This technology is created and developed by exploring and utilizing the capability of the passive acoustic-based which design intended to detect corrosion at unpiggable onshore pipeline without major modification or disrupting the operation. ORCA™ technology consists of the capabilities and functionalities to perform analysis and assessment utilizing real-time and historical data to detect the corrosion behavior over the period. If these corrosions are injurious in nature, further response either immediate or schedule can be executed to prevent pipeline failure. The passive, low acoustic-based sensor installed at 2 ends of the pipeline which communicate through Data Acquisition System (DAQ) which subsequently transmit data via public mobile network linking through virtual private network, wide area network which transferred data storage to the digital server. A specialized analysis software capable of performing data pre-processing, cleansing, AE features identification & sizing with Deep Learning capability & post processing with determination of risk and integrity to facilitate system real time capability are also discussed in this technical paper. Acoustic Emission transducers installed between the test section and software to collect and filter the data. The technology has been deployed on one Feed Condensate pipeline back in 2020/21 with continuous data collection. Higher accuracy was achieved comparing against latest intelligent pigging (IP) data. The validation has been conducted by using Mean Absolute Error (MAE) method and API 1163 matrix and this higher accuracy level has been obtained through the maturity of deep learning in adapting with the environmental and process conditions. ORCA™ has been approved for replication on PETRONAS 18 nos. of onshore unpiggable pipelines from 2022-2026. The positive value creation is estimated for long term application by 20% OPEX reduction over the life cycle. The technology will help to eliminate the occurrence of pipeline failure due to improper integrity management. In conclusion, ORCA™ will change the way of managing the integrity of unpigable pipeline as previously ICDA & ECDA approached has been used in estimating the integrity condition of the pipeline.
Keeping pace with the industry digital transformation accelerated by the 2020 pandemic, PETRONAS sees the opportunities of sustaining the forward momentum of its Pipeline Integrity Management System (PIMS) digitalization deployment as it becomes more deeply integrated in day-to-day operation. After two years of utilizing digital PIMS, the platform services have matured, and PETRONAS is able to reap the benefits of having a centralized digital platform for pipeline related information. The aspiration for the pipeline digital PIMS is to give near real-time insight of overall pipeline condition and risk, and for operators to perform proactive actions to eliminate downtime by identifying early warnings of failure. The immediate value of digital PIMS implementation was having the legacy data being contextualized and transformed into structured data, which is the backbones for descriptive, predictive and prescriptive big data analytics. The platform was devised as such that integration with Enterprise application for data ingestion was made easier. As of to-date, digital PIMS is able to pull and push data to PETRONAS Enterprise Resource Planning tool, geographic information system (GIS) supported software, as well as operational monitoring real-time data through Supervisory Control and Data Acquisition (SCADA) system. In addition to conventional deterministic fitness for service analytics modules, the platform is also currently integrated with analytics modules, primarily for onshore and offshore pipeline threats such as internal corrosion, free span, geohazard and damage from third party. By implementing predictive analytics approach to assess pipeline threats, it will assist stakeholders and operators in optimizing inspection campaign and rectification, thus ultimately reduce OPEX throughout pipeline remaining lifecycle.
Reinforced Thermoplastic Pipe (RTP) design has been improved to meet the very specific requirement of handling corrosive fluids such as crude oil and sour gas up to certain pressure. RTP might have been widely used for onshore application. However, its application as offshore pipeline is not common compared to carbon steel or flexible steel pipeline due to some limitations. PETRONAS Carigali Sdn. Bhd (PCSB) has undertook a pipeline replacement project at offshore Peninsular Malaysia to reverse flow 17km of existing 12" carbon steel pipeline with 3" Reinforced Thermoplastic Pipe (RTP) pipeline from Platform-A to Platform-B for crude and condensate services. This technology was the first being implemented by PETRONAS and in Asia Pacific region for offshore application. RTP pipeline was installed from the Shut Down Valve (SDV) of Platform A to SDV of Platform B by insertion methodology into existing 12" carbon steel pipeline. Special inline connectors were used to connect different sections of RTP pipeline, which came in several reels. Specific inspection to be performed at the connection considering the swaging method used and its effect. RTP hang-off and end termination was conducted upon completion of RTP insertion. Specific RTP pre-commissioning and hydrotest procedure was developed and executed with certain acceptance criteria. The pipeline was then commissioned smoothly indicating the successful completion of the project. It has proven that RTP pipeline insertion for offshore application was technically feasible for a long pipeline. This technology of offshore RTP pipeline provides alternative to the conventional carbon steel pipeline with the advantages of anti-corrosion, high flexibility and low total lifecycle cost. The aim of this paper is to highlight the analysis and methodology for RTP Pipeline Insertion for offshore application as well as the technical challenges during offshore execution.
Flexible pipeline is a technically and economically viable solution for brownfield's EOR project, and with reference to one of PETRONAS Carigali's recent EOR projects, is the enabler for this EOR development. This paper provides a review of available pipeline solutions to fulfill EOR project's gas and water injection requirements which are vital to the success of the EOR technology implementation. A comprehensive technical assessment addressing the risk, advantages, limitations and also a brief overview on cost benefits have been performed on selected unconventional pipeline technologies, in comparison to rigid pipeline, using one of PETRONAS Carigali's recent EOR projects as the field case study. The EOR project case study key design drivers and constraints, mainly the ultra-shallow water depths ranging between 8m to 50m LAT, congested seabed with existing infrastructures, large areas of coral outcrops at multiple locations and the relatively high design pressures and design temperatures present great challenges in choosing the optimum pipeline solution. Feasibility of available unconventional pipeline technologies are evaluated against the project design drivers and the most viable solution is compared to the conventional rigid pipeline solution. Considerations are also given to design complexity, installation requirements, operation and integrity management. Complete selection criteria and matrixes are provided and supported with market information.
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