Coiled Tubing Pipeline Laying (Reeled Pipe).
Coiled Tube Pipeline is a relatively new technology. The service offers an economical alternative to conventional sub sea control lines and offshore small diameter flow line construction techniques. Additionally, simple installation of onshore surface or buried flow lines for gathering centres, tie-ins and high-pressure injection lines.
Coiled Tubing Pipeline has the following advantages over conventional pipelines: -
- Higher Strength and Pressure Rating.
- Several Kilometres without Tube Welds.
- Elimination Of The Cost Of Welding, Heat-Treatment, X-Ray And Inspection Services.
- Dramatic Reduction of Installation Time and Equipment.
- Excellent Flow Characteristics and Design Life.
- Hydro-Tested And Corrosion Protected At The Plant.
In addition to a full oil and gas field capability, SAPESCO have Coiled Tubing Pipeline lay equipment and technology for laying Pipelines up to 4½" diameter.
Equipment is also suitable for laying submarine multi-core communications cables, umbilical hydraulic lines and electrical power cables.
Coiled Pipe System
Description:
Modular built system consisting of diesel driven hydraulic power pack, spooling unit, spool loading cradle and skidding system DNV approved.
Service for lay up to 4.5 Coiled Pipe on sub-sea and land based tie-ins.
Power Pack Control Cabin
| Primary mover | 471 Detroit Diesel Max 127 BHP | ||
| Dimensions | Length 3300mm 10 ft 8 |
Width 2250mm 7 ft 4 |
Height 2227mm 7 ft 3 |
| Weight | 6,000 Kg | ||
| Clutch | Wichita air operated clutch 110 PSI | ||
| PTO | Triple outlet drives | ||
| Hydraulic System | Sun-Strand pump SPV24 main/P 1500 auxiliary Max WP: 3000 PSI closed loop system with quick disconnect points. | ||
| Fuel Capacity | 380 litres | ||
| Fuel Consumption | 0.7 Litres per Minute (LPM) under full load | ||
| Hydraulic oil capacity | 380 litres | ||
| Control Panel | Engraved stainless steel panel giving central control and visual displays, tension indicator, hydraulic and PTO controls. | ||
| Safety | Emergency stop, fuel stop, fails safe system. | ||
Spooler Tension Module
2 x Proclaim hydraulic motors with auto brakes. Hydraulic skidding and loading rams with controls. Skid beams with auxiliary mounting framework for containing pipe guide and roller system.
| Dimensions | Length 5m 16 ft 4 |
Width 2740mm 8 ft 10 |
Height 3304mm 10 ft 8 |
| Weight | 8,000 Kg | ||
Spool Lifting Cradle
2 x Raising Rams 30 ton lift
2 x Skidding Rams 35 ton push & pull
2 x Skid Beam Gripper Rams 35-ton grip.
| Dimensions | Length 3.2m 12 ft 5 |
Width 3,201mm 10 ft 5 |
Height 1,450mm 4 ft 8 |
| Weight | 4,000 Kg | ||
Welding Station
Full weather protected welding station to allow welding and NDT services to be carried out.
| Dimensions | Length 3200m 10 ft 5 |
Width 2400mm 7 ft 9 |
Height 2300mm 7 ft 6 |
| Weight | 2,000 Kg | ||
Workshop/Stores:
Complete with all necessary handling and rigging equipment to carry out coiled pipe laying operations.
| Dimensions | Length 3450m 11 ft 3 |
Width 2404mm 7 ft 9 |
Height 2510mm 8 ft 2 |
| Weight | 1,000 Kg | ||
Certification
DNV certificates of conformity and fitness to S 11974,289 safe area. Continued manned service.
Commissioning Leak Test (CLT)
Definition: “System” Defined as that part or whole of a process unit containing pipes and vessels or pipeline conveying product liquid, gas or products of dual or three-phase classification.
