OTC 21228 Emergency Pipeline Repair Equipment: Site Integration Tests and Post SIT Engineering

OTC 21228
Emergency Pipeline Repair Equipment:

Site Integration Tests and Post SIT Engineering
Armando Rebello, Ray Ayers, Randy Long/Stress Engineering Services
Copyright 2011, Offshore Technology Conference

This paper was prepared for presentation at the Offshore Technology Conference held in Houston, Texas, USA, 25 May 2011.
This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material does not necessarily reflect any position of the Offshore Technology Conference, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Offshore Technology Conference is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of OTC copyright.
Abstract
Since the onset of Deep Water Response to Underwater Pipeline Emergencies (DW RUPE) JIP in 2005, we have been
reporting on progress of the development of a repair system designed to repair ANSI 1500 class pipelines in the 10-inch to 241, 2 , 3, 4 , 5 , 6
inch range in water depths up to 10,000 ft

. For each pipe size, the system provides a minor repair kit with one
structural clamp, and a spool assembly kit with two connectors.
Following delivery of the repair system, composed of pipe lifting frames (PLFs), indexing base frames (IBFs), weld seam
removal and FBE removal tool, cutting and end preparation tools, connectors and clamps, the system was subjected to
System Integration Trials (SIT) in November 2009.
This paper reports on the SIT, post SIT conclusions and the path forward since the SIT, with regards to design modifications,
storage techniques, assembly of the equipment, mobilization and management of the system.
Introduction
The word that comes to mind in response to damage to pipeline infrastructure is immediate. The speed of reaction to a given
subsea pipeline repair problem will dictate the financial impact, including production loss, potential liability and reputational
damage for pollution issues, in addition to the cost of the repair itself. Consider the time it will take to order simple forgings
needed for the manufacturing of repair clamps and connectors, currently in the order of 8 to 10 weeks, let alone the time to
machine and assemble all components, and the cost of preparedness will be fully justified.
However, given the fact that the likelihood of such emergency is relatively small, many oil and gas companies still do not have
any dedicated effort established toward maintaining repair tools and consumables on the shelf.
DW RUPE is a non profit co-ownership project dedicated to such emergencies, where the cost of equipment and tools is
proportionally shared among its co-owners.
After completion of the asset acquisition phase in 2009, DW RUPE had a set of components needed to conduct repairs on
pipelines in deep water. It was important to test the tools and equipment assembled as a system, in order to identify any
problems before a real repair had to be conducted. A significant factor for the SIT was the fact that at the end of 2009, the
IBFs and PLFs supplier encountered completion issues and DW RUPE took responsibility for operational readiness and any
required improvements.
The lessons learned from the SIT were converted to a list of improvement tasks that are being implemented in their order of
priority, for completion before 2011 hurricane season.
OTC 21228
SIT Activities
The functional specifications for the DW RUPE inventory were created after a failure mode and consequence analysis
(FMECA) defined the types of repair required for the system. These functional specifications were used as input for the
design of the tools and equipment, and the factory acceptance tests (FATs) proved that individual components performed to
specifications.
Although interfaces were maintained for all components of DW RUPE throughout the acquisition phase, testing of the entire
repair suite was needed to ensure the various components were compatible and sufficient space was available for ROV
operations.
The SITs were conducted in November 2009; the setup and instrumentation diagram is depicted in Figure 1.
Figure 1 - SIT Arrangement and Instrumentation
Figure 2 - Frames Positioned for SIT Operations

Due to the symmetrical arrangement, only one side of the system was fully assembled during the SIT. The pipe of choice was
a 12.75-inch OD, API 5L Grade B with 0.375-inch wall thickness.
The objectives of the SIT were:
Test and improve the operation and maintenance (O&M) manuals for the IBF and PLF, and add photographs
of the actual assembly process to the manuals
Test and validate the finite differences Excel program developed by Stress to assist with the positioning of
the IBFs and PLFs
Measure the time and resources required for the assembly of the system for future scheduling purposes
Help define what markings to stencil on the IBF and PLF to assist with the assembly and safe operation
Better understand the logistics of mobilization (shipping preparedness, packaging and palletizing, knowledge
of weights and volumes, tools required for assembly of the units, etc.)
Ensure ROVs have room to move around the frames and tools
Check the lifting arrangement for the frames, center of gravity, correct fit of rigging, padeyes, etc.
OTC 21228
Simulate a minor repair using a structural clamp

Conduct several pipe cuts of a pipeline under tension using two types of cutting tools (diamond wire and
chop saw owned by DW RUPE), compare the performance of the cutting tools and note any handling issues
Simulate a major repair using a pair of connectors mounted on a pipe spool piece (Figure 3)
SIT Outcome and Conclusions

