Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
ABSTRACT
One hour of installation time offshore cost about 30 000 NOK, hence a
focus on mobilization and marine operations time is of essence in the
development of a new tie in system.
The objective of this paper is to present a conceptual design of a tie in
tool that shall be used to connect a 28" spool piece to a subsea structure
and a flow line at a water depth of 1000 m. (Meling, 2002 and Lien,
2000) However, neither the pipe dimension or water depth are
limitations, but are chosen as a basis for conceptual considerations.
The design process has been divided into two, a mechanical design and
a mechanical analysis part. This paper will focus on the design part, and
will be based on an iterative process with the analysis part. This process
will ensure an optimal design regarding capacity and functionality of
the tie in tool.
All design drawing and analysis have been done with the computer
program I-DEAS (Integrated Design Engineering Analysis Software),
which facilitates FEM analysis as well as regular 3D-modelling.
Existing tie in systems for large diameter pipelines in deep water are
often large in size and complicated, and require many time consuming
operations. Furthermore, most of today's systems are limited to a
maximum pipe diameter of 20".
Subject paper describes a new development of a simple, yet reliable, tie
in system for large diameter pipelines in deep waters down to 2500
meters. The system is based on simple modularized tie in heads, one at
each end of the pipeline spool, integrated with hydraulic control and
communication packages. Primary communication and control is
conducted from a PC on a vessel via acoustic modems to conduct pull
in, alignment, and connection as well as seal testing and seal
replacement if required. Secondary control can be done via a standard
work class ROV should primary control & communication system fail.
During operations the tie in spool is deployed from the support vessel
with the tie in heads installed, one at each end. Upon reaching the tie in
location subsea, pre installed guide posts on subsea terminations as well
as guide funnels on the tie in heads will roughly align the pipe spool.
Following rough alignment, the tie in head in each end will be operated
from the vessel PC while ROV provide the camera for visual feedback
to operator.
Initial time savings analysis indicates that subject tie in system has a
potential of cutting operations time down 50-70% as compared to
existing systems on the market today. Further, due to the simplicity of
the system, it is believed that tie in operations can be conducted far
more safely than is the case today due to fewer lifting and other
associated operations.
BACKGROUND
Connection method. There are several ways of connecting a flow line
to a subsea structure. Methods such as "Deflect to connect" and use of
flexible pipelines are widely used today, but the use of a rigid steel
spool is considered to be the best way of pipeline connection in the
given environment at 1000 m water depth and deeper. This method can
be used both at the start and end of the pipe-laying process. The
advantages of a spool piece are among others its flexibility and the
relatively simple process of reversing the installation process if
necessary. This is especially important in deep waters where the cost of
accessibility is high. The spool piece is fabricated on the basis of
accurate geometrical measurements (Metrology) of the area where the
spool is going to be installed. The spool is chosen to have a zconfiguration, i.e. it is shaped as a z, which is a very flexible
configuration.
INTRODUCTION
The trend in the development of offshore oilfields is towards smaller,
marginal fields at deep waters. In several parts of the world, oil and gas
reserves have been found at water depths of 1000 m and below.
Existing systems for tie in operations today are usually designed for
deep waters, but the majority of the systems have a limited pipe size
capacity of about 20". These systems are often big and complicated, and
require several time-consuming, and expensive marine operations to
install and operate. A new, relatively small and efficient tie in system
could potentially reduce the cost of tie in operations considerably.
19
aluminum frames and tools for change out and seal cleaning generally
mounted separately on the ROV. These tools can be used for different
tie in operations in the same area without recovering the tool to the
surface, which is impossible with the ROT's and the heavier ROT
Derived systems. ROV carried tie in tools can only be used to connect
flexible pipelines.
it can enter the second guide post. The use of only one guide wire
eliminates the risk of guide wire-entanglement. The guide wire is
deployed from the surface vessel, but in waters of 1000 m and below,
there are risks of an entanglement of the guide wire and the spool piece
deployment wire. This risk could be reduced with the use of buoyancy
devices in mid-waters for guide wire anchoring.
The operation is based on the following requirements:
--~.
,7"
,-~
g.
yes
no
yes
14"
2 5x3.5x5
7.1
2000
40
500
Kongsberg
Offshore
CAT
no
yes
no
12"
lxlx2
ICARUS
yes
yes
yes
22"
lx2x0.5
1600
N/A
N/A
3.5
2000
20
250
Rockwater/
Haliburton
ABB
PICT
yes
no
yes
10"
2.5x3.6x5
12
Big B r o t h e r R T S
yes
yes
yes
28"
2.3x3.6x4
350
30
N/A
Kv2erner
1500
40
800
Kv~erner
UTIS
DFCS
yes
no
yes
18"
0 8x2x3.2
1.75
900
10
N/A
SonSub
DRT
no
yes
no
42"
5x6x7
60
600
N/A
N/A
CIF
no
yes
no
22"
5x4x6
25
600
N/A
1670
CVC
yes
yes
no
18"
4xl.5x2.1
N/A
N/A
N/A
Rockwater/
Stolt Comex
Rockwater/
Stolt Comex
Cameron
Operations. All systems used for connecting pipelines under water are
based on the following three main operations:
The ROV derived systems all use two pull-in lines, have lightweight
20
INSTALLATION PROCEDURE
The main purpose here is to give a description of the tie in system
function, and the presentation is therefore simplified, leaving out some
irrelevant details. ROV activities are shown on a principal level, and
operations like seal cleaning, seal replacement and pressure testing are
left out. The installation process is divided into these main activities:
Guide Post installation. The guide post installation is the first operation
done in the spool installation process. They are installed on the tie in
porch, at the first end and second end subsea structure. Both first end
and second end structure and all of its structural components have been
previously installed.
