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OTC 21228
Emergency Pipeline Repair Equipment: Site Integration Tests and
Post SIT Engineering Armando Rebello, Ray Ayers, Randy Long/Stress
Engineering Services
Copyright 2011, Offshore Technology Conference This paper was
prepared for presentation at the Offshore Technology Conference
held in Houston, Texas, USA, 25 May 2011. This paper was selected
for presentation by an OTC program committee following review of
information contained in an abstract submitted by the author(s).
Contents of the paper have not been reviewed by the Offshore
Technology Conference and are subject to correction by the
author(s). The material does not necessarily reflect any position
of the Offshore Technology Conference, its officers, or members.
Electronic reproduction, distribution, or storage of any part of
this paper without the written consent of the Offshore Technology
Conference is prohibited. Permission to reproduce in print is
restricted to an abstract of not more than 300 words; illustrations
may not be copied. The abstract must contain conspicuous
acknowledgment of OTC copyright.
Abstract Since the onset of Deep Water Response to Underwater
Pipeline Emergencies (DW RUPE) JIP in 2005, we have been reporting
on progress of the development of a repair system designed to
repair ANSI 1500 class pipelines in the 10-inch to 24-inch range in
water depths up to 10,000 ft . For each pipe size, the system
provides a minor repair kit with one structural clamp, and a spool
assembly kit with two connectors.
6,5,4,3,2,1
Following delivery of the repair system, composed of pipe
lifting frames (PLFs), indexing base frames (IBFs), weld seam
removal and FBE removal tool, cutting and end preparation tools,
connectors and clamps, the system was subjected to System
Integration Trials (SIT) in November 2009. This paper reports on
the SIT, post SIT conclusions and the path forward since the SIT,
with regards to design modifications, storage techniques, assembly
of the equipment, mobilization and management of the system.
Introduction The word that comes to mind in response to damage to
pipeline infrastructure is immediate. The speed of reaction to a
given subsea pipeline repair problem will dictate the financial
impact, including production loss, potential liability and
reputational damage for pollution issues, in addition to the cost
of the repair itself. Consider the time it will take to order
simple forgings needed for the manufacturing of repair clamps and
connectors, currently in the order of 8 to 10 weeks, let alone the
time to machine and assemble all components, and the cost of
preparedness will be fully justified. However, given the fact that
the likelihood of such emergency is relatively small, many oil and
gas companies still do not have any dedicated effort established
toward maintaining repair tools and consumables on the shelf. DW
RUPE is a non profit co-ownership project dedicated to such
emergencies, where the cost of equipment and tools is
proportionally shared among its co-owners. After completion of the
asset acquisition phase in 2009, DW RUPE had a set of components
needed to conduct repairs on pipelines in deep water. It was
important to test the tools and equipment assembled as a system, in
order to identify any problems before a real repair had to be
conducted. A significant factor for the SIT was the fact that at
the end of 2009, the IBFs and PLFs supplier encountered completion
issues and DW RUPE took responsibility for operational readiness
and any required improvements. The lessons learned from the SIT
were converted to a list of improvement tasks that are being
implemented in their order of priority, for completion before 2011
hurricane season.
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2 OTC 21228
SIT Activities The functional specifications for the DW RUPE
inventory were created after a failure mode and consequence
analysis (FMECA) defined the types of repair required for the
system. These functional specifications were used as input for the
design of the tools and equipment, and the factory acceptance tests
(FATs) proved that individual components performed to
specifications. Although interfaces were maintained for all
components of DW RUPE throughout the acquisition phase, testing of
the entire repair suite was needed to ensure the various components
were compatible and sufficient space was available for ROV
operations. The SITs were conducted in November 2009; the setup and
instrumentation diagram is depicted in Figure 1.
Figure 1 - SIT Arrangement and Instrumentation
Figure 2 - Frames Positioned for SIT Operations
Due to the symmetrical arrangement, only one side of the system
was fully assembled during the SIT. The pipe of choice was a
12.75-inch OD, API 5L Grade B with 0.375-inch wall thickness. The
objectives of the SIT were:
Test and improve the operation and maintenance (O&M) manuals
for the IBF and PLF, and add photographs of the actual assembly
process to the manuals
Test and validate the finite differences Excel program developed
by Stress to assist with the positioning of the IBFs and PLFs
Measure the time and resources required for the assembly of the
system for future scheduling purposes Help define what markings to
stencil on the IBF and PLF to assist with the assembly and safe
operation Better understand the logistics of mobilization (shipping
preparedness, packaging and palletizing, knowledge
of weights and volumes, tools required for assembly of the
units, etc.) Ensure ROVs have room to move around the frames and
tools Check the lifting arrangement for the frames, center of
gravity, correct fit of rigging, padeyes, etc.
