Pipeline End Manifold (PLEM)

  • June 18, 2017
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COMPANY: Sigur Ros Turkmenistan 

PROJECT TITLE: Petronas Turkmenistan Block 1 Gas Development Project 

CLIENT: PETRONAS Turkmenistan

LOCATION: Turkmenistan

YEAR: 2009-2011

VESSEL: Derrick Lay Barge (DLB) Armada Installer

SCOPE OF WORK: 

MY INVOLVEMENT:

I was only invovled in the loadout of the PLEM onto a Supply vessel at Turkmenbashi Port

INTRODUCTION

Petronas Carigali (Turkmenistan) Sdn Bhd (COMPANY),  a  wholly  owned  exploration  and production subsidiary of PETRONAS, has entrusted Malaysia Marine and  Heavy Engineering Sdn Bhd (MMHE) and Technip Geoproduction (M) Sdn Bhd (CONTRACTOR) to  undertake the development of the Onshore Gas Terminal (OGT) and Magtymguly field which are located in Block 1 offshore  of  Turkmenistan  (referred to  as  PETRONAS  CARIGALI  TURKMENISTAN  BLOCK  1 GAS DEVELOPMENT PROJECT- hereinafter referred to as the “PROJECT”).

The Turkmenistan Block 1 field is an elongated field approximately 50 to 60 km long and 10 km wide offshore Turkmenistan. The Block 1 deposits will be accessed using a phased development plan sufficient to maintain a substantial flow rate for a number of years.

CONTRACTOR    has subcontracted part of the PROJECT to Sigur Ros Sdn Bhd (SGRSB) (SUBCONTRACTOR)  to perform the “WORK” as specified in the subcontract.

SUBCONTRACTOR will undertake the WORK for the following FACILITIES to be developed under the PROJECT for Phase 1A:

  • Export submarine pipelines from Magtymguly (MCR-A) to Kiyanli OGT (separate gas and condensate pipelines, inclusive of pre-installed pipeline risers at MCR·A):
    – 26″ dia. gas export pipeline, approximately 73km in length.
    – 12″ dia. condensate export pipeline, approximately 73km in length.
  • MEG supply pipeline from  Kiyanli OGT to Magtymguly  (MCR-A)  (inclusive of the pre­ installed pipeline riser at MCR-A):
    – 4″ dia. MEG supply pipeline, approximately 73km in length (this line will piggyback on the 12″ dia. condensate pipeline).
  • Condensate  loading pipelines  from  the  OGT  to the SPM buoy:
    – 2 x 12″ dia. condensate loading pipelines, approximately 7km in length each.
  • SPM buoy, complete with mooring system, risers and PLEM (engineering and procurement by others).

The signing entities for the SUBCONTRACT are between MMHE and SGRSB.

LOADOUT AND TRANSPORTATION

INTRODUCTION

The Single Point Mooring System comprising of Anchor piles, Anchor Chain, PLEM and Submarine hose and other miscellaneous  items have been fabricated at the following  fabrication  yard:

SPM system & PLEM:

Gulf Piping Co. Fabrication Yard by Bluewater Engineering Services (BES)/MMHE Mussaffa, Abu Dhabi

Pile : TBA

PRE-LOADOUT

Prior to loadout from the Kiyanly yard, inspection list shall be with referenced to SR·TKM·OPR· PLEM·SPM·S104, Loadout Coordination Manual for SPM and PLEM and also included in No. SR·TKM· OPR·PLEM·SPM-S1 00, PLEM and SPM Buoy System Transportation Study will be reviewed and completed. Any areas of potential concern will be highlighted to company’s. The loadout is also detailed  in the  above  document.

LOADOUT AND TRANSPORTATION

Loadout list for the transportation barge for SPM System and PLEM is shown in the Document No. SR-TKM-OPR-PLEM-SPM-S100

General arrangement and seafastening details for loadout of the pipeline and miscellaneous items are also included in the above report.

