Geronimo Rodriguez, Oil States, explains why an emergency pipeline repair system (EPRS) is a necessary, fail-safe solution to secure the reliability and integrity of subsea infrastructure.
As subsea infrastructure is as vital to global economies as offshore pipelines, failure is not an option. These assets must operate reliably while moving essential production miles to shore from water depths ranging from 1000 – 10 000 ft. This can be challenging, as such assets are susceptible to corrosion defects as well as external forces including impact damage from ship anchor-chain drag as well as dropped objects from platforms – all of which can render assets inoperable. Disruption to pipeline operations due to mechanical failures or external damage can lead to serious consequences that encompass environmental impact as well as substantial production and financial losses.
When a pipeline is compromised by a defect or sustains damage, operators must respond rapidly to contain the damage and complete repairs or risk extended downtime. To react swiftly, asset owners must prioritise investments in incident planning. Ideally, the plan that is put in place must be comprehensive, straightforward and easily executable, and the best way to achieve those objectives is to implement a permanent solution – one that reduces complexity during a high-pressure scenario and allows for carefully orchestrated, efficient and safe repair.
Building a resilient network
Integrating resilience factors into pipeline engineering, procurement, construction and installation (EPCI) programs and installing an emergency pipeline repair system (EPRS) are crucial measures for minimising operational disruptions over the service life of an offshore pipeline. Combining both technical services and the latest subsea repair technologies, an EPRS offers a holistic solution that can protect and maintain pipeline mechanical integrity.
Designed as an integrated contingency package containing specialised tools, spare parts and detailed response protocols that facilitate urgent repairs, a typical EPRS includes:
- Fully assembled clamps, connectors, and fittings.
- Gaskets, seals, and spare fasteners.
- Technical and Service team support.
As a first step in building resilience, operators must evaluate existing assets to determine which of the most valuable pipelines cannot be rendered inoperable for an extended period. The next step is to customise and pre-install an EPRS that can be quickly accessed and deployed in the event of an emergency.
Because a breach in pipeline integrity and subsequent repairs can have significant and costly operational and environmental consequences, time is of the essence. Operators must have immediate access to spare components and repair solutions to mitigate damage and reduce downtime. With predefined repair equipment suites that are customised for a pipeline’s specific operating conditions, an EPRS allows operators to shave months off the downtime typically required after an emergency event. The time savings from an integrated solution combined with having immediate access to spare equipment can amount to millions in cost avoidance.
Fast emergency repair
Emergency repair technology providers offer a way to rapidly return pipelines to operation following an integrity issue. When a pipeline sustains damage that takes it out of service, having access to a complete package of field-proven technology solutions to perform repairs is essential.
As an example, Oil States’ robust EPRS capabilities transform pipeline emergency response from reactive to proactive damage control, minimising downtime risk and disruption. The lead time for a new EPRS system is at least 18 months. However, having this hardware already built and properly maintained will reduce the readiness time as the system can be available in two weeks.
Associated proprietary subsea technologies for fast emergency repair include misalignment connectors, swivel ring flanges, mechanical pipe end connectors and diverless leak repair clamps, all of which support the pre-installed EPRS as a holistic solution for reinforcing offshore pipelines. Each component is customised for a project’s unique needs.
Understanding the unique operating conditions of offshore environments, a team of highly specialised subsea pipeline system experts is essential to deliver design, manufacturing and support for pipeline construction, repair and expansion projects.
Future-proofing mega projects
A recent Middle East project where OSI provided an EPRS package demonstrates its appropriateness for emergency response and field reinforcement. To tap additional gas reserves in part of the world’s largest non-associated natural gas reservoir, an operator desired to expand its operations in the Persian Gulf. The operator desired to add nearly 20 million tpy of LNG production capacity before the end of the decade. With recoverable reserves of more than 900 trillion ft3 of gas, the targeted field holds approximately 10% of the world’s known reserves. Expansion of the operator’s project includes EPCI of nearly 250 km of offshore and onshore gas pipelines, connecting facilities that would supply feed gas for two additional LNG trains.
Oil States manufactured the first EPRS for 38 in. diameter pipelines in 2015 to help the operator manage the integrity of its vast pipeline network. System hardware was designed as a permanent fixture for preventative maintenance to help optimise uptime reliability for the operator’s mature gas wells and ensure the necessary level of readiness to respond to an emergency repair in real time. The package was designed specifically for the project, meeting the required wall thickness parameters and fluid compatibility checks. Although the EPRS has fortunately not been necessary to date for incident resolution, having the system available as a contingency solution helps future-proof asset integrity and provides foundational support for new construction.
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Read the article online at: https://www.worldpipelines.com/special-reports/17042025/a-critical-contingency-for-offshore-pipelines/