES YES YES NO YES YES YES YES N/A NO

ARE.ED 4LATERAL ARECUNA

16" N/A 550.LBS 100° F 13592 x N/A N/A YES YES YES YES YES NO YES YES YES YES N/A NO

OED- 16LATERAL ARECUNA

6" N/A 440.LBS 440° F 3335 x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO

OED- 20LATERAL MEREY

6" N/A 500.LBS 500° F 258 x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO

Welded Sleeves

Composite Wraps

Hot Tap StoppleRepair Clamps

Repair & Rehabiliation

Hot TapSINGLE Stopple

DOUBLE Stopple

PER WALL THICKNESS (*)

Cutters, Pilots, Etc. (**)

Hot Tap StoppleWall Thick

Inches

Crude Oil

Natrl Gas

Technicians

Start

Pipe Location

Daily Production BBD / mfcm

Fittings

Pipe Contents Fittings TechniciansEquipment

Repair & Rehabiliation

Pipe Description

Nominal Pipe Size

Inches

Operating Condtions

Max Op Press. (Psi)

Max Op Temp

(F)H2S %

OED- 20MEREY

6" N/A 500.LBS 500° F 258 x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO

LED-13LATERAL

ADAS10" N/A 600.LBS 120° 2400 x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO

MED-20LATERAL MEREY

20" N/A 500.LBS 126° 82000 x N/A N/A YES YES YES NO NO NO NO YES YES NO N/A NO

MED-20LATERAL MEREY

12" N/A 550.LBS 126° DOS LINEAS 10200 x N/A N/A YES YES YES NO YES NO NO YES YES YES N/A NO

OED-27LATERAL MEREY

12"N/A

400.LBS 118° 154 x N/A N/A YES YES YES NO YES NO NO YES YES YES N/A NO

MED-15LATERAL

BARE12" N/A 700.LBS 114° 1287 x N/A N/A YES YES YES NO YES NO NO YES YES YES N/A NO

MED -4LATERAL MEREY

6" N/A 400.LBS 120° 726 x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO

MED-18LATERAL MEREY

6" N/A 600.LBS 122° 2803 x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO

LATERAL DE GUARA

P. T. O 24" N/A 200 LBS 90° 4500 x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO

OED-11 P. T. O 4" N/A 120.LBS 102° 956 x N/A N/A YES YES YES NO YES NO NO YES YES NO N/A NO

COB P. T. O 36" 36" N/A 500 LBS 116° 190,000 x N/A N/A NO NO NO NO NO NO NO YES YES NO NO NO

PTOKM 127 (T-51) 30"

N/A710 LBS 102° 449,000 x N/A N/A YES YES YES NO NO NO NO YES YES YES N/A NO

Page 14: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Equipment for Tapping

1 Tapping Machine TM 2400 complete

1 SANDWICH Valve adapter 48" 600#

1 Cutter holder 46"

2 STOPPLE Cutter 46"

2 Pilot drill 46"

Equipment for Bypass

1 Tapping Machine TM 2400 complete

1 SANDWICH Valve adapter 36" 600#

1 Cutter holder 12" to 30"

2 Standard Cutter 36"

2 Pilot drill 36"

2 SANDWICH Valve 36" 600#

TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position operations on 46“ 600# steel pipes with 36" bypass

