Canusa-CPS Offshore Evolution & Lessons Learned Upstream...

Canusa-CPS

Offshore Evolution & Lessons Learned

Upstream Conference & Exhibition

Bucharest

Thursday 23rd April, 2015

Dan Pearson – Area Manager Onshore Western & Central Europe

Ten Business Units

2

Bredero Shaw Coatings

- corrosion protection - insulation - weight / protective - internal flow efficiency

Desert NDT

Flexpipe Flexible composite

pipe for: - oil and natural gas

gathering lines - oilfield water and

fluids

PIPELINE & PIPE SERVICES

DSG-Canusa

Heat shrink tubing for sealing and protection

ShawFlex

Control, instrumentation cable

PETROCHEMICAL & INDUSTRIAL

Canusa-CPS

Weld inspection - Radiographic - Ultrasonic - Offshore and

onshore

Shaw Pipeline Services

Joint protection Pipe coating

materials

Socotherm Coatings

- corrosion protection - weight / protective - thermal insulation

Guardian • Drill pipe/tubular

inspection • Inventory

management services

Integrity Management

Weld inspection - Radiographic - Ultrasonic

Evolution of offshore pipeline projects

Offshore Innovations

2001-2: Blue Stream Project 10-24" OD x 15,000 joints Introduction of GTS-PP Onshore Sections & Compressor Station

Blue Stream

GTS-PP Heat Shrink Sleeve System

http://www.offshore-technology.com/projects/blue_stream/index.html



2002-3: Green Stream Project > 600 km x 32" OD GTS-PP in S-Lay Saipem Castoro Sei

Green Stream




2004-6: Langeled Project 1,200 km x 42-44" OD Acergy Piper & Allseas Solitaire

Langeled

http://www.statoil.com/STATOILCOM/SVG00990.nsf?OpenDatabase&lang=en





2006-8: Dolphin Project 160 km x 36" & 480 km x 48" OD Induction Heating Saipem Castoro Sei and Castoro 2

Dolphin

Induction Heating Generators & Coils

http://www.total.com/en/home_page/

http://www.dolphinenergy.com/index.html






2007-9: Medgaz Project 207 km x 24" OD Semi-Automated GTS-PP (6.0 mm Thickness) Saipem Castoro Sei & S-7000

Medgaz

Custom edge-reduced sleeve design

Chamfered overlap and underlap seams

Thick central sleeve area

Medgaz

Automated Sleeve Welders

Manual Sleeve Welders

Conditioning Ovens

Sleeve Spacer Tools







2009-11: Nord Stream Project 2,400 km x 48" OD Saipem Castoro Sei & Allseas Solitaire

Nord Stream







2009-11: Nord Stream Project 2,400 km x 48" OD Saipem Castoro Sei & Allseas Solitaire

South Stream Project

*Adapted from Peritus International Ltd. Engineering Paper, February 23-24, 2011

Difficulty Index for Deepwater Pipelay Projects

Tupi (2,130 m - S)Medgaz (2,152 m - J/S)

Galsi (2,822 m - J/S)

Blue Stream(2,150 m - J/S)

South Stream(2,000 m - J/S)

Walker Ridge (2,175 m - J/S)

Urugua (1,360 m - J/S)

USAN (850 m - S)

Greater Plutonio(1,500 m - J)

Langeled (400 m - S) Nord Stream (210 m - S)

Green Stream(1,200 m - S)

Liwan (1,500 m - J/S)

0

500

1000

1500

2000

2500

3000

1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 2025Year

Wat

er D

epth

x Pi

pe D

iamet

er

Offshore Pipeline Trend

Lessons Learned

General FJC Design

3 layer systems for 3 layer mainline coatings

FJC Selected to Match Performance, Temperature, Service Selected for MLC – PP HSS for 3LPP – PE HSS for 3LPE – Liquid Epoxy for FBE

{Mirrors the mainline coating

PE/PP Mainline Coating Sealant

FBE Primer

Steel Pipe

Weld Bead

Cross Linked PE/PP Backing

3 mm thick Adhesive

Epoxy Primer

General FJC Design

Force cured liquid epoxy – Same properties and thickness required as for the FBE layer of the mainline

3LPE / 3LPP coating – Uniform coating thickness, always > 100 μm, and 200-300 μm recommended

for maximum resistance to cathodic disbondment (especially at high temperatures)

– Allows pre-inspection of primary anti-corrosion layer prior to HSS application – Ensures DFT is maintained after application with no displacement during

application of outer coating layer – Ensures full cure of LE layer in applied FJC system prior to leaving the vessel

