Holistic Design of HTHP Pipeline: PETRONAS’ Experience

Abstract

When the oil and gas price was declining rapidly in 2016, it is prudent for global oil operator to identify opportunity to reduce the development cost. This is where all form of cost optimisation and holistic design approach have to be conducted, especially when dealing with High Pressure and High Temperature (HPHT) pipeline which normally requires higher CAPEX. Referring to a field case example from one of PETRONAS’s HPHT pipeline project in Malaysia waters, initial analysis had identified that a 24-inch subsea FWS HPHT pipeline with 40mm concrete coating thickness (for its on-bottom stability requirement), requires three numbers of ‘buckle trigger’s in order to manage the pipeline lateral buckling issues. Hence, a holistic design approach had been conducted to re-evaluate such requirement, commenced with detail assessment to look for all possible opportunities to reduce the pipeline temperature, one of it is to have a greater heat transfer from the pipeline. This exercise had landed into detail assessment on the pipeline on-bottom stability requirement which resulted in indication that the 24-inch FWS pipeline, that have a thicker wall thickness at the upstream portion, would be self-stabled - no requirement for concrete weight coating. Thus, benefitting from the results, further detail analysis had been conducted to assess the overall heat transfer from the pipeline as well as the impact towards the pipeline lateral buckling design, which lead to elimination of lateral buckling mitigation requirement. Unfortunately, further analysis had shown that in the absent of concrete weight coating, the pipeline un-concrete weight coated section i.e. hot end area and the field joints, would have rapid condensation and exposed to the intolerable top of line corrosion risk. Also, based on past experience with local installation contractor, there will be possibility of installation issue for the un-concrete coated pipeline with the tapered bracelet anode. Following that, thorough analysis had been performed and successfully mitigated the issue by applying field joint coating material with U-Value of 52 W/m2K to the 3LPP-Coated linepipe. As for the subsea flange connection, it is covered with thermal insulation, whereas the anode at the un-concrete coated section utilized anode sled mechanism. This holistic design approach had successfully reduced the project cost in line with PETRONAS’ aspiration i.e. low cost development project; and most importantly the ‘body of knowledge’ i.e. experiences, lessons learnt and good practices are captured in PETRONAS Technical Standard for future replication