Inspection Maintenance and Repair of Deepwater Pipelines PDF

Inspection Maintenance and Repair of Deepwater Pipelines
DNV RP-F113
Deep and Ultra-deepwater Pipelines Conference
27 - 28 September 2011, Novotel Paris Les Halles
Ian Nash
Inspection Maintenance and Repair of

Deepwater Pipelines
Introduction
R
Requirements
i
t ffor pipeline
i li iinspection:
ti
what,
h t when
h and
dh
how
Pipeline maintenance and routine inspection
Pipeline damage during installation and operation in

deepwater, causes and effects
Understanding the real risks and potential need for repair
Repair systems, tools and techniques

Ian Nash

Deepwater Pipelines
Requirements for pipeline

inspection: what, when and how

Ian Nash

Deepwater Pipelines
Typical Characteristics of Deepwater Pipelines
Water depths are beyond diver limits and all activity (IMR) is remote
Wall thickness are typically high } Materials, Welding, buckling
Operating pressures are typically very high or very low
Ambient external pressures are high, commonly similar to internal operational

pressures } Coating and Insulation Degradation
High levels of Insulation are commonly required } Insulation Degradation
All
inspection,
maintenance
and
6C } CP, Flow
Assurance, Materials
Waters are typically
cold
approx 4C-
Pi li
Pipelines
tend
d not to b
be protected
db
by a concrete coating
i
} Damage
D
Geohazards can be significant } Spanning, Buckling, Damage, Bend Stability,

Turbitity and Debris flows
Slugging within produced fluids is common } Spanning, Fatigue
Greater tolerances Survey inaccuracy, installation accuracy
Metocean and environmental conditions tend to be benign } Stability
Seabed mobility is less dominant } Scour, Spanning
Corrosion coatings tend to be of very high quality } Corrosion, Damage
repair is performed remotely

Ian Nash

Deepwater Pipelines
BASELINE SURVEY
The ongoing assessment of inspection findings will involve comparison of data
with that recorded during previous inspection campaigns.
This will allow trends to be extrapolated and judgments made regarding the
urgency of remedial action.
This process necessarily commences with the acquisition of the measurement of
internally and externally taken values at the commencement of pipeline service,
known as a Baseline Survey.
On completion
l
off the
h installation
ll
off the
h d
deepwater Pipelines,
l
an as-built
b l survey
will be undertaken by the Installation Contractor to ensure that the
construction is fit for service. Similarly the Subsea Commissioning Team will
undertake
d t k surveys tto establish
t bli h correctt functionality
f
ti
lit and
d initial
i iti l iintegrity
t
it off th
the
system.
Together
g
the As-Built and Commissioning
g surveys
y will fform the Baseline Survey
y
against which future inspection will be measured.

Ian Nash

Deepwater Pipelines
INSPECTION STRATEGY (1)

Planned inspection campaigns are an integral part of the IMR strategy, the
purpose of the inspections being to monitor pipeline system integrity over time
and to monitor the impact of the subsea and production environments on the
pipeline.
Understanding and confirming design assumptions
Routine inspections may indicate a requirement for more specific investigations
involving detailed or specialist techniques. The normal physical inspection tasks
undertaken on the Deepwater Pipelines can be split into locations internal and
external to the pipeline.
Internal and External locations are typically periodically inspected by Pigging
and
d ROV/AUV methods
th d respectively.
ti l
Permanent monitoring methods also exist and are becoming more
commonplace.
p

Ian Nash

Deepwater Pipelines
INSPECTION STRATEGY (2)

With deepwater lateral buckling and walking issues, Inspection strategy needs
to include interaction with the designers.
designers
If your system is anticipated to have multiple start up and shut down scenarios
you will need to understand what the designers anticipated happening and how
to monitor
i
i
it.
In addition there may be need to reconfirm whats happened once the pipeline is
in operation.
p
I.e. the designers
g
have p
probably
yp
planned ffor the worst case,, but iff
things are not that bad and/or the operational approach changes this can result
in very different results to those planned and design for.
The requirement for and frequency of inspection will most commonly be
determined using risk based techniques

Ian Nash

Deepwater Pipelines
INSPECTION METHODS
Location
Method
Technique
Magnetic Flux
Defects
Spanning/Burial
Ultrasonic
Pigging
Visual
Calliper
Internal
P
Permanent
Monitoring
Geometry (XYZ)
Corrosion
Probe/Spool
Sand Probe
Visual
Corrosion
Dents
Gouges
leak
CP Failure
Geometry XYZ
Inspection
Burial
ROV
Acoustic
C i D
Coating
Damage
Hydrate
CP Probe
Weld S
Scanner
Tomography
Scanning
Side Scan
External
Movement
Buckle
Vibration
Visual
AUV
G
Geometry
t (XYZ)
Sidescan
Permanent
Monitoring
Ian Nash
Cracking
Fatigue
Vibration
Strain

