GP 43-02 30 June 2005 - Guidance on Practice for Principles of Offshore Pipeline Design and Project Execution

Document No.

GP 43-02

Applicability

Group

Date

30 June 2005

Guidance on Practice for Principles of Offshore Pipeline Design and Project Execution

GP 43-02

BP GROUP

ENGINEERING TECHNICAL PRACTICES

30 June 2005

GP 43-02 Guidance on Practice for Principles of Offshore Pipeline Design and Project Execution

Foreword This is the first issue of Engineering Technical Practice (ETP) BP GP 43-02. This Guidance on Practice (GP) is based on parts of heritage documents from the merged BP companies as follows:

Amoco A PN-PL-5L-G A PN-PLD-00-G

Piping—Pipeline—API 5L Steel Line Pipe—Guide. Piping—Pipeline Design—Guide.

BP Amoco Exploration Ltd. S/UTG1173/00

Design Guidelines for Steel Catenary Risers; Deepwater Developments, Upstream Technology Group, BP Exploration; Revision 3, December, 2000, H-1284.03-10.05-NID-001. This Guidance on Practice (GP) is not a stand alone document. It shall be used in accordance with other ETP Documents Series 43 for pipelines, which provide further detail necessary to undertake and execute a pipeline project. This document is intended to provide an understanding of the key features, requirements, and issues relating to an offshore pipeline system in terms of design and project execution. It uses reference material available in BP and Amoco heritage documents. GP 43-00 stands above GP 43-02 to provide a foundation high level overview for a pipeline system, giving technical project definition. In undertaking a pipeline project the MPCP shall be adopted to ensure that the elements and requirements of the CVP are followed as applicable to the scale of the project.

Copyright  2005 BP Group. All rights reserved. The information contained in this document is subject to the terms and conditions of the agreement or contract under which the document was supplied to the recipient’s organization. None of the information contained in this document shall be disclosed outside the recipient’s own organization without the prior written permission of the Director of Engineering, BP Group, unless the terms of such agreement or contract expressly allow.

Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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Table of Contents Foreword ........................................................................................................................................ 2 1.

Scope .................................................................................................................................... 3

2.

Normative references............................................................................................................. 3

3.

Terms and definitions............................................................................................................. 3

4.

Symbols and abbreviations .................................................................................................... 3

5.

Offshore pipeline project overview ......................................................................................... 3 5.1. Third party Interfaces and reputation........................................................................... 3 5.2. CVP phases................................................................................................................ 3 5.3. Key tasks and deliverables ......................................................................................... 3 5.4. Pipeline system........................................................................................................... 3 5.5. Pipeline not piping....................................................................................................... 3 5.6. Environmental and Social Impact Assessment studies (ESIAs) .................................. 3

6.

Appraise and Select design phase......................................................................................... 3 6.1. General....................................................................................................................... 3 6.2. Design basis ............................................................................................................... 3 6.3. Hydraulic analysis-line sizing ...................................................................................... 3 6.4. Pipe wall thickness and material grade selection ........................................................ 3 6.5. Preliminary route selection.......................................................................................... 3 6.6. Pipeline stability .......................................................................................................... 3 6.7. Pipeline trenching and burial ....................................................................................... 3 6.8. Pipeline freespan evaluation ....................................................................................... 3 6.9. Pipeline and cable crossings....................................................................................... 3 6.10. Shore approach .......................................................................................................... 3 6.11. Offshore tie-ins and risers ........................................................................................... 3 6.12. Pipeline pigging .......................................................................................................... 3 6.13. Pipeline corrosion design ............................................................................................ 3 6.14. Preliminary pipeline stress analysis............................................................................. 3 6.15. Pipeline components................................................................................................... 3 6.16. Pipeline installation- pipelay and trenching.................................................................. 3 6.17. Pipeline integrity ......................................................................................................... 3

7.

Define and Execute pipeline project phases .......................................................................... 3 7.1. Detailed engineering phase ........................................................................................ 3 7.2. Surveys and ESIA....................................................................................................... 3 7.3. Design finalisation....................................................................................................... 3 7.4. Pipeline installation analysis ....................................................................................... 3 7.5. Pipeline construction and installation (Execute) .......................................................... 3

8.

Execute success.................................................................................................................... 3

Annex A (Normative) List of 43 Series Engineering Technical Practices ......................................... 3 Annex B (Informative) Deliverables Checklist.................................................................................. 3 Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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Bibliography .................................................................................................................................... 3

List of Figures Figure 1 - CVP Phase ..................................................................................................................... 3 Figure 2 - Project Phase Flow Diagram........................................................................................... 3 Figure 3 - Offshore Pipeline Appraise and Select Design Activities................................................. 3


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1.


Scope This GP provides guidance on the principles of the design and project execution phases for offshore pipeline systems transporting both hydrocarbons and associated fluids. It is applicable to offshore pipelines, flowlines, injection lines, and risers. Where appropriate, a pipeline system herein includes the pipeline and pump/compressor facilities and terminal(s) when, for example, identifying an optimum pipeline system design. More detailed guidance on the design of the pipeline, pump/compressor facilities and terminals is covered elsewhere by more specific GPs. The applicability of this document starts at the Access phase of CVP and continues through to Operations. The Business Unit Leader, Project Manager, and EA have responsibility to ensure that this GP is followed. This document, whilst designed for BP as Operator, is also applicable, as far as practical, for non-operated undertakings.

2.

Normative references The following normative documents contain requirements that, through reference in this text, constitute requirements of this technical practice. For dated references, subsequent amendments to, or revisions of, any of these publications do not apply. However, parties to agreements based on this technical practice are encouraged to investigate the possibility of applying the most recent editions of the normative documents indicated below. For undated references, the latest edition of the normative document referred to applies.

