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FLOODING, CLEANING GAUGING & HYDROTESTING FOR 32” PIPELINE DURING PRE-COMMISSIONING PROCESS

Mohamad Shukri Bin Rahmat

860103-10-5375

SX091166KKJ04

Background Study

PETRONAS Carigali Sdn. Bhd. has undertaken the development of the NC3 gas field located in

SK316

Block,

approximately

Bintulu, Sarawak.

200km

North

of

The water depth

107m.

in NC3 field is around 104m-

Subsea Pipeline connects NC3 Drilling Platform to Existing Riser Platform E11R-C. The processed gas will be evacuated to shore via the existing trunkline through E11R-C or dedicated newly-to- be-installed trunkline to shore

Background Study

Field of NC3 and E11-RC Platform

Background Study

The transportation of gas from fields (offshore) to

the

shore

pipeline.

is

normally

by

using

Pipeline

pre-commissioning is

the

the

sub-sea

process

of

proving the ability of a pipeline and piping systems to contain product without leaking. In this cases, the said product is gases

The

gross

volume

of

the

processed

gas

is

660MMSCFD including 20% CO2.

Installation

of

the

pipelines

will

be

completed

before the offshore facilities are in place

Background Study

To discuss the requirements to perform the flooding, cleaning, gauging and hydrotesting of 32” dia. x 75.5 km pipeline from E11RC platform to NC3 platform, problem statement and how to overcome while doing the said services.

PROBLEM STATEMENT

Pipeline Details

Table below shown summarizes of the 32” Dehydrated Gas & Condensate Pipeline details covered by the procedure of Flooding, cleaning, gauging, dewatering and hydrotesting of offshore oil and gas pipelines during pre-commissioning

PROBLEM STATEMENT

PROBLEM STATEMENT

PROBLEM STATEMENT 3/6/16 8

PROBLEM STATEMENT

Flooding,

cleaning and gauging (FCG)

operation can be defined as the flooding

operation will introduce chemically treated filtered seawater into the offshore pipeline sections

The

cleaning

operation

construction

debris

from

pipeline surface

will

the

remove

internal

PROBLEM STATEMENT

Failure to perform one of these Pre-Commissioning tasks as mentioned will lead to:

  • 1. Gas ingress into the water during flooding may make hydro testing difficult.

  • 2. Inefficient dewatering of the pipeline may lead to hydrate formation in gas lines or corrosion problems during production.

  • 3. The tasks also take time to perform under difficult conditions.

  • 4. Piping Internal Gauging (PIG) operation that may get stuck inside a pipeline section

  • 5. Bad gauging performance, bad cleaning/testing/drying performance

  • 6. Work Schedule delay

PROBLEM STATEMENT

PROBLEM STATEMENT 3/6/16 11

PROBLEM STATEMENT

PROBLEM STATEMENT 3/6/16 12

PROBLEM STATEMENT

PROBLEM STATEMENT Dewatering Pig Flooding, Cleaning, Gauging Pig 3/6/16 13

Dewatering

Pig

PROBLEM STATEMENT Dewatering Pig Flooding, Cleaning, Gauging Pig 3/6/16 13

Flooding, Cleaning, Gauging Pig

PROBLEM STATEMENT

Objectives of Study

To presents an analysis and requirements to perform of part of pipeline Pre-commissioning process which is flooding, cleaning, gauging and hydrotesting of 32” dia. x 75.5 km pipeline from E11RC platform to NC3 platform

To

discuss

the

problems

that

could

be

encountered during

flooding,

cleaning,

gauging

and

hydrotesting

during

pre-

commissioning

process

while

install

and

commissioning of these 32” Pipeline

 

To discuss

the Risk Management in the Pre-

Commissioning

3/6/16

Phase

during

flooding,

15

Scope of Study

Pipeline Pre-commissioning process of 32” Pipeline

Flooding operation which will introduce chemically treated filtered seawater into the offshore pipeline sections.

Cleaning operation which will remove construction debris from the internal pipeline surface.

Gauging operation which will confirm that there are no pipeline deformations or intrusions/interruption.

Hydro testing operation to treat water used to drive the cleaning and gauging pigs will be discharged to the environment at

3/6/16

16

Flooding

Pipeline Filling or in other name Flooding can be explained as method which can be carried out by propelling PIG’s through the pipeline with water or free flooding with water.