Deepwater Pipelines
Protection Integrity (mattresses/

Rock/Covers)
INSPECTION DEFECT MATRIX
Internal
Crracking
Pro
otection
In
ntegrity
Vibration
Buckle
B
Mo
ovement
Hydrate
H
Coating
C
Damage
CP
PFailure
Erosion
leak
Gouges
G
Technique
Dents
D
Method
Co
orrosion
Location
Spaanning/
Buriial/Scour
Defect
MagneticFlux
Ultrasonic
Visual
Pigging
Calliper
Geometry
(XYZ)
Corrosion
Permanent
Probe
Monitoring
SandProbe
Visual
Acoustic
CPProbe
ROV
WeldScanner
Tomography
External
AUV
Permanent
Monitoring
SideScan
Visual
Acoustic
Sidescan
Vibration
Strain

Ian Nash

Deepwater Pipelines
Risk Based Inspection Concept

Identify
Threats/Hazards
to Pipeline
Assess
Inspection
History
DNV RP-F116 (Sec H1)

The risk assessment comprises the following main
tasks;
Failure Mode
Susceptibility
to Threat
Likelihood of
Failure
Consequence
of Failure
a) Establish equipment scope

Remaining
R
i i
Life or
Inspection
Grade
b) Identify threats
c) Data gathering
d) Data quality review
e) Estimate probability off ffailure (PoF)
Risk Factor
f) Estimate consequences of failure (CoF)

g) Determine risk
Risk
OK?
Mitigation
Measure to
reduce
susceptibility
h) Identify risk mitigating measures

i) All equipment threats have considered
j) Determine aggregated risk
Inspection
Scheme

Ian Nash
k) Planning of inspection, monitoring and testing

activities

Deepwater Pipelines
10
Targeted Inspections
Design
Dossier
Code
Requirements
Defect Type1
Defect
selected
Defect Type 3
Defect Type 4
Review
design
Review
previous
inspections
Defect Type 5
Inspection R
Records
Defect Type 2
Defect Type 6
Prepare &
Perform
Targeted
I
Inspection
i
Determine
most likely
location
Record
Results
No
Defect
observed?
Yes
Assess Defect &
Determine Correction
Stop

Ian Nash

Deepwater Pipelines
11
Deepwater Pig Inspection

Pig Inspection of offshore pipelines tends to look for internal problems.
Generally running pigs in offshore pipelines is very similar to running in onshore
lines, after the wall thickness and higher pressures are taken in to consideration.
The most favoured inspection methods are either ultrasonic or magnetic flux
inspection.
Magnetic flux is limited by magnet strength, ie get enough magnetism in the wall
of the pipe to enable good results to be obtained.
obtained
Ultrasonic can inspect very thick wall pipe but Ultrasonic's have to be run in a
liquid medium.
The main difference between offshore and onshore is the length of run between
pig traps, as Offshore pipelines tend not to have intermediate compression
stations with conveniently located pig traps.
traps The pig must not get stuck in the
pipeline as retrieving it will be much more expensive than from an onshore
pipeline. The pig must stay alive and recording data (battery duration may be an
issue)
Ian Nash

Deepwater Pipelines
12
Deepwater ROV Inspection
Traditionally, external inspection, of deepwater pipelines is performed using

work ROVs deployed from DP ROV support vessels.
These vessels are expensive, and they may not be available when they are
needed most.
In deep waters, ROVs become heavy to handle from these vessels, because
of long umbilicals; and they become prone to breakdowns.
ROV inspections of long transmission lines can be very slow and may take
many months to complete end to end
Weather downtime is also an issue for ROV support vessels when working
in harsh and hostile environments