BP GP 43-00 GP 43-05

Guidance on Practice for Pipeline Systems (Overview Document). Guidance on Practice for Environmental and Social Impact Assessment of Pipelines. Guidance on Practice for Selection and Use of Industry Codes and Standards. Guidance on Practice for Route Data Acquisition and Route Selection for Pipelines. Guidance on Practice for Onshore Pipeline Design Details. Guidance on Practice for Offshore Pipeline Design Details. Guidance on Practice for Linepipe Procurement. Guidance on Practice for Guidance on Practice for Pigging, Pig Launchers, and Receivers. Capital Value Process Getting Health Safety (Security) and Environment right Guidance on Certification Integrity Management Major Projects Common Process (mandatory for E&P)

GP 43-08 GP 43-10 GP 43-20 GP 43-21 GP 43-31 GP 43-50 CVP gHSEr GOC IM MPCP

US/British/International Codes and Standards 3.

Terms and definitions For the purposes of this GP, the following terms and definitions apply: Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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Design Life Period selected for the purpose of verifying by design that a replaceable or permanent component is suitable for the anticipated duty. Design Pressure The Design Pressure selected as the maximum sustained pressure exerted by the pipeline contents to which a pipeline is to be designed. This pressure is normally determined by a combination of the pipe wall thickness, diameter, material grade and design factor ultimately selected. Flowline A pipeline rigid or flexible that transports unprocessed fluids, typically at high pressure and temperature, from the wellhead to the first downstream process or collector component. Injection line A pipeline rigid or flexible that directs processed liquids or gases into a formation, wellhead, or riser to support hydrocarbon production activity. MAOP Maximum Allowable Operating Pressure or internal sustained pressure at which a pipeline system, or parts thereof, is allowed to be operated - This pressure is determined (i.e., qualified) by the hydrotest (i.e. hydrotest pressure/1,25 or 72% of SMYS, whichever is the lesser), taking into account any elevation effects. Note: MAOP =/< the Design Pressure. MATP Maximum Allowable Transient Pressure or internal transient pressure at which a pipeline system or parts thereof is allowed to be operated - This pressure is limited to 10% above the MAOP. MOP Maximum Operating Pressure at which the system is normally required or set to operate (e.g. taking into account any margins required between the operating set points and the MAOP). Note: MOP =/< MAOP. Offshore Export line A pipeline that transports oil and gas fluids, normally processed, between offshore platforms or between an offshore platform and a shore facility. Offshore pipeline Piping that transports fluids between offshore production facilities or between a platform and a shore facility. Pipelines can be classified into three categories, flowlines, injection lines, and export lines. The use of the word ‘pipeline’ in this GP applies to all three categories. Pipeline The installation through which fluids or gases are conveyed, including pipe, pig trap, components and appurtenances up to and including the isolation valve(s) at the boundary limits. Pipeline System The pipeline(s) including flow control, metering, tankage, pumping and compression, control and data acquisition, communications, and associated buildings. SMYS Specified Minimum Yield Strength required by the specification or standard under which the material is purchased. Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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Definitions relating to CVP are given in MPCP.

4.

Symbols and abbreviations For the purpose of this GP, the following symbols and abbreviations apply:

5.

BoD

Basis of Design

BU

Business Unit

CP

Cathodic protection

DSP

Decision Support Package

EA

Engineering Authority

ESIA

Environmental and Social Impact Assessment

FEED

Front End Engineering Design

FM

Finance Memorandum

HSSE

Health, Safety, Security, and Environment

MoC

Management of Change

O&M

Operations and Maintenance philosophy

PEP

Project Execution Plan

PHSER

Project Health, Safety, and Environmental Review

SoR

Statement of Requirements

SPU

Strategic Performance Unit

TI

Technical Integrity

Offshore pipeline project overview

5.1.

Third party Interfaces and reputation

5.1.1.

General

a.

The contact with third parties, e.g. central, regional and local authorities, land owners and users, field operators, public utilities, non governmental organisations (NGOs), special interest groups, financial institutions (lenders), upstream suppliers, downstream customers, contractors, etc., which is an integral part of an offshore pipeline, should not be underestimated. Offshore pipelines have a major impact on the environment and bring BP closer to the public. In carrying out the pipeline design, construction, and conducting ESIAs, the required interface and liaison with government, regulatory authorities, and the public is intense. From the Access and Appraise phases, understanding the regulatory ‘playing field’ early to determine what is needed and how to resource the Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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project contributes to success. Once in Execute, regulatory matters that require interface and interaction with government authorities can begin to dominate resources and should always receive the maximum attention for a successful project. b.

GP 43-05 provides detailed guidance for conducting ESIAs, a subject that importantly shall receive management and team attention from Access and on throughout the subsequent project phases.

c.

Accordingly, there are significant reputation issues that should be considered and addressed at an early stage.

d.

To ensure that consultations commence early, appropriate specialists shall be involved for BP from the start.

e.

Integration of the “reputation” team with project management to prepare an explicit action and monitoring plan is essential. Many large scale sensitive projects involve funds being borrowed from financial institutions.

f.

Hence the potential involvement of infrastructure leaders shall be recognised.

g.

These issues shall be addressed by the BU/project management at Access for implementation of a plan within Appraise.

h.

Such a plan shall be integrated and updated with the ESIA activities. These issues impact on various stages of the project from Appraise through to Operate and may drive many technical and commercial decisions.

5.1.2.

Commercial

a.

Commercial internal liaison shall be considered as a key matter for attention from Access.

b.

The project team should have a commercial/business lead to ensure that business understanding is related throughout the team, linking across the BU to achieve a two way flow of information.

c.

