Reel-lay Method to Allow for Direct Tie-in of Pipelines

Per R. Nystrm1, Geir Endal2, Odd M. Lyngsaunet1

1 IKM Ocean Design
Stavanger, Norway
2 Statoil ASA
Oslo, Norway

ABSTRACT
Various methods exist to connect a pipeline end to a platform or a
subsea structure. Normally, a separate spool or jumper is used, but a
direct tie-in is advantageous if this can be used. Different ways of direct
subsea tie-ins exist, however the main challenges with these methods
are relatively large forces on the connection and large pipeline stresses
close to the connection point.
This paper shows how application of residual curvature near the end of
the pipeline can be utilized for direct tie-in of pipelines to subsea
structures. This is done by solving the existing direct tie-in challenges
with large forces on the connection and large pipeline stresses close to
the connection point.
Tie-in forces will be illustrated for the main variables affecting the
pipeline tie-in point such as: soil friction, residual curvature parameters,
tie-in and operational loads, various tie-in systems and their
requirements. Effect on lay initiation and lay down will be outlined.

KEY WORDS:

Pipeline; reel-lay; straightening; direct; tie-in;

residual; curvature.

BACKGROUND
The reel-lay method is frequently used for installation of smaller
diameter offshore pipelines. The installation process involves onshore
fabrication of pipe sections, loading of the pipe onto the reel ship
(spooling on), and finally unreeling during the offshore installation.
The pipeline is normally plastically bent on the reel and over the
aligner, due to which the pipeline runs through a straightener system
before leaving the reel ship, ref. Fig. 1. The straightening scheme is
normally a three point bending system, and the position setting of the
system is hydraulically adjustable, and can be quickly altered as
required, e.g. by change in the pipeline outer diameter.
The quick, hydraulic adjustment of the straightener system can be
utilized to create sections with residual curvature in the pipeline. This
method was patented by Statoil in 2002 in Norway, Denmark, UK and
USA. The intention is that these residual curvature sections provide
axial flexibility in the pipeline similar to an expansion loop, either to
accommodate compressive or tensile forces.

Figure 1: Sketch of reel ship and pipeline.

The residual curvature method was used successfully to control global
buckling and expansion on the 14 - 16 dual diameter Skuld pipeline
in the Norwegian Sea in 2012, Endal and Egeli (2014). The Skuld
pipeline was installed by Subsea 7 using their reel ship Seven
Oceans. A total of 25 such residual curvature sections were installed
along the 26 km long route. Each section was 70 m long and had a
residual strain of approximately 0.2%. Figure 2, shows as-laid survey
data from two of these sections (KP 13.1 and 15.1).
In addition to showing how effective the method is with regards to
controlling global buckling, the Skuld project also demonstrated its
installation friendliness.

Figure 2: Typical Skuld Pipeline residual curvature sections (as-laid).

Recent work performed by Statoil and IKM Ocean Design have also
proven that the axial flexibility achieved by the residual curvature
method, can be utilized for other purposes also:
1)
2)

Utilizing the reel-lay method to conform the pipeline to the

seabed topography, Endal et al (2015).
Direct tie-in: Installing residual curvature sections at pipeline
ends to remove the requirement for tie-in/expansion spools.

This paper investigates how the residual curvature method can be

utilized for direct tie-in of pipelines to subsea structures.

PIPELINE TIE-IN SOLUTIONS - GENERAL

A subsea pipeline in operation experiences large axial effective forces
as a consequence of pressure and thermal effects. If the pipeline is tied
directly into a subsea structure, these compressive forces can be
transferred directly into the subsea structure piping. At a platform, a
pipeline that is tied directly into a riser may cause unwanted
deformation or stresses in the riser or elbow, Palmer and Ling (1981).
During tie-in to a platform riser or a subsea structure, significant forces
are required to move an as-laid pipeline axially. Factors such as
pipeline axial stiffness, submerged weight, seabed friction resistance
etc will oppose movements in the opposite direction of the pipeline
route. Hence, it is generally a better solution to allow for some
movement to occur. The proposed solution has a dual purpose, 1) to
provide the system with enough flexibility to tie- in the pipeline and 2)
to accommodate the expansion movements caused during operation.
The connection of pipelines to risers, subsea structures and other
pipeline systems may be performed with various types of connections
and installation techniques. Some of the main factors to be considered
for the selection of an optimal tie-in solution could include:

Risk issues
Comparative costs
Type of service, design loads
and design life
Pipe material
Water depth and
hydrodynamic loads
Pipeline end expansion
Field layout and pipeline
routing
Tie-in area congestion
Size of equipment/tools and
access requirements
Method of metrology
Tolerances
Equipment capacities, quality
and track record

Protection requirements
No. tie-ins to be performed, as
well no. different type tieins/sizes etc, standardization
Fishing activity at the location
Seabed condition
Installation method, schedule
and lay direction
Pigging requirements
Market situation
Vessel limitations
Region of the world where the
project takes place
Development and long term
strategic plans
National and operator
requirements

