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DETAILED DESIGN FOR THE REPLACEMENT OF HZ19-2 AND HZ19-3 PIPELINES

Contract no.: Contractor doc. no.: 09J01490-PRO-CA-000-003 Job no.:

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011/09 09J01490 of 11

Company doc. no.: CACT-190-C-590-L-901

DETAILED DESIGN REPLACEMENT OF HZ19-2 AND HZ19-3 PIPELINES

Sealines Transient Conditions Analysis

D0 C0
REV.

25/11/10 15/09/10
DATE

Approved for Design due to SOW change to PIP Issued for Company Approval due to SOW change to PIP
REVISION TITLE

Gattoni Gattoni
PREPARED

Bonci Bonci
CHECKED

Cilia Cilia
APPROVED

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Sealines Transient Conditions Analysis

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INDICE 1 GENERAL ................................................................................................................................. 3 1.1 Scope of the Study ............................................................................................................. 3 1.2 References ......................................................................................................................... 3 1.3 Acronyms and Abbreviation ................................................................................................ 3 2 CALCULATIONS ....................................................................................................................... 4 2.1 Cool Down analysis ............................................................................................................ 4 2.1.1 Calculation data ........................................................................................................... 4 2.1.2 Methodology ................................................................................................................ 5 2.1.3 Results ........................................................................................................................ 5 2.2 Warm-Up analysis .............................................................................................................. 7 2.2.1 Calculation data ........................................................................................................... 7 2.2.2 Methodology ................................................................................................................ 8 2.2.3 Results ...................................................................................................................... 10

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DETAILED DESIGN - REPLACEMENT OF HZ19-2 AND HZ19-3 PIPELINES

Sealines Transient Conditions Analysis

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1 1.1

GENERAL Scope of the Study This report studies the main transient conditions which the pipelines should be subjected: Cool-down transient condition: This condition occurs when the fluid inside the pipeline is stopped for an operative requirement or emergency shutdown and its temperature decrease. Warm-up transient condition: This condition occurs during the pipeline start-up phase when the pipe is pre-heated above the fluid cloud temperature in order to avoid oil solidification.

The simulation has been performed for both subsea pipelines included in the SOW, PL1 (that connect HZ19-3 platform and HZ19-2 platform) and PL2 (that connect HZ19-2 platform to the PLEM).

1.2

References Ref. Doc. No. [1] 09J01490-GEN-SP-000-001 [2] 09J01490-PRO-CA-000-001 Title Basic Engineering Design Data (B.E.D.D.) Steady State Process Simulation Report Rev D1 D2

1.3

Acronyms and Abbreviation

BEDD BBLD FPSO ND PIP PL1 PL2 PL3 PLEM SoW TD Basic Engineering Design Data; Barrel Liquid per Day Float, Production, Storage and Offload (facility) Nominal Diameter Pipe In Pipe Pipeline HZ19-3 to HZ19-2 Pipeline HZ19-2 to PLEM Pipeline HZ25-3 to HZ19-2 Pipe Line End Manifold Scope of Work Tender Document

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Sealines Transient Conditions Analysis

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CALCULATIONS

2.1

Cool Down analysis This study aimed to determine how long takes the lines conveying the reservoir fluid to cooldown from the operating conditions to the cloud point after that the same are shutdown from the steady state operation. From physical point of view it is to be highlighted that cool-down is basically a local phenomenon that depends from the initial temperature at given pipeline point, pipeline diameter and sea water environment temperature. Stated this, and considering that pipeline temperature is almost flat (i.e. the temperature does not change too much between inlet and outlet), it can be concluded that cool-down of lines having the same diameter and operating at the same temperature is practically independent from the pipeline length. Only the horizontal pipeline (PL1 and PL2) has been simulated and has been shown the results. The operative case considered for the study is the Case 40B (40,000.0 BBLD at FPSO vessel - Min pipelines inlet temperature) where is reached the min temperature at FPSO of 60.8 C (see ref [2]).

