PIPELINE REPAIR AT

KP 110 – KP 133 KUALA TUNGKAL TO

PANARAN TGI OFFSHORE PIPELINE
18th-June-08
 FEED Handover Meeting Agenda

1. Project Introduction
2. Problem Definition
3. Design Basis
4. Pipeline Mechanical Design
5. Pipeline Outline Installation Analysis
6. Repair Methodology
7. Cost Estimate and Schedule
8. Valve Skid Design
9. EIA Review
10. HAZID & HAZOP Action Items
11. Prof. Andrew Palmer’s Review
12. Closeout Report
13. Discussion and Close Out
 Project Introduction

KP 133.5

KP 110.5
 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
 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
Project Introduction
 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
Design Basis of Replacement Pipeline
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Mechanical Design
Pipeline Installation Analysis
Pipeline Installation Analysis
 Final Repair Method

 Repair Method

• Zero Downtime Method Micros oft

PowerPoint Presentation
Schematic Diagram
 Comparison Between Both Methods

Cost
Flange
Barred 5D Gate Shut-down
Connections/ Hot Taps STOPPLE
Tees Bend Valve Time Hardware Construction Total
KaMos Gaskets
Cost Cost Cost

CM – Reduced 6
Nil 4 Nil Nil Nil 4 – 6 Wks US$3.3 US$30M US$33.3
Downtime (4 in-place)

Zero
8 2 x 28”
Downtime 6 4 2 4 Nil US$9.6M US$40M US$49.6
(6 in-place) 2 x 16”
Method

Note:
2. CM – Conventional Method
3. The hardware cost stated above includes 10% for transportation cost.
 Comparison Between Both Methods
Reduced Downtime Method Zero Downtime Method

Advantages • No flange connections along the • Zero Shut-down time and any delay
pipeline in construction will not disrupt flow
• Involves less construction and to the consumers
diving work • Restoration of full design pressure
before completion of repair
• Equipment procured offers flexibility
to switch to reduced down time
method
Disadvantages • Stoppage of gas supply to • 6 flange connections
consumers for 4 to 6 weeks • Involves more construction / diving
• Delay in construction work will result work
in more stoppage of gas supply to • 6 In-place hot-tap clamps
consumers
• After commissioning sales gas will
have some water till complete
dryness is achieved
• Equipment procured does not offer
flexibility to switch to zero down time
method
• 4 In-place hot-tap clamps
Material Cost US$3.3M US$9.6M
Construction Cost US$30.0M US$40.0M
 Comparisons of Risks
Reduced Downtime Method Zero Downtime Method

1. Emergency Response Plan required 1. Emergency Response Plan required

1. Gas Freeing the abandoned pipeline 1. Gas Freeing the abandoned pipeline

1. Potential of buckling the pipeline during above 1. KaMOS gasket failure

water tie-in
1. Presences of large amount of water and air 1. Experienced Hot-tap contractor should be
pockets in the pipeline while restoring the flow engaged
1. Gas supply shut down time can increase due to
construction delays
1. Experienced Hot-tap contractor should be
engaged
Shut-Down Time for Reduce Downtime Method
Overall Schedule for Zero Downtime Method – Best Scenario
Overall Schedule for Zero Downtime Method - Realistic
 Potential EPCC Contractors

Pipelay Subsea
Cal Dive  

Saipem  

Global  

Acergy  

Technip Subsea 7  
Valve Skid Design
Valve Skid Design
Valve Skid Design
Valve Skid Design
EIA Action Plan
EIA Action Plan
EIA Action Plan
 HAZID & HAZOP Action Items

 HAZID Action Items – Adobe Acrobat 7.0

Document

 HAZOP Action Items – Adobe Acrobat 7.0

Document
Dr Andrew Palmer’s Review and Actions
Required
Dr Andrew Palmer’s Review and Actions
Required
Dr Andrew Palmer’s Review and Actions
Required
 Project Status – Engineering

 Pipeline Mechanical Design

S/N Activities Status Further Actions
1. 28” Pipe WT and Concrete Done -
Thickness
2. 16” Pipe WT and Stability Done EPC Contractor to check suitability of the available 16” pipe from
Stockist. For a !6” dia 11.1 mm thick a 40mm concrete is
required. EPC Contractor to proposed method to ensure stability
of pipeline if 16” pipe is not concrete coated.
3. Small Diameter Pipings, WT Done EPC Contractor to check suitability of the available 6” pipe from
and Stability Stockist. EPC Contractor to ensure stability of piping during
operation.
4. Cathodic Protection Design Done No CP is proposed for the temporary piping as it is exposed to
sea water for a short period only. There is enough margin on the
anodes provided on the permanent facilities to take care of the
temporary piping.
5. Pipelay Analysis Done EPC Contractor to perform detailed dynamic lay analysis based
on their proposed pipe laybarge
6. Bottom Roughness Done EPC Contractor to perform pre-engineering survey and update
the Bottom Roughness Analysis. Span rectification if required.

7. Overall Schematic Done EPC Contractor to perform final HAZOP and HAZID and update
overall schematic.
 Project Status – Engineering

 Installation Methodologies

S/N Activities Status Further Actions

1. Zero Downtime Method Done EPC Contractor to develop a detailed execution plan and
procedures for this method

2. Reduced Downtime Method Done -

3. Comparisons between Methods Done -

4. HAZID and HAZOP Done EPC Contractor to perform HAZID and HAZOP based on the
execution plan and procedures developed by EPC Contractor
 Project Status – Engineering

 Valve Skid Design

S/N Activities Statue Further Actions

1. Piping Analysis - Caesar II Done
Model EPC Contractor to carry out detailed design of Valve Skids .

2. Structural Analysis - SACS Done EPC Contractor to re-check installation analysis and design
Model
installation aids based on the final skid design and equipment /
vessel proposed for installation.
3. Drawings Done
EPC Contractor to develop detailed fabrication drawings.
 Project Status – Engineering

 Material Specifications
S/N Activities Status Further Actions
1. Flanges, Bolts, Nuts, Gaskets Done -
and Fittings

2. Subsea DBB Expandable Gate Done -

Valves / Gate Valves

3. 5D Induction Bends Done

4. Subsea Mechanical Connectors
& Hot Tap Assembly
5. Field Welding and NDT
Done EPC Contractor to attend all FAT testing for both mechanical
connectors and hot tap assemblies
EPC Contractor to perform mock testing before the actual
installation works
Done EPC Contractor to prepare welding and NDT procedures

6. Construction Materials Not Done All non-long lead and construction materials to be procured by
EPC Contractor
 Project Status – Engineering

 Installation Specifications

S/N Activities Status Further Actions

1. Pipeline Installation Done EPC Contractor to develop all necessary installation procedures

2. Survey and Monitoring Done EPC Contractor to develop detail survey and monitoring
procedures.

3. Pipeline Cleaning, Gauging, Done EPC Contractor develop detail pre-commissioning procedures.
Pigging and Hydrotest Final HAZOP and HAZID need to be performed
 Project Status – Engineering

 Drawings

S/N Activities Status Further Actions

1. Pipeline Alignment Done EPC Contractor to update based on pre-engineering survey and
identify locations where span rectification is required

2. Tie-in Arrangements Done  EPC Contractor to update based on final arrangement

proposed and approved by PMT / TGI
 EPC Contractor to perform HAZOP and HAZID based on the
final arrangement and make necessary adjustments
3. Valve Skid Details Done EPC Contractor to include details of installation aids and prepare
fabrication drawings.
Discussion and Close Out