Design and Development of an Angled Clamp for Repair of Pipeline Leaks

at Remote Locations in Deepwater

INEMUGHA, Daniel Ateinyari

A Preliminary Proposal

March, 2019
Design and Development of an Angled Clamp for Repair of Pipeline Leaks
at Remote Locations in Deepwater

INEMUGHA, Daniel Ateinyari

MEng (Mechanical Engineering), University of Sussex, United Kingdom

Research Proposal Submitted to the Postgraduate School, Rivers State

University, Nkpolu-Oworowurokwo, Port Harcourt, in Partial Fulfilment
of Requirements for the Award of Master of Technology (M.Tech) Degree
in Marine and Offshore Engineering (Subsea Option) of the Centre of
Excellence in Marine and Offshore Engineering

ii
 DECLARATION

I, INEMUGHA, Daniel Ateinyari hereby declare that this research proposal represents my

original study and has not been previously submitted elsewhere nor this university for the

award of any degree.

------------------------------------------ -------------------------------

Signature of student Date

iii
 CERTIFICATION
We certify that this research work carried out by INEMUGHA, Daniel Ateinyari at the Centre

of Excellence in Marine and Offshore Engineering, has achieved its objectives, both in scope

and quality as a partial fulfilment of the requirements for the award of the degree of Master of

Technology (M.Tech) in Marine and Offshore Engineering (Subsea option), Rivers State

University, Nkpolu-Oroworukwo, Port Harcourt, Nigeria.

Supervisors

1. Dr. V. C. Ossia …………………………………. ………………………………….

Signature Date

2. Engr. M. Inegiyimiema …………………………………. ………………………………….

Signature Date

3. Mr. Ramaiah Narendranath …………………………………. ………………………………….

Signature Date

Dr. Ibiba Douglas …………………………………. ………………………………….

(Director, Centre of Excellence) Signature Date

Name …………………………………. ………………………………….

(Dean, Faculty of Engineering) Signature Date

Name …………………………………. ………………………………….

(External Examiner) Signature Date

iv
 ACKNOWLEDGEMENT
First and foremost, I want to give all gratitude to God almighty for the life, strength, wisdom
and knowledge in undertaking this project proposal.

To my supervisors, Dr. Ossia, Engr. Morrison and Mr. Ramaiah Narendranath, thank you so
much for your guidance all through this challenging and interesting project.

I would also like to express my heartfelt appreciation to Shell Petroleum Development

Company (SPDC) for their sponsorship of the programme at the Centre of Excellence. The
conducive environment at the centre was the key in completing this dissertation.

My deepest gratitude to the lecturers and experts from the Rivers State University, Shell
Nigeria Exploration and Production Company (SNEPCO) and other universities and industrial
establishments for their support and input towards the success of this work.

Engr. Keribo Belema was very resourceful in this proposal and was always there to brainstorm
ideas. Your participation and advices was very useful. My regards to you and your family.

To my colleagues, it has been a wonderful ride with you all. You all participated to make this
proposal a success in one way or the other. Thank you.

v
 DEDICATION

I dedicate this work to my dear wife

Marcelina for her understanding and

help while working on this project.

vi
Table of Contents
DECLARATION ................................................................................................................. iii

CERTIFICATION ............................................................................................................... iv

ACKNOWLEDGEMENT ..................................................................................................... v

DEDICATION ..................................................................................................................... vi

LIST OF FIGURES ........................................................................................................... viii

CHAPTER 1: INTRODUCTION .......................................................................................... 1

1.1 Background/Justification of the study...................................................................... 1

1.2 Statement of the Problem ........................................................................................ 2

1.3 Aim and Objectives of the Study ............................................................................. 3

1.4 Scope of work ......................................................................................................... 4

1.4.1 Limitation of the study ..................................................................................... 4

1.5 Research Approach ................................................................................................. 5

1.6 Significance of the Study ........................................................................................ 6

CHAPTER 2: LITERATURE REVIEW ............................................................................... 7

2.1 Extent of Past Work..................................................................................................... 7

2.2 Research Gap and Current Work ............................................................................... 11

CHAPTER 3: MATERIALS AND METHODS .................................................................. 12

3.1 Data Collection.......................................................................................................... 12

3.2 Hardware Requirements ............................................................................................ 12

3.3 Software Requirements.............................................................................................. 13

CHAPTER 4: WORK PLAN AND COST ESTIMATE ...................................................... 14

4.1 Research Activities and Duration............................................................................... 14

4.2 Cost Estimate ............................................................................................................ 15

