PIPELINE AND WELL INTEGRITY MANAGEMENT

Transcription

1 FORCE Technology NORWAY AS Foto: BP - Valhall Lifetime assessment of pipelines and wells PIPELINE AND WELL INTEGRITY MANAGEMENT

2 Speaker Håkon Hallem FORCE Technology NORWAY AS Head of Department Integrity Management NORWAY TRONDHEIM

3 Agenda 1) FORCE Technology Competence - Experience 2) Pipeline and Well Integrity Management - Lifetime assessment of pipelines and wells Database for Wells, linking corrosion models together with actual operational data Analysing of Well and Pipeline data by CorPos (Software for corrosion assessment of both pipelines and wells) Pipeline assessment by FiGS Field Gradient Sensor (coating defects and anode activity)

4 FORCE Technology - Experience FORCE Technology can show one of the longest trackrecords regarding Integrity Management Projects and Services in the North Sea, Norway (long-term frame agreements) More than 20 years experience with Integrity Management Projects More than 35 years experience with Integrity Services More than 70 years experience with testing and verification of structures

5 FORCE Technology Competence (1/2) I N SP & M O N NDT Inspection Advanced Inspection NDT certification of inspectors and equipment Load/Response sensors Monitoring systems M A TE R I A L S T R U C T U R E Material selection/ verification Cathodic protection (CP) Coating and surface protection Welding consultancy/ Certification Laboratory services (testing and analysis) Failure assessment Design Reanalysis Modification Global and local analysis Verification

6 FORCE Technology Competence (2/2) I N TE G R IT Y Project Management Topside Corrosion Management Risk Based Inspection Planning Subsea and Pipeline Inspection Management Well Integrity Management (e.g. Wellhead fatigue) Maintenance Management Well Integrity Management How to combine data collection with corrosion analysis Pipeline Inspections Management Inspections and lifetime assessment of pipelines (Coating damages and CP status) Maintain safety, optimise production and reduce downtime to support a sustainable production.

7 Well Integrity Integrity Issues Well Integrity is a global industry challenge. Harsh conditions and extended design life places greater demands to the integrity management of wells. Wells with integrity issues Gulf of Mexico North Sea, UK North Sea, Norway 6650 wells wells wells 3 1) US Minerals Management Service survey, ) SPE forum North Sea Well integrity Challenges, ) Norwegian Petroleum Safety Authority, Well Integrity, 2006.

8 Well Integrity CMIS for Wells Integrity and performance failures, due to corrosion 1) FORCE Technology has developed a database (CMIS) for Wells - an application for Well Integrity Management. CMIS for Wells is a database linking corrosion models together with actual operational data, providing a platform for risk evaluation of wells. SERVER INTERNET ACCESS ANALYSING PRODUCTION DATA DATA TRANSFER OFFSHORE 1) OTM Consulting & Archer market survey 2010

9 Well Integrity CMIS for Wells - Data A new way of collecting, treating, visualizing and distributing important well information to relevant personnel

10 Well Integrity CMIS for Wells - Data WELL HEAD BOTTOM HOLE FLOW RATES Production data

11 Well Integrity CMIS for Wells - Analysing Corrosion calculations visualised

12 Well Integrity CMIS for Wells - CorPos Developed by FORCE Technology

13 Pipeline and Well Integrity CorPos CorPos-AD A Pipeline Integrity Management Tool Internal Corrosion Rate profile calculations based on fluid flow analysis (OLGA ) and NORSOK CO 2 corrosion model (MIC, H 2 S) Combines analysis with monitoring data or intelligent pigging data (pitting information) Manages monitoring data, pig inspection data and inspection data (findings, flaws). Compares the corrosion attacks (depthlength) with the ultimate limit state curve (ULS) based on DnV RP F-101. Provides What-If analyses capability to view consequences of changes in the flow or environment parameters