Consumables

6 STOPPLE Fitting 46X48" 600 RF

6 LOCK-O-RING Plug 48"

6 Blind flange set 48" 600 RF

12 STOPPLE Sealing element 46"

6 Coupon reinforcement 46"

6 LOCK-O-RING Fitting 46" x 36" 600 RF

Example of Equipment Needed

2 Pilot drill 46"

2 SANDWICH Valve 48" 600#

Equipment for Plugging

2 STOPPLE Hydraulic cylinder

2 STOPPLE Housing 48" 600#

2 STOPPLE Plugging head 46"

Equipment for Completion

1 LOCK-O-RING Plug holder

1 LOCK-O-RING Bypass gauge

2 SANDWICH Valve 36" 600#

1 LOCK-O-RING Plug holder 12" to 36"

1 LOCK-O-RING Bypass gauge

Equipment for equalization1 Drilling Machine T-101

1 Carrying case for T-101

1 Drive socket

1 Air motor for T-101

1 Threaded valve adapter 2"

2 Drill 1 7/16"

2 Full bore valve 2"

1 Plug holder

6 LOCK-O-RING Fitting 46" x 36" 600 RF

6 LOCK-O-RING Plug 36"

6 Blind flange set 36" 600 RF

6 THREAD-O-RING Fitting 2" complete

14

You need to knowwhat to buy

Page 15: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Technician Skills Inventory: Gap Analysis

TECHNICIAN KNOWLEDGE AND SKILLS INVENTORYT.D. WILLIAMSON PIPELINE INTERVENTION GAP ANALYSIS

CUSTOMER PDVSA SAN TOMÉOPERATING UNIT ING. MANTENIMIENTOCONTACT FRANKLIN MATA 58-414-190655 (Cel)/ 58-283-2301698 (Of)DATE 06/14/2006

EXPERIENCE: YES / NO

EQUIPMENT KNOWLEDGE

OPERATION & PROCEDURE KNOWLEDGE

FACTORY TRAINED

FIELD AUDIT DATE

CERTIFICATION DATE

YES YES YES NO NO NO

IDENTIFICATION NUMBER: C.I.: 8.971.860, AGE 39

JUAN BRONT (TECHNICIAN: 6 YEARS, MECHANIC: 6 YEARS)

HOT TAP & STOPPLE EQUIPMENTT-101 Drilling Machine YES YES YES NO NO NO

YES YES YES NO NO NOYES YES YES NO NO NOYES YES YES NO NO NOYES YES YES NO NO NOYES YES YES NO NO NOYES YES YES NO NO NOYES YES YES NO NO NOYES YES YES NO NO NOYES YES YES NO NO NO

Pipeline Medium Pressure TempGas:Liquid: Sour Water 80 PSI 140 ° FCrude oil 650 PSI 140 ° FLPG: 600 PSI 80 ° FHi-Flow:Gasoline 80 PSI 80 ° FDiesel

SHORTSTOPP 60 Plugging Machine

STOPPLE Plugging (less than 500 psi)SHORTSTOPP 60 Plugging Machine

Hydraulic Cilinder 6" - 12"

Hydraulic Cilinder 24" - 36"

660/760 Tapping Machine1200 Tapping Machine

T-101 Drilling Machine360 Tapping Machine

Hydraulic Cilinder 14" - 22"

Page 16: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Technicians Training & Certification by TDW

� Hot Tapping & Plugging Equipment

� Selection of Equipment Mix: Size, Pressure, Etc.

� Basic Maintenance of Key ComponentsComponents

� Trouble Shooting� Application engineering � HSE Training� Written Exams

16

Page 17: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

ONSHORE

Service Centre Set Up

o Customer ownedo TDW premises – “Fire Station”

17

Page 18: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Equipment Maintenance by TDW

� Restoration & Certification of Original TDW Equipment by Factory Standards (OEM)

� Detailed Diagnostics� Validation of Equipment Performance

with Written Test Protocols� 1-Year Guarantee: Labor & Parts� Maintenance Records

18

Page 19: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

• Operational :– 24 hour x 365 day emergency cover– Mobilisation within an agreed time– Agreed repair methodologies– Detailed work plans for each emergency– TDW Trained and Certified Technicians– Full Personnel Safety Compliance– Job Safety Analysis

TDW Emergency Response Services

– Job Safety Analysis– OEM Maintained equipment– Fully auditable service

• Commercial :– Multi-year contract for operation and maintenance– Agreement based on 24 hour availability– Agreed rates for retention, per operation and / or

maintenance activities

19

Page 20: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Scope of EPRS Services:

In-Country Equipment & Personnel

– Site assessment– Project Management– Training & drills– Excavation and civil acivities, including site reinstatement