Spool deployment. The tools have been placed and locked onto the
spool prior to the spool deployment. This can be done onshore, or on
the installation vessel.
D E S I G N BASIS F O R N E W T I E I N T O O L
The tie in system shall be used for both first and second end tie in of a
rigid steel spool piece to respectively a subsea structure and a flowline.
Water depth is 1000 meters or deeper. The dimension of the pipeline is
28" nominal size or larger and the wall-thickness is set to be 35 mm.
The spool piece is chosen to have a Z-configuration because of its
flexibility. There are mainly two issues concerning the configuration of
a spool piece, expansion due to temperature changes and deflections
during installation of the spool. Forces and stresses due to deflection
during installation are of main interest, and this chapter will focus on
some elements regarding these issues, as well as installation aspects.
Pipeline material data and dimension of a 28" spool piece are listed in
Table 2.
(X65)
210000
448
..
f..
The ROV and the tie in equipment are taken to the surface.
Unit
meter
meter
meter
MPa
MPa
Scale
0.711 (28")
0.641
0.035
f..
.C.
First end spool connection. After the spool has been deployed on the
seabed and the lifting frame removed, the first end connection operation
can start. This is the "easiest" of the two connection operations, and
requires the least forces.
Second end spool connection. The second end spool connection can
start after the first end is connected. The spool is firmly anchored in the
other end, and the spool requires both alignment forces as well as axial
pull-in force in the second end connection operation. The total force
needed here are much higher than in the first end connection.
First end tool removal & second end tool removal. After the spool has
been connected, the tie in tools are disconnected and hoisted to the
surface.
Density Seawater
(kg/m3)
1025
The tie in tool should function without the use of guide wires.
21
minimum.
The tie in system should consist of as few modules as
possible.
Pull-in beam. The main function of the pull-in beams is to transfer the
forces generated from the pull-in cylinders on the tool to the tie in porch
in each end of the spool. There is a beam on each side of the tool and
they have both mounted guide funnels on the first end tool, and grippers
on the second end tool.
Guide funnels. The guide funnels are mounted on the pull-in beams on
the first end tool. The funnels are used to guide the spool onto the tie in
porch on the subsea structure. A guide wire is threaded through one of
the funnels, and acts as guidance for the spool. Both funnels enter guide
pins located on the subsea structure, and this ensures a correct
placement of the spool on the seabed.
Grippers. The grippers are mounted on the pull-in beams on the second
end tool, and takes hold of the second end tie in porch configuration in
the tie in process. It consists of two saucer shaped plates mounted in the
end of a Y-beam. The gripper is connected to the pull-in beam in the
same way as the guide funnel.
Cylinders. There are six double acting hydraulic cylinders on the tool,
two large pull-in cylinders and four smaller locking cylinders. The
cylinders are powered with hydraulic pressure and actuation signal from
the ROV. This presentation of the cylinders merely presents the number
and location of the cylinders. Sizes and actual configuration depends on
factors, as force required, manufacturer etc.
Soft landing. There are two soft landing cylinders mounted onto the
main structure. These cylinders act as shock absorbers on the tool when
it is deployed on the tie in porch on the seabed. When the tool or spool
is lowered down to the seabed, it could receive quite a large impact
when the spool hitting the subsea structure. This impact could lead to
serious damage to both the spool, tool and subsea structure.
The basic principal behind the soft lands is an oil filled cylinder with a
piston moving back and forth. The piston has holes in it, allowing the
fluid to evacuate through it. This ensures that the piston can move
slowly in an axial direction. The piston is held in an extended position
by a spring mounted on the cylinder.
Corrosion anodes. The corrosion anodes prevent the tool from
corroding in periods of long seawater exposure. The anodes are made of
a zinc alloy, which corrodes instead of the metal of the tool. The
number and sizes of the anodes are dependent on the amount of
corrosion protection needed. Generally, it is wise to disperse the anodes
evenly around the tool to achieve the best effect. There are five anodes
placed on the tool, one on each of the three u-shaped plates of the main
structure, and one on each of the pull-in beams.
ROV interface. The ROV interface acts as an interface between the
ROV and the tool. It is mounted on top of the tool and provides docking
facility for the ROV to lock on to. It also has a panel with actuators
used by a ROV to manually control the hydraulic cylinders of the tool.
The ROV use a robotic arm to manipulate the actuators.