Statoil. The new technology allows remote controlled repair by

hyperbaric welding of large diameter subsea pipelines in water depths
down to 1300 meters, Berge (2015).
Above water weld examples are structures that are inline in the pipeline
string or at the pipeline end before being installed. Alternatively, the
pipeline end can be recovered to surface for the structure to be welded
in before being lowered to the seabed again. Another case is above
water midline tie-ins where two pipeline ends are lifted up to a vessel
and welded above water and placed down on the seabed again. Pipeline
pull-in through a J-tube followed by welding to topside piping is also
an example of this approach.
Bolted flange connections are a common and reliable connection
method, with standard flanges covering a wide range of pipeline sizes.
While typically installed by divers, there are also two different diverless systems capable of handling bolted flanges (MATIS and
BRUTUS), Corbetta and Cox (1999).
Mechanical clamp connectors are designed to simplify the manual
operations required to establish a seal compared to bolted flanges. The
most common mechanical connectors are the clamp and the collet type.
Both designs are very well suited for diver-less operations, requiring
typically a torque tool or a linear hydraulic actuation, respectively.
Other mechanical connections such as swaging and ball grip connectors
(eg. the proprietary Morgrip coupling) are also available for special
purpose use, i.e. connection of bare pipe.
Typically, the various types of tie-in at subsea structures and platforms
can be grouped into the following main and sub-categories:
Spool tie-ins: In general, spool pieces are the most common tie-in
solution due to their versatility, flexibility and low risk.
Rigid spools. Horizontal tie-in solutions are traditionally considered for
applications within diving depth, where snagging loads represent a
threat (trawl, anchor etc) and in regions of significant hydrodynamic
loads. Diver-less horizontal tie-in systems are available for the entire
water depth range. Vertical tie-in systems are also available and are
mainly used in deep water developments where conditions allow it and
favours it compared to a horizontal solution. The rigid spools can be
shaped in almost any configuration, placing very little restraint on the
approach headings of pipelines towards structures. The geometry often
takes the shape of L, Z, M, U or similar depending on the required
flexibility required, pipeline routing etc. The flexibility in the spools is
related to the length of the legs/offsets. Figure 3 shows a typical layout
of rigid spools of both L and Z shape. This is the most common
approach for connecting a pipeline to a subsea structure or a platform
riser.

The most common connection methods are:

a)
b)
c)
d)

Hyperbaric welding
Above water weld
Bolted flange connectors
Mechanical clamp connectors

Hyperbaric welded connections have been commonly used for tie-in of

large diameter and high pressure oil and gas pipelines, and hyperbaric
welding is considered a highly reliable and efficient tie-in method. It is
also considered a flexible method seen from a pipelaying and tie-in
operation point of view. Another application where hyperbaric welded
pipeline connections are being used, is for pipeline repair projects. The
method is traditionally limited to diver depths, however a remote
pipeline repair system has recently been patented and qualified by

Figure 3: Typical Rigid Spool Layout at Subsea Template

Flexible spool/jumper/tail. The main advantages of using a flexible tiein solution versus a rigid spool are the reduced tie-in forces, roomy
installation tolerances, and no requirement for metrology and
fabrication after pipeline/structure installation. On the negative side,
industry experience indicates that flexible pipes, jumpers and tails are

more vulnerable than rigid pipe solutions, and thus have a reduced lifetime compared to a rigid solution. In addition, flow assurance issues
could also be a concern for flexible. A typical flexible tail tie-in layout
is shown in Figure 4.

Then, with the assistance of installation aids such as buoyancy, chains,

winches, clump weights etc, the pipeline end is deflected and pulled
across to the tie-in point with the planned configuration. The first
diverless deflect to connect tie-in was performed on the Troll Oil
project, Holmen and Fagerlund (1994). Challenges with the deflect to
connect method is alignment, the seabed space required and that high
forces may be transferred into the tie-in point.
A quasi direct tie-in method, is by installing the subsea structure after
the pipeline is in place. The structure is lifted/pulled into position
assisted by the tie-in tool or docked straight onto the guide system as
outlined in Figure 7. Normally, this approach is used where the subsea
structure is relatively small and is connected to a flexible riser or rigid
spool on the other side.

Figure 4: Typical Flexible Spool Layout at a Subsea Template

Direct tie-in methods. The main challenges with the existing direct tiein methods are relatively large forces on the connection and large
pipeline stresses close to the connection point.
Direct pull-in to the platform J-tube: A pipeline pull-in to a J-tube is a
common way of connecting the seafloor pipeline to a platform and it is
normally used for pipeline initiation, Walker and Davies (1983). A
typical pipeline pulled-in through a platform J-tube is illustrated in
Figure 5.