The presence of a leak indicates that a pathway exists into and out of a system. The pathway may allow liquid or gas to ingress or egress that area which is leaking.
The leak tightness of a system can be determined in one of two ways Firstly by vacuum detection and secondly, by pressurisation.
Under special circumstances vacuum testing used. Mainly vacuum detection is employed for detecting molecular level leaks in porous welds or fabricated materials. In practise, the principle of pressurising a system to its operating pressure with an inert carrier and trace gas is employed. The pressurisation method has become the de-facto standard for oil, gas, petrochemical and industrial applications.
SAPESCO extensively employs the pressurisation method. This consists of injecting an inert carrier, usually 99% nitrogen, with 1% helium as the trace gas. Other gasses, such as CO2, Arcton or Halides can also be used but there is no cost advantage to using these products.
A commissioning leak test (CLT) is recommended for the pre commissioning of all process plant. This recommendation is not limited to gas plant systems. A leak tight system is not just beneficial to Health, Safety and the Environment (HSE) it also produces cost saving benefits, minimises downtime and proves a system prior to hand-over.
A CLT TEST ELIMINATES HAZARDS AND PROTECTS YOUR INVESTMENT
CLT testing offers the following advantages:
- The oxygen content is reduced, thereby avoiding potentially explosive mixtures.
- The system is tested at its working pressure with a gas to closely simulate “live" conditions, thus allowing instruments to be calibrated.
- Nitrogen and helium gases are inert, non-toxic and perfectly safe.
- Helium leak detection allows all leaks to be located and repaired so that a nitrogen blanket can be left indefinitely in the system for "start up".
- Operators can be trained during the CLT test.
- Cost savings - valuable production time is saved by avoiding the use of “live" gas detectors and being able to repair leaks prior to start up.
- A full historical record is provided of all leaks found, the leak descriptions, values and locations are provided. This ensures a reference point for maintenance programmes and can help with financial claims after construction.
- Residual purge gas in the system maintains dryness levels and eliminates ingress of moisture.
- Air compressor for gross leak test
- High pressure nitrogen converter
- High pressure helium injection pump
- Liquid nitrogen tanks
- Leak detection container housing: -
- Helium mass spectrometers
- Ultrasonic leak detectors
- Oxygen analysers
- Dew Point meters
- Hydrocarbon detectors
- Selection of high-pressure hoses, valves and fittings.
The full sized container provides office facilities and laboratory test unit combined with full electrical system, which meets international standards for connectivity and earthing safety.
Hydrostatic Tests
A Hydrostatic test is a strength test and not a leak test. Of primary concern to operators is the proven integrity of continuous lengths of pipeline, process vessels or sections of process system pipe work. Internationally, a multitude of standards is employed for testing of materials. In essence, SAPESCO employ current revisions of the highest standards available to ensure safe operating function of the system tested.
Unless instructed otherwise by the client, SAPESCO carry out pipeline hydro-tests to BS 8010 standard using NAMAS (National Physical Laboratory) traceable calibrated equipment.
SAPESCO would always advocate the use of a full commissioning leak test following the integrity hydro-test. This is to ensure that the system is leak tight under process conditions. A system can pass a hydro-test but fail a leak test.
In Egypt, where full integrity hydro-tests are not usually required, SAPESCO can carry out fluid pressure testing to client instructions using basic equipment.
Pneumatic Tests
Pneumatic tests are carried out on parts of process systems where containment can be provided for the high residual energy that is characteristic of such tests.
Unless instructed otherwise by the client, pneumatic tests are carried out in accordance with The Institute of Gas Engineers regulations (IGE).
Inert Gas Services
Nitrogen Purging
To nitrogen purge means the replacement of an atmosphere of an undesired composition in an enclosure by another atmosphere of required composition.
There is usually some ultimate objective when purging, such as rendering a vessel safe for receiving a hydrocarbon product or for handling a reactive material. To achieve this there is an immediate objective of adjusting the vessel atmosphere composition to have, in the example mentioned, a maximum allowable oxygen concentration.