14 Pipeline and Well Integrity CorPos What is Pitting PITTING Pitting corrosion is a form of localized corrosion that leads to the creation of small holes in the metal. LEAKAGE

15 Pipeline and Well Integrity CorPos CASE STUDY Future oil rate and conditions equal to the latest year INPUT DATA OUTPUT DATA Residual lifetime ~11 years. PIGGING and INSPECTION The worst corrosion attacks will develop further and the depth-length of the attacks will cross the ultimate limit state curve (red curve) after ~11 years provided equal conditions as the latest year. PIT DEPTH PIT LENGHT

16 Pipeline and Well Integrity CorPos CASE STUDY WHAT-IF Future increase of oil rate of 30% and conditions equal to the latest year INPUT DATA OUTPUT DATA WHAT-IF Residual lifetime >100 years. PIGGING and INSPECTION The worst corrosion attacks will develop further but the depth-length of the attacks are far from crossing the ultimate limit state curve (red curve) after 100 years provided equal conditions as the latest year. PIT DEPTH PIT LENGHT

17 Pipeline and Well Integrity Summary A new way of collecting, treating, analysing, visualizing and distributing important well information to relevant personnel Improved Corrosion Control Improved Process Control Increased Lifetime Reduced Safety Risk

18 New Possibilities with Accurate Field Gradient Measurements LIFETIME ASSESSMENT OF PIPELINES CP INSPECTION BY FIGS

19 Pipeline Integrity - Key features - FiGS FiGS (Field Gradient Sensor) is the only tool on the market of its kind. Through its superior sensitivity it is the ultimate tool for staying in control of your pipeline CP (Cathodic Protection) integrity: FiGS helps you to: Detect coating damages on buried pipelines (e.g. pipes with Direct Electrical Heating ) and flexibles Achieve reliable data on anode output, coating damages, current drain and other operational parameters (Pipelines, Flexibles and Structures) Optimise CP retrofitting by using real data, offering substantial cost savings Get an early warning on future problems and be able to take the necessary precautions

20 Pipeline Integrity - Key features - FiGS Measures the strength and direction of electric fields, enabling accurate calculation of anode and cathode current densities Operation velocity of ~1 km pipeline pr hour A coating damage of 3-5 cm² can be detected at 30 cm distance The detection limit of 0.1 µv/cm is way beyond any of the alternative methods Reference cell drift is eliminated by the rotation, yielding very high sensitivity

21 Pipeline Integrity Applications - FiGS Pipelines Detect coating defects Measure current output from anodes Measure on buried anodes and pipelines Use data as input to CP analyses and models Flexibles Detect coating defects and exposure of tensile armour/stress armour Structures Reliably measure current density values Measure current output from anodes Improved calculations of remaining life Use data for calibration of CP models Use measured current density values in retrofit CP design Measure current drain to buried structures like wells, piles

22 Pipeline Integrity FiGS CASE STUDY Pipeline with severe trawl damage : A coated pipeline has repeatedly been impacted by trawls. Many anodes are missing and the coating is severely damaged. A CP retrofit is necessary. What is the current requirement for retrofit? Are all the remaining anodes still connected to the pipe? What is the remaining life of the remaining anodes? What is the coating degradation along the pipe? When must the retrofit be carried out? FiGS will provide the current profile, together with potential and coating damage data. This documents the current density values and the retrofit can be optimised with respect to installation time and cost

23 Pipeline Integrity FiGS Summary FiGS can detect small coating damages at buried pipes and damages which are invisible to the naked eye at exposed pipes, enabling the operator to be proactive FiGS can measure current drain to buried structures like piles and wells and detect and quantify current leaks, e.g. through mooring systems FiGS can accurately measure current densities on structures and anodes, something which is particularly important when evaluating CP retrofitting FiGS is the only tool on the market of its kind and provides a means of solving many of your CP issues FiGS helps you to stay in control

24 FORCE Technology NORWAY AS Foto: BP - Valhall