Ian Nash

Deepwater Pipelines
13
AUV based Inspection

AUV-based Inspection in deepwater fields may provide dramatic improvements in
cost, performance, safety and reliability.
Large DPII vessels with high-end ROV spreads would no longer be required for
simple inspection.
AUVs have demonstrated solid performance requiring simple autonomy for

missions such as bathymetric survey and high resolution sonar imaging
AUVs can be deployed from small utility vessels, be capable of operations in

higher seas,
seas without the operational limitations and equipment hazards imposed
by umbilical and tether management systems.
Reduction in equipment complexity, vessel size and crew size would also result in
i
improved
d safety,
f t reliability,
li bilit and
d llower environmental
i
t l iimpact.
t
In the future AUVs would become field resident, residing in the subsea field for
periods of months. The end state of Vessel Independent Operations will achieve
f h reductions
further
d
in cost while
h l improving performance
f
and
d safety.
f

Ian Nash

Deepwater Pipelines
14
Pipeline routine inspection and maintenance

Ian Nash

Deepwater Pipelines
15
Optimisation of Routine/Scheduled Inspection
An optimum IMR plan aims to strike an appropriate balance between the

f ll i objectives:
following
bj i
maximising the availability of the pipeline system during its operating life by
maintaining and preserving its integrity, thus maximising revenue;
minimising inspection, intervention and rectification measures through the
life of the pipeline system, thus minimising through-life IMR related costs.
reducing to as low as is reasonably practicable all risks to people
people, the
environment and assets, in accordance with legislative, societal and business
requirements, thus minimising the costs of failures.

Ian Nash

Deepwater Pipelines
16
Optimisation of Routine Inspection Measures

Ian Nash
Phase 3
Phase 1
Failure rrate
The typical variation of failure rate in an

operating system with time, takes the shape
of the classic 'bath-tub' curve, and can be
divided into three phases:
Phase 1,, early
y failures or damage,
g , due to
defects in materials, incorrect installation,
incorrect operation, unexpected
environmental effects (Scouring etc)
Phase 2, random failures or damage, due
to earthquakes, impacts (dropped objects,
fishing,
g, anchors),
), etc
Phase 3, wear out failures or damage, due
to corrosion, fatigue, internal erosion,
anode depletion
depletion, coating breakdown etc

Deepwater Pipelines
Phase 2
Time
17
Minimising through-life IMR-related costs

The implication of the bath-tub curve is that relatively frequent and intensive inspection
is required in the early years, i.e.
Phase 1. As inspection data demonstrating good pipeline system* performance
accumulates, it is rational to adopt a reduced frequency and scope of inspection.
Thus a progressive reduction of inspection effort may be expected towards the end
of Phase 1 and into Phase 2
2.
Phase 2 for a typical subsea pipeline extends to several decades,
Phase 3 may not actually be reached during the operational lifetimes of many
projects.
j t H
However, if inspection
i
ti d
data
t starts
t t tto show
h
th
the onsett off wear-outt
mechanisms then an increased level of maintenance could be reintroduced.
As far as p
possible,, inspection,
p
, maintenance and repair
p
activities should be p
pre-planned
p
to take advantage of tendered contracts, optimum weather conditions and where
necessary co-incidence with planned pipeline shutdowns.
*The
Th
best way to controll some off these

b
h
i with
is
i h the
h designers
d i
h i
having
the
h experience
i
and
d being
b i
allowed the time to investigate/ design a more robust solution CAPEX vrs OPEX

Ian Nash

Deepwater Pipelines
18
Code Requirements DNV OS-F101

1. Define equipment scope ( i.e. All equipment that can lead to a failure) (DNVOS-F101, Sec. 11, D304)
2 For each equipment,
2.
equipment identify all threats which can lead to a failure (DNV-OS(DNV OS
F101, Sec. 11, D201)
3. For each threat; estimate risk (DNV-OS-F101, Sec. 11, D202)
Consequence of failure (CoF)
Probability of failure (PoF)
Propose plans for:
Inspection, monitoring and testing (IMT) (DNV-OS-F101, Sec. 11, D103)
Mitigation, intervention and repair (MIR) (DNV-OS-F101, Sec. 11, D700)
Integrity assessment (IA) (DNV-OS-F101, Sec. 11, D600)

Ian Nash

Deepwater Pipelines
19
Inspection Planning

Ian Nash

Deepwater Pipelines
20
Example Process from RP-F116

Inspection Interval

Ian Nash

Deepwater Pipelines
21
Example Process from RP-F116

Schedule Planning

Ian Nash

Deepwater Pipelines
22
TypeofInspection
ConsstAsBuiltSurvey
BaselineSurvvey
B
Phase1
""EarlyFailure
e"
Years
Phase21)
"RandomFailure"
Phase33)
"WearOutFailure"
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
IntelligentPig
VisualincludingCP
andSideScan
TowedAcousticSide
ScanSonar 2)
TargetedSpecial
Targeted
Special
Events
1) Reduction in annual inspection applies to remote subsea pipelines only 2) Acoustic side scan sonar is not always cost effective especially in
deepwater or where there are strong currents. An ROV survey with reduced scope could be considered 3) the third phase may not occur within
j
lifetimes, i.e. the Phase 2 (plateau phase) extends for several decades with well designed,
g
operated and maintained facilities.
normal project
Ian Nash