Long Term Partnerships

Comprehensivescope

– Excavation and civil acivities, including site reinstatement– HT&P Equipment & Fittings, – Welding, NDT and cold cutting– Coating removal and re-coating– Pressure testing– SmartPlug TM

– Res-Q ® Wrap– Repair clamps– Pigging & In-line Inspection

20

Page 21: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Asia Pacific� Turkey – Botas

o Customer owned equipment, TDW operatedo TDW personnel & local subcontractorso Fixed annual fee for Maintaining Readiness o Call-off services per incident on reimbursable basis

� Singapore – Exxon Mobil

TDW Current Emergency Response Contracts

Variety of Contract Types

� Singapore – Exxon Mobil o TDW is “Fire Station” for a process industry customero Service Centre at 15 minutes driving distance from the refinerieso 5-year Frame Agreement for call-off services

� Australia – consortium of pipeline operatorso Partnering by 5 local Transmission companieso Pooling of equipment owned by the customerso TDW provides ER services, operates and maintains the equipment

21

Page 22: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

South America� Venezuela – PDVSA

o Customer owned equipment, TDW suppliedo Customer owned service centres, Technicianso TDW provides maintenance, Technician training & certification

USA

TDW Current Emergency Response Contracts

USA� Alaska – Alyeska

o Customer owned equipment, TDW operated

Europe� France

o General call-off support

22

Page 23: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Case Study Onshore EPRS

23

Page 24: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

BTC Pipeline

24

Key features� From Baku – Tiblisi – Ceyhan� Consortium of 11 operators

� 1768 km long and 42”, 34” and 12” diameters� Crossing 3 countries, mountain ranges up to 2,830 metres

� Traverses 3000 roads, railways, utility lines – above/below ground� Crosses 1500 water courses up to 500 metres wide

� 1million b/d

Page 25: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Loss of containment by

Damage Scenarios

Put in place a system for response and repair under unpredictable circumstances and emergency situations

TDW Services

• Supply of equipment & materials• Call-off services per incident

Purpose of EPRS Contract

• Corrosion• Malicious damage• Illegal fittings• Earthquakes• Landslides

• Call-off services per incident• Maintain Readiness • In-country point of contact• Initial mobilization 4 hours• 24 hours working• 5 + 2 year contract(Owner to supply specified material)

25

Page 26: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Day 1 : Fire at BVS

� 26km of 42” pipe affected

� Assessment team arrived 11 hoursafter first notification

� Equipment & manpower within 24 hours of instruction

Key Events

of instruction� Specialists from Europe within 60 hours

of instruction� Determined the strategy and time

frame with customer� Identified single point contact� Ensured back-up/contingency plans� Damage successfully repaired

� Pipeline shutdown for 15 days26

Page 27: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

25 Illegal taps removed

• Manageable associated hazards• Low / medium risk• Predictable location• Known quantity (generally)• Easier planning

Pipe preparations

1

Integrity Risks

Welded fitting prior to hot tapRecovery of illegal feature1

23 27

Page 28: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Valve condition assessment42” double STOPPLE® Job with bypass

Site activities normal operations

8” bypass for temporary capping

Coating removal andre-coating

Pre-heating and welding

28

Page 29: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

• Single point contact at each base• ‘One-step-ahead’ strategy very effective• Range of repair procedures • Sub-contractor base needs strengthening• Strategic placement of equipment along

Key Lessons Learned

• Strategic placement of equipment along pipeline

• Dedicated EPRS packages at critical stations • Increased inventory across the board• Formalise maintenance activities

29

Page 30: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

1 Who is T.D.Williamson?

2 What is EPRS?

3 Onshore EPRS3 Onshore EPRS

4 Offshore EPRS

30

Main difference Offshore vs. Onshore pipelines:

Difficult Accessibility

Page 31: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

0

100

200

Sha

llow

300

400

500

600

700

800

900

1,000

1,100

Dee

p W

ater

Wat

er D

epth

[m]

