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CLIENT :
PROJECT TITLE
DOCUMENT NO.
: P5248-006-MC-RP-0006
CONTRACT NO.
CHO/2013/DFE/0002(A)
:
CH2/C5/2003/DCE/
146
WORK
WORK
ORDER
: XXX
NO.
CTR NO.
A
Rev
Date
: MC-100
MAN
NMS
MKI
Description
Prepd
Chkd
Appd
Client
Revision No.
P5248-006-MC-RP-0006
Document No. :
:
Date
:
Page
:
P5248-006-MC-RP-000x
A
XX March 2015
2 of XX
TABLE OF CONTENTS
EXECUTIVE SUMMARY
1.0
INTRODUCTION
1.1
General
1.2
Purpose
1.3
Scope
2.0
3.0
4.0
PROJECT SCOPE
2.1
Project Background
2.2
Abbreviation
10
12
3.1
12
3.2
12
3.3
13
3.4
Project Documents
13
DESIGN BASIS
14
4.1
Design Basis
14
4.2
Fluid Composition
14
4.3
Operating Envelop
15
4.4
Environmental Data
15
4.5
Formation Water
16
4.6
Fluid Analysis
16
4.7
Sour Service
16
5.0
ASSUMPTIONS
17
6.0
18
6.1
18
6.2
Acceptable Materials
18
7.0
P5248-006-MC-RP-0006
21
7.1
8.0
9.0
10.0
21
28
8.1
28
8.2
29
8.3
Pigging
29
8.4
30
33
9.1
Purpose
33
9.2
33
9.3
Inspection
36
37
38
41
P5248-006-MC-RP-0006
EXECUTIVE SUMMARY
P5248-006-MC-RP-0006
1.0
INTRODUCTION
1.1
General
PETRONAS Carigali Sdn Bhd (PETRONAS Carigali) is undertaking the rehabilitation
project of pipelines and associated topside facilities for Sarawak Operation (SKO).
The SKO Pipeline Rehabilitation project shall look at the alternative replacements
and/or upgrade options for its current pipeline facilities, with the objective to provide
continuous pipeline uptime and availability for SKO assets for the next 30 years. The
alternative means of replacement/upgrade which this Rehab project considers shall
cover the possibilities of:
1.2
Pipe-in-pipe insertion e.g. In-field Lining (IFL), Plastic lining in existing Pipeline
Purpose
The purpose of this Degradation Design Basis Memorandum is to provide
recommendation of technically acceptable materials for further evaluation in the
Material Option Study. Materials are recommended based on guidance as given in
PTS 39.01.10.12.
This document also identifies degradation threats, mitigation and monitoring for each
recommended material. Key points of drying and preservation requirements are
included in this report.
1.3
Scope
i.
P5248-006-MC-RP-0006
2.0
PROJECT SCOPE
2.1
Project Background
SKO, one of PETRONAS Carigalis three regional operations in Malaysia comprises
the Baram Delta Operation (BDO) fields, Balingian field, Bintulu Crude Oil Terminal
(BCOT) and Miri Crude Oil Terminal (MCOT). The BDO fields are located
approximately 25km offshore Miri, Sarawak in water depths ranging from 30 76
meters, while MCOT is located onshore Miri, Sarawak. The BDO field is operated
under three production clusters namely Northern Cluster (comprises Bokor, Betty and
Baronia fields), Eastern Cluster (comprises Baram and Fairley Baram fields), and the
Southern Cluster (comprises Bakau, Tukau, Siwa, West Lutong fields and MCOT).
The Balingian field is located approximately 40 km offshore Bintulu, Sarawak in water
depths ranging from 85 to 92 meters. The Balingian field is operated as a single
production cluster and comprises J4, D35, D18, Temana, Bayan and BCOT. The
BDO field started operating in 1976 while the Balingian field started operating in
1978.
SKO currently produces about 100,000 bpd of net oil to MCOT and BCOT in addition
to about 150 million scf/d of natural gas; which is forecasted to increase to 160,000
bpd oil and 250 million scf/d of natural gas from 2013 onwards. SKOs oil and gas
production is evacuated through about 175 operating pipelines and about 104
production platforms/jackets. The pipeline assets arising from integrity risk
assessment / premature failures/degradations have been confirmed with high internal
degradation risk suspected arising from Microbiologically Influenced Degradation,
necessitating a major asset rehabilitation program from 2014 to 2016.
The schematic of the BDO and Balingian Pipeline Network are shown below.
P5248-006-MC-RP-0006
SKO currently operates a total of 172 pipelines with estimated total length of 1477
km. Most of the SKO pipelines are offshore pipelines except for the terminal pipelines
with onshore sections. The operating pipelines involved have the following services
regimes:
Stabilized crude oil evacuation from major platforms to crude oil terminals
Multiphase crude oil and gas evacuation from jackets to main platforms.