Deepwater Pipelines
23
Pipeline Maintenance
Preventive maintenance
Because of the high cost and potential delays associated with intervention,
preventive maintenance should be eliminated at the design stage, wherever
possible.
ibl
Routine maintenance
Routine maintenance tasks are required
q
where the elimination off specific
p f
intervention is uneconomic or technically problematic. Normally such
maintenance would be undertaken during repair activity, or combined with
planned inspection
p
p
campaigns.
p g
Corrective Maintenance
Intervention to rectify breakdown or degradation (Corrective Maintenance) is
referred to as Repair
Repair .
Normally Subsea Facilities shall possess sufficient reliability to ensure availability
throughout the field life.
Subsea equipment that is susceptible to failure should be designed to minimize
the effort/cost required for replacement of the failed assembly.

Ian Nash

Deepwater Pipelines
24
Pipeline damage during installation and

operation
p
in deepwater,
p
, causes and effects
ff

Ian Nash

Deepwater Pipelines
25
Installation Damage Scenarios

The potential causes and effects of damage during installation Phase of the pipeline(s) are
summarized as follows:
3rd Party
Objects Dropped from Ships
Material
and
Construction
Defects
Installation
Tension failure
Station Keeping
Coating
Geohazards
Slope Stability
Route Features
Rock Outcrops,
Outcrops Cement Soil,
Soil
Shell and Coral Banks.
Pockmarks

Ian Nash
Damage to pipeline geometry and/or pipe

wall:
Gouges, Grooves and Notches.
Dents
Wet and Dry Buckles.
Overstressing or Excessive Bending.
Fatigue Damage.
Bend Pull Out
Damage
(Corrosion
and
coating):
g)
Lost & Damaged weight coating
Damaged corrosion coating
Lost & Damaged insulation coating
Anode Damage:
g
Lost anode
Disconnected anode

Deepwater Pipelines
Weight
26
Operational Damage Scenarios

The potential causes of damage during operational Phase of the pipeline(s) are
3rd Party
Trawling
Anchoring
g
Ship sinking
Ship Grounding
Shipwrecks
p
and Debris
Material
and
Construction
Defects
Sabotage
Military
y Action
Environmantal
Wind, Waves and Currents
Scour
Seabed Morphodynamics
p
y

Ian Nash
Geohazards
Earthquakes
Seismic Fault movement
Submarine Landslides
Mass Gravity Flows
Turbidity Currents
Sub-marine Volcanoes
Liquefaction
Tsunamis
Route Features
Rock Outcrops,
p , Cement Soil,, Shell and Coral
Banks.
Shallow Gas and Seepage of Gas and Fluids
Pockmarks
Mud Diapirs
p and Mud Volcanoes
Slope Instability
Mass Movements

Deepwater Pipelines
27
Operational Damage Scenarios (effects)
The effect of damage that could occur during the operational phase of the pipeline(s) are
Damage to pipeline geometry and/or pipe wall:
Rupture.
Internal Corrosion.
External Corrosion.
Corrosion
Pinhole Leak.
Gouges, Grooves and Notches.
Cracks and Fracture Propagation.
Dents and Buckles.
Buckles
Overstressing or Excessive Bending.
Fatigue Damage.

Ian Nash
Coating
Damage
(Corrosion
and
coating):
Lost & Damaged weight coating
Damaged corrosion coating
Anode Damage:
Lost anode
Disconnected anode
Over consumption
Anode pasivity
Hydrate Formation:
Pinhole Leak.
Leak
Incorrect operation

Deepwater Pipelines
Weight
28
Damage Category and Scenario

Phase
Installation
Damage Category
Specific Damage Scenario

Dry Local Buckle
Dry Propagating Buckle
Wet Buckle
Buckle/Stinger impact
Hydrate
Internal/External Corrosion
Gouge/Dent/Buckle
Overstressing
Fatigue Damage
Trawling/Anchoring
Ship Sinking/Ship Grounding
Shipwrecks and Debris
Earthquakes/Tsunami
Mass Gravity Flows and Turbidity Currents
Dry Buckle
Wet Buckle
Loss of Coating
Hydrate
Localized Damage,
No Leak
Operation
Pinhole Leak
Seismic Fault/Submarine Landslips
Liquefaction/Scour
Rupture
p
Earthquakes/Slope Stability
Localized Damage,
Minor Leak
R t
Rupture,
L
Local
l
Rupture, Extensive Length
Extensive Damage, No
Leak
Ian Nash
Rupture
Internal/External Corrosion

