IBP1124_19

THE WORLD’S FIRST REMOTE DEEPWATER

REPAIR OF RIGID RISER WITHIN A FREE
STANDING HYBRID TOWER
James Rowley , Paul Hughes 2, Pal Magne Hisdal3
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Copyright 2019, Brazilian Petroleum, Gas and Biofuels Institute - IBP

This Technical Paper was prepared for presentation at the Rio Pipeline Conference and Exhibition 2019, held
between 03 and 05 of September, in Rio de Janeiro. This Technical Paper was selected for presentation by the
Technical Committee of the event according to the information contained in the final paper submitted by the
author(s). The organizers are not supposed to translate or correct the submitted papers. The material as it is
presented, does not necessarily represent Brazilian Petroleum, Gas and Biofuels Institute’ opinion, or that of its
Members or Representatives. Authors consent to the publication of this Technical Paper in the Rio Pipeline
Conference and Exhibition 2019.

Abstract

The repair of pipelines and rigid risers in locations inaccessible by diver provide unique
challenges. The choice in repair methods is often limited to mechanical solutions (clamps,
connectors) welding or complete replacement/bypass. Driven by the cost (including lost
production) versus the perceived reliability, integrity and longevity of the resulting repair, a
risk adverse industry can be excused for demanding proven track record and technology to
underline the forward strategy. Fortunately a number of deepwater repair systems do exist to
enable the permanent repair of a pipeline in a horizontal plane; however, the successful
deployment of these systems is still incredibly limited. No one “standard” system exists to
repair pipelines or risers in constrained locations or non-horizontal alignments, therefore
when the need for this repair occurs it took a collaboration of industry specialists to design,
develop, test and deploy the World’s first vertical remote repair system.

1. Introduction

The field development in question is located in 1200m to 1500m of water. It consists of five
distinct fields which were discovered in 1999-2001, in Angola, West Africa. It has a total
estimated reserve of about 750million barrels, making it one of the biggest off Angola’s coast.

During the installation of the free standing hybrid riser tower within this field, damage to two
(2) of the gas lift risers occurred. Once installed, the damage was located at approximate
1250mwd within the bundle, however, it was known that the requirement to “gas lift”
hydrocarbons would not be required until the field was more mature, thereby confirming the
damage as non-critical. The original repair requirement, whereby the need for gas lift would
be required in the more imminent future, dated back to 2009 when an investigation into the
potential options for the reinstatement of damaged gas lift risers was conducted. To enable
field life longevity, these damaged rises had to be repaired or replaced. After the study, it was
determined that a repair of the two gas lift risers could be done with acceptable risk and at a
much lower cost than replacing the complete riser system.

Up until 2015 (when the project was initiated), the total global experience in permanent
mechanical connector deepwater pipeline repair could be summed up in eight (8) projects
spanning the industry since 1996. Through these eight operations, a total of ten (10)
______________________________
1
Chartered, Mechanical Engineer – Hydratight
2
Chartered, Mechanical Engineer – Enerpac
3
Managing Director – Connector Subsea Solutions
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mechanical connectors had been successfully deployed. Nine (9) of these had been deployed
in a horizontal installation frame; the tenth had been deployed using a remote operated ‘arm’
in near horizontal application, within the constraints of a manifold. The repair of a rigid riser
in a hybrid riser system would not only be the deepest repair ever attempted, but the first in a
vertical orientation and the first in the constrained space of a bundle.

2. Scope of Work

The pinnacle of a pipeline repair is the successful recommissioning once the repair is
concluded. In order to ensure this stage is reached successfully it is vitally important that the
foundations of the repair strategy are sound. This means that no aspect of the repair should be
assumed until the prior step and appropriate assessments are complete.

Figure 1 provides an illustration of foundation steps often used to help assess, critique and
select the correct repair strategy methodology with which to proceed. For the purpose of this
paper we will exclude confidential information and focus on key steps which either provided
a driving specification or solution that directed the outcome.

Figure 1: Repair Strategy, courtesy of IRM Systems

2.1. Identify the Damage

In any repair scenario the critical step once an issue has been acknowledged is to carry out the
appropriate level of inspection to allow, as effectively as possible, the damaged area(s) to be
readily identified.

Two gas lift risers were damaged during installation of the hybrid riser tower. The location
was within the bundle, at approximately 1250-1300mwd. The extent of the riser buckling
damage at this depth is highlighted in Figure 2.