Vent lines
P5248-006-MC-RP-0006
2.2
Abbreviation
The following definitions refer to abbreviations used throughout this document:
AISI
ANSI
API
Bbl/d
BNDP-A
BNJT-C
BOL
Bottom of Line
BWC
CA
Degradation Allowance
CAPEX
Capital Expenditures
CI
Degradation Inhibitor
CISCC
CO2
Carbon Dioxide
CP
Cathodic Protection
CS
Carbon Steel
CRA
CWC
DCS
DDBM
DSS
ER
Electrical Resistance
FFS
FWS
GRE
HDPE
HIC
HP
High Pressure
HSE
H2S
Hydrogen Sulphide
ID
Internal Diameter
IFL
In-field Liner
IP
Intelligent Pigging
P5248-006-MC-RP-0006
LCC
LP
Low Pressure
MIC
MMscfd
MOC
NACE
OD
Outer Diameter
PA
Polyamide
P&ID
PCSB
PE
Polyethylene
PEX
ppm
PTS
PVDF
Polyvinylideneflouride
RTP
Reinforced Thermoplastic
RBI
ROV
SDSS
SIL
SKO
Sarawak Operation
SLC
SRB
SSC
TOL
Top of Line
UCR
UT
Ultrasonic Testing
WGR
WT
Wall Thickness
P5248-006-MC-RP-0006
3.0
3.1
Regulation, 1985.
3.2
PTS 30.10.02.13
PTS 30.10.02.31
PTS 30.48.00.31
PTS 31.38.01.11
PTS 31.40.00.10
PTS 31.40.00.19
PTS 31.40.00.20
PTS 31.40.10.20
PTS 31.40.30.34
PTS 31.40.30.37
PTS 39.01.10.11
P5248-006-MC-RP-0006
PTS 39.01.10.12
WW ALL E 04
001
WW ALL M 04
002
MY ALL O 07002
3.3
API RP14E
API 1104
API 5L
API RP 15LE
API RP 17B
API RP 17J
DNV-RP-F101
DNV-RP-F103
M-001
NACE MR
0175
3.4
Project Documents
P5248-006-MC-RP-0006
4.0
DESIGN BASIS
4.1
Design Basis
Summary of the data that has been used as the basis for the degradation study
reported in this document are as follow:
Design Life
Design Pressure
Inlet Temperature
CO2 (in gas)
H2S (in water)
4.2
:
:
:
:
:
Fluid Composition
The data used are based on the laboratory analysis report which provided by
CoreLab. The gas composition for PL-262 is shown in Table 4.1 below:
Table 4.1 Gas Composition for PL-262
COMPONENT
NAME
CO2
N2
C1
C2
C3
iC4
nC4
C5
iC5
nC5
C6
Carbon dioxide
Nitrogen
Methane
Ethane
Propane
i-Butane
n-Butane
Neo-Pentane
i-Pentane
n-Pentane
Hexanes
M-C-Pentane
Benzene
Cyclohexane
Heptanes
M-C-Hexane
Toluene
Octanes
E-Benzene
M/P-Xylene
O-Xylene
C7
C8
C9
P5248-006-MC-RP-0006
MOLE %
WEIGHT %
COMPONENT
C10
C11
C12+
NAME
Nonanes
Decanes
Undecanes
Dodecanes Plus
TOTAL
MOLE %
WEIGHT %
100.00
100.00
C12+ is considered pseudo component. The property of C12+ is shown in Table 4.2
below:
Table 4.2: Pseudo Components
CALCULATED RESIDUE
PROPERTIES
MOLE %
WEIGHT
%
MOLE
WEIGHT
(g.mol-1)
DENSITY AT
60F (g.cm-3)
4.3
Operating Envelop
4.4
Environmental Data
The environmental data is taken from BARDEGG Pipeline Hydraulic Report
Formation WateR
4.6
Fluid Analysis
: 40C
: 21C
: 30C
: 17C
: 24.2m/s
Fluids in PL-262 comprise gas lift and condensed water. These have been analyzed
for degradation and species that may be present in the water stream.
P5248-006-MC-RP-0006
Sour Service
NACE MR0175/ISO15156 defines sour service in multiphase systems and
recommends materials that are resistant to SSC in sour service environment as
shown in Figure 4.1.
P5248-006-MC-RP-0006
5.0
ASSUMPTIONS
6.0
6.1
6.2
Acceptable Materials
P5248-006-MC-RP-0006
7.0
7.1
Internal Degradation
Type
Corrosive Process
CO2 Degradation
7.2.1
Galvanic Degradation
7.2.2
7.2.3
7.2.3
Oxygen Degradation
7.2.4
Microbiologically Influenced
Degradation (MIC)
7.2.5
Erosion Degradation
7.3.1
Under-deposit Degradation
7.3.2
Low Temperature
Embrittlement
7.3.3
P5248-006-MC-RP-0006
External Degradation
Permeation
7.3.4
Absorption
7.3.5
Atmospheric Degradation
7.4.1
Seawater Degradation
7.4.2
7.4.3
Degradation
Insulation
7.4.4
Under
Crevice Degradation
7.4.5
UV Degradation
7.4.6
7.2
Internal Degradation
7.2.1
CO2 Degradation
7.2.2
Galvanic Degradation
7.2.3
H2S Degradation
7.2.4
Oxygen Degradation
7.2.5
7.3
7.3.1
Erosion Degradation
7.3.2
7.3.3
P5248-006-MC-RP-0006
7.3.4
Permeation
7.3.5
Absorption
7.4
External Degradation
7.4.1
Atmospheric Degradation
7.4.2
Seawater Degradation
7.4.3
7.4.4
7.4.5
Crevice Degradation
7.4.6
UV Degradation
8.0
8.1
8.2
8.3
Pigging
8.4
8.4.1
Pipeline Coating
8.4.2
Riser Coating
8.4.3
9.0
Cathodic Protection
DEGRADATION MONITORING AND INSPECTION PROGRAMME
9.1
Purpose
9.2
9.2.1
9.2.2
Polymer Probe
P5248-006-MC-RP-0006
9.2.3
9.3
Inspection
9.3.1
Risers
10.0
P5248-006-MC-RP-0006