The SPM system and PLEM components will be loadout to the installation site on the following transportation barge:

Transportation  Barge Component Quantity
TBA BARGE 1

(lxWxD)

 Anchor Piles (1219mm Dia. x59ft lgth)

Anchor  Chains (73mm Dia 886ft lgth)

Chaser Pile (1219mm  Dia. X  59ft  lgth)

Chaser  Rack frame

 4 lgth

4 nos

1 lgth

1 no
TBA BARGE 2 (LX W x D) Anchor Piles (1219mm Dia. x59ft lgth)

Anchor Chains (73mm Dia 886ft lgth)

Submarine hoses

PLEM

 2 lgth

2 nos

1 lgth

1 no
TBA vessel Lx W x D SPM Turret Buoy

Floating hoses

Mooring hawser assembly

 1 no

1 lgth

1 lgth

A detailed review of all components and material loaded out will be conducted and checked against the loadout list as described in the Loadout Coordination Manual. Any discrepancies in the quantity and conditions of the SPM System & PLEM strcuture will be highlighted to company representative and recorded prior to transfer of custody of the transportation barge to subcontractor. A loadout and tie-down arrangements of strcutures on the transportation barge are shown in Fig. 2.3-1 and 2.3-2 respectively.

The tie-down and loadout arrangements for the subsequent  voyages are detailed further in Document No: SR-TKM-OPR-PLEM-SPM-S100, PLEM and SPM Buoy System Transportation Study

Prior to departure of each transportation barge from the respective loadout location, a three(3)­ day weather outlook will be obtained from the Meteorological Service and forwarded to the tug boat captain for his further action. Shelter and safe tow route shall be identified and briefed to the Tug Master by the Marine Captain

PIPELINE END MANIFOLD (PLEM)  INSTALLATION

INTRODUCTION AND KEY INFORMATION

This section details out the proposed method for the installation of PLEM near SPM system at approximately KP 7.099. DSV will be utilized for the PLEM installation work. PLEM installation will commence after completion of 2 x 12″ dia. Pipeline installation from OGT to SPM. Four points lifting with spreader bar will be used to lift up the PLEM from transportation barge and lower down to proposed location. Throughout the installation activities, ROV will be deployed  to monitor PLEM lowering and setting activities.

PLEM shall be fabricated in Gulf Piping Co. fabrication yard by Bluewater Engineering Services (BES)/MMHE in Mussaffa, Abu Dhabi. The 179ft Class Transportation Barge shall be utilized to transport PLEM to MMHE Kiyanly.

DSV will be set-up with ‘4’ point mooring and her starboard side will facing the proposed PLEM location.  Refer to Fig. 5.1·1 for barge set-up for PLEM installation.

DESCRIPTION OF PLEM

Designation                   : Gravity Based Foundation Pipeline End Manifold (PLEM)

Designed Weight          : Approximately  101.5 MT (Including concrete block weight and piping insulation)

Field                                : Approximately 7 km West from the Onshore Gas Terminal (OGT) at Kiyanly, Turkmenistan

Proposed Centre Coordinate    : E 643 695.64 m N 444 8557.93m

Water Depth                                : Approximately  20 m

Nominal Installation Coordinates PLEM

Description

 Bearing (deg.) Easting (m)

Northing (m)

PLEM Flange Centre

 260.5 643 695.96 4 448 557.93

PLEM tie·in North

 260.5 643 700.40

4 448 561.00
PLEM tie-in South 260.5 643 701.16

4 449 556.47

PLEM INSTALLATION TOLERANCE

PLEM installation tolerance are as per the following figures:

– Within± 1.5m radius offset PLEM C.O.G
– Within ± 2° orientation
– Within ± 0.1m vertical displacement

MATERIALS

Refer to section 3.6 for PLEM materials & equipment details.