Ensure the commercial and technical teams meet together sufficiently to avoid regulatory misunderstanding. Avoid cutting corners and reaching commercial agreements that create regulatory conflict.

5.1.3.

Regulatory approvals

a.

Depending on the pipeline location, where national and local requirements may dictate, the pipeline design and construction shall follow US and/or British codes and standards.

b.

GP 43-00 shall be met, including the local and national regulations.

c.

In Appraise the regulatory requirements shall be thoroughly determined to form the basis for regulatory compliance throughout the project. It is essential that there are no later surprises as the project progresses. If operating outside the UK and USA, codes, standards, and regulatory practice that we have normally come to expect shall not be assumed to rule.

d.

The following outline shall be followed to protect BP when undertaking a pipeline project: 1.

Appoint a Regulatory Interface lead who reports to the EA of the project. The EA is to take overall responsibility for the regulatory technical interface, reporting to the Project Manager and the BU management .Note that the Regulatory Interface may not be purely technical and therefore be prepared to build a License Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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to Operate (LTO) team for reputation, environment and regulatory interfaces to be properly managed. 2.

Assign responsibility within each project discipline for regulatory interface and compliance.

3.

Follow GPs 43-00, 43-08, 43-20, and 43-21 (GIS 43-211/212) to ensure BP’s requirements in design and construction are met. BP shall go beyond national and local requirements to meet these GPs.

4.

Ascertain in Appraise the codes, standards, and regulatory approval process in place for the country of operation for design and on through all project phases. In some developing countries it is possible that such standards and regulatory processes may not exist. In such a circumstance adoption of the higher of UK or USA regulatory processes would be relevant, bearing in mind that BP is seen to be acting professionally, not taking advantage, and always protecting BP’s reputation.

5.

If design and operating conditions go beyond country standards and regulatory processes, e.g., extreme operating pressures, then a risk based approach to design to demonstrate fully a safe system rather than a code compliant system shall be adopted. This requires in depth involvement of the regulatory authority to ensure understanding and acceptance.

6.

Review the regulatory requirements with the planned codes and standards to resolve conflicts.

7.

Determine differences and plan forward to ensure the project satisfies requirements. This approach shall be adopted for all project disciplines.

8.

Establish a strong relationship with all authorities to establish confidence and mutual understanding. Be prepared for difficult relationships and confusing advice. Have a strategy to manage for success. The ability to influence regulatory implementation and change is important.

9.

Prepare a regulatory approvals plan and incorporate it in the suite of key project plans.

10. Conduct regular reviews of the plan and ensure the project team is fully aware of the plan and all implications. 11. Review the plan at progress meetings and at stage gate reviews. Involve senior project management beyond the EA. 12. Meet with the regulatory authorities frequently. 13. Do not make assumptions, seek clarification and resolution. 14. Be prepared to assist the authority in their thinking and understanding. 15. When conflict arises, ensure BP senior personnel are involved to provide guidance and if necessary, resolve differences, both internally and externally. 16. Ensure that the EA builds a strong link with the authorities and provides management control in the project to expedite resolution. 17. Allow sufficient time for regulatory approvals and processes. Consider the risk potential to the project. Understand what is involved, be realistic and include contingency in the plan. This may be critical when BP is involved in assisting a developing country to update or initiate regulatory approval requirements .Be sure to manage the risk and highlight at CVP gate reviews. It may even need to be explained in the stage gate FM. Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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18. Document provision, presentations, legal support, dues/customs, and fees may be necessary and shall be allowed for, with contingency. 19. Understand the impact of the regulatory process that requires BP to satisfy other external third parties. Provide funds, time, and resources to conduct this process effectively. 20. Talk to previous projects to bring their recent regulatory experience into the project. 21. Look at the history of the regulatory regime. Many older countries, re-emerging, may look back to what they have done and know. This may not be suitable or applicable today. Be careful in conversation to bring the authority along with you. 22. Be cooperative to help developing and ‘re-emerging’ countries to prepare or rewrite their regulations. Do not take advantage, risking reputation, but do be sure to avoid unreasonable expectations, offering our own knowledge to avoid onerous, unnecessary regulation shall be considered with management involvement to protect reputation. 23. Ensure the EA, the regulatory interface lead, and project discipline leads provide the necessary expertise to meet regulatory requirements to program. Regulation goes beyond design. It applies across all CVP phases and applies to procurement, transportation, construction, installation, commissioning, and startup. 24. BP takes the regulatory lead, but recognising the limit of BP resources, ensures that the contractors are closely involved to assist the process and fully support BP in gaining approvals. 5.2.

CVP phases a.

Similar to other projects, a offshore pipeline project should consist of phases aligned to the CVP gates, following the MPCP. Although MPCP applies to projects >US100 m or 30 mbd net production or viewed as strategic investments, the intention here is that the principles of MPCP be adopted to at least ensure CVP alignment for all pipeline projects.

b.

The pipeline project may be standalone or part of a larger project, depending on the scale of the undertaking.

c.

Figure 1 illustrates the primary project phases that should be applied for the pipeline, be it part of a larger project or standalone. Figure 2, later, provides a flow diagram outlining the project phases, illustrated with the key CVP activities and deliverables.

d.

At completion of the Appraise phase the SPU/BU shall have identified a potential project opportunity and confirmed its strategic fit.

e.

As part of this opportunity, it should be apparent that an offshore pipeline system is an option or a necessity to deliver hydrocarbons.


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Figure 1 - CVP Phase

Appraisal Plan

Appraise

Define FM

Select

Define

Appraisal Plan Create a Distinctive Project

5.3.

Sanction FM

Execute

Operate

Project Execution Plan Confirm, Recycle, or Dispose

Flawless Execution

f.