2.1.1

Calculation data Hysys equation of state: Reservoir Fluid Composition: Sea Water Temperature: Pipeline Characteristics: Carbon Steel Thermal Conductivity (Note 1): Carbon Steel Specific Heat (Note 1): Heat Exchange Coefficient: Density of Pipe Material: PL1 Cloud Point: PL2 Cloud Point: PL1 Overall Heat Transfer Coefficient (Note 2): PL2 Overall Heat Transfer Coefficient (Note 2): Peng Robinson As per ref. [1] 15.6 C (60.08 F) As per ref. [1] 48.461 W/mK 0.450 KJ/kg K as calculated by PIPESYS 7870 kg/m3 48.3 C (118.9 F) 43.8 C (110.9 F) 2.600 KJ/hm2C 1.400 KJ/hm2C

Note: (1) Pipeline Thermal inertia has been considered in the calculation. (2) Coefficient has been assumed at fluid static condition. Following graphs (2.1.3.1, 2.1.3.2) shown the temperature profile along the pipelines at different time interval after shutdown.

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DETAILED DESIGN - REPLACEMENT OF HZ19-2 AND HZ19-3 PIPELINES

Sealines Transient Conditions Analysis

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2.1.2

Methodology For the thermo-hydraulic study of the pipelines included in the modelled system, the HYSYS module PYPESYS has been used since specifically developed for the calculation of single and multiphase flow pipelines. The analysis has been carried out by means of the specific Cool Down Utility of PIPESYS.

2.1.3

Results

PL1 (Pipeline from HZ19-3 to HZ19-2) Diagram 2.1.3.1 Temperature profile along the pipeline PL1 at different time interval after shutdown

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Sealines Transient Conditions Analysis

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PL2 (Pipeline from HZ19-2 to PLEM) Diagram 2.1.3.2 Temperature profile along the pipeline PL2 at different time interval after shutdown

Cool down analysis shown that pipeline shutdown is substantially no critical regarding temperature point of view since time necessary to reach the cloud point temperature is: PL1 pipeline: 104.4 Hours (4.3 days) PL2 pipeline: 129.2 Hours (5.4 days)

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DETAILED DESIGN - REPLACEMENT OF HZ19-2 AND HZ19-3 PIPELINES

Sealines Transient Conditions Analysis

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2.2

Warm-Up analysis Warm-up procedure is necessary during the pipeline initial Start-up. Before start-up the temperature of the pipeline has the same temperature as environment. In order to ensure a safety operation of the pipeline and avoid oil solidification, the subsea pipeline needs to be pre-heated. The pipeline shall be pre-heated at a minimum temperature equal to cloud point. For initial start-up pre-heating, seawater can be used as preheating medium. The lowest bottom water temperature (15.6 C) and the produced water temperature (70C) are used to calculate the pre-heating parameters. A flow rate of 150m3/h has been considered for the hot water.

2.2.1

Calculation data For the characteristics of the pipelines and the PIP insulation see ref [1]). Here below the others data used for the calculations.

Seawater Data Temperature Density Sp. Heat Capacity Viscosity Thermal Conductivity Velocity

C kg/m3 kJ/kg-K Pa.s W/mC m/s

15.00 1026 4.022 1.38E-03 0.587 0.30

Fluid Data Heat Capacity Thermal Conductivity Density Dynamic Viscosity Temperature (pumping) Pre-heating Water Flow rate