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OTC 21228 3
Simulate a minor repair using a structural clamp Conduct several
pipe cuts of a pipeline under tension using two types of cutting
tools (diamond wire and
chop saw owned by DW RUPE), compare the performance of the
cutting tools and note any handling issues Simulate a major repair
using a pair of connectors mounted on a pipe spool piece (Figure
3)
SIT Outcome and Conclusions
Upon completion of the SIT activities, a list of corrections and
additions was compiled for the IBFs and PLFs in order to correct
problem areas or to improve their functionality. Listed below are
the activities that took place following the SIT.
Preparedness for mobilization: O&M manuals and general
documentation for all equipment is currently available to co-owners
on a web based library at http://dwrupe.org
The spreadsheet based pipe lifting calculation tool accurately
predicted the lifting parameters The assembly process was timed and
resources and skill sets defined for a future mobilization Markings
and labels were stenciled In order to reduce the time to assemble
the IBFs and PLFs, larger sub-assemblies were defined and stored in
a
preassembled state (Figure 4) The lifting arrangement had to be
modified since the ROV
lifting hooks were too to the horizontal drive mechanisms
(Figure 5)
Figure 3 - Spool Piece Installation
IBFs traverse mechanism ACME thread was made longer. It was
noticed that the IBFs and PLFs may not be placed so the pipeline is
exactly on the centerline. While the PLF already has a long
traverse, the IBFs were originally made with a short traverse range
(Figure 6)
Path Forward To help maintain the systems efficiency and prevent
obsolescence, a continuous improvement program is in place for DW
RUPE. Every year, changes, improvements and modifications are
submitted for approval. For 2011, a series of small modifications
will be made, as follows:
Grapple Design modifications: The original grapple design is
based on a single rod standard double action hydraulic cylinder,
which requires volume compensation since the rod side displaces
less hydraulic fluid than the piston side, is vulnerable to leaks
or punctures, and does not allow for a mechanical override. It was
decided to convert the grapple to a mechanical system composed of
an ACME thread actuated by a hydraulic motor, with an ROV bucket in
case of a hydraulic failure (Figures 7, 8)
Figure 4 - Drive Encased in PVC Pipe for Storage
Reinforcement and tighter diameter tolerance for the IBF to
Connector guide post (Figure 9)
Add transponder buckets to the IBFs and PLFs Modifications to
the hydraulic system (hard piping,
routing of hydraulic lines) Extend lifting slings to accommodate
an as built shift of
the IBF center of gravity. Modify IBFs and PLF lifting
arrangement to ease the
ROV handling of the heavy slings Future Development
DW RUPE has two divisions:
The Pipeline Division is ready for deployment with approximately
12 Million USD in tools and equipment in inventory, and 792 miles
of pipe dedicated to the co-ownership, currently all in the Gulf of
Mexico. Pipe diameters range from 10 to 24.
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4 OTC 21228
DW RUPE continues to actively research new sealing systems and
seal materials for connectors, where the primary issue is control
of the thermal expansion of the seals under high temperature
pipeline conditions.
The Flowline Division is currently under development. Flowlines
have greater challenges, such as high pressures and temperatures,
removal of hard coating, and thicker pipe wall, typically in
diameters ranging between 4-inch and 12-inch nominal.
ACME thread for IBF: Was 4 ft long, modified to be 12 ft long
(same as PLF)
ACME thread for IBF: Was 4 ft long, modified to be 12 ft long
(same as PLF)
ACME thread for IBF: Was 4 ft long, modified to be 12 ft long
(same as PLF)
Extension PlateExtension PlateExtension Plate
Figure 5 - Extension Plates added to lifting rigging
Figure 6 - IBF Extended Traverse range
Figure 7 - Current Grapple Assembly Figure 8 - Proposed Grapple
Design
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OTC 21228 5
Connector Guide Post Redesign: Tighter
tolerances and Flange Reinforcement
Figure 9 - Connector Guide Post Modifications Acknowledgements
The authors wish to acknowledge the insight and interest of the DW
RUPE co-ownership, namely Mike Stark (Enterprise), Leith McDonald
(BP), Don Beesley and Kaya Alptunaer (ENI) and Bill Dick
(Enbridge), and the following contractors for their contribution
during the SIT: Lee Avery and Bruce Morris (Quality Connector
Systems), Noah Teichmiller (Oceaneering International, Inc.), Mike
Hargrave (Cutting Underwater Technologies). References 1 GE
Oilfield
Technology Magazine
Ayers, Ray, Rebello, Armando, The Repair Process October
2009
2 OTC 19207 A New Deepwater Pipeline Repair Capability for the
Gulf of Mexico and Other Deepwater Regions
May 2008
3 OTC 17772 Rebello, Armando, and Ayers, Ray, DW RUPE: A Low
Capex Deepwater Pipeline Repair System for the Gulf of Mexico
May 2006
4 Ayers, Ray and Rebello, Armando, DW RUPE JIP Phase 1 Final
Report
October 2005
5 Ayers, Ray and Rebello, Armando, DW RUPE JIP Phase 2a Final
Report
September 2006
6 IOPF Ayers, Ray, Rebello, Armando and Stark, Mike, DW RUPE
International Offshore Pipeline Forum, Houston, Texas
October 2007
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