British Gas SIMIAN/SIENNA 105 km 1,040 m

Texaco GEMINI 45 km 1,063 m

British Gas SCARAB/SAFFRON 90 km 650 m

Enterprise CORRIB 97 km 350 m

Shell EUROPA Norsk Hydro ORMEN LANGE

Statoil SNØHVIT170 km350 m

Reliance KG D6100 km1000 m

Nord stream1000 km210 m

Diver limit

Example of a pipeline profile

Trends in Offshore Pipelines

1,100

1,200

1,300

1,400

1,500

1,600

1,700

1,800

1,900

2,000

2,100 Ultr

a D

eep

Wat

er

Wat

er D

epth

[m]

2,200

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

Tie-back Distance [km]

ExxonMobil MICA 47 km 1,326 m

TOTAL CANYON EXPRESS 92 km 2,198 m

1,040 m

Shell MENSA 109 km 1,615 m

Shell EUROPA32 km

1,158 m

Gas development

Oil development

Norsk Hydro ORMEN LANGE120 km1,100 m

Longer pipelines

Deeper water

31

Page 32: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Incidents of Offshore Pipelines/Risers Gulf of Mexi coto 2004

601

500

600

700N

umbe

r of I

ncid

ents

Occurrence Index

Damage AssessmentOFFSHORE

322

218 210153 137

67 65 4217 10

0

100

200

300

400

Corro

sion

(Inte

rnal

)

Natur

al H

azar

ds

Impa

ctUnk

nown

Corro

sion

(Ext

erna

l)

Structu

ral (

Design

)M

ater

ial D

efec

tLin

e Plug

gage

Ancho

ring

Constr

uctio

nEro

sion

Failure Cause

Num

ber o

f Inc

iden

tsto

tal 1

842

32

Page 33: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

Corrosion Dry Buckle

Paraffin Scale Hydrate Plugs

Failure Mechanisms & Damage types

Anchor DragsImpact Damage33

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C O N F I D E N T I A L

BP CATS Anchor Drag

Anchor Damage Example

34

Transmed Anchor Drag

Kvitebjorn Anchor Drag

RECENT ANCHOR DRAGS

High (difficult) Detection IndexDamage not seen in 2006Damage detected in 2007

BP CATS Anchor Drag

Page 35: Emergency Pipeline Repair System - oilpera.com · Emergency Pipeline Repair System EPRS ... TDW STOPPLE Equipment to perform 3 Double STOPPLE ® position ... 6 STOPPLE Fitting 46X48"

C O N F I D E N T I A L

50100150200250300350400450500

Risk Priority Index= Occurrence x Severity x Detection

Risk Priority Index (Operational) – GoM

• Highest index of 350 to 450: Anchor snag

• Others with high RPI : Buckling; Dropped objects

• Corrosion nowhere to be seen

High Risk Priority Index

OFFSHORE

050

Ancho

r Sna

g (Wet

Buckle

)

Ancho

r Sna

g (Dry

Buckle)

Thermal B

uckli

ng (D

ry)

Dropp

ed O

bject N

ear P

latfor

m (W

et)

Dropp

ed O

bject A

way F

rom

Platfo

rm (W

et)

Thermal B

uckli

ng (W

et)

Dropp

ed O

bject N

ear P

latfor

m (D

ry)

Mud

slide B

reak (

Miss

issipi

Cany

on)

Paraffin

Acc

umula

tion

Dropp

ed O

bject A

way F

rom

Platfo

rm (D

ry)

Inlin

e Equ

ipmen

t Fail

ure:

valve

s, fla

nges e

tc

Dropp

ed O

bject N

ear P

latfor

m (D

ent)

Dropp

ed O

bject A

way F

rom

Platfo

rm (D

ent)

Hydra

te For

mati

on

Source: Deep Water RUPE Report 35

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C O N F I D E N T I A L

Pipe content management

Find the Damage

Damage Assessment

Damage Finding / Locating System

Pin hole leak;Piggable dent

Minor Internal Blockage

Wax or HydratesNon-piggable dent;

Rupture

Major

Suspend Flow

Rupture?