Heating Fuel kJ/kg C 4.043 W/mC 0.657 kg/cu.m 1000 Pa.s 0.44 70 C 3 150 m /h

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DETAILED DESIGN - REPLACEMENT OF HZ19-2 AND HZ19-3 PIPELINES

Sealines Transient Conditions Analysis

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2.2.2

Methodology The calculation has been performed using the characteristic equations for the heat transfer. The main formula has been reported in the following. The average rate at which heat is lost from or gained by fluid through a section of pipe, due to steady state heat transfer between the fluid and the pipe surroundings is: Q = Dot L U0 (Tf Ts) Q = Average Heat Transfer Rate (kJ / h) U0 = Overall heat transfer coefficient (Based on the area A0) (W / m2 K) Dot = Overall outside pipe diameter (including all layers of insulation) (m) L = Pipe Length (m) Tf = Average temperature of the flowing fluid in the pipe (C) Ts = Average temperature of the pipe surroundings (C)

Overall Heat Transfer Coefficient: 1 / U0 Dot = Rfilm + Rpipe + Rc + Rsurr

Inside Film Resistance (Rfilm) It is the resistance to heat transfer that results from the layer of fluid adjacent to the inside surface of the pipe wall. Rfilm = 1 / (hi Di) Di = Inside pipe diameter (m) hi = Inside convective heat transfer coefficient (W / m2 K)

Pipe Wall Resistance (Rpipe) It is the resistance to heat transfer due to the pipe wall. Rpipe = ln(Do / Di) / (2 kpipe) Do = Outside pipe diameter (m) kpipe = Thermal conductivity of the pipe material (W / m K)

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Sealines Transient Conditions Analysis

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Pipe Coating/Insulation Resistances (Rc) It is the sum of the heat transfer resistances due to any coatings, each term is: Rc = 1 / (2 kc) ln[1 + 2 tc / Dci] Tc = Thickness of coating (m) Dci = Inside diameter of the particular layer of coating (m) kc = Thermal conductivity of the coating material (W / m K)

Surroundings Resistance (Rsurr) It is the resistance to heat transfer that results from the layer of sea water adjacent to the outside surface of the carrier pipe. Rsurr = 1 / (ksf C2 Resf n Prsf0.333) Ksf = Thermal conductivity of the surrounding (W / m K) C2, n = Parameters that depend on the value of Resf Resf = Reynolds Number of the surrounding Prsf = Prandtl Number of the surrounding

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DETAILED DESIGN - REPLACEMENT OF HZ19-2 AND HZ19-3 PIPELINES

Sealines Transient Conditions Analysis

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2.2.3

Results Following graphs show the temperature along the pipeline length at different time interval. The line highlighted in blue is the temperature profile of the pre-heated water during a generic time instant. It is evident at a fixed time, the difference of temperature between the fluid and the pipe.

PL1 (Pipeline from HZ19-3 to HZ19-2) Diagram 2.3.3.1 Temperature profile along the pipeline PL1 at different time interval after starting pre-heating

Diagram shows, that the last part of the pipeline, reaches the Cloud Point Temperature (48.3C) after a time of 8359 seconds equal to about 2.3 hours.

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Sealines Transient Conditions Analysis

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PL2 (Pipeline from HZ19-2 to PLEM) Diagram 2.3.3.1 Temperature profile along the pipeline PL2 at different time interval after starting pre-heating

Diagram shows, that the last part of the pipeline, reaches the Cloud Point Temperature (43.8C) after a time of 56141 seconds equal to about 15.6 hours. It has to be considered that the pipelines PL1 and PL2 during normal operation convey respectively 370 m3/h and 450 m3/h of fluid, while the water flowrate considered in this calculation is 150 m3/h. If the pre-heating water flowrate should be near these values, preheating time will be quite lower. The advantage in term of time saving is useful mainly for PL2 where the length of the pipeline (34.5 km) is the main responsible of the relevant higher pre-heating time. It is important during pipelines start-up procedures take into account of the results shows in this transient analysis. The times indicated above are a parameter that shall be respected during the pipeline pre-heating phase. These times are respectively 2.3 hours for PL1 and 15.6 hours for PL2. This calculation does not substitute the necessity of control the fluid temperature by pipeline instrumentation during the normal start-up procedures, but it is a significant indication to estimate the pre-heating procedures time duration.

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