Figure 5: First End Direct Tie-in: Pull-in to J-tube and Lay Away
Direct tie-in subsea, connect and lay away: This is a simple
alternative for tie-in, but is normally for first end tie-ins. Due to the
expansion forces being transferred directly into the subsea structure or
riser, this method is relying on a robust tie-in structure or that
expansion forces are absorbed in an adjacent pipeline section, e.g. by an
anchor or a curve in the pipeline route.
Deflect to connect, see Figure 6: This direct tie-in method involves
laying the pipeline down at a predetermined target, angle and distance
relative to the structure/connection point.

Notes:

A) Subsea structure being pulled-in and lifted towards the as-laid

pipeline end. Details of equipment, aids etc not shown.
B) Pipeline, structure and flexible riser pulled-in

Figure 7: Direct Tie-in of Subsea Structure to Pipeline

DIRECT TIE-IN BY RESIDUAL CURVATURE FROM REEL-LAY
General: The new direct tie-in method presented in this article utilizes
the reel-lay installation method to create local residual curvature in the
pipeline, as described by Endal and Egeli (2014). By installing
prebent sections at or close to the end of the pipeline, direct tie-in
may be enabled without the need for tie-in spools, large start-up/laydown areas, while still achieving acceptably low tie-in and connection
forces.
It is believed that this approach has the potential to enable many more
tie-ins by direct connection, hence permitting large cost and schedule
savings for subsea development projects, as separate spools or flexible
jumpers become superfluous.

Figure 6: Pipeline Direct Tie-in with Deflect to Connect Method

The same axial and lateral flexibility utilized for direct tie-in, will be
even more efficient when it comes to absorbing and controlling
expansion forces/movements caused by pressure and temperature loads
during the operating condition. In fact, pipeline expansion effects can
be seen to neutralize the tie-in forces remaining in the system.

Other advantages of the new technique are considered to be:

A residual curvature section can be quickly installed.

Reference is made to the Skuld project where 25 such prebent sections where installed with an average installation time
of 10-20 minutes per location, Endal et al (2014)
No straightening trials were found required, Endal et al
(2014)
Is considered a robust method even if residual strains varies
somewhat.
It will provide the means to efficiently reduce expansion
forces for existing direct tie-in methods also.

Figure 8 below shows the concept with implementing tie-in and

expansion loop as an integrated part of the pipeline end section.
0.2 % to 0.3 % residual curvature strain can efficiently be created in the
tie-in and expansion loop sections using the straightener system on
the reel ship during installation, as proven on Statoils Skuld project in
2012, Endal and Egeli (2014).
Buoyancy and/or additional weight should be considered installed on or
close to the pipeline end to ensure adequate rotation of the tie-in and
expansion loop, if required.

Figure 8: First End Direct Tie-in using The Residual Curvature

Method Under-Straightened Section
A single under-straightened section can be used as on Skuld, Roy et al
(2014), or a combination of over-under-over straightened sections can
be introduced as depicted in Figure 9. If it necessary to reduce tie-in
forces further, friction resistance can be reduced by placing buoyancy
along the residual curvature and transition sections.

Figure 9: First End Direct Tie-in using The Residual Curvature

Method Combining Over-Under-Over-Straightened Sections plus
other installation aids
This will ensure a laterally stable pipeline end, in order to achieve lay
down tolerances. A straight section is typically 50 100 m long,
however the length depends on several factors such as water depth, pipe
soil interaction, submerged weight, residual lay tension, dynamics,
tolerances, terrain, tie-in system, structure to be tied into etc. Axial,
lateral and heading tolerances are important aspects of the method
presented. The analyses cases presented later in this paper, will
investigate these issues further. It is generally found however, that the
method is quite robust with regards to the tolerances mentioned.
First end tie-in: A direct tie-in using the residual curvature method is
considered to have more advantages at the pipelay initiation end (first
end tie-in) compared to the second end. At the first end, the pipeline
can for instance be initiated against a return sheave arrangement on the
subsea structure and lowered/docked in a controlled manner onto a
guide post/landing frame etc depending on the tie-in system being
employed, see Figure 10. The residual curvature section is introduced
approximately 100 m away from the pipeline end in accordance with
the methodology presented by Endal et al and Roy et al in 2014.
Careful assessment of influencing factors should be accounted for
during design in order to ensure that the residual curvature section
rotates in the sagbend into the horizontal plane. Additional installation
aids such as the possibility to pull the section down via a subsea winch
etc should be considered. However, as was experienced on the Skuld
project, all 25 residual curvature sections rotated as planned.

A wire tensioning system using a standard torque tool is also

considered to be an efficient method in order to retract the pipeline end
if necessary and to maintain a stable pre-bent section. Using the wire
tensioning system is also considered a time efficient method for
retracting the pipeline away from the subsea structure in a controlled
manner.
An alternative to the wire tensioning system may be to use
buoyancy/airbag as shown in Figure 11. These will have a similar effect
as the wire system, i.e. cause the residual curve to be compressed and
the pipeline end to retract.
Figure 9 shows another variation of the residual curvature section
method, i.e. combining over and under-straightened sections. This will
take slightly more time to install, but may have some advantages in
terms of a more defined pre-bent section and potentially slightly easier
to control the heading towards the subsea structure.
As shown in Figure 9, buoyancy can also be more evenly distributed
along the residual strain section in order to reduce friction resistance
and thus ease installation loads. It is considered beneficial with a short
straight section between the pipeline end and the start of the residual
curvature section.

