GAS PIPELINE CONFERENCE Design, Construction, Engineering, Management and Maintenance Ist — 2nd December 1994, Jakarta, Sahid Jaya Hotel PAPER RENTIS METHOD OF PIPELINE ENGINEERING Presented by Herman Perera (CEng M.LStruct.E) P.T WIRAZEE ADHI ZEE ENGINEERING CONSULTANTS PTE LTD el10 20 30 60 TABLE OF CONTENTS INTRODUCTION ‘TOW METHODS OF PIPELINE INSTALLATION 2.1 On Surface Tow (Rentis Method) 2.2 Below Sutface Tow 2.3 On-Bottom Tow 24 OfF-Boviom Tow 2.5 Comparison Of Tow Methods RENTIS METHOD 3.1 Description 1 Pipeline Make Up 2 Pipeline Launch 3 Pipeline Tow 4 by x 3 3 3.1.4 Pipeline Installation 1 L i L 3.2 Benefits and Economies 3.2.1, Cost Benefits 32.2 Low Powered Tugs 3.213. Pracicality 3.2.4 Disadvantages 3.2.5 Weather Windows and Environmental Conditions BUGEL YARD 5.1 Pipeline 5.2 Pipe Make-Up 5.3 Pipeline Launch S44 Pipetine instalation LAUNCH AND INSTALLATION OF ARIT LLAA-LLB PIPELINES Second Launch First Lavneh 6 62 6.4 Conclusions ZEE engineering _INTRODUCTION In Indonesia there are a number of marginal il/gas fields that nee¢ to be brought in line. The activating of these fields have been postponed due tothe prevailing 10W pve oferudelgas, and the high cost of development of these fields. There are many ost factors associated with sich field development. Pipeline instalation and Jacket Concepts ae two major contributing factors to this expenditure. Unless cos effective methods for pipeline instalation and jackets are conceptualized ané implemented the evelopment of these fields will be postponed indefinitely. Further these cost feffective concepts will also help in the current projects that are being caried out “The objective of this paper is to present a very simple and low cost method of pipeline installation known as the "Reatis Method”. In May this year for the first time in Indonesia this method was successfully utilised in installing a pipeline bundle between jackets LLA and LLB for Adantc Richfelé Indonesia Ine, (ARI. “This paper will desribe generally the various "Tow" methods of pipeline installation with spectal emphasis on the "Rentis Method". It will also present the Atlantic Richfield Indonesia Inc. (ARID) LLA to LLB pipeline bundle as z case study ZEEE engineering= ___ZEE engineering INSTALLATION ‘The Tow methods of pipetne instalation have been in use forthe last two decades. ‘These methods have successfully been implemented universally, fom harsh ‘environmental conditions inthe North Sea to friendly sea states in Brunei “Tow methods of pipetne installation requite relatively small vessels for transporting Pipe strings and installation a site. Furthermore they have the advantages of pipeline assembly and onshore testing, Tow methods offer large installation cost reductions When compared ta the traditional lay barge method. In Tow methods the pipe strings are assembled onshore, tested, and towed to the required destination and installed at location. Projects where tow methods have been used include the following : |, tm 1974 Brunei Shell commenced the launch of a large number of pipetines ‘sing On-Surface Tow method, 2. fn 1976 three sections of 32 inch lines were bottom towed about S miles and liad to a concrete compression plaform standing in 300 ft of water. The platform was located about mid way between Frigg Field and St. Fergus, 3. In 19779 7,400 36" diameter pipeline was made up at Stavenger, Norway and towed 236 miles to conect tothe Condeep A platform. The (ow route encountered water depth of 1,260 ft 4. In 1977 23,400 ft section of 10" diameter reserve loading line in the Argyll Field compiex was eut and towed along 2 15-iile route and positioned 10 ‘operate as 2 Flow line between two well heads, This work was done in 250-ft water depths Currently there ae four (2) tow methods commercially in use, There are numerous adaptations and variations of these basie methous ‘The basie Tow methods ace On Surface Tow Below Surace tow n-Bottom Tow OfF-Bottom Tow “These tow methods are briefly deserted inthe following pages,2a 22 ZEE engineering _ ON SURFACE TOW (RENTIS METHOD) ‘The On-Surface Tow method is iustated in sketch Fig.2.01, ‘Surface Tow uses buoyancy tanks to support the pipeline at water sutface. In audition to the primary iow vessel a second vessel is needed for contol of Floating pipe