Deepwater Pipelines
29
Based on the damage scenarios and risk assessment it is clear that:

The pipeline installation contractor should have fully developed procedures
and all necessary equipment mobilised and ready for implementation in the
event of dry or wet buckles, prior to the start of deepwater pipelay
operations.
The operator
p
should have fullyy developed
p
procedures and all necessaryy
p
equipment ready for implementation prior to the start of operations, to cater

for the following scenarios:
Hydrate formation.
Localised damage (i.e. dent or pinhole leak).
Local Rupture.
Rupture over extensive pipeline length.

Ian Nash

Deepwater Pipelines
30
This Recommended Practice (RP) is intended to provide criteria and guidelines for the qualification of
fittings and systems used for pipeline subsea repair and/or modifications and tie-ins.

Ian Nash

Deepwater Pipelines
31
Understanding the real risks and potential need

for repair
MEIDP Example
E
l

Ian Nash

Deepwater Pipelines
32
MEIDP Example (3500m WD)

Ian Nash

Deepwater Pipelines
33
Intervention Zones
Based on this preliminary information, the route has been divided into five different
intervention requirement zones.
1) Shallow Water Zone (0 to 150m WD)
2) Continental Slope Zone (150m to 2500m WD)
3) Deep Water Section (2500m to 3500m WD)
e ote Sea
Seamount
ou t Sect
Section
o (300
(300m to 3000
3000m WD))
4)) Remote
Middle Indus Fan
Upper Indus Fan

Ian Nash
Sh lf
Shelf
4
3
Abyssal
Plain
Slope
Qualhat
Seamou
nt
Rise
Abyssal
Plain
North Murray
Ridge
Dalrymple
Trough
South Murray
Ridge
Rise
Abyssal
Plain
Slope
5) Indus Fan Section (2500m to 3000m WD)

Deepwater Pipelines
34
Typical QRA for Deepwater Pipelines
MEIDP QRA Risk Contributors and % contribution
Ship sinking (40

(40.24%)
24%)
Objects dropped from ships (19.91%)
Ship grounding (14.07%)
Material and construction defects (11.17%)
External corrosion (10.62%)

(
)
Anchoring (3.23%)
Internal corrosion (0.63%)
Trawling (0.12%)

Ian Nash

Deepwater Pipelines
35
Typical QRA for Deepwater Pipelines
6.00E-03
3.00E-03
Most likely
location for
Intervention is the
deepest
p
water
5.00E-03
2.50E-03
4.00E-03
2.00E-03
1 50E 03
1.50E-03
3.00E-03
1.00E-03
2.00E-03
5.00E-04
1.00E-03
Rise
Abyssal
Plain
Qualhat
Seamou
nt

Ian Nash
Abys
sal
Plain
North
Murray
Ridge
Dalrym
ple
Trough
South
Murray
Ridge
Sl
o
p
e
0.00E+00
0.00E+00
Middle Indus Fan
Upper Indus Fan

Deepwater Pipelines
Abyssal
Plain
R
is
e
Sl
o
p
e
Material and construction defects

External
corrosion
Material
and construction defects
Internal
corrosion
External
corrosion
ShipInternal
grounding
corrosion
ShipDropped
sinking objects
Dropped
objects
Anchoring
Anchoring
Trawling
Trawling
Shelf
36
Repair Scenarios and Types
Repair Scenario
Repair Type
Dry Buckle
Profiled clamp or Spool and /or External protection

(Rock Dump)
Excessive Plastic Strain

Wet Buckle
Spool (External protection)[[1]]

Spool,
Rupture
Spool, (External protection)
Internal Corrosion
Clamp or Spool
External Corrosion
Clamp or Spool
Coating Damage
Clamp or Spool, (External protection)
Pinhole leak
Clamp
Dents, Gouges,
g
Grooves, Notches
Clamp
p and /or External p
protection
Cracks, Fracture Propagation
Clamp
Hydrate Blockage
Hydrate removal
Excess Unsupported Span
External protection i.e. strakes, mechanical support (frame,

rock ,jetting additional analysis
Anode damage / depletion
Anode replacement
Note: [1]. External protection inside ( ) denotes a secondary measure