Figure 10: First End Direct Tie-in using The Residual Curvature
Method Typical Initiation Overview.
Hub capacity is often seen to be a governing factor for pipeline tie-ins
using diverless systems. Since hubs on subsea templates typically could
be elevated 2.5 m above the seabed floor, vertical alignment between

pipeline end and the hub is a key parameter. In order to compensate for
this, the hub can typically be tilted slightly downwards, say 3, 5 or 7.
However, further vertical alignment will in many cases be needed. This
has on several projects been solved by introducing rock supports or
adjustable mechanical supports in the adjacent free span.
After the pipeline is pulled down and safely landed in the tie-in
porch/landing frame, the pipeline is ready for the final stroke-in and
finally the clamp connector is made up and the seal can be tested.
Most major tie-in vendors have modern and efficient systems that are
applicable for this method. The latest generation tie-in systems are
compact, modular and simpler compared to the previous generation
tools that also included winch pull-in capability. The basis for all the
new tie-in systems is a stroke and connect functionality. As discussed
by Olsen (2013), the new generation tie-in systems HCCS, HCS and
UCON, are based on landing the termination head into the porch,
letting the ROV stroke the hubs together by the temporary stroking tool
and engage the connector. Also other tie-in systems are available, that
will provide the same functionality as the three mentioned above. Some
minor modifications to the structure or equipment may be required,
however these are considered small.
Detailed routing and pipeline rotation design is required in order to
ensure that the subsea layout has space for the lateral displacements
that the method requires. If two or more pipelines, cables etc are
approaching the subsea structure along a common corridor, they should
have sufficient separation in order to allow displacements and/or
rotations in the opposite direction.
Second end tie-in: Even though the proposed method is considered
more suitable for a first end tie-in, it is also considered relevant and
suitable for a second end tie-in as well. Hence, the solution may be
utilized generally on a project without having different solutions at first
and second end tie-in points.
One feasible approach to a second end tie-in, is to install and lay down
the pipeline end with a heading passing slightly on the outside of the
subsea structure to be tied into with sufficient clearance, see Figure 11.

Notes:

1) Both a wire tensioning system and buoyancy indicated as method

to retract pipeline end to allow lift and shift into docking position.
Pipeline end retraction may also be needed for pipeline laydown
tolerance reasons.
2) Details regarding tie-in tool/hardware, guidepost, bumper plate,
vertical alignment supports and other details are not included

Figure 11: Second End Tie-in using The Residual Curvature Method
Laydown Position, Ready for Lift, Shift & Docking Operation.
The target box axial tolerance is a crucial parameter for second end tieins and minimizing tolerances is important. The pre-bent section in
combination with the wire tensioning system or buoyancy, provides the
possibility to retract the pipeline end considerably. However, in the
event that the pipeline end is installed outside of the planned target box,
the pipeline end may have to be recovered to surface for length
adjustment (as on any other project).

After lay down of the pipeline end, the position of the end relative to
the tie-in point and the 3D perimeter of the structure should be checked
and evaluated. Following the relative pipeline end position, the wire
tensioning system can be tensioned up in order to retract the pipeline
end in order to create sufficient access for the lateral lift, shift and
handling towards the tie-in porch on the subsea structure. The lift and
shift operation should be performed with the vessel crane supported by
ROV visuals, winches, required installation aids etc. After landing the
termination head directly into the porch, the stroking and engagement
of the connector can be made in accordance with the specifics of the
selected tie-in system.

Note:

Details wrt tie-in tool/hardware, porch, guidepost/funnel, bumper,

vertical alignment supports and other details are not included.

Figure 12: Second End Direct Tie-in using The Residual Curvature
Method Final Make-up of Clamp Connector.
General Rotation Control: Achieving approximately 90 pipeline roll of
the residual curvature section during installation is advantageous for a
safe and robust design, because then the pipeline has a lateral deflection
and the residual curvature section is in contact with the seabed. If the
pipeline does not roll the residual curvature section may be free
spanning as well as being exposed to hydrodynamic loads, trawl loads
etc. Pipeline roll has been assessed analytically in Appendix A, and it is
seen that the pipeline will roll approximately 90 during installation.
This was also the experience from the Skuld project in 2012 (Endal and
Egeli, 2014). The additional weight when waterfilling the pipeline will
be an eccentric load that will encourage the pipeline to rotate until
contact with the seabed. Hence, the pipeline will want to rotate
towards 90.
An alternative to control the direction of rotation is to attach a clamp at
either end of the prebent section with a cantilever arm with attached
buoyancy to the arm. The arm can then be fixed at 3 or 9 oclock
depending on which direction the rotation should take place. The
clamp/arm arrangement could also be extended to have a second
function including compressing the prebent curve. Then, buoyancy can
be attached in the middle with a wire extended to each clamp arm.
Careful assessment of influencing factors should be accounted for
during design in order to ensure that the residual curvature section
rotates as planned into the horizontal plane. Additional installation aids
such as the possibility to pull the section down via a return sheave or a
subsea winch etc should be considered. However, as was experienced
on the Skuld project, the residual curvature sections rotated as planned
(Endal and Egeli, 2014).