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Figure 2: Gas Lift Riser damage within Hybrid Riser Tower

2.2. Consult pipeline intervention Companies

To ensure project risk mitigation, the deployment of field proven technology wherever
possible was of paramount importance. Within the industry, there are a number of remote
pipeline repair systems that have been developed, however, many of these systems have not
gone beyond System Integration Trials (SIT) or wet trials. Indeed, the remote installation of
connectors is rare within our industry.

Pipeline intervention Companies, in consultation with the Operator could confirm the
following remote repair projects:
1) 1996, Statoil Halten – 2off 16” 190Barg Remote Couplings
2) 1996, Statoil YME – 1off 4” 170Barg Remote Coupling
3) 2002, Statoil Snorre Vigdis Riser – 1off 12” 285Barg Remote Coupling
4) 2008, Total Girassol – 1off 12” Remote Coupling
5) 2009, Statoil Kviteborn – 2off 28” 178Barg Remote Couplings
6) 2010, Statoil Troll C Manifold – 1off 6” 340Barg End Cap
7) 2015, Statoil Gullfaks – 1off 12” 389Barg Remote Coupling
8) 2015, Statoil Midgard – 1off 20” 240Barg Remote Coupling

This track record provided the selection criteria for the Connector (given one supplier having
supplied all but one of the successfully installed remote connectors); however, it further
proved that the installation system could not be based on a field proven solution, so it would
require development based on existing technology. From previous experience there are key
challenges that needed to be addressed and overcome.

Table 1: Steps in pipeline repair

Step Remote Installed

Static pipeline needs exposing for Pipe restraint cutting
access Pipe cutting
Pipe handing & lifting/ pulling frames
Identifying suitable fixed reference Fixed anchor point
point for repair
Remove coating ROV pipe coating removal tool
Pipe Cutting ROV pipe cutting tool
Pipe End Preparation ROV pipe inspection tool
Aligning connector Hydraulic controlled positioning system
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Installing connector Hydraulic controlled positioning system

Verifying connector position Sensors with electronic feedback to surface
Activate connector Remote Operated Subsea Tensioners
Seal verification test Remote operated hydraulic test system
Recover installation equipment ROV operated disengagement system

From these core steps, outlined in Table 1, it could be reviewed and identified which could be
achieved using existing tooling, which would require modifications to standard tooling, and
which required complete bespoke solutions. The classification of these tools could be
managed through API 2009 Technology Readiness Level Assessment.

From these discussions the following items were deemed as critical:

1) Pipe preparation within accurate tolerance
Mechanical connectors are designed to operate within a predetermined and engineered
bandwidth. The more this bandwidth is pushed, the less optimum the design becomes
which increases risk of failure (e.g. a wrench designed for a specific nut size will be
accurately machined to a tight tolerance, reducing risk of slip. An adjustable wrench
designed for multiple diameters introduces less accuracy, increasing the risk of slip).
In order to provide the highest potential for successful activation first time, the control
of tolerances is critically important.

2) Accurate alignment and installation

Alignment is both important for the operation and activation of the repair connectors,
but also managing the loads exerted onto the pipe (risk of overstressing the riser). In
the best case scenario, misalignment can lead to uneven activation of the gripping and
seal element which may negatively affect activation. In the worst case scenario
misalignment could prevent the connector fitting onto the pipe, or the pipe itself being
overstressed causing further damage. As with any tolerance, accuracy remains critical.

3) Verification monitoring
Visual verification through ROV camera(s) can be severely limited due to the
installation system, location and environment. A positive affirmation of completed
activation steps is required through hydraulic and/or electronic sensors. Should the
seal test be unsuccessful, the lack or installation information creates a huge list of
potential failures which would take considerable time to review, assess, identify and
repair – leading to a very high “cost of failure” – a list that can be mitigated with the
selection of the correct monitoring systems.

Visual verification can provide a level of reassurance during installation

(complimenting monitoring and verification systems) however; the mechanical
connector needs to be set up with the appropriate references and visual indicators that
are useful for an ROV pilot to spot and record. This type of requirement is an example
where field experience in different installation environments creates the need.