In the majority of cases, the requirement is to replace an active atmosphere by an inert one, and this most usually involves the use of nitrogen, or nitrogen with helium in the event of a CLT test.
When nitrogen purging, it is necessary to know exactly what is required from the purge. In the oil, gas and petrochemical industry there are two main requirements.
- The removal of a flammable substance from a vessel/ container such that on opening the vessel/ container and mixing its atmosphere with oxygen an explosive mixture is not formed.
- The removal of oxygen from a vessel/ container such that on introducing hydrocarbons to this vessel/ container an explosive mixture is not formed.
Prior to purging, it is necessary to know which substances you are dealing with. Certain hydrocarbon products are more flammable than others i.e. they require less fuel or less oxygen than others to form an explosive mixture.
When designing the purge regime it is necessary to know what is being purged, or introduced following a purge. The product characteristics provide details of the Lower Explosive Limit (L.E.L.) and Upper Explosive Limit (U.E.L.), additionally, the minimum percentage of oxygen required to form an explosive mixture with the substance / product.
There are four main types of purging:
- Displacement Purging. Example: By pipeline pig. Open systems.
- Dilution Purging. Example: Continuous replacement until desired oxygen content is reached. Used in an open-ended systems where the exhaust can be continuously vented to atmosphere.
- Pressure Cycle Purging. Example: Used extensively for closed systems. This technique involves several pressurisations and depressurisations to achieve target levels.
- Vacuum Purging. Example: Used with closed systems to implement complete atmosphere changes in contaminated systems. Often used with vacuum drying.
Nitrogen Foam Inerting (NFI)
The shutdown of process system operations for vessel or pipe work modifications may require hot cuts to be made in systems that contain or have contained flammable hydrocarbons.
For hot work, a nitrogen purge is insufficient for ensuring the safety of work. Liquid hydrocarbons can leave a residue on the inner walls of vessels and pipe work and on the application of heat such as a cutting flame, will vaporise. When the cut is made, oxygen will be introduced with the vaporised liquids creating an explosive atmosphere. This explosive atmosphere, combined with the presence of the naked flame of the cutting torch, is an extremely hazardous situation.
Nitrogen foam is produced by injecting nitrogen gas through a surfactant/ water mixture. Nitrogen injection is closely regulated to obtain an optimum expansion ratio, (i.e. the ratio of gas to liquid volume). The use of foam closely resembles a detergent bubble formation. When a section of foam breaks down, either due to the application of heat or pressure, then nitrogen is liberated and flows out of the cut under the pressure of the bulk foam, thus maintaining inert conditions.
Within SAPESCO personnel experience are applications involving aircraft fuel tanks, pipeline vapour isolations, LPG and LNG liquid pool isolations. Specific detail is available on request.
Relief Valve Testing and Calibration
The SAPESCO Relief Valve Testing Service is used to test and calibrate the set pressure of relief valves and to carry out leakage tests in accordance with API 527.
The Equipment package consists of a 60:1 ratio Gas/Gas booster pump, pressure accumulator and control panel.
The relief valve under test is pressurised very slowly with nitrogen and the pressure monitored on two 150 mm test grade (+ 0.1% FSD) pressure gauges, connected into a manifold with a NAMAS traceable Budenberg Figure 80 dead-weight tester, and recorded on a chart recorder. The set pressure is established from the calibrated chart recorder and dead-weight tester. The leak rate, at 90% of the set pressure is then measured by using a bubbler (as defined by API 527), and a flow meter. In addition, the thermal characteristics are recorded and mathematically modelled with inputs of pressure to give reportable trends.
When a relief valve has been leak tested, or re calibrated, a certificate of calibration/ test is issued and the relief valve identified and locked with a lead seal.
The equipment package is transportable, having dimensions 8 ft x 8 ft x 8 ft, weighing 5 tons.