For clarity, Select is the phase in which project feasibility should be addressed.

g.

The Define phase should relate to FEED for the chosen concept from Select.

h.

Detailed design should normally commence late in Define to give greater definition to the sanction FM.

i.

In Execute, detailed design and construction should be completed.

Key tasks and deliverables a.

As part of creating and executing a flawless project, the key elements shown in Figure 2 should drive the project to be distinctive and successful.

b.

The priority throughout the project shall be to manage closely the highest risk of all, the subject of HSSE. The objective shall be to fully satisfy BP expectations (gHSEr), from Access, Appraise to handover.

c.

This should be the approach to conducting the project, thereby meeting MPCP expectations.

d.

The Appraisal Plan outlines work activities for Appraise and Select and should be updated as a live document in these phases.

e.

A project Quality Plan, for assurance and control, shall be prepared and maintained throughout the project.

f.

High priority shall be given to TI, as this is the key for providing integrity to the project from inception, through design, procurement, construction, and installation.

g.

The SoR, including an O&M, shall provide the basis for the development and assessment of concepts, meeting the BU technical, operational, and business expectations.

h.

The O&M should contain such things as sparing, availability expectations, and outline maintenance, operations, and logistics philosophy with high level strategies (for example manning, extent of automation, use of contractors, integrity etc.).

i.

The PEP shall explain how the project will be delivered, setting out the strategies, system, plans, estimates, and procedures.

j.

The PEP and SoR shall be subject to a MoC process. The PEP, later at Define, should be finalised to support sanction. Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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Figure 2 - Project Phase Flow Diagram

ACCESS SPU/BU identify potential project

Statement of Requirements (SoR)

Appraisal plan

APPRAISE & SELECT Concept evaluation

Regulatory Interface

Chosen Concept Basis of Design – Cost/programme

Operations

Management of Change process (MoC)

HSSE/Risk/Integrity Management/Quality

Preliminary Project Execution Plan (PEP) Define FM

Decision Support Package (DSP) Define Gate

NO

End or Recycle

YES HSSE/Risk/Integrity Management/Quality

Operations Input

DEFINE Detailed Design Project Execution Plan – final (PEP)

Sanction FM

Regulatory/3rd Party Interfaces Basis of Design (BoD) Decision Support Package (DSP)

Execute Gate

NO

YES HSSE/Risk/Integrity Management/Quality

EXECUTE Construct/Install/Test/ Commission

Regulatory/3rd Party Interfaces

Operate Pipeline Decommission System Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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k.

The BoD, which represents the conversion of the SoR into a technical basis, shall describe what is to be designed and built. It too shall be subject to MoC.

l.

The DSP shall document the basis of the FMs submitted by project.

m.

The DSP should be a comprehensive compilation of support information, across all elements, commercial and technical.

n.

Throughout the project phases, certain fundamental expectations shall be observed to support and comply with BP Group Policy. 1.

PHSERs, including Security, shall be conducted at specific stages in the CVP process, satisfying gHSEr.

2.

In addition to PHSERs, the framework requirements of gHSEr shall be followed in all project CVP phases.

3.

HSSE shall be given detailed attention and treated as a priority throughout the design as this underpins and supports the construction and operation phases.

4.

The BP Group IM Functional Standard shall be adopted by the project as part of the Quality plan, and to satisfy the Operational requirements. Within the ETP Library, Pipeline Series 43 GPs are available to provide more detail relating to Quality, IM, HSSE, and Risk Management practices. Annex B provides a non-exhaustive list of design and installation activities to act as a guide check list in applying this GP.

5.4.

Pipeline system a.

Although this GP addresses the design principles for an offshore pipeline, such a design should not be undertaken without due consideration being given to the requirements of, and impact on, the necessary pump/compressor facilities, and terminals.

b.

For this reason, the pipeline shall also be designed as a system. This is particularly important during the initial pipeline design stages when key decisions need to be taken, consistent with the design throughput requirements, with respect to issues such as: • • •

Pipeline diameter. Design pressure. Wall thickness, etc.

Important to this decision making process are issues such as: • • • • • • c.

d.

The number & location of the pump/compressor facilities, Driver and pump/compressor type. Machine configuration. Sparing. Fuel selection. Need for surge relief systems/tankage, etc.

The requirements of any terminal shall be included, such as: 1.

Number and size of storage tanks.

2.

Number and type of marine loading systems.

3.

Need for volatile organic compound (VOC) recovery, etc.

Further, BP corporate and any other regulatory requirements relating to ESIA expectations (e.g. energy efficiency and emission targets) need to be taken into consideration. Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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e.

5.5.

The above issues and new pipeline technologies should be carefully considered in conjunction with one another at an early stage during the pipeline design, such that an optimised pipeline system (i.e. pipeline, pump/compressor facilities and terminal) can be identified, and not one developed from isolated decision making.

Pipeline not piping Although both pipelines and piping transport fluids from one location to another, due to the differences in relative costs and impacts on the community and the environment, the design and construction of offshore pipelines shall be considered very differently from piping. Due to piping’s relatively low cost, which typically represents about 5% of the total facility cost and its proximity to the main operation, many rules-of-thumb are applied to piping design and construction for expediency, which should not be applied to pipelines. Pipelines, due to their potential length and size, may cost more than the facilities with which they are associated. The application of piping rules-of-thumbs to pipeline design and construction may increase the cost by significant factors, with little tangible benefit or increase in safety.

5.6.

Environmental and Social Impact Assessment studies (ESIAs) a.