Bypass

NO YES

Suspend Flow

Controlled DECOM

Uncontrolled Flooding

Continue Flow(Shallow water)

Replace pipeFabr/ Lay

Repair

management

No Cut out

Leak RepairClamp

StructuralClamp

No Cut out

Chem Injection System(+ Hot Tap)

Re-commissioning

Cut out

HyperbaricWeld

FlangesIn-Line

ConnectorsSurface

Lift&Tie-in

Re-commissioning

Hot Tap Stopple

Pipeline Isolation

Short - by DSV Long - by Laybarge

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C O N F I D E N T I A L

Temporary Isolationto preserve inventory

SmartPlug® Isolation – Preventive Measure

Repair Scenario – Damage Limitation

Operated

by

Total

24” SmartPlug in

new line being laid

36” SmartPlug in

existing export line 37

Total

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C O N F I D E N T I A L

TDW Remotely OperatedClamp Installation Tool

Repair Clamp

Repair Scenario – Minor Damage

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C O N F I D E N T I A L

Bypass – with Hot Tap & STOPPLE isolation

Required Material & Equipment:

• Hot Tap & Plugging

Repair Scenario – Major Damage

Leak Cut-Out – with SmartPlug isolation

39

• Hot Tap & Plugging • Fittings• Clamps• Isolation Technology• Marine spread

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C O N F I D E N T I A L

Surface Tie-in

Repair Scenario – Major Damage

• Cut out damaged section• Recover each end onto

laybarge• Re-lay with overlap• Lift both ends & weld• Lay over

40

Required Material & Equipment:

• Isolation technologies• Marine spread

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C O N F I D E N T I A L

Deep Water Pipeline Repair DW RUPE

Repair Scenario – Deep Water

Source: Deep Water RUPE Report 41

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C O N F I D E N T I A L

Deep Water Flowline Repair DW RUPE

Repair Scenario – Deep Water

42

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C O N F I D E N T I A L

Typical EPRS Pre-investments

� EPRS Study : - Establish Risk Priority - Establish overall EPRS scenarios and needs

� Saving Time : - Establish Framework Agreement for aerial / subsea surveys - Pre-invest in critical Long Lead materials,

e.g. line pipe; clamps; fittings.

Critical

� Impact – Anchors, Dropped objects� Leak study – rupture, water ingress� Decomm/Re-comm� Repair options – isolation, cut-outs� Procurement – materials, spreads� Project organization

Offshore

e.g. line pipe; clamps; fittings.

� Saving Costs : - Framework Agreement for marine spread & equipment -- Develop Repair Scenarios for rapid execution (SmartPlug Tool)

� Saving Pipe Inventory : - Pre-invest in Isolation, Bypass , Hot Tap equipment- Pre-invest in Decommissioning/Re-commissioning needs

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C O N F I D E N T I A L

Case Study Offshore EPRS

44

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C O N F I D E N T I A L

An operator in Malaysia identified a leaking clamp on a 24-inch subsea gas pipeline operating at 750 psi in 70 metres water depth. TDW launched two SmartPlug isolation tools separated by inhibited

seawater to straddle the defect to allow it to be cut and replaced.

After the cut, each end of the pipeline which was isolated at 750 psi was lifted to the surface in order to weld a flange onto the pipeline,

because the operator did not want to install gripped flanges.

After the cut, each end of the pipeline which was isolated at 750 psi was lifted to the surface in order to weld a flange onto the pipeline,

because the operator did not want to install gripped flanges.

Mini Case Study: Malaysia Midline Repair

After lowering the ends, a spool piece was inserted and bolted to the flanges.

After lowering the ends, a spool piece was inserted and bolted to the flanges.