Upon completion of the SIT activities, a list of corrections and additions was compiled for the IBFs and PLFs in order to
correct problem areas or to improve their functionality. Listed below are the activities that took place following the SIT.
Preparedness for mobilization: O&M manuals and general documentation for all equipment is currently available to
co-owners on a web based library at http://dwrupe.org
The spreadsheet based pipe lifting calculation tool accurately predicted the lifting parameters
The assembly process was timed and resources and skill sets defined for a future mobilization
Markings and labels were stenciled
In order to reduce the time to assemble the IBFs and PLFs, larger sub-assemblies were defined and stored in a
preassembled state (Figure 4)
The lifting arrangement had to be modified since the ROV
lifting hooks were too to the horizontal drive mechanisms
(Figure 5)
IBFs traverse mechanism ACME thread was made longer. It
was noticed that the IBFs and PLFs may not be placed so the
pipeline is exactly on the centerline. While the PLF already
has a long traverse, the IBFs were originally made with a
short traverse range (Figure 6)
Path Forward
To help maintain the systems efficiency and prevent obsolescence, a
continuous improvement program is in place for DW RUPE. Every
year, changes, improvements and modifications are submitted for
approval.
Figure 3 - Spool Piece Installation
For 2011, a series of small modifications will be made, as follows:
Grapple Design modifications: The original grapple design is based on a single rod standard double action hydraulic
cylinder, which requires volume compensation since the rod side displaces less hydraulic fluid than the piston side, is
vulnerable to leaks or punctures, and does not allow for a mechanical override. It was decided to convert the grapple
to a mechanical system composed of an ACME thread actuated by a hydraulic motor, with an ROV bucket in case of
a hydraulic failure (Figures 7, 8)
Reinforcement and tighter diameter tolerance for the IBF
to Connector guide post (Figure 9)
Add transponder buckets to the IBFs and PLFs
Modifications to the hydraulic system (hard piping,
routing of hydraulic lines)
Extend lifting slings to accommodate an as built shift of
the IBF center of gravity.
Modify IBFs and PLF lifting arrangement to ease the
ROV handling of the heavy slings
Future Development
DW RUPE has two divisions:
The Pipeline Division is ready for deployment with

approximately 12 Million USD in tools and equipment in
inventory, and 792 miles of pipe dedicated to the coownership, currently all in the Gulf of Mexico. Pipe
diameters range from 10 to 24.
Figure 4 - Drive Encased in PVC Pipe for
Storage
OTC 21228
DW RUPE continues to actively research new sealing systems and seal materials for connectors, where the primary
issue is control of the thermal expansion of the seals under high temperature pipeline conditions.
The Flowline Division is currently under development. Flowlines have greater challenges, such as high pressures
and temperatures, removal of hard coating, and thicker pipe wall, typically in diameters ranging between 4-inch and
12-inch nominal.
ACME thread for

IBF: Was 4 ft long,
modified to be 12 ft
long (same as PLF)
Extension Plate
Figure 5 - Extension Plates added to lifting

rigging
Figure 6 - IBF Extended Traverse range
Figure 7 - Current Grapple Assembly
Figure 8 - Proposed Grapple Design
OTC 21228
Connector Guide Post Redesign: Tighter

tolerances and Flange Reinforcement
Figure 9 - Connector Guide Post Modifications
Acknowledgements
The authors wish to acknowledge the insight and interest of the DW RUPE co-ownership, namely Mike Stark (Enterprise),
Leith McDonald (BP), Don Beesley and Kaya Alptunaer (ENI) and Bill Dick (Enbridge), and the following contractors for
their contribution during the SIT:
Lee Avery and Bruce Morris (Quality Connector Systems), Noah Teichmiller (Oceaneering International, Inc.), Mike
Hargrave (Cutting Underwater Technologies).
References
1
GE Oilfield
Technology
Magazine
OTC 19207
OTC 17772
4
5
6
IOPF
Ayers, Ray, Rebello, Armando, The Repair Process
October 2009
A New Deepwater Pipeline Repair Capability for the Gulf of Mexico

and Other Deepwater Regions
Rebello, Armando, and Ayers, Ray, DW RUPE: A Low Capex
Deepwater Pipeline Repair System for the Gulf of Mexico
Ayers, Ray and Rebello, Armando, DW RUPE JIP Phase 1 Final
Report
Ayers, Ray and Rebello, Armando, DW RUPE JIP Phase 2a Final
Report
Ayers, Ray, Rebello, Armando and Stark, Mike, DW RUPE
International Offshore Pipeline Forum, Houston, Texas
May 2008
May 2006
October 2005
September 2006
October 2007

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OTC 21228

Emergency Pipeline Repair Equipment:

Copyright 2011, Offshore Technology Conference

inch range in water depths up to 10,000 ft

Figure 1 - SIT Arrangement and Instrumentation

Figure 2 - Frames Positioned for SIT Operations

Simulate a minor repair using a structural clamp

SIT Outcome and Conclusions

Figure 3 - Spool Piece Installation

For 2011, a series of small modifications will be made, as follows:

The Pipeline Division is ready for deployment with

ACME thread for

Figure 5 - Extension Plates added to lifting

Figure 6 - IBF Extended Traverse range

Figure 7 - Current Grapple Assembly

Figure 8 - Proposed Grapple Design

Connector Guide Post Redesign: Tighter

Ayers, Ray, Rebello, Armando, The Repair Process

A New Deepwater Pipeline Repair Capability for the Gulf of Mexico

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