PREPARATORY WORK

  1. Deploy ROV to perform debris survey on the PLEM proposed installation
  2. Prepare rigging  required  for  PLEM  i.e. wire  rope slings  and shackles.  Ensure  lifting rigging is in good condition and come with valid certificates. Refer Fig. 5.5-1
  3. Bring alongside PLEM transportation barge to portside of the Refer to section 2 for PLEM arrangement on the transportation barge.
  4. Transfer personnel to PLEM transportation barge e. welders, fitters, rigger and scaffolders for preparation work to cut PLEM tie-down seafastening. Refer to Fig. 2.3-2 for tiedown seafastening  drawings.
  5. Transfer lifting rigging to the PLEM transportation Rig-up lifting rigging to the PLEM as per Fig. 5.5-2 Connect necessary tag lines for PLEM orientation and setting.
  6. Paint all edges of the PLEM and mark corners A, B, C, and D for easy
  7. Attach control tugger lines to PLEM for orientation
  8. Install a high powered USBL beacon at the ROV and two numbers on the lifting sling
  9. Test and calibrate all electronic equipment including USBL beacons and ROV tracking
  10. Ensure beacons are complete with extended life battery pack (freshly charged).
  11. Prepare rigging required for PLEM concrete block base i.e. wire rope slings and shackles. Ensure lifting rigging is in good condition and come with valid certificates. Refer Fig. 5.5-3
  12. Transfer lifting rigging to the PLEM transportation Rig-up lifting rigging to the PLEM Concrete block base foundation and connect necessary tag lines for PLEM orientation and setting. Refer Fig 5.5-4 and 5.5-5

PLEM INSTALLATION

The PLEM will be positioned with reference to the surveyor’s navigation screen and ROV. The positioning and orientation of the PLEM will be monitored using ultra short baseline (USBL) acoustic positioning system

Two survey transponders/high-powered beacons will be installed at the PLEM frame to mark the corridor/window. The ROV will be used to provide visual display setting of the PLEM. A third survey beacon will be installed on the ROV in order to provide a check on the PLEM position prior to release it. A check on the survey system will be done to ensure USBL beacons are referring to the same coordinate system as the barge navigation system.

  1. Set-up DSV as per 5.1·1
    Safety Note: SUBCONTRACTOR Marine Capt. (MC) and Offshore Construction Supt. (OCS) to ensure proper coordination and communication between  anchor  handting  tugs  and  main  work barge during anchor handling activities and ensure all survey 8: positioning equipment  in working condition and calibrated. Reference for anchor positioning shall be made to the appr·oved anchor  patterns and pre-lay survey  report by SUBCONTRACTOR. Limiting weather criteria specifications for all activities will be at SUBCONTRACTOR  OCS discretion and governed by Company’s Marine Guidelines of permitted operations.
  2. ROV will be deployed to examine the seabed conditions i.e. scar marks, depressions, etc. Any debris shall be removed from the PLEM proposed location either using ROV or divers. Refer to Fig. 5.6·1 for PLEM footprint and debris survey.
  3. Meanwhile inspect the PLEM rigging and check against drawing lifting Refer to Fig. 5.5-2
  4. Install tugger lines at 2 locations  on the  PLEM and install taglines  to  control the  PLEM orientation  during initial lifting from the barge
  5. Surveyor will  determine  a  target  location  calculated  for  the  position,  enter  it into  the navigation software and shown of the navigation display
  6. Lift up the PLEM using DSV crane and lower it down until approximately 5m off the Refer Fig. 5.6·3
  7. ROV will constantly monitor the lowering process of the PLEM to the target laydown
  8. Once the PLEM has been orientated to the correct heading within the target location, then it can be lowered down to the
  9. ROV will take fixes on 4 corners of the This is to double check the position and orientation given out by the beacons.
  10. Upon confirmation by the Field Engineer and Surveyor and acceptance by Client Site Diver will remove the riggings from the PLEM by unshackle the four points lifting slings from PLEM padeyes.
  11. Disconnect/remove all control tugger lines from PLEM frame and recover to ROY to perform as built installation video survey on the newly installed PLEM.
  12. Prepare for the next installation work

PLEM Concrete Block Base Foundation Installation

  1. PLEM concrete block shall be install upon completion of submarine hose, control umbilical and hydraulic/electric jumper  hose installation
  2. 2 nos, 12T and 8 nos, 5T of concrete block will be located on the PLEM for the foundation base of the Refer Fig.5.5-3 and Fig 5.5-4 for the details of the concrete block and Fig. 5.6.1·2 proposed location to install.
  3. 4 Point lifting will be used to lifting concrete block from the transportation barge to the installation proposed Refer Fig. 5.5·5
  4. The method and DSV setup for the concrete block installation will be similar as PLEM installation sequence

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