Additionally, in-situe valve seat lapping repairs can be carried out with transportable miniature air operated or electrically operated equipment.
A fully equipped testing unit for hydraulic testing and calibration is available. The relief valve test bed contains a modern sealing mechanism with hydraulic rams to position and retain the valve to be tested.
“Smart” monitoring of pneumatic and hydraulic tests is also available. In addition to the standard traceable instrumentation, programmable “Smart” transmitters are linked to a data acquisition and analysis computer. Full trend monitoring of pressure and temperature data for hydraulic and pneumatic tests can be overlaid and interpreted to determine re-seating / re-sealing capability. The results can be used to identify units which may “chatter” after initial operation and be used in the decision making process for repairs.
Cathodic Protection Surveys, Design & Installation
Cathodic protection is an electrical method that prevents corrosion of materials in water, soil or chemical solutions (electrolytes). It stops the electrochemical process by changing the electrical, not the chemical conditions.
The process of cathodic protection is generating an electric current, which passes through the electrolyte and creates a potential barrier at the material surface. This barrier is maintained by a continuous flow of current to the surface.
The barrier is measured before and after cathodic protection is applied. A standard reference electrode and a voltmeter are used to measure the size of the barrier that must be created. Usually barriers of 300 milli-volts (mV) are sufficient to stop corrosion.
The amount of current needed to create this barrier change depending on chemical and physical properties of, the electrolyte, temperature, materials, coating materials, prevailing pressure and other factors. Current required will vary from as little as 2 microamperes per sq. ft of metal surface area, to as much as 300 milli-Amperes per sq. ft.
SAPESCO will perform the survey for client facilities and/or pipe lines, design the best Cathodic Protection method, procure the materials and install the cathodic protection system.
Materials Supply
SAPESCO adopt the philosophy that before, during and after any service is performed some material content will be required and we aim to fulfil that requirement.
SAPESCO provides pipeline pigs. The pigs are manufactured in the United States by Girard Industries. SAPESCO are the main distributors for all Girard products including pig “Valves and Tees” and launchers and receivers etc.
To aid our clients, SAPESCO have provided everything from stud-bolts to forklift hire. From zone-II generators to water trucks. From bottled helium to weld gasses. Whatever your needs we are versatile enough to rise to the challenge.
Hot Oil & Control Lines Flushing
SAPESCO has a hot oil flushing capability. During the pre-commissioning phases for turbine systems, it is usually necessary to ensure that all particulate matter is removed from the lubrication system oil lines and main seal oil lines.
PLC / PID control, explosion proof pumps and auxiliary equipment provide a package which can deliver heated flows giving a Reynolds number >4000. This ensures adequate entrainment of the contaminants. Add the high flow filter packages and particulate sizes <5 microns can be removed.
Water Injection
SAPESCO can design, fabricate, install and commission a water injection package to suit your needs. When Al Furat, the largest operator in Syria, looked at water injection requirements they turned to SAPESCO for a turnkey package. SAPESCO won the contract for engineering design, speed of delivery and installation, and price. SAPESCO is the largest oilfield services contractor in Syria.
Auxiliary Services
Power Generation
SAPESCO can provide “North Sea / Offshore” oil field quality power generators with the following features: -
- Inbuilt fuel day tank
- Super silenced units
- Chalwyn Valve Emergency System
- BS / EN Fully Rated Spark Arrestor
- External Manual Emergency Shut-down button
- Emergency shutdown
- Microprocessor controlled outputs
- International standard connections for 3-phase Neutral and Earth
- Dual voltage outputs to suit client requirements.
- Frequency can be set to 50 or 60 Hertz.
- Synchronised phase units for larger generators. (Parallel Operations)
- International standard external distribution systems.
- Installation of additional diesel storage tanks, if required.
Power generators can be supplied in the following sizes, depending on availability: -
20; 48; 150; 300; 500; 800; 1250 kVA (Other Variants Available)
14-KVA & 18-KVA Refinery safety equipment equipped lighting towers can also be made available. Please ask for details.
