ZAP-LOK™ SYSTEM FOR PIPELINE INSTALLATION

JANUARY 2019
Cortez Subsea

Focused on Advancing Technology and Maximising Value, Cortez Subsea is an enabler of subsea pipeline and
inspection solutions for the oil and gas industry. Providing subsea pipelay and inspection services together with
our trusted partner companies we are able to work closely together we can bring real benefits to our clients.

Our proven approach towards services and technologies are project focused aligned with strong engineering
capabilities providing solutions that are safe, innovative, environmentally beneficial and cost effective….we
challenge the conventional.

Subsea Pipelines Subsea Inspection

 Zap-Lok™ System for Pipeline Installation

Zap-Lok™ Connector
 Cortez Subsea and NOV Tuboscope work together
with the aim to reduce the cost of subsea pipeline
installation up to 150mtr w.d by applying the Zap-
Lok™ mechanical interference connector.

 Standard rigid S-Lay pipelay capability based on

installing the pipelines using the patented Modular
Pipelay System (MPS®) and Zap-Lok™ mechanical
connections on standard line pipe material from a DP2 Modular Pipelay System
vessel.

 We work with various operators and offshore

contractor across the industry sector, providing them
the ability to reduce cost and increase profitability.
2. Zap-Lok Mechanical Interference Connection
2.1 Overview.

Diameter. (NPS): 2 to 16-inch (50-400mm)

Wall thickness: Up to 1.000” (25.4mm)
Material: Grade B to X70; SMLS, HFI or ERW
Service: Sweet and sour crude, gas, condensate, water, steam
Pressure: As per line pipe material specification
Corrosion Barrier: Epoxy / Phenolic – up to 2% H2S, CO2, Acids, SRBs

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2. Zap-Lok Mechanical Interference Connection
2.2 Operating Envelope

Test Average Result Compliance

Axial Tension 70% UTS ASME B31.4 / B31.8, ISO 21329 (app. Level 4)

Axial Compression > 95% UTS ASME B31.4 / B31.8, ISO 21329 (app. Level 4)

Internal Pressure > 95% UTS ASME B31.4 / B31.8, ISO 21329 (app. Level 4)

Bending > 95% UTS ASME B31.4 / B31.8, ISO 21329 (app. Level 4)

Fatigue – in air DnV D Class weld curve BS 7608 F2 / DNV C1, ISO 21329 (app. Level 4)

Fatigue –in water DnV C2 Class weld curve BS 7608 F2 / DNV C1, ISO 21329 (app. Level 4)

Stress Corrosion Cracking No reduction in strength NACE MR0175 / NACE TM0177 – Method A

1 month exposure at 130°F and 500psi in brine with 1,000ppm

Crevice Corrosion No reduction in strength
acetic acid, 30% CO2, 70%N2

Electrical Resistivity ±1μΩ / connection N.B. 10A, 25mV FSD

2. Zap-Lok Mechanical Interference Connection
2.2 Operating Envelope

Make-Up Loads - Static

Stresses during mandrel insertion Stresses following pin insertion.

12-inch, 0.500” wt, Grade X65

2. Zap-Lok Mechanical Interference Connection
2.2 Operating Envelope

Installation Loads - Dynamic

Bending to 140m radius Bending to 67m radius

Separation of
pin from bell

Hoop stress and bending

moment on pin end
Pin wrinkling

Bending to 30m radius.

12-inch, 0.500” wt, Grade X65
2. Zap-Lok Mechanical Interference Connection
2.2 Operating Envelope

Service Loads - Static

Pressure to Failure Tension to Failure Bending and Tension

12-inch, 0.500” wt, Grade X65

2. Zap-Lok Mechanical Interference Connection
2.2 Operating Envelope

Service Loads - Dynamic

DNV-RP-C203 and Zap-Lok S-N Curves in Seawater with CP vs. Weld Curves
1. Zap-Lok Mechanical Interference Connection
Powder & Liquid Coatings
2.3 End Preparation

• Mobile plant reduces handling costs – 3 x 40ft ISO containers

• Safe production of ends with Zap-Lok experts and local labour
• High production rate of 2,000-3,000m/12hr shift
• QC checks conducted at plant ensuring consistency of shipped product.
• Repeatability of production method permits CAR insurance on connection.