ESIA studies which should be initiated in Access, prior to Appraise, shall be conducted throughout all CVP phases to assess the potential impact of pipeline construction and operation. Early initiation of the ESIA process is a key to project success to gain Permits to programme. For a major project in a sensitive area this might take as much as a year or two. Prior local and national BP Group commitments shall be ascertained to ensure compliance by new projects. After initial desk top/screening studies, a Scoping study would be undertaken with the objective of identifying the potential environmental risks as the basis for more detailed investigation and resolution (i.e., the ESIA), design mitigation, base line surveys, etc.

b.

ESIA undertakings shall be compatible with the proposed design and construction methods and vice versa. This is an iterative process such that design and construction plans may need to vary to meet ESIA undertakings. Communications between the ESIA and project technical teams, seeking, integration, is key for the decision process to be correct.

c.

Whilst not all projects require the same level of ESIA, an ESIA screening process shall be carried out to identify: 1.

Critical environmental and social risks.

2.

Potential impacts.

3.

Liabilities.

4.

Significant or unusual regulatory compliance requirements.

5.

Other concerns of the national and international stakeholders. Attention to this in Access is not too early for option selection. It helps impacts to be fundamentally determined early. GP 43-05 provides a comprehensive guide for ESIA execution. Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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6.


Appraise and Select design phase

6.1.

General a.

Depending on the pipeline location, where national and local requirements may dictate, the pipeline design and construction shall normally follow US and/or British Codes and Standards, selected in accordance with the GP 43 series.

b.

GP 43-21 is the ETP for offshore pipeline design and construction to be followed, unless local requirements exceed those in GP 43-21.

c.

The major design activities illustrated in Figure 3 should lead to the completion of the BoD required to move to Define and Execute.

d.

Operations personnel should be involved early in Select, with continued effort to build the Operations team from Select through Define and Execute within the project team, thereby being ready for commissioning and start-up. A good quality O&M philosophy document providing a firm basis for design, leading to comprehensive O&M procedures should help achieve success. Understanding and preparing the requirements for handover certification in accordance with GOC is also a key activity. Figure 3 - Offshore Pipeline Appraise and Select Design Activities BoD Development • Product data, design life & throughput • Line sizing & hydraulics • Offshore environmental and climate data • Preliminary offshore geophysical & geotechnical data • Operability & availability • Risk assessment & QRA

SoR

Interface with Regulatory Authorities

Appraise & Select

• • • •

Valves Controls Telecomms Leak detection

Pipeline Route • Alignment • Crossings • Surveys • Shore approach

• • • •

Pipe wall thickness Steel grade Design factor Flexibles

Tie ins • Wyes • Subsea structures • Spoolpieces

Pipe Coatings • Corrosion coating • Cathodic protection • Thermal insulation

On-bottom Stability • Trenching evaluation • Weight coating

Pipe Structural Analysis

ESIA

Pipeline Installation Evaluation

Operation, Maintenance, Repair • Potential free span • Soil erosion • Inspection

Preliminary Cost Estimate and Programme

Preliminary BoD

e.

The Appraise stage is the period when BP shall provide the design expertise supported by a contractor(s) for certain elements, as required by the project. Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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f.

Transferring from Appraise to Select should involve competitive tendering to appoint a Select phase contractor working under BP management. Depending on contract strategy and technical needs this contractor may later be the Define and possibly even the Execute contractor. GP 43-03 provides guidance on the contract approaches that can be adopted.

g.

Such a contractor should transfer to Define, subject to achieving the required level of performance. This provides the level of expertise necessary for comprehensive definition in support of sanction.

h.

An option to re-bid Define shall always be retained in Select, allowing BP sufficient time to replace a poorly performing contractor for example or to enhance the contracted expertise, or to suit the contracting strategy.

i.

The BP project team shall be resourced to ensure that the team has core pipeline design and project skills and experience.

j.

The outline organisation should be started in Appraise, thinking ahead to subsequent project stages.

k.

Key project positions should be filled by BP personnel, for example: 1.

Project Manager.

2.

Construction Manager.

3.

Operations Manager.

4.

Interface Manager.

5.

Engineering Manager and Engineering Authority.

6.

Services Manager.

7.

HSSE Lead.

8.

Contracts and Procurement Lead. Guidance to achieve good organisational capability is provided in MPCP.

6.2.

Design basis a.

At the onset of Appraise, the data received at Access shall be verified for absolute validity.

b.

The BoD shall be prepared along with the SoR to provide uniform and consistent data for design.

c.

In particular, field, environmental, geotechnical, and, where appropriate, reservoir data of high quality shall be available.

d.

A gap analysis on the data shall be completed early in Appraise.

e.

Areas of data weakness shall be rectified including the undertaking of further data research and offshore surveys, as may be necessary.

f.

An ESIA screening or desk top study, including social impact, shall be conducted. (See GP 43-05).

g.

Importantly, the ESIA team, both BP and Consultant, shall be managed to ensure that unintentional and/or unacceptable external commitments are not made.

h.

Primary specific up-to-date design information should include, but not be limited to: 1.

Environmental, geophysical, and geotechnical data. Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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2.

Fluid data for transportation.

3.

Design flow rates, including peaks and turn down.

4.

Pipeline inlet/outlet pressure and temperature conditions.

5.

Hydraulic design parameters (e.g. internal pipe roughness)

6.

Potential route options, including restricted or sensitive areas (e.g. ”constraints” map).

7.

Seabed profile data.

8.

Major crossings and topographical features.

9.

National, local, and governing design codes.

10. Expected operating life. 11. Potential third party users and possible future expansion provisions. 12. Reservoir management plans/impact on pipeline usage. 13. Potential conflicts with existing facilities/pipelines and new developments. 14. Any known operating or control conditions that could influence the design 15. Economic evaluation of the design options.