DATA FOR PIPELINE CASE STUDY

In order to further document the potential for the new direct tie-in
method, a number of detailed FE analyses were conducted in the
commercial pipeline simulation package SIMLA (MARINTEK), see
model overview in Figure 13. SIMLA is a special purpose computer
tool for static and dynamic engineering analysis of offshore pipelines
during design, installation and operation.

Case

C
Figure 13: SIMLA FE model for Residual Curvature / Direct tie-in
analyses (exaggerated lateral scale)

A typical 12 pipeline case in the North Sea is considered for the study
cases.

Main data for the example pipeline analysed in this paper are given in
Table 1.

Case Pipeline Characteristic

Material grade

Value
DNV SML 450

Nominal steel pipe OD

323.9 mm

Nominal wall thickness

15.9 mm

External Coating Thickness

Design pressure

40 mm PP
130 barg @ +30 m

Design temperature
Submerged weight (empty/waterfilled)

50 C (max)
29.3/98.1 kg/m

Pipeline Transportation Product

MAllowable (empty/operation)

Gas
480/430 kNm

Water Depth
Friction Coefficient (axial/lateral)
Residual Lay Tension

300 m

Description
Base Case with 70 m @ 0.26% residual curvature section, 15
m transitions on either side of the curved section, waterfilled
pipe and no buoyancy (Wsub =98.1 kg/m) , 1500 m model
length and 100 m straight section towards tie-in point, 1.5 m
stroke.
As Case A, but with 68.8 kg/m buoyancy from tie-in point
until end of residual curvature section, Wsub=29.3 kg/m (i.e.
the same effective submerged pipe weight as in empty
condition).
As Base Case, but where the wire tensioning system is
compressed 1.2 m prior to pipeline termination head docks
into the tie-in porch. After docking, the 1.2 m wire retraction is
gradually released prior to stroke-in. This is followed by
applying pressure and 1.0 m feed-in from the pipeline side
(operational condition).
As Case B, but with 40 m instead of 70 m long residual
curvature section, 1.5 m stroke.
As Case B, but with wire tensioning system attached, reducing
the wire length 10 m in order to see what tensile forces are
required for the wire.
As Case A and B, plus rotating the termination head up to 5
about the vertical axis in order to simulate the bending
moments for correction of misalignment.

Table 2: Study Case Description

CASE STUDY RESULTS

General Results
Required stroking force is the first main parameter to be addressed with
regards to the feasibility of the new direct tie-in method. Figure 14,
shows stroking forces for Case A, B, C and D. Case A without any
installation aids exceeds the stroke capacity of some of the relevant tiein systems. Case B, C and D all give maximum stroking forces of less
than 220 kN for 0.5 m stroking distance. If the tool capacity is 280
300 kN, a stroke length of 0.75 m to 1.0 m can be achieved for these
three cases. It is therefore concluded that the required stroke force is
well within the capacity of applicable tie-in systems if buoyancy and/or
a wire tensioning system is used.

0.6
40 kN

Table 1: Data for the case study (12 pipeline)

The analysis cases investigated in the work are listed in Table 2.
The focus for the analysis cases were to address primary questions such
as:

Forces to stroke the hubs together and engage the connector

Bending moments required to correct misalignment

Operational effects (pressure and thermal expansion)

Effect of curve length

Effect of friction/buoyancy

The possibility to retract the pipeline end for a second end tiein and/or generally for handling and disconnection.

Figure 14: Stroke Force vs Distance

The second principal question to be checked is bending moment
required for heading misalignment (Case F). Figure 15, shows bending
moment about the vertical axis as a function of rotation applied at the
tie-in point. Most state-of-the-art tie-in tools have an alignment
capacity of 300 kNm or more. Based on this, it can be seen that an
alignment of more than 3.2 can be achieved for Case A (base case -

waterfilled condition without buoyancy) and that more than 5

alignment can be achieved if buoyancy is used.

Alternatively, the pipeline will have high residual capacity for other
type of loads, eg. trawl loads.

Figure 15: Bending Moment vs Rotation Applied at the Pipeline End

(Case F).

Figure 17: Bending Moment Utilization

Case A
As seen above in Figure 14, the force is 400 kN for 0.5 m stroking and
consequently too high for the applicable tie-in tools. Hence, it is
concluded that the considered 12 pipeline case cannot be tied in
directly in waterfilled condition without the assistance of installation
aids.
Case B
Case B is as Case A, but with 68.8 kg/m buoyancy applied after
pipeline water-filling along the residual curvature section and transition
lengths. As seen in Figure 14, the force needed to stroke 0.5 m is 185
kN, i.e well within the capacity of available tie-in tools.