Ian Nash

Deepwater Pipelines
37
Repair systems, tools and techniques

Ian Nash

Deepwater Pipelines
38
Emergency Pipeline Repair System

The minimum functional requirements identified for an emergency repair system are
listed as follows:
Operable
p
at water depths
p
up
p to deepest
p
water of the p
pipeline
p
((3500m))
Operable on pipe size(internal diameter) of pipelines (24)
Operable with steel wall thickness up to maximum and relevant coatings
(40.5mm)
Operable
O
bl on soft
ft seabed
b d soils
il (soft
( ft calcareous
l
clay
l and
d silt)
ilt)
Operable on seabed slopes (of up to 28 degrees)
Capable of providing a repair capability extending from minor dents to
replacement
p
of multiple
p p
pipe
p jjoints
While not mandatory, it is advantageous if the system(s) and equipment also exhibit
the following characteristics:
Modular and/or lightweight
Minimum number of components
Incur minimal shut down and/or reduction of operation
Minimum CAPEX investment

Ian Nash

Deepwater Pipelines
39
Repair System Components

An overall pipeline repair system to install a clamp or spool requires an
extensive array of equipment to conduct a repair operation.
operation The repair
systems generally perform tasks from the following list:
Metrology of the pipeline damage and repair site
Isolation of the damaged section of pipe with internal plugs if required
Soil excavation
Pipeline lifting, locally at the repair site or completely to the surface
Pipe coating removal
Pipe cutting
Removal of damaged section
Pipe
p end surface p
preparation
p
Metrology of the pipeline for clamp and spool piece preparation
Transport and positioning of clamps, spool pieces and connectors
Closing and sealing clamps and connectors
Testing the repair
Lower the pipeline to the seabed
Removal of repair system equipment
Ian Nash

Deepwater Pipelines
40
Why Tooling is Needed

Equipment
DP Support Vessel
Pipelay Vessel
Purpose
Platform from which to operate ROVs and conduct repair operations.
Working platform in the event that an extensive section of damaged
pipeline has to be relaid/replaced.
Flooding/Dewatering/Drying Various purposes including:
Spread
Pressure equalisation prior to cutting (flooding).
Coupling for intelligent pigging (flooding).
Removal of water (dewatering).
Drying prior to returning to service to minimise water content and
risk of hydrates.
Seabed Dredging/Levelling
Exposure of the pipeline, if locally trenched or buried, to allow for survey
Equipment
and/or repair operations.
Pipeline Lifting
f
Frames
Elevation off pipeline off
ff the seabed in the vicinity off any repair, for
f the
purpose of improving access for repair equipment and operations.
Subsea Measurement Tool
Performance of measurements between pipeline ends for accurate spool
piece and connector assembly
assembly.
Pipeline Cutting Tool
Cutting of pipeline (and coatings) to allow removal of any damaged
sections.
Ian Nash

Deepwater Pipelines
41
Why Tooling is Needed

Equipment
Pipeline Coating
Removal Tool
External Weld Bead
Removal Tool
End Preparation Tool
Pipeline Recovery
Tool
Pipeline Repair
Clamp
Subsea Pipeline
Connectors
Replacement Spool
piece
Hydrate Blockage
Removal Spread
p
Purpose
Removal of external pipeline coatings in the vicinity of any section that has
been cut (by the Pipeline Cutting Tool). Required in the event that the Pipeline
R
Recovery
T
Tooll grips
i the
h pipeline
i li on iits externall steell surface.
f
Removal of external longitudinal weld seam (SAW linepipe) to prevent
interference on connector seal.
Machining of the end face of the pipeline to prevent interference on connector
seal.
Tool connected to the end of the cut pipeline to allow recovery to surface.
Designed to allow the pipeline be dewatered and isolated prior to recovery.
Permanent clamp installed around the pipeline in the vicinity of minor damage
(i.e. dent) for the purpose of ensuring the structural integrity of the pipeline
without the need for cutting out and replacing an entire section of pipe.
Connector assembly and modular system used for the installation and
connection of a new section of pipeline.
New section of pipeline used to replace area of damage.
Accidental ingress of moisture into the pipeline can cause formation of a
hydrate
y
p
plug.
g Hydrate
y
removal is p
possible byy various p
passive methods but mayy
ultimately require a deepwater hot-tap operation at actual location of the
hydrate where the spread taps a hole into the pipeline and injects hydrate
removal chemicals.