6.3.

6.4.

i.

Throughout all phases of the project, data and deliverables generated from inception shall be kept intact, including contractor generated information.

j.

Such data, e.g. pipe tracking, material certification, and Geographical Information System shall be transferred electronically to operations as specified and agreed with the Operator.

Hydraulic analysis-line sizing a.

Selection of the correct pipe size and grade for hydraulics, pressure containment, and strength is a key to project success in that technical pipe selection shall also include economic considerations as part of the technical decision process.

b.

Hydraulic analysis shall be conducted for the various pipeline routes and configuration options to determine pipe sizes and pumping/compression requirements.

c.

Standard pipe diameters (including wall thicknesses and driver types) should be used unless there is a significant financial advantage to do otherwise, as may be the case on very long pipelines.

d.

Any system containing intermediate pumping/compression should be optimised considering the initial capital investment (CAPEX), the operational cost (OPEX), including the cost of energy over the life of the pipeline (OPEX), emissions, fuel availability, operability (e.g., standardisation of driver type), and any other future investments associated with either the pipeline or the pumping/compression facilities.

Pipe wall thickness and material grade selection a.

Selection of pipe wall thickness and material grade shall comply with the applicable identified codes and standards.

b.

An economic evaluation of material type and thickness across the options for the pipeline system should be undertaken.

c.

In addition to satisfying internal pipe conditions, due consideration shall be given to external factors such as external pressure and installation techniques ,crossings, water depth, environmental impacts (e.g., seismic activity, mud volcanoes, currents, etc.), and third party activities and installations.


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d. 6.5.

The material grade shall be selected to provide metallurgy compatible with the expected welding procedures and corrosion resistance requirements.

Preliminary route selection a.

The preliminary pipeline routing options and shore approach shall take due account of the various technical, environmental, safety, security, and social factors including anticipated developments. GP 43-10 concentrates on the route selection process.

b.

The pipeline should be routed to avoid, where possible, geologically unstable areas.

c.

Adequate time should be allowed to select the optimal route, which may not be the shortest route, and ensure that relevant views are heard, and that permissions, regulatory requirements, and environmental/safety impacts do not impact the project schedule. It is important to recognise the issues that can affect route selection, in particular the potential related schedule impacts that can result.

d.

Apart from the need for early consultation with affected/interested parties, routing decisions shall not be made such that the route becomes fixed without allowing time for material consultation with those parties, stakeholders, and partners. This is to allow such parties adequate time to influence the route selection, as appropriate, within the project schedule. This may mean that initial routing discussions take place during Appraise with a routing “corridor” generally agreed with the stakeholders early in Select to avoid project delays. This is important for an offshore pipeline, but unlikely to be as demanding as for an onshore pipeline.

6.6.

6.7.

e.

Preliminary geophysical and geotechnical surveys shall be carried out early in Select.

f.

Permit restrictions for the use of explosives, ground water, and hydrotest water acquisition and disposal may influence the route selection for both onshore and offshore sections of the pipeline system.

Pipeline stability a.

The pipeline shall be designed to be stable on the seabed under a range of external conditions for both construction and operations.

b.

A review of the steel thickness and pipe coating thickness to achieve the optimum economic pipeline weight, consistent with the requirement for the pipeline to be stable on the seabed, shall be conducted.

c.

The impact of pipeline weight and overall size on the selection of the pipeline installation technique (lay vessels) shall be assessed.

d.

Other options for achieving enhanced pipeline stability should be considered, as necessary, such as trenching & burial, rock dumping, mattresses, rock anchors, etc.

Pipeline trenching and burial a.

The benefits of pipeline trenching and burial for pipeline stability and physical protection shall be reviewed.

b.

Fishing, shipping, and seagoing activities shall be considered to determine the trenching requirements.

c.

Pipe burial may also be utilised to reduce pipeline thermal loss and importantly to eliminate upheaval buckling. Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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d. 6.8.

6.9.

6.10.

Pipeline freespan evaluation a.

The maximum pipeline free spans shall be calculated by analysing the impact of vortex induced vibrations on the fatigue life of the pipeline for the installation, flooded, and operating conditions.

b.

The risk and consequences of snagging of the freespans (e.g., fishing activities) shall be assessed.

c.

Action shall be taken to reduce the length of unacceptable free spans (e.g., by dredging or rock dumping) and to monitor any growth of the free spans during construction and operation.

Pipeline and cable crossings a.

Operators of existing pipelines and cables on potential pipeline routes shall be consulted.

b.

Physical support and protection at the crossing points shall be established and agreed with the third party operator, to provide minimum and maintained clearance between the new and existing pipelines and/or cables.

Shore approach a.

In selecting the preliminary pipeline routes, the shore approach shall form part of the route selection process.

b.

It is most important in evaluating the shore approach to consider:

c. 6.11.

Pipeline trenching and burial are expensive techniques, so their use should be considered very carefully.

1.

A location (i.e., with adequate water depth) that enables the installation and trenching vessels to come close inshore.

2.

A location which provides adequate space onshore for the pulling operation and /or pipe string fabrication

3.

Existing and potential developments in close proximity to the landfall.

4.

Environmental and safety sensitivity.

5.

The geotechnical conditions

6.

Long term erosion of the shore.

7.

Social and security impacts by location.

8.

Alternative landfall design options such as cofferdam/onshore trenching/directional drilling.

Consideration should be given to the impact of the tide on the water depth and on cross currents.

Offshore tie-ins and risers Subsea tie-ins are required at platform risers and subsea assemblies, such as wellheads, manifolds, and mainline lateral valved connections. a.

The tie-in spoolpiece arrangement shall accommodate the pipeline expansion (i.e., mainly thermal expansion) and maintain the loading onto the connecting riser or subsea assembly within the allowable limits.

b.

