SUBSEA ENGINEERING HANDBOOK YONG BAI QIANG BAI AMSTERDAM(cid:129)BOSTON(cid:129)HEIDELBERG(cid:129)LONDON NEWYORK(cid:129)OXFORD(cid:129)PARIS(cid:129)SANDIEGO SANFRANCISCO(cid:129)SINGAPORE(cid:129)SYDNEY(cid:129)TOKYO GulfProfessionalPublishingisanimprintofElsevier GulfProfessionalPublishingisanimprintofElsevier 30CorporateDrive,Suite400,Burlington,MA01803,USA TheBoulevard,LangfordLane,Kidlington,Oxford,OX51GB,UK (cid:1)2010ElsevierInc.Allrightsreserved. Nopartofthispublicationmaybereproducedortransmittedinanyformorbyanymeans, electronicor mechanical,includingphotocopying,recording,oranyinformationstorage andretrievalsystem,withoutpermissioninwritingfromthepublisher.Detailsonhowto seekpermission,further informationaboutthePublisher’spermissionspoliciesandour arrangementswithorganizationssuchastheCopyrightClearanceCenterandtheCopyright LicensingAgency,canbefoundatourwebsite:www.elsevier.com/permissions. Thisbookandtheindividualcontributionscontainedinitareprotectedundercopyrightby thePublisher(otherthanasmaybenotedherein). Notices Knowledgeandbestpracticeinthisfieldareconstantlychanging.Asnewresearchand experiencebroadenourunderstanding,changesinresearchmethods,professionalpractices, or medicaltreatmentmaybecomenecessary. Practitionersandresearchersmustalwaysrelyontheirownexperienceandknowledgein evaluatingandusinganyinformation,methods,compounds,orexperimentsdescribed herein.Inusingsuchinformationormethodstheyshouldbemindfuloftheirownsafetyand thesafetyofothers,includingpartiesforwhomtheyhaveaprofessionalresponsibility. Tothefullestextentofthelaw,neitherthePublishernortheauthors,contributors,or editors,assumeanyliabilityforanyinjuryand/ordamagetopersonsorpropertyas amatterofproductsliability,negligenceorotherwise,orfromanyuseoroperationofany methods,products,instructions,orideascontainedinthematerialherein. LibraryofCongressCataloging-in-PublicationData Applicationsubmitted BritishLibraryCataloguing-in-PublicationData AcataloguerecordforthisbookisavailablefromtheBritishLibrary. ISBN:978-1-85617-689-7 For informationonallGulfProfessionalPublishing publicationsvisitourWebsiteatwww.elsevierdirect.com 101112 10987654321 PrintedinUSA PREFACE MAY 2010 Subsea engineering is now a big discipline for the design, analysis, construction, installation and integrity management of subsea wellheads, trees, manifolds, jumpers, PLETS and PLEMs, etc. However, there is no book available that helps engineers understand the principles of subsea engineering. This book is written for those whowish to become subsea engineers. With the continuous encouragement of Mr. Ken McCombs of Elsevier, theauthorsspentacoupleofyearswritingthisbook.Theauthorswouldlike to thankthoseindividualswhoprovided editingassistance(Ms. LihuaBai& Ms. Shuhua Bai), initial technical writing for Chapters 1-4 (Mr. Youxiang Cheng), Chapters 6-8 (Mr. Xiaohai Song), Chapter 11 (Mr. Shiliang He), Chapter 5 (Mr. HongDong Qiao), Chapter 23 (Mr. Liangbiao Xu) and Chapter 27 (Mr. Mike Bian). They are employees of Offshore Pipelines & Risers (OPR) Inc. ([email protected], www.opr-inc.com, www.baiyongoe. com). Thanks to all persons involved in reviewing the book, particularly Ms. Mohanambal Natarajan of Elsevier, who provided editory assistance. We thank our families and friends for their support. The first author would like to thank Zhejiang University for their support for publishing this book. Prof. Yong Bai & Dr. Qiang Bai Houston, USA j xxv ABOUT THE AUTHORS ProfessorYongBaiisthepresidentofOffshorePipelines&RisersInc.in Houston, and also the director of the Offshore Engineering Research Center at Zhejiang University. He has previously taught at Stavanger UniversityinNorwaywherehewasaprofessorofoffshorestructures.Hehas alsoworkedwithABSasmanageroftheOffshoreTechnologyDepartment and DNVas the JIP project manager. Professor Yong Bai has also worked for Shell International E & P as a staff engineer. Through working at JP Kenny as manager of advanced engineering and at MCS as vice president of engineering, he has contrib- utedtotheadvancementofmethodsandtoolsforthedesignandanalysisof subsea pipelines and risers. Professor Bai is the author of the books Marine StructuralDesignandSubseaPipelinesandRisersandmorethan100paperson the design and installation of subsea pipelines and risers. OPRhasofficesinHouston,Texas,USA;KualaLumpur,Malaysia;and Harbin, Beijing, and Shanghai, China. OPR is engaged in the design, analysis, installation, engineering, and integrity management of pipelines, risers, and subsea systems such as subsea wellheads, trees, manifolds, and PLET/PLEMs. Dr.QiangBaihasmorethan20yearsofexperienceinsubsea/offshore engineering including researchandengineeringexecution.Hehasworked at Kyushu University in Japan, UCLA, OPE, JP Kenny, and Technip. His experience includes various aspects of flow assurance and the design and installation of subsea structures, pipelines, and riser systems. Dr. Bai is coauthor of Subsea Pipelines and Risers. j xxvii LIST OF ABBREVIATIONS A&R - Abandonment and recovery AA - Anti agglomerate AACE - Advancement of cost engineering AAV- Annulus access valve ACFM - Alternating current field measurement AHC - Active heave compensation AHV- Anchor handling vessel AMV- Annulus master valve APDU - Asphaltene precipitation detection unit APV- Air pressure vessel ASD - Allowable stress design ASV- Annulus swabvalve AUV- Autonomous underwater vehicle AWV- Annulus wing valve B&C - Burial and coating