Pre-manufactured materials produced in ISO certified factories – no field chemistry

Specialized formulations to match mainline coating specifications

General FJC Design

Single wrap products in mainline coating thicknesses

Profiled / customized FJC solutions allowing for reduced FJC thickness at overlaps onto mainline coating – Faster installation times / faster contact with pre-heated mainline coating to promote

optimal conditions for fusion – Reduce potential for mainline coating disbondment at cutback edges by overheating

Custom edge-

reduced sleeve design

Chamfered overlap

and underlap

seams

Thick central sleeve area

Design of FJC Specifications

Differences between Industry, Project & Company Specifications

ISO 21809-3 is only a starting point – not a replacement for a Project or End-User specification – Not enough to simply state in a spec that Field Joint Coatings must comply with ISO

21809-3 – As stated in Clause 6.1,

– “designer needs to select the appropriate field joint coating from those available in the Standard based on parent coating compatibility, line pipe construction, location and operating conditions.”

– Goal should always be to create joint coating with equivalent performance (and with full compatibility) to the factory applied coating to avoid any compromise in pipeline integrity

– End Users must be active in defining the standard they require – End Users must take responsibility to define required standard and open up or

narrow down the choice available as appropriate to the circumstances – The Standard can be used as a tool to bring the various elements of the supply

chain together


Mainline coating, temperature, mechanical properties, anti-corrosion properties, design life, service conditions, construction conditions, special performance criteria, track record, total installed cost, etc. should all be considered

FJC should be selected to match performance of mainline pipe coating – No need to downgrade coating specifications at the field joint – Products/systems now available from numerous suppliers


Coordination required between mainline coating and FJC specifications

PQT’s / PPT’s performed with production intent products and equipment – Project pipe OD(s) – Production cycle times – Specialized testing for pipeline construction – bending, roller box,

friction clamps – Simulated service testing – now more readily available

– Include in deepwater qualification programs as mandatory to demonstrate suitability of coatings for the intended deepwater service at design conditions


Example of Pre-Qualification Testing involving; - Application of materials onto project pipe using project equipment

- Simulation of quenching and roller box testing within same process

Advanced Products

3LPP Coating Requirements

Test / Property Factory Coating NFA 49-711

Factory Coating DIN 30678

GTS-PP System Specifications

Adhesion to Steel @ Ambient Temperature ≥ 250N/cm ≥ 100N/cm

@ 50°C > 250N/cm

Adhesion to Steel @ Max. Operating Temperature

≥ 80N/cm @ 110°C

≥ 80N/cm @ 90°C

> 80N/cm @ 110°C

Adhesion to 3LPP @ Ambient Temperature N/A N/A Fused

Impact Resistance (Pass Holiday Test) ≥ 10J/mm ≥ 5J/mm

30 Impacts > 10J/mm

Indentation Resistance ≤ 0.1mm @ 23°C ≤ 0.4mm @ 110°C ≤ 0.3mm @ 90°C < 0.1mm @ 23°C

< 0.4mm @ 110°C

Industry Best Practices – Application

Surface preparation – abrasive blasting (mandatory) – Ensure clean, well prepared surface for optimal coating adhesion & performance

Induction heating (mandatory) – Uniform heating across width & around circumference of joint – Penetrating heat for lasting effect – Controlled & repeatable heating process with faster heating times – Indirect heating of MLC overlap area prevents damage & bonding issues


Cycle time optimization – Conditioning ovens

– Pre-heat FJC materials prior to application

– Ensures consistent starting point for application

– Reduces application time

– Tube welding – Enables the production of tubular

field joint coating system prior to application on the joint, during other application steps

– Potential to save 45-60 s from the critical FJC application path

Field Joint Coating Services

Field services / supervision / support should be supplied by FJC materials manufacturer as a condition of supply – Operator training & accreditation

– Training completed with same products, application equipment and for project specific conditions

– Validity of training limited to project or 1 year from issue – Equipment set-up

– Ensure optimal set-up of coating stations and equipment for coating quality, health and safety and application speed

– Process optimization – Supervision during construction

– Higher expectations to ensure quality and achievement of intended design life

– Support Contractor QA programs

Approach is next best alternative to automation


Automated application – Automated systems now available for partial / full application of the field

joint coating – Faster and more consistent installation times producing best-in-class

application quality with guaranteed productivity

- 36”OD System

Thank you

Dan Pearson +44 7810 186 790

[email protected]

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