Hydraulic
Hydraulic
Spool/Running tool
Guide wire
ROV
ROV
ROV
TIE I N T O O L P R E S E N T A T I O N
The conceptual design of the tie in tool is presented in the figure 3 and
4. The design that is shown in the figures represents the conceptual
design.
Main structure. The main structure makes up the frame of the tie in tool.
It provides structural stiffness and absorbs the main forces in the pull-in
operation. It also functions as a reference for the other parts of the tie in
tool. To make this as rigid as possible, it is important to have interacting
stiffeners both lateral and axial. The goal is to make it as stiff as
possible, and in the same time make it as light as possible.
Glide tubes. There are four glide tubes mounted on the tool. These tubes
are function as a reference structure for the pull-in beams mounted on
each side of the tool. The beam is held in place lateral and vertical by
the tubes, but is allowed to move freely in axial direction. These tubes
also contribute to the rigidity of the tool, being quite solid and placed on
each corner of the main structure.
STRESS ANALYSIS
Finite element analyses of the structures have been performed for
different load cases associated with first end and second end pull in.
The results show acceptable stress levels in the different parts of the
structure for actual load cases
RESULTS
Different properties of the new tie in tool that has been designed are
given in Table 5, together with properties of similar tie in tools used
today. The table has the same property categories as Table 1.
Table 5 Comparison matrix of the new tie in tool
22
~-~
.~:
~:
~-
~
~
;z
t~
%"
~Z
t.<
c~
t<
AUSTIN
yes
yes
yes
28"
3xl.8xl.5
4.5
2500
30
800
ICARUS
yes
yes
yes
22"
lx2x0.5
3.5
2000
20
250
Authors
ABB
BBRTS
yes
yes
yes
28"
2.3x3.6x4
1500
40
800
Kva~rner
DRT
no
yes
no
42"
5x6x7
60
600
N/A
N/A
Rockwater/
Stolt C o m e x
CHC
yes
yes
no
18"
3xl.5x2.1
N/A
N/A
N/A
Cameron
CONCLUSION
There are very few tie in systems on the market to day that are capable
of connecting big pipelines (28") on deep water levels (1000 m and
beyond). Kva~rner's Big Brother tie in system is the only one of the
systems evaluated that is capable of connecting a 28" pipeline at 1000
m. This system was used for the first time in the summer of 1999.
The tie in operation of a 28" rigid spool requires the use of relatively
high forces. The pull-in capacity of 300 kN and the alignment capacity
of 800 kNm sets high demands to performance and structural strength
of the tie in tool. The design has been modified through an iterative
process with the structural analysis, and the final design is optimized
with regards to structural strength and rigidity.
REFERENCES
Meling, M.O.(2000): "Autonomous Subsea Pipeline Tie In S y s t e m Mechanical Design", MSc Thesis Department of Mechanical
Enginering and Material Science, Stavanger University
College, Stavanger
Lien, A (2000):Autonomous Subsea Pipeline Tie In SystemMechanical Analysis, MSc Thesis Department of Civil
Engineering, Stavanger University College, Stavanger
The tool is quite simple. There are only three mechanisms on the tool,
the pull-in, spool lock-on and the tie in porch lock-on mechanism.
Having few mechanisms is considered to be an advantage, as the
possibility of failure is reduced on a simple tool. Use of the same type
--r--
Win~
Lifting wire
Guide line
~
W e l l l ~ Struct'~, ~
l
~
\
I
Guide funnel
Spool piece
~ N-] ~ ~
~
/--~).eline termination
23
Installation vessel
1"
"
Lifting wire
Tie in tool
2~ Guide funnel
Wellhead structure
~
Pipeline termination
J,
Spool
.
_-
Control Umbilical
Guide pin
Wellhead structure
ROV
-t
Pipeline termination
Tieintool
///////Z
D: Connect tie in tool to spool termination
E: Remove guide pin and guide line Why remove the guide posts on a first end tie-in?? Isn't the guide posts the reaction point during
stroking operation.
Control Umbilical
ROV
Wellhead structure
. ~ _
Tie in tool
?2%L.~.
24
Spool
F: ROV docks on the tie in tool and supplies hydraulic power and control signals
G: Tie in tool pull in spool end and align terminations
H. ROV activate connection unit
Figure 2 Tie in operation
25
".~-i
', ~
"~t',<,,,.;;,~-.+'~-
/9'.
..: ~ , ,
x.
..,
, ,~.~y~,.
..,..
ai{~).....
.<-S;~>I i~:ig.:>~-:..;:
......
i!{~... :::}%
,'(>'%..~"
<7 ~;"
,>.>
, . . ~ ' , : .,0(~""
,
.,f../.-..: . .::'
. < < , ,SG~
..,t.. ........
~i iii~>~"5~:>"
.~?'~i:!;;;
>~~:7:~','':-~
(
,,a
,";
,
.... / /
.,
(~..~,,x,~ .71,..*" /.
if"
. . . . ..%.-~.
/1
i: ~.i I
>.-
........
~?;--..I>>?",'"}12}."
,.~ i .......C -~..... j~-v
,.
--.
}ii
-;.,..
;i/
. .
. . i}l
26