The design for any future tie-ins should allow for connection without affecting flow in the operating system. Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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c.

In normal circumstances the piping arrangement should allow for pigging and inspection operations. There are numerous connection techniques for subsea tie-ins.

d.

Careful selection of the most suitable subsea tie–in technique is essential.

e.

Design of supports for risers and J-tubes as single pipes or in bundled form shall take account of: 1.

Static and live loadings.

2.

Thermal stresses.

3.

Platform/structure settlement.

4.

Fatigue. Materials for risers and J-tubes need careful selection as they are particularly vulnerable to erosion and corrosion.

f.

Riser and j-tube clamp design, external protection, and inspection provisions shall receive close attention during the design.

g.

Full consideration of the installed and installation deflections and tensions shall be taken into account in the design. For floating and fixed platforms in deep water, where steel catenary risers are normally used, careful consideration needs to be given to the increased movement and larger tensile forces.

6.12.

6.13.

6.14.

Pipeline pigging a.

The operational and testing needs for pigging shall be identified.

b.

The pipeline system shall be designed to accommodate internal inspection tools.

c.

Pig traps and closures shall be designed to ensure safety and integrity in operation.

d.

Pig trap design shall incorporate the needs determined by the nature of the fluids and the pigging regime (e.g. in the case of wax, consideration should be given to the: pig trap volume, pig handling facilities, flushing systems, hydrotesting and wax disposal systems). GP 43-50 provides detailed guidance for pigging and pig trap design.

Pipeline corrosion design a.

Internal and external corrosion of pipeline systems shall be managed to minimise the risk of pipeline failure or loss of operability.

b.

Design of the pipeline system shall include appropriate internal and external corrosion protection provision for both the installation and operating phases of the pipeline. Depending on the operational procedures and perceived risks, additional wall thickness, internal/external coatings and CP systems shall be considered.

c.

Careful consideration shall also be given to the continuity of the external corrosion protection system over the field joints.

Preliminary pipeline stress analysis Analysis shall be performed to ensure pipe stresses and deflections under installation and operational conditions do not exceed allowable values.

6.15.

Pipeline components Rigorous and proper valve and pipeline component selection (tees, wyes, etc.) is critical for the future operability and integrity of the system. Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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a.

Components to be installed subsea shall be selected to avoid long term high inspection and maintenance costs.

b.

The attention to detail required for valve selection should not be underestimated. This is particularly valid for the selection of subsea isolation valves (SSIVs) and Emergency Shutdown Valves (ESDVs) when determining their need and location in the system.

6.16.

Pipeline installation- pipelay and trenching a.

As part of the preliminary pipeline design a review of the potential pipeline installation methods shall be assessed for their suitability. The physical design of the pipeline and its routing are influenced by the technique and type of installation vessel(s).

6.17.

b.

Importantly, options should be kept available to the project to ensure a competitive contracting environment for installation.

c.

A review of the availability of suitable vessels in the region during the anticipated construction period should also be determined.

Pipeline integrity To ensure safe operation, integrity techniques shall be established and allowed for in the preliminary design, i.e. leak detection systems, corrosion assessment, inspection access, communications, and overall controls including subsea components.

7. 7.1.

Define and Execute pipeline project phases Detailed engineering phase Referring again to Figure 2, the move to Define occurs with the approval of the Define FM. It is at this Define stage that the preferred design is developed to a more detailed level in order to produce a final PEP and BoD, leading to a Sanction FM, which upon approval moves the project to the Execute phase. a.

The SoR shall be updated in Define to ensure Operations and BU requirements accord with the project definition. Depending upon the selected contract strategy and the scale of the project it is normal for the Define design phase (FEED) to be undertaken by the competitively chosen Select phase contractor, under BP management.. This contractor could then move to Execute for construction, subject to sanction. However, the Select/Define contractor selected may be best suited to those CVP phases only, not having the required construction capability and as a consequence there would be a need to bid in Define for Execute construction contractor(s). It is important to ensure that bidding is undertaken in time to complete the sanction FM to the required accuracy. GP 43-03 provides guidance on contract strategy.

b.

Depending on the project programme, in order to protect the planned completion of Execute, some long lead materials, such as pipe, coating, and large valves may be ordered in Define before Sanction, with cancellation provision in the Define budget. This would be subject to FM approval.

c.

The BP Global Line Pipe Agreement shall be utilised for pipe procurement. The BP Global Line Pipe Agreement offers programme flexibility and time savings.

d.

The REI shall be used for procurement of rotating equipment if required by GP 43-31. Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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7.2.


Surveys and ESIA a.

7.3.

Based on the Select survey scope and findings, a detailed offshore/landfall geophysical and geotechnical investigation shall be conducted over the proposed pipeline system corridor. 1.

This survey should be undertaken at the beginning of Define to support the design basis.

2.

Such a survey could be pre-funded in late Select depending on the time available in the project programme.

b.

A full ESIA should be conducted during Define to ensure environmental impacts are accommodated in the design and cost estimate, and vice versa.

c.

For the project to move forward into Execute, the ESIA should be completed and approved at or very shortly after the start of Execute.

Design finalisation a.

The design undertaken in Select and Define (clause 6) should be taken in Execute to an “Approved for Construction” status.

b.

A comprehensive series of deliverables shall be produced including:

c.

1.

Alignment sheets.

2.

Working drawings.

3.

Data sheets.

4.

Equipment/material specifications.

5.

Hydraulic design reports

The deliverables should become the basis for procurement, construction, and installation. Annex B is a checklist of deliverables.

7.4.

7.5.

Pipeline installation analysis a.