Portable Steam
Many instances of shutdown operations have required additional support services to supplement existing facilities. For example, during a shutdown on a refinery, existing steam facilities may be non-operational and steam is required for purging, cleaning vessels or as a heat source for chemical cleaning activities.
SAPESCO can provide containerised steam units to cater for shutdown, start up and pre-operational needs. The following are some of the salient features incorporated into the “portable” steam units: -
- Designed to meet DNV 2.7.1 lifting regulations.
- New design and build to incorporate a fuel tank and water / condensate return tank.
- Emergency shutdown system designed to be tied into client systems to enable complete shutdown in the event of an emergency.
CONTAINER SPECIFICATION
DIMENSIONS:
| Length: | 6058mm |
| Width: | 2438mm |
| Height: | 2833mm |
| Weight Gross: | 13900Kgs |
| Shipping Weight Dry: | 12500Kgs |
CERTIFICATION:
Det Norske Veritas 2.7-1
Lloyds Register of Shipping
Bureau Veritas
CLASSIFICATION:
| Rig safe, Integral Spark Arrestor Fitted:- | 316 Stainless Steel |
| Boiler Vessel: | BS2790 Class 1 ASME 1 CE Certified |
ELECTRICAL
| Power Requirement: | 3-Phase 440 Volt 60Hz |
| Starting current:- | 32 Amps per Phase |
| Running Current:- | 10 Amps per Phase |
CONNECTIONS
| Water Inlet: | 1 off 0.75” Crows Foot |
| Steam Outlet:- | 1 off 2” Figure 200 WECO Steam Unions |
TECHNICAL SPECIFICATIONS
STEAM GENERATOR:
| Year of Manufacture: | 2002 |
| Type: | MX 5000 |
| Design: | Reverse flow wetback three passes system |
| Steam Output: | 4500 to 6000-lb/hr (2000 to 2700-Kgs Hr-1) |
| Working Pressure: | 30 to 150psi (2 to 10 Bar) |
| Discharge Temperature: | 271 to 363F (133 to 184C) |
| Fuel Type: | Gas Oil |
| Part Load Fuel Consumption: | 1-Tonne Hr-1 Delivered @45 L Hr-1 Fuel |
| Water Consumption: | 1700-Litres Hr-1 Max Open System |
| Steam Outlet / Condensate Return | 2” Fig 200 WECO Steam Union |
| *Water Feed tank Capacity: | 800 Litres |
| *Fuel Tank Capacity: | 1500 Litres |
| Voltage: | 380-440V @ 50/60 HZ |
| Burner Motor: | 7.5Kw |
*Integral of Container
Product development at SAPESCO is a continuous process, and we reserve the right to amend specifications without notice. Please check for latest version.
High Pressure Air
Booster Compressors
There are an increasing number of occasions where high-pressure air is required in the oilfield, petrochemical, gas, pipeline and industrial sectors of business.
SAPESCO can provide a number of pressure booster packages to complement our fleet of high volume high-pressure air compressors. A number of examples where these can be applied are listed below.
- Deep-water exploration: Pipeline displacements circa 100 to 135-bar g.
- Pneumatic Testing of large-diameter large-volume pipelines.
- Air Drilling
- Template cleaning
- Jet blasting
Fitted with a Caterpillar 3408 DIT engine producing 535 BHP at 2100rpm, the Boosters are capable of discharge pressures up to 2000psi (138 Bar).
- Built in pre-cooler, intercooler and after-cooler to reduce outlet temperatures.
- Skid mounted machine with 4 point lifting frame.
- Stainless steel spark arrestor.
- Auto lubrication to both engine and compressor.
- Automatic over speed shutdown.
- Amot pneumatic system with safety shutdowns.
- Single or two-stage operation.
- Fitted with built-in pulsation dampers to reduce vibration when operated.
- On board control valves for total flow control.