Case C
This case is as Case A, except that a wire tensioning system is used to
compress the prebent curve by 1.2 m in the sagbend during laydown
prior to the pipeline end docks into the tie-in porch. Hence, a large the
deflected shape is large. After docking, the pipeline is flooded and wire
is gradually released prior to stroke-in. The release of the wire causes
the pipeline to push back towards the tie-in point and thus reduce the
stroking force, see Figure 14. After stroking 0.5 m, the pipeline is filled
with gas, pressurized and subsequently given a 1 m pipeline feed-in.
Figure 18 shows the deflected shapes for various steps in the process.

In order to investigate the combination of tie-in and operating loads the

0.5 stroke-in is followed by operational loads, i.e. design pressure and
1.0 m feed-in from the pipeline side towards the residual curvature
section.
As seen in Figure 16, the lateral displacement reduces when pipeline is
stroked-in by 0.5 m. When pressure and temperature feed-in is applied,
the lateral displacement increases again, and reaches a maximum of
12m when subjected to operational loads.

Figure 18: Case C - Displaced Shapes

Bending moment utilizations for Case C is shown in Figure 19.
Maximum utilization is 0.6 considering both tie-in and operational
phases.

Figure 16: Displaced Shape

Figure 17, shows that the bending moment utilization is peaking during
tie-in and that operational loads reduces the utilization. The reason for
this reduction is that the stroke-in operation has stretched the curve
while operational loads causes the curve to pass through its neutral
position and into a compressed shape.
Figure 19: Case C - Bending Moment Utilization
Based on the results from Figure 17, it can be concluded that the
considered residual curvature section is in a good position to
accommodate far higher thermal expansions than the analysed 1.0 m.

The effective force distribution at various load steps are shown in

Figure 20. The compressive effect of the wire system is clearly seen in

the as-laid & docked & prior to wire release step. Releasing the wire,
causes the effective force to drop to almost zero at the prebent section,
while the 0.5 m stroke increases the tensile force at the tie-in point. As
the pipeline is de-watered and filled with gas (reduced submerged
weight compared to a waterfilled pipe), the pipeline shape becomes
more relaxed and the tensile forces reduces again. Pressure and pipeline
feed-in causes the pipeline effective force to go into compression.

Figure 22: Displaced Shape 40 m long residual curvature section

Case E
With regard to the potential for second end tie-in, the feasibility of the
method retracting the pipeline end is an important check. One way of
achieving such retraction is by using a standard torque tool and the wire
tensioning system illustrated in Figure 11. Alternatively, a buoyancywire arrangement can be used as also indicated in Figure 11.
Figure 20: Case C Pipeline Effective Force Development
Figure 21 shows a comparison between Case B and C with respect to
the axial forces acting at the tie-in point during tie-in and operation.
Even though Case B and C have two approaches to control tie-in
forces, they both give relatively low forces on the tie-in point during
both tie-in and operational phases. The maximum compressive force
experienced by the connector during operation is only ~60 kN (for both
cases).

Figure 23 shows the pipeline end retraction and the associated wire
force as a function of shortening the wire length in Figure 11. This
shows that using small tensile loads can easily retract the pipeline end
by several meters. For instance, a load of 100 kN can retract the
pipeline end 3.5 m.

Figure 23: Pipeline End Retraction vs Tension in Wire Tensioning

System (see definition in Fig. 24).

Figure 21: Forces Acting on Tie-in Point During Tie-in & Operation
for Cases B & C

As seen from the bending moment utilization in Figure 24, a retraction

of 2 m gives a bending moment utilization of approximately 0.82 while
a 5 m retraction gives over-utilization. Based on these results, a
maximum end retraction of approximately 3.5 m can be accepted. If
required, the use of buoyancy could further increase the allowable
retraction length as well as the force required.

Case D
This case is as Case B except for a 40 m residual curvature section
length. As shown in Figure 14, the stroke-in force is slightly higher
than for Case B, however still feasible for the applicable tie-in tools.
The displaced shape configurations for different stroke-ins are shown in
Figure 22. Due to the residual curvature section being 40 m instead of
70 m, also the lateral displacement prior to stroke-in is slightly reduced
compared to Case B.
The maximum bending moment utilization for 0.5 m stroke length is
0.74 for this case.
Figure 24: Bending Moment Utilization vs Pipeline End Retraction
using the Wire Tensioning System

Pipeline lateral displacements for the various retraction lengths are

shown in Figure 25. An approximate out-of-straightness of 17 m will be
the result of a 3.5 m end retraction.

ACKNOWLEDGEMENTS
The authors wish to thank the managements of Statoil and IKM Ocean
Design for permitting publication of this paper.