strings This hold back vessel ean generally be smaller than the Irimary tow vessel as itis only requited to exert a relatively small tension force on the string. [At the instalation site, the pipeline is lowered to the seabed by sequentially Srpping the buoyancy tanks. It must be noted that at all phases the pipeline ‘mus be maintained at designed tension ‘The main advantage of the Surface Tow is the relatively low horsepower requirements of the tow vessels. The buoyancy system is maintained atthe water surface hence, need not be designed for extemal pressure conditions. “This means low cost buoyancy tanks sich as used 45 gallon oil drums could be used. The disadvantage is suscepibility to surface conditions such as ‘marine trac and environmental conditions BELOW SURFACE TOW. “The below Surface Tow method is illustrated in sketch Fig.2.02 Below surtace Tow uses floatation devices 10 support pipe string. below significant wave actions, Spar buoys are generally used to limit the amount of | surface motion vansferred tothe pipe ine “The tow and installation techniques for below surface tow is similar to that of On Surface Tow. One of the main disadvantages of his technique is the cost involved in the spat buoyancy system, which needs ballasting. an deballasing capabilites Furthermore, the buoyancy tanks ned to be designed to withstand external pressures, hence they are expensive23 wassrepss ZEE engineering ON-BOTTOM TOW ‘The On-Bottom Tow is illustrated in sketch Fig2.03, On Botiom Tow requires certain design considerations which differ fram the criteria for other Tow techniques. ‘This difference in design approach is primarily because all but the leading end of the pipe string is in constant contact with the sea floor. In On-Bottom Tow design, the tow route is one of the basic design factors. Route considerations affect coating, design for abrasion criteria, stability ‘uring tow, tow vessel size and optimum length of towed pipe Tine segments. ‘The primary advantages of On-Bottom Tow include 1. Minimal exposure to severe weather conditions. 2. Very safe abandonment procedure. 3. Non requirement of a hold back vessel “The main disadvantages of this method are 1. Higher horsepower requirements forthe ow vessel 2. Possible damage to pipeline coating 3. Possibilities of the pipeline being caught in seabed obstructions 4. Price increase in pipeline coating. 5, Expensive buoyancy system may be required 10 reduce the tow force2 ZEE engineering | ‘OFF-ROTTOM TOW “The OFF Bottom Tow is illustrated in sketch Fig2.04, ‘OfF-Bowom Tow is an adaption of the Below-Surface technique. It also | requires both Primary tow vessel and a smaller hold-back vessel. Buoyancy tanks ace attached (0 the pipe strings at specified interval. Lengths of chains are suspended from the buoyaney tanks. During tow, the "weight ofthe chains raised off the sea flor balancing the buoyancy forces in the system, and the pipe string is supported ata predetermined design height off the sa floor | If the tow route includes areas where lateral curtent might affect the stability fof the pipe, the length of chains pulled along the seabed could be designed to provide lateral stability. Should the tow route cross existing pip lines or other ‘obstructions, the tailing tug can exert tension on the line causing a change in the string configuration, The amount of tension controls the height 10 which te line raised above the seafloor. The line wll retun 10 ts nocmal towing configuration as tension is released | Primary advantages ofthe OFf-Bowtom Tow are 1, Relatively tow horsepower barges. 2, Exposure to other marine trai limited. 3, Exposure to adverse weather conitions low. 4. Can be lid down easily for extreme bad weather situations “The main disadvantages are L.The design of the buoyancy tanks which have to be designed with pressure vessel ratings to avoid a hydrostatic collapse. 