2.3. Develop Repair Strategy

In order to take the world's first deepwater riser repair through concept development, front
end engineering design, detailed engineering, manufacturing, testing verification and be ready
for installation; numerous challenges had to be resolved e.g.:

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 Avoid overstressing gas lift risers during installation

 Remotely land, align, install, activate and test connectors
 Operate with limited access outside and inside the hybrid riser tower
 Avoid fatigue in highly utilized risers and structures
 Limit size and weight of equipment to maximize installation envelope
 Avoid fixing vessel crane to risers or riser tower at any time
 Optimize interfaces with Operator and Vessel and ROV Contractor

2.3.1 Design Challenges

For each of the two (2) separate riser repairs, the following main operational steps needed to
be performed:
1) Replace the gas lift manifold at the base of the hybrid riser tower
2) Cut and remove the damaged section of the gas lift riser
3) Remove piggy-back clamps and jack riser out from tower to allow access
4) Install Mechanical Connectors with hub termination
5) Fasten the spool piece onto the 12" Water Injection Riser, onto which the gas lift riser
is piggybacked above the repair location

To achieve step 4, a storyboard was created by working backwards through the process.
 The Mechanical Connector was to be a permanently installed item, this drove the
requirement for the installation tool and surface finish tolerances.
 To provide a stable frame for accurate alignment, the unit needed to be anchored.
 The anchor element had to be structurally sound, without damaging the riser.
Therefore control over surface finish and tolerance was required.
 A mechanical coating removal tool would be required to achieve these tolerances, but
this tool required 360degree access to enable full circumferential coating removal
 To provide access, the pipe would not only need to be cut and supported, but the
buoyancy in the hybrid tower would need to be removed.

An accurate storyboard (sample shown in Figure 3) enabled each step to be reviewed,

interrogated and critically, a Failure Mode Effect Analysis (FMEA) to be conducted. Through
interrogation of each step, the design specification for the required tooling could be created
while retaining the overall holistic approach of the entire project. The resulting scope of work
in terms of required tooling technology readiness level (risk, development, testing) could then
be reviewed.

Figure 3: Extracts from original storyboard, followed by detailed animation

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2.3.2 Operational Challenges

Operation interfaces between the Operator, Vessel Contractor, ROV operator and Installation
& Tooling suppliers needed to be robust. Therefore, prior to mobilization the repair required
highly detailed pre-dive & operation procedures to prevent the risk of significant delays that
might have otherwise occurred. To ensure the procedures are detailed, accurate and
encompass the various potential situations that can occur in a new scenario, it is critical that
these are developed, checked, and approved by an experienced, multidiscipline team. To
verify the robustness of these procedures it was decided to perform both a Site Integration
Test and shallow water wet trails. Through the operation of the system these procedures could
be fully tested and verified.

It was also important to determine the wet storage limits. If, for whatever reason, the
operation required to be interrupted, it was critical that the operational capacity of the
equipment in this specific environment was fully understood.

2.4. Design Intervention Tooling

2.4.1 Pipe Jack Out and cutting

The damaged sections needed to be bypassed, so following a highly detailed inspection the
cut location was analyzed and identified. In keeping with the tolerances of the project, a
square (90 degree) cut was required at the riser end. Although diamond wire saws are
common for subsea application, for a 4” riser the decision to use a circular blade enabled a
more compact unit to be deployed – a vital feature when dealing with a riser bundle.

The cut riser then needed to be jacked out to allow access to the cut end. This jack-out
operation needed to be anchored in location to ensure the riser was not overstressed. This
operation created at least not more than 4 degrees incline on the riser as illustrated in Figure 4

Figure 4: Riser cutting and Jack-Out operation

2.4.2 Buoyancy Removal

The gas lift riser was secured against the buoyancy within the hybrid riser tower. To gain
access for the coating to be removed, this buoyancy first needed to be removed. This was
achieved through the supply of a custom engineered buoyancy removal tool, a milling
machine that would secure onto the riser, then using a sweeping arm, machine out the
buoyancy, illustrated in Figure 5. Key challenges involved the milling of the tough
glass/epoxy composite, while optimizing the tool rigidity versus making it lightweight and
suitable for ROV installation.
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Figure 5: Buoyancy Removal Tool and operation illustration

2.4.3 Coating Removal

Due to the depth it was required that a mechanical coating removal tool was deployed. It was
paramount that all coating was to be removed without damage or impact onto the parent
material. With the access granted from the buoyancy removal tool, there was sufficient space
to deploy a field proven coating removal system in the vertical alignment. Key challenges
involved toughness of the fusion bonded epoxy coat (for which proprietary technology was
required).