©2016 Tuboscope | NOV Wellbore Technology - Proprietary and confidential. Zap-Lok Technology - 06/09/16 | 10
2. Zap-Lok Mechanical Interference Connection
Powder & Liquid Coatings
1.3 End Preparation

©2016 Tuboscope | NOV Wellbore Technology - Proprietary and confidential. Zap-Lok Technology - 06/09/16 | 11
2. Zap-Lok Mechanical Interference Connection
Powder & Liquid Coatings
2.4 End Preparation Quality Control

 Tuboscope inspectors
complete 100% visual
and dimensional
inspections using
calibrated equipment
during end preparation.

 100% MPI and 10% UT

are generally conducted
for offshore products.

 3 x control burst tests

are completed on joints
taken from each mill
heat.

©2016 Tuboscope | NOV Wellbore Technology - Proprietary and confidential. Zap-Lok Technology - 06/09/16 | 12
2. Zap-Lok Mechanical Interference Connection
Powder & Liquid Coatings
2.5 Installation Equipment

8000-16 press

©2016 Tuboscope | NOV Wellbore Technology - Proprietary and confidential. Zap-Lok Technology - 06/09/16 | 13
2. Zap-Lok Mechanical Interference Connection
Powder & Liquid Coatings
2.6 Jointing

16-inch, 0.843” wt, Grade X65

©2016 Tuboscope | NOV Wellbore Technology - Proprietary and confidential. Zap-Lok Technology - 06/09/16 | 14
2. Zap-Lok Mechanical Interference Connection
Powder & Liquid Coatings
2.7 Installation Quality Control

©2016 Tuboscope | NOV Wellbore Technology - Proprietary and confidential. Zap-Lok Technology - 06/09/16 | 15
2. Zap-Lok Mechanical Interference Connection
Powder & Liquid Coatings
2.8 Certificates of Conformity

• BV witnessed certificate of conformity demonstrating

onshore compliance with ASME B31.4

• Lloyd’s Register Energy conformity certification for

offshore compliance as per DNV-OS-F101

Zap-Lok Technology - 06/09/16 | 16

1
3. Internal Plastic Coating (IPC)
3.1 Flow efficiency & Corrosion Coatings

Smoothness - Limited design life

Flow efficiency - Thickness: 40-125μm
coatings - Air-cured
Consistent - Sometimes holiday checked
surface - 4-5 yr life in harsh conditions
Internal Plastic
Coatings
Chemistry - 20-50 year design life
Corrosion - Thickness: 150-500μm
coatings - Heat-cured
Thickness - Rigourously holiday checked

Starting Point:

Corrosion Flow
Provide
Coatings Efficiency
But not vice versa
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3. Internal Plastic Coating (IPC)
3.2 Manufacture

Pre-cleaning Thermal cleaning Internal shot blasting

Primer and pre-heat IPC application Thermal cure

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Quality control External Varnish Bundling and shipment
3. Internal Plastic Coating (IPC)
3.2 Manufacture
3. Internal Plastic Coating (IPC)
3.3 Reductions in CAPEX and OPEX

Pressure Rating: 𝑀𝐴𝑂𝑃 = 𝑓 × 𝑆𝑀𝑌𝑆 ×

For onshore applications, by applying IPC the corrosion allowance, tcorr, can be removed entirely such that we only
need to consider wall thickness for pressure containment, tpress, thus saving raw material costs.

For offshore applications, again no corrosion allowance is required. The interesting trick here is to maintain a large
wall thickness, i.e. increase tstab, to give the required on-bottom stability as we know this will not be corroded or
eroded. This enables the design engineer to negate the requirement for CWC therefore reducing CAPEX.

. .
𝑑𝑉 𝑔𝐷 ℎ 𝜀 3.17𝜐 𝐿
Flow Efficiency: 𝑑𝑡
= −0.965
𝐿
log
3.7𝐷
+
𝑔𝐷 ℎ
Valid for turbulent flow where Re > 2,300

We can see that the above equation that the volume flow rate of a fluid is proportional to the surface roughness e.
Specifically 𝑽̇ ∝ log 𝝐.

Generally speaking for 6-12” pipe we can see that the differential in steel surface roughness (45mm) to that of IPC
(1.5mm) leads to flow improvements of around 20% for crude to 30% for gas transmission. These ameliorations
increase production rates and lead to reduction in raw material costs – reducing CAPEX.