REFERENCES ................................................................................................................... 16

vii
LIST OF FIGURES
Figure 1 - Research Approach 5

Figure 2 - Angled clamp design 9

Figure 3 - Gantt chart 14

viii
 CHAPTER 1: INTRODUCTION
1.1 Background/Justification of the study

Subsea pipelines can be compared to the veins and arteries in the human body in terms of its
function. They are responsible for the transportation of oil and/or gas from the reservoir to
where they are needed. This is a very important area in the oil and gas industry as damage to
the pipelines could pose serious financial losses. Contemporary repair of these pipelines usually
involves cutting the damaged section and replacing it with a new one. This can lead to pipeline
shutdown. Also, replacing the new pipeline section usually involves welding which can pose
explosive risk.

A safer, quicker and less costly method in repairing damaged subsea pipeline sections can be
with the use of a mechanical clamp. Mechanical clamps are typically assembled and bolted
together around the damage or leak in a pipeline. The clamps have elastomeric seals that
provide pressure containment of the leaking fluid. Although, clamp repair technology has been
successfully used as we would see in CHAPTER 2: LITERATURE REVIEW, the research of
the key equipment which is diverless full structure permanent pipeline repair clamp in the
technology has just started according to AEA Technology Consulting (2001). Modern clamp
repair technology usually employ an ROV to assist with its installation. Modern clamps are
specifically designed to fit on straight pipes and whereby the pipe is deformed radially and a
straight clamp cannot surround the pipe’s outer geometry, the use of an angled clamp becomes
necessary. Mohammadi (2011) introduced this idea and was able to lay a background design
of the device (CHAPTER 2: LITERATURE REVIEW).

This study will present a design and development of an angled clamp for repair of pipeline
leaks at remote locations in deepwater development. The proposed design and technology for
this solution is an automated diverless hydraulic clamp. Emphasis will be laid on the design of
the sealing mechanism.

1
1.2 Statement of the Problem

One thing every oil and gas operator should dread is a damage to their subsea pipelines.
Millions of dollars could be lost if it takes too long to repair the leak or if repairing them would
mean shutting down the whole system.

The use of conventional clamps have become a fast way to repair little to moderate damage
such as a pin-hole leak. Whenever the damage is due to external forces and the pipe is deformed
radially and a straight clamp cannot surround the pipe’s outer geometry, then recovering,
cutting and repairing the pipe section is usually recommended. This method is too expensive,
risky and time consuming. Also, attempting to bring a shallow water pipeline to the surface for
a repair could cause several other unknown leaks.

It is hoped that this study will present a design and development of an angled clamp for repair
of pipeline leaks caused by external forces where the pipeline is deformed radially. The
proposed design and technology for this solution is an automated diverless hydraulic clamp.

2
1.3 Aim and Objectives of the Study

The aim of this study is to design and develop an angled clamp for repair of pipeline leaks at
remote locations in deepwater development. To achieve the aim, the following objectives are
set:

i. Review/Survey of various clamps designed, patented and/or implemented in the

industry.
ii. Carry out an evaluation of different clamp concepts.
iii. Identification of the best conceptual design for further detailed design and implement
the appropriate detailed particular design. All designs will be adhering to the relevant
codes and standards.
iv. To carry out an FEA analysis of the chosen clamp design and compare it with the
relevant codes and standard.
v. Validation of the particular design to ensure ease of installation under live pressure.

3
1.4 Scope of work

The scope of this study shall include:

i. The design and development of the clamp will be carried out using Autodesk Inventor
2018 assuming a 12 inch damaged pipeline.
ii. Evaluation of different clamp design concepts for the repair.
iii. The Finite Element Analysis (FEA) of the clamp will be done using ANSYS 19.1
Professional version.

1.4.1 Limitation of the study

i. The fabrication and manufacturing process of the clamp will not be covered in this
study.

4
1.5 Research Approach

The approach to adopt for this research in summarised in the figure below

Existing clamp Design

study and Need for Requirements and Conceptual design
a clamp specifications

Detailed design of
Evaluation of the
the chosen concept Particular Design
various design
with material and Calculations
concepts
selection

Finite Element
Detailed Clamp
Analysis of the
Drawings
clamp

Figure 1 - Research Approach

5
1.6 Significance of the Study

The importance of this study include:

i. This study would help provide a foundation to the design and development of an angled
clamp capable of repairing pipeline leaks as a result of damaged by an external force.
ii. This study would present a detailed design analysis of the sealing and containment
mechanism.