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C O N F I D E N T I A L

Mazara

Case Study: TransMed Anchor Drag

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C O N F I D E N T I A L

TransMed Pipeline System

1 S

2 S

Damage Consequence

Line 3S completely severed Line 2S dented and lifted out of trench

Line 3S completely severed Line 2S dented and lifted out of trench

3 S

4 S

Blue : Pipelines before the incidentRed : Pipelines after the anchor drag

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C O N F I D E N T I A L

Damage Consequence

Cut out sections of the damaged 26” gas lineCompelling evidence of the severe consequences of anchor drags

Cut out sections of the damaged 26” gas lineCompelling evidence of the severe consequences of anchor drags

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C O N F I D E N T I A L

POST-EVENT SCENARIO ANALYSIS

Damage Type Characterization

Physical Characterization

Pipeline Operating Condition

Expected Downtime Range

Downtime Mitigation Measures

Pigable Dent (Buckle) |

< 10% reduction in P/L I.D.

Pipe remains dry and pressurized

None initially, 4 weeks during

Temporary Repair clamp

Repair Scenario

This was an emergency repair, no EPRS was in place

(Buckle) | in P/L I.D. and pressurized weeks during repair and RTO

clamp

Unpiggable Dent (Buckle)

20” Line

> 10% reduction in P/L I.D.

Pipeline remains dry and pressurized

2 weeks initially during damage assessment, then 6 weeks during repair and RTO

Temporary repair clamp

Rupture

26” Line

Unpigable inline, penetration of pipeline wall

Release of gas, possible localized flooding of pipeline

Immediate shut-down, 10 weeks to repair and RTO

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C O N F I D E N T I A L

Surface Tie-in

• Prepare pipeline

Repair Option selected – Surface Tie-In

• Prepare pipeline• Cut out damaged section• Recover each end onto

laybarge• Re-lay with overlap• Lift both ends & weld• Lay over

50

• Equipment delivery wasrequested to be in 6 weeks• The company chose a totally diverless repair

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C O N F I D E N T I A L

TDW SmartLift ™ Customised SmartLift TM

Pipeline Recovery Tools.Inserted at the cut end

Functions:

Isolation Option to manage pipeline inventory

Functions:- Isolation tool- Pig launcher/receiver- Lifting head

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C O N F I D E N T I A L

Summary Repair Sequence

52

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C O N F I D E N T I A L

Details of 20” Isolation sequence

• Run & set Barrier pigs

Dent

• Pigs running into PRT catcher• PRT ready for lifting operation

• PRT inserted

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• Pipeline cut

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C O N F I D E N T I A L

Specialized 20” Barrier Pig

•Estimated 14% Reduction at dent location.•Pig designed for 20% reduction. (16” ID)

TDW SmartTrack TM system - critical to the isolation :

� ATEX approved transponder mounted in pig body� ATEX approved transponder mounted in pig body� Two-way through-wall communication� Electromagnetic signals� Wireless communication - transponder & transceiver� +/- 5cm accuracy.� Data provided through-wall on internal pressures

Remote transceiverTopside Transceiver& PDA Eexd

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C O N F I D E N T I A L

Diverless Installation

SmartLift TM Pipeline Recovery Tools

55

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C O N F I D E N T I A L

Pigging Activity

Recovery of Barrier Pig & PRTOn-board Pig Detection Screen

� Pigging distances 150km in dry gas� Zero on-site safety incidents

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C O N F I D E N T I A L

Decommissioning / Recommissioning Spread

� 700t of Equipment� 2 x Air/N2 Spreads capable ofdelivering 6000 scf/m 70 bar and dewpoint of - 40oC

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C O N F I D E N T I A L

� Growing trend among operators to develop an EPRS

� Planning and essential investments must be made in advance

� Differences in approach between Onshore & Offshore EPRS:

o Focus for Onshore on:� Investment in equipment , inventory, resources

Overall Conclusions Onshore & Offshore

� Investment in equipment , inventory, resources

o Focus for Offshore on:� EPRS Study – complex scenarios� Realistic emergency cases ranked by Risk Priority Index� Frame Agreements to cut long response times� Management of pipeline inventory: isolation & bypass vs.

DECOMM/RECOMM

� Common point between Onshore & Offshore EPRS:

Think Ahead 58