REFERENCES
Berge, JO, Repair of subsea pipelines by a remote welding system,
Presented at the Offshore Pipeline Technology (OPT) conference,
Amsterdam, February 2015.
Corbetta, G and Cox, DS, Deepwater Tie-ins of Rigid Lines: Horizontal
Spools or Vertical Jumpers, Presented at the Offshore Europe
Conference, Society of Petroleum Engineers, Aberdeen, Scotland, 7-9
Sept 1999.
DNV OS-F101, Submarine Pipeline Systems, 2013.
Figure 25: Lateral Displacement vs Pipeline End Retraction using the
Wire Tensioning System

Duckworth, SW, Supple, WJ, Neilson, WT, Flowline Tie-ins,

Advances in Underwater Technology, Ocean Science and Offshore
Engineering, Vol. 10, 1986.

Case F
As concluded above under General Results, alignment of the pipe end
can easily be done within the capacity of the applicable tie-in systems.

Endal, G, Ness, OB, Verley, R, Holthe, K and Remseth, S (1995),

Behaviour of offshore pipelines subjected to residual curvature during
laying, Proc of 1995 OMAE, Volume V, Pipeline Technology.

CONCLUSIONS

Endal, G and Egeli, H (2014). Reel-lay method to control global pipeline buckling under operating loads 2014 OPT Conf, Amsterdam.

This paper has shown that residual curvature sections created during
reel-lay installation enables direct tie-in of pipelines at both first and
second end tie-ins.
The traditional direct tie-in challenges with large forces on the
connection and large pipeline stresses close to the connection point are
solved. Tie-in forces and alignment moments are found to be well
within the capacity of existing stroke and connect tie-in systems. In
addition, efficient methods to control rotation and lay tolerances have
been identified.
The residual curvature method is seen to be effective for both tie-in and
operational loads. Forces in both conditions can be more or less
neutralized.
Residual curvature sections can be effectively installed, as documented
by Endal and Egeli (2014). A cost comparison between the new direct
tie-in method and a conventional spool installation and tie-in indicates a
cost saving potential of MUSD 1.8 per pipeline end in favor of the new
technique, ref. Appendix B.
Other benefits of the new direct tie-in method are:

All reel-lay contractors can do it.

It also provides the means to efficiently reduce expansion
forces for existing direct tie-in methods.
The proposed method reduces the number of potential leak
points in the pipeline system.
The method allows one uniform pipeline code and criterion to
be used throughout the entire pipeline system. In this paper
the allowable bending moment criteria according to DNV
OS-F101 has been used.
Construction vessel size may be reduced and schedule may be
more relaxed (the need for spools are eliminated)
Less parties involved (spool design, fabrication etc).
The proposed direct tie-in method will work very well in
combination with residual curvature sections elsewhere along
the route for free span reduction (Endal et al 2015) and
thermal buckling and expansion control (Endal et al 2014).

Endal, G, Giske, SR, Moen, K, Sande, S, Reel-lay method to control

global pipeline buckling under operating loads, Proc of the 33rd
OMAE Conf, June 8-13, San Francisco, USA
Endal, G, Rao, V, Ragupathy, P and Sriskandarajah, T, Pipeline roll
during reel-lay installation due to piggyback DEH cable and local
residual curvature, Proc of the 33rd OMAE Conf, June 8-13, San
Francisco, USA.
Endal, G and Nystrm, PR (2015), Opportunities gained by local
residual curvature during reel-lay installation, 2015 OPT Conf,
Amsterdam.
Endal, G, Nystrm, PR and Lyngsaunet, OM (2015), Reel-lay method to
make pipelines conform to uneven seabed topography, To be
presented at ISOPE Conf, Hawaii, USA, 2015
Holmen, C and Fagerlund, ES, Application of the "Deflect to connect"
tie-in method of two pipelines in parallel in deep water with diverless
connections - major findings from Troll oil pipeline engineering, Proc
of the 8th Underwater Technology Conference, Bergen, 1994.
Hydratight, MORGRIP TM Quickcoupling, www.hydratight.com.
MARINTEK, SIMLA - a special purpose computer tool for engineering
analysis of offshore pipelines during design, installation and operation.
www.sintef.no/globalassets/upload/marintek/pdf-filer/sofware/simla.pdf

Nystrm, PR, Lyngsaunet, OM and Foss, P (2014), Betraktninger for

installasjon av rrledninger i krevende terreng - Considerations for
installing pipelines in challenging terrain, NPF Pipeline and Risers
Conference, Trondheim, October 2014.
Olsen, J, Operational experiences using the latest generation remote tiein systems, www.ffu.no, Vol. 1 - 2013.
Palmer, A, Ling, TS, Movements of Submarine Pipelines Close to
Platforms, OTC4067, 13th Offshore Technology Conference,
Houston, 1981.
Roy, A, Rao, V, Charnaux, C, Ragupathy, P and Sriskandarajah, T,

Straightener settings for under-straight residual curvature of reel laid

pipe, Proc of the 33rd OMAE Conf, June 8-13, San Francisco, USA.
Statoil (2002) Method for pipelaying from a coil to the sea bed,
controlling thermal expansion, Norwegian patent 314056, PCT patent
EP1358420, US patent US6910830.
Statoil Petroleum AS, Remote-controlled joining system, PCT patent
PCT/NO2005/000248, US patent US8708216 B2.
Walker, AC, Davies, P, A design basis for the J-tube method of riser
installation, 2nd OMAE Symposium, 1983.