2. Complex buoyancy system with chains and tanks equipped for ballasting and debalasingZEE engineering ___ esmqaorza sozouoaata aosomes OWISSMIONS 33 Ze Sng oP ll dR a ecL 2, Lage numberof smal pipelines (..tllow 10° dia tobe ised i he nat fue Heace numberof launches fom one jad 3, The nes are shor (ess han 3.0 kn) 4. Relnively shor tow stan. | | 5. Favourable weather conditions for the major prt of the yea. | | The word "Rents" in the Malay language means a long straight track in the jung Mt 3.0. RENTIS METHOD (Of the faur (4) tow methods described in section 5.0 the On-Surface Tow is ‘considered to offer the best solution for most of the small diameter, short pipeline installations in Indonesia, “The majo: considerations taken for this inference are Brunei Shel’ fist On-Surface Tow pipeline was made up and launched from along cleared sretch in the jungle, hence the name “Rentis" for the On-Surface Tow | ‘method of installing pipelines. Since the installation ofthe frst Rents Line in 1974 a large numberof pipelines hase ben sucessfully installed by using this method. —2EE engineering Cost benefits DESCRIPTION The Rents method may be briefly described in the following four () ‘operational sages, 3 1.1 Pipeline Make-Up “The pipeline, or bundle is made up in convenient strings onshore. A type! Rentis yard is shown in sketch Fig.3.01. The pipe strings are rolled on to a launchway and the complete pipeline is made up and | hydrotested. Sufficient Buoyancy tanks are attached to the bundle to Keep it afloat.Zee svar 3.1.2, Pipaine Launch Once the pipeline is made up and tested, the launching will commence Pleese refer to sketch Fig. 3.02 for typieal launch, ‘When the trailing end ofthe pipeline is ata suitable distance from the sa, the holdback tension is transferred t the Trailing Tug, Please refer to sketch Fig. 3.03 for Holdback Tug procedure, 3.1.3. Pipstine Tow Always maintaining the requiod tension, the pipeline is towed tothe required destination maintained by the pre-decided Tow corridor. Pease refer to sketch Fig. 5.08 Ppsinetastttaton | The pipeline i positioned correctly so the tension from the leading tow tug is transferred to winch atthe initiation platform via a block at the Dotom af the jacket bracing. While maintaining design tension the first string of buoyancy tanks ae stripped. When the pipeline has stabilized the second string of buoyancy tanks are stripped. This sequence is repeated “until all the buoyancy tanks are removed from the bundle The hold back tension is reduced and the pipeline will setle on the seared Pleise refer to sketch Fig.3.05 for typical pipeline instalation procedure 3.2. BENBEITS AND ECONOMIES [As it is the intention of some Indonesian Oi! Companies to install « number {of small diameter short length pipsines in the coming few years, the Rentie method offes a viable and. economical solution for the installation of these Pipelines | “The main benefits ofthe Reatis method are | 1. Low insatiaton cos. | 2. Ue of low powered tg bls compared 19 & Dern Lay Rage LY octane Ass 32a 322 323 Cost Benefits “The main cost advantage associated with the Rentis method is due 19 the possibility of making up and launching many pipelines from 2 single shore city. It may not be posible to recover the capital cost, Incurred in seting up shore ciliies from a. single launch Preliminary studies show a minimum of four w five launches are requited for capital expenditure recovery ‘Toarrive at ost henefits ofthe Rents method compared withthe DLB method a number of parameters will have t0 be qualified and ‘quantified. These include the following items; 1, Oi company pipeline installation program for short and long, 2. Rents yard location and shore facilites, 3. Barge spread rates and deployment conditions. 4. Mabide Mob costs 5. Rents yard operation philosophy, ete Low Powered Tugs “The Reatisrethod facilitates the use of low powered tugs. These tgs ound De sOvFeed easly and at very competitive sates. The OW 1B ‘oat range i approximately 20 to 30 tonnes Bollard pul Practicality Rents isa well tried! and tested method. Over the last twenty (20) yeses a numer of lnes have been installed in Brunei and Malaysia by Using this method, As the environmental conditions in the Indonesian field are similar to those of Brune and Malaysia the adapation of the Rents method by Indonesian companies is Topical and practical ZEE engineeringSs Parse Le Hieae a mat a sia Eu IN/<0) : a a i i | “FAA Hl fi le Aaa TET | iT 4 EEK II : : Hes] i &r Jars aos HS u f 1 ! iZEE engineering 3.2.4 Disadvantages 328 [As mentioned in section 3.2 the primary advantage in the Rentis method isthe cost savings. However the disadvantages canbe itemized as follows 1. Suscepribity to environmental conditions. 