It should be mentioned here that IPC also eliminates the requirement for corrosion inhibition – reducing OPEX.

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3. Internal Plastic Coating (IPC)
Powder & Liquid Coatings
3.4 Line Pipe Coating Performance

Coating TK-44LP TK-70 TK-70XT TK-15 TK-15XT

Temperature 107°C (225°F) 107°C (225°F) 107°C (225°F) 149°C (300° F) 149°C (300°F)
Flexibility >19 mm >25.0 mm >12.0 mm >2.28 mm >3.71 mm
(Ring Crush) (0.750 inch) (1.0 inch) (0.5 inch) (0.09 inch) (0.146 inch)

Abrasion 0.0018 0.0018 0.00106 0.0102 0.0071

resistance mm/1000 mm/1000 mm/1000 mm/1000 mm/1000
cycles cycles cycles cycles cycles

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3. Internal Plastic Coating (IPC)
Powder & Liquid Coatings
3.4 Line Pipe Coating Performance

Coating Temperature Pressure Liquid Phase Gas Phase Duration

TK-44LP 121°C (250°F) 5,000 psi Water / 50% CO2/50% CH4 16 hours
Hydrocarbon
TK-70 135°C (275°F) 5,000 psi Water / 50% CO2/50% CH4 16 hours
Hydrocarbon
TK-70XT 135°C (275°F) 5,000 psi Water / 50% CO2/50% CH4 16 hours
Hydrocarbon
TK-15 149°C (300°F) 9,000 psi Water / 100% CO2 120 hours
Hydrocarbon
TK-15XT 149°C (300°F) 9,000 psi Water / 100% CO2 120 hours
Hydrocarbon

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Zap-Lok™ Track Record - Subsea
APPROVED USERS DIAMETER

2.375 116 KM
2.875 24 KM
3.5 865 KM
4.5 1,875 KM
6.625 1,442 KM
7.625 45 KM
8.625 553 KM
10.75 943 KM
12.75 511 KM
(blank)

PRODUCTION

Gas Water 262 KM

Oil Other 14 KM
Water
Oil 5,352 KM
Other
Gas 726 KM
0 1000 2000 3000 4000 5000 6000
 Modular Pipelay System

 The Cortez designed and patented MPS® allows Zap-Lok™ and other mechanical MPS™
connected pipe to be laid from a standard DP 2 vessel.

 The MPS® comprises all the equipment necessary to perform pipelay on standard
pipe sizes of 2” to 16” in an S-lay configuration.

 The modular nature of the MPS® is adjustable in width and length to cater for
available deck space and the amount of product to be laid for a particular project.

 Significant cost savings over traditional pipelay methods

 Allows customers to dictate their own schedule

 Installation onto a range of DP vessels with min 800m2 deck

 Up to 5km lay rate in 24hrs

 150m water depth operating

 Stinger range 4” to 16” pipe

 Tensioner range up to 65Te

Modular Pipelay System®
Zap-Lok™ Pipeline Installation

Zap-Lok™ connected pipelines have been installed from a number of offshore barges and vessels using
traditional anchor lay spread and dynamically positioned vessels. Since the first offshore pipeline was installed
in 1982 by Shell Oil in the Gulf of Mexico the range and complexity of the installation vessel has only been
dictated by the total pipeline length and water depth for installation. Using the “S-Lay” method for pipelay Zap-
Lok™ pipelines can be installed in water depth of up to 300mtr.
Modular Pipelay System®

800m2 DECK
PIPE SIZE
LAYABLE PIPE
(INCH)
(KM)

4 45
INSERT6PICTURE HERE
30
8 18
10 13
12 10
14 8.5
16 6.3
Modular Pipelay System®

2000m2 DECK
PIPE SIZE
LAYABLE PIPE
(INCH)
(KM)

4 105
6 70
INSERT PICTURE HERE
8 42
10 30
12 23
14 20
16 15
Track Record - Pipelines

