SiRCoS Submarine pipeline repair system - Marcogazmarcogaz.org/downloads/updated/1_Spinelli.pdf ·...
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SiRCoS Submarine pipeline repair system Carlo Maria Spinelli - Bratislava, 18-19 September 2008
Transcript of SiRCoS Submarine pipeline repair system - Marcogazmarcogaz.org/downloads/updated/1_Spinelli.pdf ·...
SiRCoSSubmarine pipeline repair system
Carlo Maria Spinelli - Bratislava, 18-19 September 2008
Title of event
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Introduction to subsea pipelines
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3Pipeline damage & scenarios
4SiRCoS Repair System
Deep water projects
Outline
5Conclusion
Title of event
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1 Introduction to subsea pipeline
Thousand kilometres of marine pipelines have been laid in European seas for 30 years;
Since the early 70’s, pipeline industry has constantly improved design, materials and techniques for construction, operation;
Offshore pipelines have been scoring a remarkable record of safety and reliability;
DELIVERYNETWORKNorth sea network
Trans Mediterranean Pipeline Green Stream Pipeline
Blue Stream Pipeline
400 m w.d.650 m w.d.
1200 m w.d.
2200 m w.d.
1970-1980
2000-20041980-1990
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1.1 Introduction to subsea pipeline “The offshore challenge”
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1975 1980 1985 1990 1995 2000 2005 2010 2015
Year
Diff
icul
ty in
dex(
dept
h x
OD2 )
/ re
f. ca
se
Snam Messina crossing
Europipe II
Amoco Aquaba II
Blue Stream
BP Mardì Gras
Green Stream
Ormen Lange
Medgaz
North Stream
South Stream
Galsi
Snam Messina crossing as normalizing reference case : 20" OD x 500 m w.d.
Trans Mediterranean Pipeline I & II
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Introduction to subsea pipelines
2
1
3Pipeline damage & scenarios
4SiRCoS Repair System
Deep water projects overview
Outline
5Conclusion
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2 Deep water projects overview
New pipelines are being under costruction / evaluation in deep waters;
Installation, inspection, maintenance and repairs methods must be improved to face new challenging situations, as example :
J and S laying techniques,
pipe steel performance, high wall thickness, roundness, isotropy etc.
Medgaz Pipeline North Stream Pipeline Galsi Pipeline
South Stream Pipeline
24”x 300 km depth 2700m
48” x lenght 1200 km
32” 900 km depth 2200m
24” x 200 km depth 2150m
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2.1 Deep water projects overview
900-1200 km
1200-2700 m
Deeper water Longer path Larger diameter
Up to 48” OD
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Introduction to subsea pipelines
2
1
3Pipeline damage & scenarios
4SiRCoS Repair System
Deep water projects overview
Outline
5Conclusion
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3 Pipeline damage
Offshore pipeline operational reliability is high, but ………:
in shallow water vessels may dent or damage pipelines;
in deeper water larger vessels may drag anchors, trawl gear are able to bend or move pipelines;
internal and external corrosion are potential threats of leaks;
Pipeline
Fishing vessel
Trawl gears
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3.1 Pipeline damage & scenarios
Submarine pipelines are operated in a physically and technically harsh environment:
objects dropped from vessels can also damage pipelines.
When a pipeline damage occurs, partial or overall transportation disruption over a long period might have severe economical consequences :
a need has been recognized to develop and put in place asystem to make diverless emergency repairs to the pipelines.
The incentive for the oil/gas producers is to minimize the expensive downtime of the production systems.
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Introduction to subsea pipelines
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3Pipeline damage & scenarios
4SiRCoS Repair System
Deep water projects overview
Outline
5Conclusion
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4 SiRCoS Repair System
SiRCoS Repair System (stands for Sistema Riparazione Condotte Sottomarine):It’s a diver less repair system for deep water pipelines developed by Saipem/Sonsub for Eni.
It comprises a suit of:equipment, components, tools
ready for intervention in case of damage at subsea trunk lines.
SiRCoS permanent repair can be obtained by the:- clamp installation on a local damage;- replacement of a pipe section for longer and more severe damages,
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4 .1 SiRCoS Repair System
Main SirCoS Operational Specifications:
Maximum water depth: 2,200 mMaximum seabed slope: 10° transversal, 15° longitudinal (30° for the repair clamp)Sea bottom visibility: close to zero
Pipe size: 20” to 32” (larger diameters may be included, too), Pipe material: steel grade up to API 5L X70 equivalentPipe coating removal: both anticorrosion coat & concrete coating up to 100 mm
thick
SirCoS fits the most challenging pipeline operative conditions and……
after the repair the pipeline will remain piggable.
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4.2 SiRCoS Repair System (Movie)
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4.3 SiRCoS Repair System
RPCs (Repaired Pipe Components) specific for each pipeline to be permanently installed:- repair clamp for small local damages,- spool pieces to be used for the replacement of pipe sections,- pipe end connectors,
.
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4.4 SiRCoS Repair System
Common Intervention Equipment (CIE) is the set of equipment and sub-sea Modules to install the Repair Pipe Components. It can be used on more than one pipeline:
1 x Cutting tool,1 x Installation Module for the End Connector-Forging Tool, 1 x Coating Removal Tool to remove coating and the concrete coat, 4 x H-Frames and jacking clamps to clamp & lift the pipe sections
. 1 x Installation Module for the spool piece,2 x Docking modules,1 x Acoustic metrology set,1 x Installation Module for the repair clamps 2 x Isolated Hydraulic Power Units (IHPU) fed by the WROV to control all the previous modules
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4.5 SiRCoS Repair System Connection system
Forging Tool.One Forging Tool is necessary to install the End Connectors on each System of Pipelines.
C C
PipeEnd Connector
Forging Tool
Hydro ForgingWater inlet
Pipe End after cuttingEnd Connector & Forging tool
Metal to metal connection
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4.5 SiRCoS Testing & Certification
The engineering phase of the system and mainly the connection device, is fully compliant with the DNV RP F113 “Pipeline Subsea Repair”.
Most of the tests have been planned to verify the load and seal capability of the metal-to-metal connection, by :
Laboratory tests;
Full scale tests on reduced connectors;
Shallow water testing.
At the end of these steps, SiRCoS repair system has been certified by DNV for the “Type Certification”
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ClientsRPC’s built in 2007 for GreenStream 32“ OD pipeline RPC’s built in 2008 for Medgaz 24” OD pipeline now under testingRepair Service Contract signed by GreenStream in 2008Negoziation with other pipeline operators in Far East
ImprovementsBlue & South Stream (Sour Service and high walled pipe > 40 mm.)Nord Stream (larger diameter extension -- 48”)
4.6 SiRCoS Update
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5.1 Conclusion
The long lasting commitment of Eni-Saipem/Sonsub in offshore projects since 70’has allowed to design, test, qualify a diverless pipeline repair system. It consists of a set of modular tools, suitable to operate on a wide range of
pipelines (20” up to 32” and over). The system requires the support of conventional work class ROVs and vessels, it’s
maintained to be promptly available within the shortest mobilisation schedule.Eni owns this unique repair technology, certified by Det Norske Veritas during
open water tests, SiRCoS is now available to other operators in the form of repair services carried
out by Saipem/Sonsub.SiRCoS provides significant advantages to any subsea pipeline operator for which
reliable operation management are vital to guarantee the cost effectiveness of its own transportation network.
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Many thanks to all the Saipem/Sonsub division for its strong support in developing this repair system,
mainly
Sergio Fabbri, co-author and Roberto Brandi.
Thank for Your attention.