BM - Bending moment BOPD - Barrels of oil per day BR - Bend restrictor C/WO - Completion and workover CAPEX - Capital expenditures CAPEX - Capital expenditures CAT- Connector actuation tool CCD - Charge-coupled device CCO - Component change-out tool CDTM - Control depth towing method CFP – Cold flow pipeline CG - Center of gravity CI - Corrosion inhibitor CII - Colloidal instability index CIU - Chemical injection unit CMC - Crown-mounted compensator CoB - Cost of blowout CoG - Center of gravity CP - Cathodic protection CPT- Compliant piled tower j xxix xxx Listofabbreviations CPT- Cone penetration test CRA - Corrosion-resistant alloy CV- Coefficient value CVC - Pipeline end connector CVI - Close visual inspection DA - Diver assist DCU - Dry completion unit DDF - Deepdraft semi-submersible DEG - Diethylene glycol DFT- Dry film thickness DGPS - Differential global positioning system DH - Direct hydraulic DHSV- Downhole safety valve DOP - Dilution of position DP - Dynamic positioning DSS - Direct simple shear DSV- Diving support vessel EC - External corrosion EDM - Electrical distribution module EDP - Emergency disconnect package EDU - Electrical distribution unit EFAT- Extended factory acceptance test EFL - Electric flying lead EGL - Energy grade line EH - Electrical heating EI - External impact EOS - Equation of state EPCI - Engineering, procurement, construction and installation EPU - Electrical power unit EQD - Emergency quick disconnect ESD - Emergency shutdown ESP - Electrical submersible pump FAR - Flexural anchor reaction FAT- Factory acceptance test FBE - Fusion bonded epoxy FDM - Finite difference method FE - Finite element FEA - Finite element analysis FEED - Front-end engineering design Listofabbreviations xxxi FEM - Finite element Method FMECA - Failure mode, effects, and criticality analysis FOS - Factor of safety FPDU -Floating production and drilling unit FPS - Floating production system FPSO - Floating production, storage and offloading FPU - Floating production unit FSHR - Free standing hybrid riser FSO - Floating storage and offloading FSV- Field support vessel FTA - Fault tree analysis GL - Guideline GLL - Guideline-less GoM - Gulf of Mexico GOR - Gas/oil ratio GPS - Global positioning system GSPU - Polyurethane-glass syntactic GVI - General visual inspection HAZID - Hazard identification HCLS - Heave compensated landing system HCM - HIPPS control module HCR - High collapse resistance HDM -Hydraulic distribution module HDPE - High density polyethylene HFL - Hydraulic flying lead HGL - Hydraulic grade line HIPPS - High integrity pressure protection system HISC - Hydrogen-induced stress cracking HLV- Heavy lift vessel HMI- Human machine interface HP/HT- High pressure high temperature HPU - Hydraulic power unit HR - Hybrid riser HSE - Health, safety, and environmental HSP - Hydraulic submersible pump HT- Horizontal tree HTGC - High temperature gas chromatography HXT- Horizontal tree HXU - Heat exchanger unit xxxii Listofabbreviations IA - Inhibitor availability IBWM - International bureau of weights and measures IC - Internal corrosion ICCP - Impressed current cathodic protection IE - Internal erosion IMR - Inspection, maintenance, and repair IPU - Integrated production umbilical IRP - Inspection reference plan IRR - Internal rate of return ISA - Instrument societyof America ISO - International Organization for Standards IWOCS – Installation and workover control system JIC - Joint industry conference JT- Joule Thompson KI - Kinetic inhibitor L/D - Length/diameter LARS - Launch and recovery system LBL - Long baseline LC - Life cycle cost LCWR - Lost capacity while waiting on rig LDHI - Low dosage hydrate inhibitor LFJ - Lower flexjoint LOT- Linear override tool LP - Low pressure LPMV- Lower production master valve LRP - Lower riser package LWRP - Lower workover riser package MAOP - Maximum allowable operating pressure MASP - Maximum allowable surge pressure MBR - Minimum bend radius MCS - Master control station MEG - Mono ethylene glycol MF - Medium frequency MIC - Microbiological induced corrosion MMBOE - Million barrels of oil equivalent MOPU - Mobile offshore drilling unit MPI - Magnetic particle inspection MPP - Multiphase pump MQC - Multiple quick connector Listofabbreviations xxxiii MRP - Maintenance reference plan MTO - Material take-off NAS - National aerospace standard NDE - None destructive examination NDT- Nondestructive testing NGS - nitrogen generating system NPV- Net present value NS - North sea NTNU - The Norwegian universityof science and technology O&M - Operations and maintenance OCR - Over consolidation ratio OCS - Operational Control System OHTC - Overall heat transfer coefficient OPEX - Operation expenditures OREDA - Offshore reliability data OSI - Oil States Industries OTC - Offshore Technology conference PAN - Programmable acoustic navigator PCP - Piezocone penetration PGB - Production guide base PHC - Passive heave compensator PhS - Phenolic syntactic PIP - Pipe in pipe PLC - Programmable logic controller PLEM - Pipeline end manifold PLET- Pipeline end termination PLL - Potential loss of life PMV- Production master valve PMV- Production master valve PoB - Probabilityof blowout POD - Point of disconnect PP - Polypropylene PPF - Polypropylene foam PSCM - Procurement and supply chain management PSV- Production swabvalve PT- Pressure transmitter PTT- Pressure/Temperature Transducer PU - Polyurethane PWV- Production wing valve