6
 CHAPTER 2: LITERATURE REVIEW
2.1 Extent of Past Work

A couple of repair methods were available to repair a subsea pipeline in the past. One repair
method required the damaged section of the pipeline to be recovered to the surface in order to
conduct the necessary repairs on the deck of a vessel. Generally, this method was limited to
pipelines of small diameter in relatively shallow water. A second method involved conducting
the repair subsea by divers, using either repair clamps or hyperbaric welding techniques. This
method also had limitations related to water depth and pipeline size.

It is known to utilize a remotely operated vehicle (ROV) in profound water to disjoin and
recoup a subsea pipeline. United States of America Patent No. 5044827 (1991) unveiled a
technique for separating and recuperating a subsea pipeline. The ROV is conveyed underneath
a bit of the pipeline after which an emptied lift sack is brought down to the pipeline. The
collapsed lift sack is situated under the pipeline and after that expanded until a segment of the
pipeline has been raised off of the seabed. A cut off saw is brought down to the raised segment
of the pipeline. The cut off saw is clamped to the pipeline preceding separating the pipeline.
The cut-off observed is then removed from the separated pipeline. A recovery head is brought
down to the raised end of the separated pipeline and after arrangement is set in the raised end
of the disjoined pipeline. A recovery head is lowered to the raised end of the severed pipeline
and after alignment is placed in the raised end of the severed pipeline. The recovery head is
activated to establish a gripping relationship with the pipeline. A recovery cable is brought and
lowered down to the recovery head. The recovery cable is recovered to recoup the recovery
head and the pipeline to the water surface.

As the offshore pipeline industry keeps on wandering into more profound and more profound
waters, an ever increasing number of pipelines of expanding distance across are being laid in
water profundities past the scope of jumpers. Because of an assortment of elements, for
example, pipeline measure, seabed bearing limit, ocean flows, and lay flatboat every day rates,
a solid and reliable technique for fixing leak in subsea pipelines without recovery to the water
surface or the utilization of jumpers and hyperbaric welding is required. The technique ought
to limit the measure of treatment of the harmed pipeline. Besides, the strategy for fixing the
pipeline leak ought to limit expenses and reliance on vessel movements because of ocean
conditions, for example, hurl, roll, or pitch, which can result in a lot of reserve time and cost
(United States of America Patent No. 5425599, 1995).

7
In an assortment of designing applications, clamping or containment devices are utilized for
applying an internally radial pressure upon a by and large cylindrical shaped item or body. For
instance, sleeve-like clamping devices are utilized, particularly in oil and gas transmission
applications, to make butt joints between abutting areas of a pipeline where customary welding
strategies cannot helpfully or monetarily be utilized. Thus, clamping devices are used to effect
emergency repairs on pipeline ruptures. In a to some degree distinctive kind of use, it is at times
important to contain a very pressurized liquid or gas, created by, say, an explosion, in a round
and hollow chamber which must be equipped for being opened for access to the inside thereof.

One understood clamping device for the above intentions is the split sleeve. This sort of devices
for the most part involves a round and hollow or sleeve-like body which is longitudinally split
into two mating.

It has long been recognized that, despite its utility, the split-sleeve clamp possesses a number
of confinements and detriments. For one thing, it is a time consuming matter to tighten the
many bolts of a split-sleeve clamp, a distinct disadvantage when the clamp is being used in a
hostile environment, for example, when it is being applied by divers to an underwater pipeline.
Further, if the clamp is to be subjected to any considerable amount of stress, it is critical that
the bolts be equally torqued in order to avoid localization of stress and the ensuing phenomenon
whereby the bolts, one-by-one, "unzip"

Mohammadi (2011) in his study investigated various methods for repairing damaged pipelines
beyond diving depth. He noted that present clamps are designed and are fit for straight pipes
and in real cases especially when the damage is due to external forces, the pipe is deformed
radially and a straight clamp cannot surround the pipe’s outer geometry. To solve this
challenge, he proposed an angled clamp design. This clamp design is a combination of two
straight clamps that are connected by the use of a ball joint arrangement (Figure 2).

8
Figure 2 - Angled clamp design

The radial and longitudinal sealing is like average clamps for the straight parts. For the ball
joint segment, when all parts are gathered together around the pipe, an actuation component
empowers the sealing and packs the annulus between two shelves of ball joint. A ball or wedge
holding component can likewise be used to oblige the longitudinal loads and displacement. The
sealing and gripping mechanism can be in duplicated rows, depending upon the geometry and
space.