2. Once launched the installation process becomes ireversible 3, Cannot be “Iaid down" in case of bad weatrer. 4, Can only be launched during favourable weather windows, hence, restricted by time Imerference with marine trate 6. Location of suitable shore facilites. 7. Initial eapital expenditure in setting up shove facilites ‘Weather Windows and Environmental Conditions Since the Rents method is very sensitive to environmental conditions, permissible operational waves and currents need fo be specified and installation corridors established Considering the Brunet experience, pipelines have been successfully installed for sea sates of 4 to 6 fect waves and ? knot curtens From the eiteria established by Brunei Shell, or :pproximately eight (8) months of the year the weather and se8 sate conditions provide favourable pipe towing and laying conditions in Intonesi._ZEE engineering 4.0 BUGEL YARD ‘A suitable pipeline fabrication and launch yard was located at Boge! in Indramanyu. [From an aerial search, this ste was identified with a staight river in a paddy field Further, this field was located by the side of a main trunk road from Jakarta to CCirebon which provided good access facilites, ‘After site visits and preliminary engineering it was decided to adopt a modified Rentis method and use the river to our advantage. In the traditional Rents method the whe pipeline length has to be assembled on tracks. Initial costing found this to be expensive, although used items such as rail tricks anc bogeys were to be used, A very cost effetive plan was developed as follows 1) Constuet a short launch track on coer at the ever bend, 2) The made up pipetnes are launched into the river and held 3) This process was continued until the whole pipeline bundle was launched into the river 4) The pipe bundle was held in the river for favourable weather conditions For yard layout, please refer to sketch Fig 4.01 ‘wosrepat anZEE engineering 5.0 PIPE MAKE UP AND INSTALLATION “This section briefly describes the procedure adopted for pipeline make up, launch and installation of the ARII LAA to LLB pipelines, Sl PIPELINE ‘The ARI LLAA to LB pipeline bundle was a follows Line Pipe LL 6,625" O/D X 0,5" WT, X52, 1"X160 pet concrete coated 12 3S" O1DX 03" Wr, X52 1.3 Bundle 4800.0 ft long 2. Buoyancy 212 gia drums = 1440 nos 22 Buoyancy = ure Please refer 10 sketch Fig.5.01 for platform location and Fig.5.01/A. for bundling arrangement 52 PIPEMAKE UP Please ceer to sketches Fig, 5.02 and Fig. 5.03, 1. Line pipes each forty (40) feet in Fength are stock piled in racks. The storage should be such 1 facilitate easy hang. ‘The line pipes are welded double jointed and X-rayed, 3. From the fielé joint sation the line pipes are pusted on to pipe racks to make up one hundred and sixty (160) feet pipe stings. The pipe Strings are wcrayed 4. The pipe strings ate rolled on tothe slorage ave The pipe strings (6" and 3 pair) are transfered to launch tack and thon bined 6. The pipeline bundle is then pushed on co the end of the Iaunchway and the buoyancy system i assembled worst a53 ZEE engineering 4. The second string of pipelines (160. long) are then rolled onto the Jaunchoay and bundled, 8, ‘The leeding end of the 2nd string is welded on t0 the trailing end of the frst sting. 9, ‘The pullnead is welded on to the leading end of the pipeline. 10, By means ofa pully block and bulldozer the pipeline is pushed on 10 the river and held 11. This sequence is repeated until the whole pipeline bundle is launched fino the ever PIPELINE LAUNCH [A sudy of the environmental conditions is conducted to determine wether the appropriate clear weather window for launch, tow-out and installation of pipeline bundle is possible. Once the launch is approved by the COMPANY {he Following sequence willbe adopted. The tow cable long enough to be shackled on to the {ow tue is shackled on to the pall bridle ‘The leading tug moves as close as possible to the shore line and assumes a postin inline with the pipeline pl ection. ‘The tow cable is passed on through a tension meter onto the leading tug. ‘The leading 1g gradually pulls the pipeline bundle into the sea ‘nce the trailing. end of the pipeline bundle is at a sufficient water _.ZEE engineering 6.0 