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FMC offers a complete range of sled systems including PLETs (Pipeline End Terminations), PLEMs (Pipeline End
Manifolds) and In-line Sleds to meet virtually all manifold project requirements. Sled designs include options
for first-end, second-end or midline installations from vessels with J-lay, S-lay or reeled capabilities. In
addition, sleds range in complexity from a single hub with manual isolation valve to multiple hubs with
actuated valves, chemical injection, pig launching capabilities and more.
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ROV-installed clamp.
Isolated pipeline damage is characterized by a small hole or crack and is most often a result of localized corrosion; a
defect in a pipeline weld that went undetected during installation; a metallurgical defect; or impact from a dropped item.
In general, a clamp that firmly encapsulates the pipeline and provides a reliable seal around the damaged area should be
adequate for the repair.
Extensive pipeline damage can result from an unfortunate incident during pipelay operations or an event during the life of
a field for instance dragging of anchors, mudslides, upheaval buckling, or pipe walking. In most cases, the pipeline
cannot be lifted back to the surface, and the damaged pipeline section has to be removed and replaced subsea with an "on
bottom" repair spool piece.
Dual Grip and Seal connector showing the "grips" and seals at each side of the
connector.
To repair pipelines in deepwater, ROV-installable and operable versions of split-sleeve type clamps have been developed.
Alignment saddles are normally incorporated for landing and positioning of the clamp on the pipeline. The design of the
body bolts allows for tightening by a standard work-class ROV using a low torque or impact-type wrench, or integrated
hydraulic stud tensioners. Following activation by the ROV of the hydraulic pressure, the connector mechanically locks so
that hydraulic pressure does not have to be maintained. Standard diverless Grip and Seal type split-sleeve clamps have
been manufactured for pipe sizes from 8-44 in. (20.3 cm--1.12 m) OD and ratings of ANSI 900 to 2500, and have been
installed in water depths up to 7,000 ft (2,133 m).
When a pipeline is damaged severely and or deformed over a certain length, the affected section must be removed and
replaced. If the pipeline cannot be lifted back to the surface, an "on bottom" pipeline repair has to be performed. A spool
piece repair (pipe replacement) necessitates cutting of the pipeline in order to remove the damaged section, with the
replacement section connected to the pipeline on the seafloor. While hyperbaric welding can be used to connect the spool
piece directly to the pipe in shallow water within the range of diver operations, this technique can be extremely costly.
Further design advances led to the development of a second generation system ideally suited to situations where the repair
spool piece is relatively short, and where the seabed is sufficiently flat. More importantly, the amount of steel work left on
the seabed after the repair is greatly reduced.
The (single) diverless Grip and Seal connector is modified to form a dual Grip and Seal connector whereby the end of the
repair spool piece and the pipeline end are contained within one connector housing. A dual Grip and Seal connector is
fitted to each end of the repair spool pieces and equipped with an ROV-operable telescopic action. When the repair spool
piece is positioned on the seabed and aligned with the pipeline ends via the diverless pipeline lift frames, the connector is
stabbed over the pipeline end using the telescopic device, allowing the connector to Grip and Seal around both the
pipeline end and spool piece end. Dual Grip and Seal connectors have been manufactured for various oil companies in
sizes ranging from 6 to 24-in. (15.2-61 cm). They were selected for Total's Girassol 12-in. (30.5-cm) diverless pipeline
repair in deepwater Angolan block 17, performed at the end of 2009.
The most effective and economical method of adapting deepwater pipelines to allow for future subsea tie-ins involves use
of "midline tie-in sleds" modular units that consist of flowline piping; a connection structure for a future diverless
pipeline connection; a block valve to isolate the future tie-in line; a piggable Y fitting to combine the trunkline with the
future tie-in line; and mud mats.
The sled is welded into the pipeline like an ordinary joint of pipe and is designed to be easily installed via S-lay or J-lay.
In a later stage, the new pipeline is installed close to the existing pipeline and the new tie-in is performed using a jumper,
fitted with standard diverless pipeline connectors, and connected to the midline tie-in sled at one end on the existing
pipeline and the pipeline end termination (PLET) of the new line.
A pipeline network is generally designed upfront with midline tie-in sleds built in to the pipeline system and installed
during the pipelay operations, to facilitate connection of future pipelines into the existing pipeline network. However,
during the Mars pipeline repairs, Shell took the opportunity to fit out the repair spoolpiece with a future tie-in hub. The
same applies for the Typhoon repair where a future tie-in point was incorporated in the repair connection structure.
Shell's Perdido field is in the Alaminos Canyon block 857 in the Gulf of Mexico, in 7,800 ft (2,377 m) of water. The field
is in an area with little export infrastructure: to install an export line all the way to shore would be extremely costly and a
major challenge due to the difficult seabed conditions. The closest existing offtake system was the ExxonMobil Hoover
Offshore Oil Pipeline System (HOOPs). Shell obtained approval from ExxonMobil to tie the Perdido export pipeline into
HOOPS, even though there was no connection link available in the HOOPS line, and any pipeline shut down would have
to be kept to a minimum. But based on its experience with the Mars on-bottom diverless pipeline repairs, Shell decided, as
an industry "first," to use the same pipeline repair principle for the Perdido tie-in.
The operation entailed:
Cutting and removing a 28-ft (8.5-m) long section from the HOOPS pipeline
Using a Grip and Seal connector, attaching a single pipeline connection hub on the upstream end of the pipeline
Using a Grip and Seal connector, attaching a dual pipeline connection hub (including a piggable Y) to the
downstream part of the pipeline
Installing a jumper on the two HOOPS hubs in order to ensure flow through the existing HOOPS pipeline.
A pipeline connection hub is now available for the future Perdido export line tie-in. The system went through various
rigorous onshore SITs and shallow water tests which resulted in a successful subsea installation, in 4,500 ft (1,372 m)
water depth, using multiple ROVs, with the shutdown of the HOOPS pipeline limited to 17 days. The Perdido export line
was subsequently connected to the connection hub on the HOOPS pipeline tie-in assembly.
Acknowledgment
Based on a paper presented at the Offshore West Africa 2012 conference in Abuja, Nigeria, Jan. 25, 2012.