Wang & Fan (2012) explained the hot-plugging technology for their clamp design. It was
established on the basis of the theory of dynamic sealing structure. The clamp was installed on
the outside of the leaked part so as to form a confined space between the surface of the leak
part and the clamp. When the injecting pressure of sealant was higher than the pressure of
leaked liquid, the sealant which was under the action of outside pressure would be injected into
the confined space through the bolt hole, and then the confined space would be filled with
sealant. At last the confined space would keep certain pressure so as to prevent the liquid
leakage.

9
An epic strategy for fixing leak or generally damaged metallic pipelines utilizing composites
was presented by Sum, et al (2016). The strategy utilizes a uniquely designed resin-infused
composite clamp. This is a critical improvement over financially accessible metal clamps,
giving lightweight and corrosion safe advantages. The design, investigations and testing
displayed in his study demonstrate that these advantages are notwithstanding giving firm
quality and dependability to the repaired structure. Their design incorporated a blend of
calculations and design of experiment optimization with Finite Element models. The created
design approach appeared to be powerful for designing different clamp sizes. Testing included
short-and long haul survival tests of the clamp according to industry standard, as well as hot-
wet conditioning followed by mechanical testing of the composite material.

Thapa (2017) designed a subsea oil and gas repair clamp which is composed of the clamp body,
the master bolts, hydraulic cylinders, compressed bowl, tension slips, tighten flange, flange
bolts, drilling holes, circumferential sealing module, axial seal, and sacrificial anode. He
highlighted the sealing performance of the clamp as the primary performance of the clamp
device. His design used double sealed circumferential and longitudinal seals thereby increasing
the reliability of the seal of the clamp. In choosing the material to use for the clamp, he chose
a material the same or higher than the pipe material to be repaired. ASTM A105 forging for 12
inch NPS and larger, He noted that ASTM A516 Gr. 70 pressure vessel plate for 10” NPS and
smaller are used in other countries. By comparing the comprehensive performance of the above
two materials with Q235R, the Q235R was chosen as the clamp body material for his design
and ignored the diameter size of the pipeline.

10
2.2 Research Gap and Current Work

Mohammadi (2011) proposed an idea of an angled pipeline repair clamp to be used especially
when the damage done to the pipeline is due to external forces. Straight clamp are unfit for this
purpose because the pipe is deformed radially and a straight clamp cannot surround the pipe’s
outer geometry. The idea of Angled-clamp that is presented in his project can be developed for
damaged angled pipes and for spool connection where alignment is hard to achieve. This study
will go further to carry out a detailed design on this idea.

He pointed out that his diverless repair clamp can be improved in three aspects:

i. Integrity compensator referring to the sealing material and mechanism.

ii. The largest challenge with the present method refer to application tools involved in the
repair operation. The remotely controlled tools in deeper waters on a very remote
seabed (where the alignment tolerances are for instance in the range of a few
millimetres) require upgrading. The hydraulic system in deeper waters under high
pressures have shown their own difficulties.
iii. Marine Operation challenge which can be summarised in ROV designs and operation.

From these three key aspects pointed out, this study will seek to develop a sealing mechanism
for the clamp capable of operating in deep waters.

A novel method of fixing subsea pipeline leak utilizing composites was presented by Sum, et
al (2016). The use of composites exhibited light weight and corrosion resistant advantages over
metal clamps. Thus, the use of fibre reinforced composites will be evaluated for use in this
design for certain components as far as possible.

The clamp sealing performance was highlighted as the primary performance of the clamp
material by Thapa (2017). He used double sealed circumferential and longitudinal seals for his
clamp design thereby increasing the reliability of the seal of the clamp. This study will go
further to improve upon the sealing mechanism of the clamp.

Wang & Fan (2012) designed their clamp on the basis of the hot plugging technology. This
study will seek to further use this technology for the design of the angled clamp.

11
 CHAPTER 3: MATERIALS AND METHODS
3.1 Data Collection

Identifying the purpose of the design and defining its requirement was done by undertaking an
extensive literature review. This identified different state of the art in clamping technology and
research trends in the field. Most importantly, this literature survey identified few research gaps
which should be addressed in order to propel subsea pipeline repair clamping technology. The
results of this step have been presented (CHAPTER 2: LITERATURE REVIEW).