APPENDIX A - PIPELINE ROLL DURING INSTALLATION

The residual curvature sections are in the vertical plane on the reel ship.
Endal et al (1995) have shown that concave downward residual
curvature in the pipeline may lead to twist (roll) as it moves through the
suspended section and the underbend (sagbend) where it is bent in the
other direction.
The tendency to pipeline roll due to intermittent residual curvature can
be estimated by a simplified analytical energy approach. The total work
from the surface to the seabed is assumed to consist of a bending and a
roll contribution. Minimization of the total bending and rotational
energy conducted in the suspended section of the pipeline gives the roll
angle. The shape functions associated with the procedure are shown in
Figure A1.
The total work to bend and twist a 12 pipeline from the surface to the
seabed is shown in Figure A2 for roll angles between 0 and 180. The
calculations assume the pipeline being rotationally fixed at the reel
ship, but free to rotate at the seabed. The length of the section with
residual curvature is varied in the calculations (0m, 70m, 90m and
110m). The residual strain is assumed to be 0.20% in the residual
curvature section. The figure may tell much about the probability for
pipeline roll:
o

The pipeline has resistance towards roll if the curve is

monotonically increasing.

When the curve is relatively flat for smaller angles and

thereafter increasing, then the pipeline is relatively unstable
and may easily roll to an angle where further roll requires
increased energy.

When the curve has a clear minimum point, pipeline roll is

easily initiated, ending on a roll angle in the area where the
curve has its minimum.

Figure A1: Total work to bend and twist a 12 pipeline from surface to
seabed (300m water depth), at various lengths on the section with
residual curvature (0.2% local residual strain).

Figure A2: Simplified analytical approach estimating pipeline roll

Copyright 2015 The International Society of Offshore and Polar

Engineers (ISOPE). All rights reserved.

APPENDIX B COST COMPARISON

Table B1 shows an outlined cost comparison between the new direct
tie-in method and a traditional spool installation and tie-in. The same
12-inch case as presented in Table 1 is the basis for the comparison.
Cost Item - Description

Qty

Engin., Procurement & Fabrication

Residual Curvature Design & Analysis
Installation engineering for DTI, aids
Spool design
Transport & Installation engineering
PLET engineering
1
GRP cover engineering2
Hardware Cost
Spool proc,fab & testing, lifting, rigging
1
Tie-in system procurement (DTI), 1
Porches inc, hubs, connectors & HP caps
Tie-in system procurement (spool), 2
Porches inc, hubs, connectors & HP caps
PLET Procurement
1
GRP covers for spool
5
GRP covers for DTI, at template
2
Additional GRP cover for PLET
1
Extra allowance for installation aids
Tie-in tooling cost4
1
Extra pipe for DTI (say 50 m)
50
Sheave arrangement on subsea structure
1
Marine Operations3
Alignment supports (design+install)
3
Rock foundations for PLET & spool
1
Reel-lay vessel extra time for DTI (4 hrs 4
assumed)
Stroke and connection DTI (6 hrs 0.25
assumed
with
small
offshore
construction vessel)
Rock dumping of free spans prior to 1
GRP cover installation
GRP cover installation - DTI
Spool metrology
1
Spool transport & installation
2
Stroke and connection of spool (8 hrs 0.33
assumed
with
medium
offshore
construction vessel)
GRP cover installation spool
-

Total Cost (MUSD)

Unit
Cost
Cost
Price
DTI
Spool
(MUSD) (MUSD) (MUSD)
0.1
-

0.1
0.1
0.1

0.1
0.4
0.1
0.16

0.4
0.65

0.65

0.4
-

0.65

1.3

0.1
0.06
0.06
0.1
0.001
0.25

0.12
0.7
0.05
0.25

0.1
0.3
0.1
0.3
-

0.03
0.1
0.025

0.1
0.1

0.1
-

0.2

0.05

0.1

0.1

5
0.1
0.25
0.25

0.2
-

0.1
0.5
0.1

0.3

2.6

4.4

Notes: 1) DTI = Direct Tie-In method

2) 2 GRP covers assumed for DTI. 5 GRP covers assumed plus
1PLET cover for spool case.
3) Mob/demob cost will typically be shared between several activities.
Since the direct tie-in method may be carried out with a smaller
construction vessel, there may be a small cost in mob/demob also
4) A tie-in tool is required irrespective of the diverless tie-in method.
The tool cost is considered the same for both alternatives and not
included in the comparison

Table B1: Cost Comparison between direct tie-in and spool