LAUNCH AND INSTALLATION OF ARI LLAA-LLB PIPELINES. ‘Actually there were two (2) launches The first attempt failed and the second launch was successfull, This section will fist describe the successful launch then the unsuccessful one ad the causes for its flue, 6.1 SECOND LAUNCH “The second launch was initiated at 05.00 hours on 1Sth May, 1994. The weather conditions were not very satisfactory. According to the weather reports the permissible window was only 48 hours. Aflera lengthy site meeting it was decided to go ahead withthe launch, The pipeline launch went smoothly although the sea was foe (4) foo, Daring the tow preparation which included hitching. up the holdback vessel the sea conditions deteriorated and the tow preparation lasted around to (2) hours “There was a storm East to West and we were experiencing six (6) to seven (7) Foot sas, [At ihis stage a contingeney action was decided. ‘Me pipeline was yovwed imo the siocm heading. for shelter at Indramauy hay. This was successfully accomplished at around 14,00 hours. On reaching the shelter the tailing tu, ‘ropped anchor and the required fension was maintained by the leading tug by positioning in the line ofthe storm. [At approximately 16.00 hours the storm ceased. ‘The pipeline was examined for damages. Although some buoyancy tanks were los he line was in good stape. AL this stage it vas decided to continue with the tow. The ralling tug was activated and the pipeline direction was reversed by engaging in along, circular tow with the leading tug back in the required direction of tow. ‘The tow vas re-commenced at around 19,00 hours. The sex state was favourable and there was a strong current East 0 Wwes! which enable the tow to proceed at an average speed of four (8) Knots. After taking all the equized precautions the pipeline reached the destination the next day at saxound 6.00 hours, During the tow there was constant communication between the wo tgs. ‘The pipeline was maintained atthe roquited tension and straight line with the and fof navigational lights weorepses 6nena tir —miieennenensinl EE engineering. 62 ‘There were minor problems and set backs at the installation stage. The Pipeline bundle was held in positon for longer than anticipated but but around 15.00 hours the Line was lad successfully. ‘The post ive survey reported the positioning of the bundle was very closed to what is ideally required. Within two clays of installation the risers were hooked up and the subsea tie-in completed, Tee lines were hydrotested and found tobe in good order. FIRST LAUNCI (On 16th March, 1994 the pipeline was launched at approximately 3.00, hours. ‘The tide was high and the weather conditions were very favourable The trailing tug was hooked up and the tow commenced a approximately 8.00 hours [After about one (1) hour of tow the leading tug reported engine rouble. After consultation, i was decided to continue with the tow ata very reduced speed ‘of approximately .5 knots. Emergency messages were sent fr a replaceient vessel. At ths stage the weather was calm and the Tine was not in danger. [Around 12.00 hours, the seas got rough and there was further trouble wit the leading tug. Te reported that it was heading towards the fishing traps and is about tobe grounded, Then the tailing tug reversed and headed cowaris the storm. Tye reverse path taken inflicted a very sharp “F* bend on the bundle. During this reverse tow the cable atthe leading tug got entangled in the propeller end the towing had 10 be stopped. This exposed the bundle ro heavy seas without any tension, which eventually resulted in the Reavy loss of booyancy druns and the bundleZEE engineering 63 CONCLUSIONS ‘The ARM LLAA to LLB pipeline bundle was successfully installed by using the Reatis method. ‘Associated with the projet are the following mile stones. 8) Installed under adverse weather conditions 1) Flirt such instalation in Indonesia ©) The tow route was approximately 50 miles long probably the longest tow in Asia For Reatis method to be sucessfal the Following need to be adhered a engineering and supervision at all stages af the project, b) Implementation of very strict QA/QC procedures including selection of vessels, ©) All procedures (including contingency and emergency) must be clearly writen and implemented