Ian Nash

Deepwater Pipelines
42
Example Lifting Frame

Ian Nash

Deepwater Pipelines
43

Ian Nash
Split
(i..e.
Repair Clamp
Sleeve))
Intellige
ent Pigging Eq
quipment
Hydrate
e Removal Sp
pread
Pipeline
e Recovery T
Tool
(with d/w
w capability)
Connec
ction System a
and
Spoolpiec
ce
d Dredging / Levelling
Seabed
Equipm
ment
Coating
g Removal Too
ol
Weld Be
ead Removal Tool
Pipe Cu
utting Tool
Metrolog
gy Unit
ROV Su
upport Vessel
Deep Water Repair System

Components
Pipelay Vessel
Dry
Local
Buckle
(recoverable)
Dry Local Buckle (nonrecoverable)
Dry Propagating Buckle
(non-recoverable)
Local Wet Buckle (non(non
recoverable)
Hydrate plug
Localised damage, no
leak
Localised damage with
leak
Rupture, local
Rupture,
extensive
length
Flooding/Dewatering / Drying
Spread (Onshore)
Pipe Lifting Device (i.e.
H-frame
es)
Damage Equipment Matrix

Deepwater Pipelines
44
Repair Systems and Clubs

Equipment Name
Main Contractor / Operator

p
Systems
y
Bespoke
Chevron Petronius Repair System
Oil States / Chevron
BP Mardi Gras Pipeline Repair System
Oil States / BP
SIRCOS
ENI / Saipem (Sonsub)
Pipeline Connection and Repair Systems (PCRS)
Oceaneering
Total Girassol Pipeline Repair System
Subsea 7
Repair Clubs
Shell Deepwater Pipeline Repair System
Shell HOLD (there are two version of the Shell club?)
DW RUPE
DW RUPE
Pipeline Repair System Pool
Technip (Norway), Deep Ocean, Statoil

Newly Founded Repair Clubs
Emergency Pipeline Repair Equipment Sharing

(EPRES)
??
Ian Nash
South East Asia Pipeline Operators Group (SEAPOG)

Pipeline Repair Operators Forum Australasia (PROFA)

Deepwater Pipelines
45
Candidate Systems Capability

Pipeline Repair Systems
Up to 3500m
Sonsubs SIRCOS currently can work up to 2200m
Saipem indicates it can be upgraded for higher water depths
Deepwater Pipeline Repair System from Oceaneering and Oil States
Oceaneering indicates depth requirement of 3500m can be
currently rated to about 3000m.
designed and manufactured

Oil States indicates further tests are required to re-qualify their
system for 3500m rating
EPRSCapabilityinTermsofMEIDPRequirements
Oil States
OilStates
Saipem
Oceaneering
210%
200%
190%
180%
170%
PercenttageofRequirements
160%
150%
140%
130%
120%
110%
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
WaterDepth
(m)
ConnectorSize WallThickness
(in)
(mm)

Ian Nash
SeabedSlope
(deg)
SeabedSoil PipelineCoating
Concrete
Strength(kPa)
(mm)
Coating(mm)
<600m

Deepwater Pipelines
46
Summary of Inspection for Deepwater Pipelines
Intelligent pigging is the primary form of internal inspection

ROV are the primary tool for performing external inspection
The development of AUVs for flypast inspections may give benefits deepwater by
isolating the vehicle from surface influences
Risk Based methods have been established for determining Inspection regimes (DnV
RP116)

Ian Nash

Deepwater Pipelines
47
Summary of Repair for Deepwater Pipelines

Installation Phase
Damage scenarios during installations and operation pose differing levels of risk.
The most significant potential damage scenarios during the installation phase are
dry and wet buckles.
The technology and methodologies required for rectification of installation phase
damage (i.e.
(i e buckles) are a direct extension of techniques used for similar events in
shallow water, and currently exists with installation contractors and specialist
equipment suppliers.

Ian Nash

Deepwater Pipelines
48
Summary of Repair for Deepwater Pipelines

Operational Phase
Several potential damage scenarios exist during the operational phase. The most
significant are where a damaged section of pipeline needs to be reinforced, replaced

or cleared of a hydrate blockage.
Where a replacement pipeline section is required, the length could vary significantly
d
depending
di on th
the nature
t
off th
the eventt causing
i the
th damage
d
(a
( ffew meters
t
to
t severall
kilometres in the event of a geohazard (i.e. slope instability).
There is a wide range of qualified or nearly qualified equipment for the subsea
repair both currently available and under continual development.
repair,
development The equipment
exists both as individual components (equipment, tools and fittings) and full
systems.
Some repair systems are owned and operated on a club
club basis,
basis by a group or
consortia of pipeline operators. The clubs at present operate in specific
geographical locations.
The need to access the p
pipeline
p
at both ends for the p
purpose
p
of re-commissioning
g
(i.e. flooding, cleaning, dewatering, etc.), is inherent in many of the repair scenarios.
Access facilities and the provision of adequate space for equipment (particularly
dewatering) are significant.