With the pipeline system defined, precise installation analysis work shall be conducted.

b.

Such study should extend over the complete range of construction activities and available construction equipment to ensure that every aspect of the pipeline system is considered, including the impact of the ESIA approval conditions and the weather.

c.

This should result in definition of the type of installation methods best suited to the project conditions, contractor’s personnel and equipment, and selected route.

Pipeline construction and installation (Execute) a.

Subject to sanction, for a large scale pipeline project, an Engineering, Procurement, and Construction contractor should be appointed in Select to complete the Define/Execute phases. Such contractors shall have the expertise to confirm the design, undertake construction and installation engineering, and finalise costs and plan aligned to the prime construction vessels at his disposal in Select to support the Define FM.

b.

The contractual arrangement for a pipeline project shall never dilute BP’s involvement and control.

c.

Subcontractors may be sought for example for specialist activities, particularly geotechnical surveys, trenching, dredging, rock dumping, subsea tie-ins, survey, field joint coating, and pre-commissioning.

d.

Contracting a pipeline project may possibly be organised such that BP manages the project in Define, assisted as required by specialist consultants and contractors. Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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8.


e.

In Define, the major procurement and construct phases (for Execute) may be tendered such that a main contractor(s) takes the project to completion under BP management.

f.

Early procurement of long lead items funded within Define, as a BP responsibility, may become a necessary activity to protect the project programme.

Execute success In any project, particularly a pipeline project, a successful Execute outcome ensures a project is completed to the highest integrity, safely meeting BP HSSE expectations, on time and under planned capital budget. Pipeline projects extend over significant areas and distances and as such generate high risk and potential impact. They are often seen as secondary, especially when part of a major project. An offshore pipeline must interface with other offshore activities and this adds complexity. So key to success is excellent planning, close cooperation, and communication. a.

HSSE, particularly safety in Execute, is a major risk area and shall be managed closely, fully satisfying BP Expectations from Appraise to Operate.

b.

In addition to attention to safety, the subject of security shall also receive due consideration. More and more projects are executed in sensitive areas where the security of personnel and facilities is critical.

c.

BP inspection or independent inspection shall be employed and resourced with the highest calibre personnel consistent with the perceived and evaluated risks. Quality in design, fabrication, and especially construction is a major risk. Comprehensive inspection, especially in pipe manufacture, coating application, welding, joint coating, pipeline installation, and pre-commissioning is essential. By 2006 BP will have a new TI process that will provide a standard to be adopted to ensure QA/QC, as one of the tools to deliver TI. GP 43-04 relates to Pipeline QA/QC.

d.

The contractual arrangement for a pipeline project, with strong emphasis on independent inspection, shall never dilute BP’s involvement to the extent that the pipeline system integrity can be jeopardised. The contracting and procurement options in terms of contract type and strategy are numerous. GP 43-03 offers contract strategy advice. However, regardless of contract arrangements, if a pipeline project is to be successful for all involved, the quality of resources and relationships is crucial. Proven experience within both BP and Contractors’ teams, with attention to good communication, goes a long way to reduce risk.


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Annex A

(Normative)

List of 43 Series Engineering Technical Practices By accessing the ETP website the most up to date list of the Series 43 documents is available. In particular GP 43-21 underpins the outline statements provided in this GP. The link is List of Series 43 ETPs.


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Annex B

(Informative)

Deliverables Checklist This list of key offshore pipeline project design and installation activities is not fully encompassing. It only guides the reader. In Appraise and Select these technical activities are taken usually to a preliminary stage – in Define and Execute the activities become final to achieve project completion: •

Pipe diameter, wall thickness, material grade selection and design factor

•

Pipeline hydraulic analysis (steady, transient and system availability)

•

Geophysical and geotechnical surveys

•

System optimisation study

•

Route selection including shore approach site, including full route alignment sheets

•

Process drawings (P&IDs, PFDs) and cable diagrams (instrument, electrical, comms.)

•

Construction and operation pipeline stress analysis, including environmental effects

•

Pipeline trenching and burial requirements

•

Stability analysis, weight coatings for protection and stability

•

Pipeline and cable crossing design

•

Riser and subsea tie-in design (plus J-tubes)

•

Subsea manifold, valving configuration, and protection structures

•

Pipeline appurtenances and component design (flanges/fittings/valves/pig traps/etc.)

•

Pipeline material, coatings and corrosion protection provisions

•

Inspection techniques and appurtenances

•

Pipeline integrity – leak detection design

•

Pigging and pig trap requirements in construction and operation

•

Pipeline installation analysis

•

Pipeline welding and inspection procedures

•

Pipeline field coating and inspection procedures

•

Pipeline field joint and CP design

•

Pipeline abandonment and recovery procedures

•

Quantified Risk Assessment (QRA)

•

Control and communication systems

•

Testing, pre-commissioning, and commissioning procedures

•

Line fill and start-up procedures

•

Operation, maintenance, and repair procedures

•

O&M

•

Oil spill response plan

•

Environmental Risk Assessment (ERA)

•

ESIA Downloaded Date: 6/17/2008 10:59:54 PM The latest update of this document is located in the BP ETP and Projects Library

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•

PHSERs

•

gHSEr compliance

•

Hazard/Risk/Opportunity identification and management

•

Span correction and post installation stability provision

•

Marine and anchoring procedures

•

Cost estimate

•

Schedule

•

Risk analysis


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Bibliography BP [1]

GP 43-03 Guidance on Practice for Pipeline Project Execution.

[2]

GP 43-04 Guidance on Practice for Offshore Pipeline Project Execution.


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GP 43-02 30 June 2005 - Guidance on Practice for Principles of Offshore Pipeline Design and Project Execution

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