TITLE RIGID PIPLINE INSTALLATION

CLIENT BOURBON SUBSEA / TOTAL GABON

VESSEL DP3 VESSEL - BOURBON 808

EQUIPMENT MPS®, 8000-12T PRESS, 20Te TENSIONER, 35Te A&R WINCH

LOCATION GABON

PERIOD SEPTEMBER 2016 – JULY 2017

168.3mm OD (6-inch), 10.97mm WT, API 5L X65 PSL2, SMLS,

PIPELINE DETAILS
3LPE Coating

CONNECTION ZAP-LOK™ JOINT

DESCRIPTION The scope of work at the Total Torpille sector, located 50 km

south of Port Gentil, Gabon is the installation of a 6” water
injection pipeline between TRMPFK and HYMPFC Platforms
(approx. 25.2 Km) and the associated risers and the subsea
connecting spools at each platform. Cortez Subsea provided
our Modular Pipelay System (MPS™) and associated pipeline
installation equipment, aids and personnel to install the
pipeline using the Zap-Lok™ mechanical connector.
Track Record - Pipelines

TITLE RIGID PIPELINE INSTALLATION

CLIENT SOLSTAD OFFSHORE PTE / CHEVRON THAILAND

VESSEL DLB NORCE ENDEAVOUR

8000-12T ZAP-LOK™ PRESS, MPS RENDER UNIT, IN-BUILT

EQUIPMENT
PIPELINE INSTALLATION SPREAD

LOCATION THAILAND

PERIOD MARCH 2016 – JULY 2016

273.1mm OD (10-inch NB), 12.7mm WT, Grade API 5L X42

PIPELINE DETAILS
PSL2, ERW, FBE Coating

CONNECTOR ZAP-LOK™ JOINT

DESCRIPTION Zap-Lok™ pipeline installation, 3 x 10 lines totalling 9km to

be installed in 80mtr WD in the Gulf of Thailand from the
DLB Norce Endeavour. Scope includes engineering, Zap-Lok™
end preparation, connection testing and offshore operations
using the NOV Zap-Lok 8000-12T unit. The Norce Endeavour
was on contract to Chevron Thailand to perform both
platform and pipeline installation.
 Shallow Water Pipelay Vessel

 Cortez Subsea are also developing a dedicated shallow water pipelay vessel. This vessel is aimed at larger capacity projects for
new and replacement pipelines in mature fields.

SWPLV

Length 120mtr Breadth 24mtr Draft 4mtr DP Class 2 Acc. 90 persons

Semi-automated pipe
7000Te pipe carry
5km per 24hr lay rate handling, temp Sea state 5 operability 2 knts current operability
capacity
controlled
Cost Benefits
Material Costs - Zap-Lok / IPC versus Traditional Basis of Design (BOD)
 Zap-Lok / IPC BOD: 25km x 12-inch, 17.5mm wt, API 5L Gr. X52N PSL2, 3LPE HFI, SG 1.25
 Standard BOD: 25km x 12-inch, 12.7mm wt + 3mm CA, API 5L Gr. X52N PSL2 HFI, 3LPE, 40mm CWC, SG 1.25

COST [USD] Line Pipe Zap-Lok ends IPC 3LPE CWC

6,000,000

5,000,000

4,000,000

3,000,000

2,000,000

1,000,000

0
Zap-Lok / IPC BOD Standard BOD
Cost Benefits
Installation Costs - Zap-Lok / IPC versus Traditional Basis of Design (BOD)
 Zap-Lok / IPC BOD: 25km x 12-inch, 17.5mm wt, API 5L Gr. X52N PSL2, 3LPE HFI, SG 1.25
 Standard BOD: 25km x 12-inch, 12.7mm wt + 3mm CA, API 5L Gr. X52N PSL2 HFI, 3LPE, 40mm CWC, SG 1.25

COST [USD] PM&E Mob/Demob Installation

7,000,000

6,000,000

5,000,000

4,000,000

3,000,000

2,000,000

1,000,000

0
Zap-Lok / IPC BOD Standard BOD
 Cost Benefit

 The combination of the Zap-Lok connector and MPS® enable the end user to significantly reduce the pipeline installation
operating cost.

Traditional Enabling
 Conclusions

 Zap-Lok connectors, having gained full industry acceptance, qualification and significant track
record enable end-users to dramatically reduce installation costs of in field gathering systems.

 IPC is a fully qualified and proven system that gives lifetime corrosion integrity to in-field
flowlines enabling the modified design techniques to be used to provide a more cost effective
pipeline basis of design,

 The combined Zap-Lok technology is best suited to shallow water installations, encompassing
relatively sour service where it is an ideal option for most applications.