Ian Nash

Deepwater Pipelines
49
Acknowledgements
The author would like to thank South Asia Gas Enterprise PVT Ltd. for giving permission to
publish aspects of this work, and the team in Peritus, for their continued hard work.

Ian Nash

Deepwater Pipelines
50
References
I Nash & P Roberts OPT 2011,

2011 MEIDP The Deepwater Gas Route to India
India, February
23-24,
I Nash & P Roberts DUDPC 2011, Case Study: MEIDP Installation, intervention and
Repair,
p , Sept
p 27-28
Peritus International, 18001.01-REP-IIDP-Y-0014 MEIDP, Emergency Pipeline Repair
Systems, Aug 2011
Peritus International, 18001.01-REP-IIDP-Y-0007 MEIDP Quantified Risk
Assessment Update, Dec 2010
Dan McLeod, Emerging Capabilities for Autonomous Inspection Repair and
Maintenance, OCEANS 2010 (ART)
DNV RP-F116 Integrity Management of Submarine Pipeline Systems
DNV RP-F113 Subsea Pipeline Repair

Ian Nash

Deepwater Pipelines
51

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Inspection Maintenance and Repair of Deepwater Pipelines

Inspection Maintenance and Repair of

Pipeline maintenance and routine inspection

Pipeline damage during installation and operation in

Understanding the real risks and potential need for repair

Repair systems, tools and techniques

Deep and Ultra-deepwater Pipelines Conference

Inspection Maintenance and Repair of

Requirements for pipeline

Deep and Ultra-deepwater Pipelines Conference

Inspection Maintenance and Repair of

Typical Characteristics of Deepwater Pipelines

Wall thickness are typically high } Materials, Welding, buckling

Operating pressures are typically very high or very low

Ambient external pressures are high, commonly similar to internal operational

High levels of Insulation are commonly required } Insulation Degradation

Geohazards can be significant } Spanning, Buckling, Damage, Bend Stability,

Slugging within produced fluids is common } Spanning, Fatigue

Greater tolerances Survey inaccuracy, installation accuracy

Metocean and environmental conditions tend to be benign } Stability

Seabed mobility is less dominant } Scour, Spanning

Corrosion coatings tend to be of very high quality } Corrosion, Damage

repair is performed remotely

Deep and Ultra-deepwater Pipelines Conference

Inspection Maintenance and Repair of

Deep and Ultra-deepwater Pipelines Conference

Inspection Maintenance and Repair of

INSPECTION STRATEGY (1)

Deep and Ultra-deepwater Pipelines Conference

Inspection Maintenance and Repair of

INSPECTION STRATEGY (2)

Deep and Ultra-deepwater Pipelines Conference

Inspection Maintenance and Repair of

Inspection Maintenance and Repair of

Protection Integrity (mattresses/

INSPECTION DEFECT MATRIX

Deep and Ultra-deepwater Pipelines Conference

Inspection Maintenance and Repair of

Risk Based Inspection Concept

DNV RP-F116 (Sec H1)

a) Establish equipment scope

f) Estimate consequences of failure (CoF)

h) Identify risk mitigating measures

Deep and Ultra-deepwater Pipelines Conference

k) Planning of inspection, monitoring and testing

Inspection Maintenance and Repair of

Deep and Ultra-deepwater Pipelines Conference

Inspection Maintenance and Repair of

Deepwater Pig Inspection

Inspection Maintenance and Repair of

Deepwater ROV Inspection

Traditionally, external inspection, of deepwater pipelines is performed using

Deep and Ultra-deepwater Pipelines Conference

Inspection Maintenance and Repair of

AUV based Inspection

AUVs have demonstrated solid performance requiring simple autonomy for

AUVs can be deployed from small utility vessels, be capable of operations in

Deep and Ultra-deepwater Pipelines Conference

Inspection Maintenance and Repair of

Pipeline routine inspection and maintenance

Deep and Ultra-deepwater Pipelines Conference

Inspection Maintenance and Repair of