Flooding • Pipeline Filling or in other name Flooding can be explained as method which can

Cleaning Gauging

Pipeline Cleaning is carry out by pushing PIG’s or Gel PIG’s through the pipeline to remove any debris dirt

Pipeline Gauging is carried out to prove the dimensional quality of the internal diameter of the pipeline

Cleaning Gauging • Pipeline Cleaning is carry out by pushing PIG’s or Gel PIG’s through the

Hydrotesting

• Hydrotesting is a process by which the pipeline in question is the pressure tested to
• Hydrotesting is a process by which the pipeline in question
is the pressure tested to a predefined pressure above the
operating design pressure of the pipeline.
3/6/16
19

Hydrotesting

RESULT AND DISCUSSION

To aid in the planning of such operations, a

number of analyses can

be undertaken to

determine the duration to perform each of these tasks.

The mathematical models can be used to optimise the equipment required (hoses, pumps, compressors).

The subsea heads, hot stabs, and pig tracking system worked flawlessly during FCG (Flooding, Cleaning, Gauging) operations.

RESULT AND DISCUSSION

All FCG pigs performed as expected and no damage was observed. The water filtration, additive system, and pumping spread operated consistently at or above their specified duty levels.

Air content confirmed to be well within the Det Norske Veritas (DNV) requirement of less than 0.2% demonstrated the flooding operation's success

A final cleaning run removed less than 2 kg of construction debris in each section. Iron oxide and small amounts of sand and some red-coloured dust were also removed.

a of 32Pipeline

RESULT AND DISCUSSION

Pressure Test Data of 32” Pipeline during Hydrotesting

Sectio

Lengt

Volum

Test

Pressurizati

Volum

Stabili

Pressure

n

h

e (Cu

Pressur

on Duration

e

zation

drop

(km)

M)

e

(hr)

Added

period

during

(barg)

(Cu M)

(hr)

test

period,

%

1

75.5

120,08

110

  • 14.5 2,148

 

1

0.028

9

2

151.0

241,24

230

  • 29.0 4,128

 

3

0.058

0

RESULT AND DISCUSSION

As a result:

Analysis of Pipeline Pre-commissioning system and method to provide output that can be used for pre-commissioning operation is explained.

The problems that could be encountered without a clear knowledge of how the operation will proceed can be avoided.

The operation can be monitored by comparing recorded and predicted values by using mathematical module and from past experience.

The Risk Management in the Pre-Commissioning Phase of an oil and gas pipeline project undertaken

Pre-commissioning may therefore be defined as all the checks that are to be completed prior to commissioning being permitted to commence.

CONCLUSION

Successfully performing Pre-commissioning process

which

include

the

cleaning,

gauging, filling,

hydrotesting of 32” dia. x 75.5 km pipeline from

E11RC platform to NC3 platform based on Pressure Test Data

Pressure drop during test period is less than 0.2% which can be defined as the pipeline is clean from debris and other material tolerance

These process is managing to meet client schedule and safety is in zero tolerance and now the said pipeline is successfully returned to Petronas to commence a gas flow.

CONCLUSION

The

design

of

pipeline

is

important

requirement. The

designer

has

to

foresee

construction requirements and

all

project

constrains have to be incorporated in design.

his

Any insufficient design can cause of problems for construction and pre-commissioning phase

Risk

cannot

be

eliminated

as

such

pre-

commissioning activities contains high risk that cause of schedule and cost impact

RECOMMENDATION

Flooding and Pigging subsea pipelines using a remote flooding module (RFM). This enables the use of available hydrostatic head to flood and pig subsea pipelines while meeting the project requirements in terms of pig speed, filtration, and chemical treatment.

Recommended to use of ROV driven pumping units to complete flooding and pressurization

The use of smart gauge tools (SGT) to gauge pipelines without using aluminium gauge plates.

RECOMMENDATIO

N

Using of subsea data loggers to record pressures and temperatures during subsea testing, and use of systems to transmit this data to surface in real-time during the test.

To have a good plan before performing pre- commissioning process

Review the quality document and certificates completed with conformance inspect of materials and equipment are also conducted probably to prevent risk at work process

Thank You