Figure 6: Coating Removal Tool

2.4.4 Riser Hang Off Anchor Clamp Installation

A friction collet gripping system, as shown in Figure 7, was selected to provide the secure
anchor and reference point for the installation tooling. This unit would be remotely installed
by ROV. Key challenges included designing a lightweight yet robust system that accounted
for the fragility of the 4” riser. To this end extensive and highly detailed analysis of the riser
interface and interaction with the entire system was undertake along with physical testing to
prove the design.
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Figure 7: Riser Hang Off Anchor Clamp including surface inspection

2.4.5 Connector Alignment, Installation, Activation (AIA) and Test Frame

With a secure hang-off anchor point from which to secure the Alignment, Installation and
Activation (AIA) system, the required tolerances (angle, stroke length etc.) could be specified
for the installation system. Given that the entire installation system is a significant size,
weight and cost, and due to the need to complete two riser repairs, it was determined that it
should be removable and reusable. Key challenges included the alignment and install-ability
onto the Anchor Clamp, while also enabling the mechanical, hydraulic and electrical
interfaces with the Mechanical Connector.

Figure 8: Connector Alignment, Installation& Activation Frame during FAT

2.4.6 Mechanical Connector

The specification of the mechanical connector required DNV GL Type Approval, recent field
proven track record and qualification as a permanent repair. The ability to interface this with
the Alignment, Installation, Activation and Test Frame made it desirable that the chosen
supplier could draw on existing pre-dive check, installation and activation procedures for
similar units.
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Figure 9: Mechanical Connector - 4” Remote Flange Adaptor

Key challenges were in the development of a lightweight remote mechanical connector to fit
within a very constrained space. The remote connector needed to retain hydraulic and
electronic sensors to enable monitoring and feedback of the operation, as well as the hydraulic
means (remote tensioners) to activate the gripping and sealing sections. To achieve this
requirement, a new set of remote tensioners needed to be developed (that could perform to the
same standard as the Companies existing range) along with the hard piping of all integrated
control and monitoring systems which would interface with the Installation frame. Typical
horizontal repairs provide much large space envelopes with less restriction on weight.

2.4.7 Offshore Repair

With all offshore repairs, the likelihood of success significantly increases when there are
stringent documents and procedures put in place. The challenge with this repair was the limit
of tested procedures available. As this was a totally new operation, there was no archive,
resource or prior experience that could be easily utilized to ensure robust plans. Therefore the
plans needed to be created. The experience and track record with remote mechanical
connectors provided substantial tested and proven pre-dive, operation and installation
procedures that could form a check and balance. The new procedures were tested at both
factory acceptance testing, system integration testing and shallow water wet trails. By
adopting such a stringent test program, each step in the procedure could be reviewed, tested
and modified if required – providing the most robust procedures at point of installation.

Figure 10: Offshore deployment, installation and completion

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3. Summary

The repair was hugely successful. Delivered on budget, on schedule and installed within the
expected shutdown window – each step was successfully completed during the first attempt.
This success was achieved through the detailed planning, development and testing of each
component and the complete system. Procedures and installation instructions could be
developed and tested prior to offshore deployment, giving the companies involved in the
collaboration the required time to manage each interface, whether that is physical tooling
interfaces or team structure and reporting.

The time was only available due to the critical repair being a non-emergency i.e. it could be
scheduled without impacting production. If the damage had occurred during production due to
another root cause (erosion, corrosion, dropped objects, impact, etc.) then production would
likely halt while a “quick” or “emergency” repair was pursued. In this event the constraint on
time might have increased the acceptable levels of risk, lead to expedited delivery of
unproven technology with additional contingency (more expense), with higher risk of failure.

It is worth noting that since 2015 a further four (4) remote repair operations, deploying seven
(7) connectors have been successfully completed. Two (2) further operations deploying four
(4) connectors are planned for 2020. As illustrated in figure 11, this suggests the trend for
remote repairs are increasing.

Number of Remote Mechanical

Connectors Installation
6
No. of Remote Mechanical

4
Connectors

0
1990 1995 2000 2005 2010 2015 2020 2025
Year

Figure 11: Trend for remote connector repairs

The notable increase in the industries requirement for remote repairs could be due to the sheer
volume of assets and infrastructure that each year age a little more. Corrosion remains the
highest cause of pipeline failure within the industry – an aging pipeline has a great probability
of corrosion occurrence. However, it is also in part to the risk adverse strategy that many
major operators are working towards. Remote repairs are now being planned in locations and
water depths that are accessible by trained divers. Although diver installed systems have
fewer costs associated, the potential risk to the divers who operate in such extreme
environments remains a concern. A risk which can be mitigated through field proven
technology.

With the increased demand for these remote systems, and the risk associated with not having
an Emergency Pipeline Repair System strategy in place, future investment in further remote
repair technologies seems the next logical step to a safe, leak-free industry.

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