During this phase, all materials was collected from journals, textbooks, and research papers
gathered from the library and internet. While collecting data, the main components of the clamp
were also identified.

After identification of the gaps, the next step employed was the translation of these knowledge
gaps into clearly defined research objectives. The five main research objectives identified
were:

i. Literature review into various clamps designed and patented in the industry.
ii. Carry out an evaluation of different clamp concepts.
iii. Identification of the best conceptual design for further detailed design. All designs will
be adhering to the relevant codes and standards.
iv. Identified clamp should be capable of installation at live pressures with emphasis laid
on sealing and hydraulic performance.
v. To carry out an FEA analysis of the chosen clamp design and compare it with the
relevant codes and standard.

3.2 Hardware Requirements

The following are the list of hardware materials needed for this project.

i. An Intel core i7 high performance computer with unlimited internet access and online
libraries. This high performance computer was needed to run the software needed for
this study.
ii. Writing materials: a logbook was provided for recording the progress and everything
about the project including all conventional writing materials.
iii. An Mp3 recorder: This was used to record important discussions on the project.

12
3.3 Software Requirements

The following are the list of software required for this study:

i. Autodesk Inventor 2019 Professional Version.

ii. ANSYS 19.1 Professional Version.
iii. Microsoft Office Suit including OneDrive for cloud storage of very important
documentation throughout the project.

Various concepts of the clamp will be designed and modelled in Autodesk Inventor. Autodesk
Inventor is Computer Aided Design (CAD) modelling software package. The selected concept
is then further designed and analysed with ANSYS. ANSYS is a Finite Element Analysis
(FEA) software. The analysis divides a given structure into smaller and discrete fundamental
parts called elements. An analysis of each element is then carried out using the required
mathematical formula. Finally, the solution as a whole is determined through the summation
of the individual solutions of the elements. In this process, analytical problems too complex to
solve are solved by dividing the problem into smaller and simpler problems.

In ANSYS, when a structure is modelled, individual sets of matrix equations are automatically
generated for each element. The individual sets of matrix equations can be combined into a
global set of matrix equations because the elements in the model share common nodes. This
global set computes and solve simultaneously all of the nodal deflections and relate them to
the nodal forces. The state of deformation of each element is known when displacements for
all nodes are known. Thus, stress can then be determined through stress– strain relation (Kutz,
2006).

This finite element method together with the CAD package (Autodesk Inventor) will be used
extensively to design and analyse the clamp.

The clamp is then evaluated and verified with relevant codes and standards.

13
 CHAPTER 4: WORK PLAN AND COST ESTIMATE
4.1 Research Activities and Duration

The research activities and duration slated for this project will be provided in the Gantt chart
below:

DURATION IN MONTH, 2019

ACTIVITTY March April May June July August September October November
Literature Review/Preliminary studies

Writing of Chapter 1 and 2

Writing of Chapter 3
Research Proposal
Proposal Defence
Analysis and Results
Thesis
Research Seminar
Final Defence

Figure 3 - Gantt chart

14
4.2 Cost Estimate

For the purpose of this project, the materials needed have already been provided for as standard
materials at the Centre of Excellence in Marine and Offshore Engineering building. Also since
this project will continue during the internship, all the materials mentioned earlier will be
arranged by the Director at the Centre of Excellence in Marine and Offshore Engineering,
Rivers State University.

15
REFERENCES
AEA Technology Consulting. (2001). Temporary/permanent pipe repair - Guidelines.
Norwich: Her Majesty’s Stationery Office. Retrieved Febuary 26, 2019, from
http://www.hse.gov.uk/research/otopdf/2001/oto01038.pdf

Gray, D. A. (1991, September). United States of America Patent No. 5044827. Retrieved
Febuary 28, 2019, from http://www.freepatentsonline.com/5044827.html

Hall, V. N. (1995). United States of America Patent No. 5425599. Retrieved Febuary 28, 2019,
from http://www.freepatentsonline.com/5425599.html

Kramer, J. D., Chen, J., Iyke, S., Cheta, V., & Jack, S. (2006). simulating viv production. port
harcourt: Adventure Works Press.

Kutz, M. (2006). Mechanical Engineers’ Handbook: Materials and Mechanical Design (3rd
ed.). New Jersey: John Wiley & Sons.

Mohammadi, K. (2011). Repair methods for damaged pipeline beyond diving depth. Masters
Thesis, University of Stavanger. Retrieved Febuary 28, 2019, from
https://brage.bibsys.no/xmlui/bitstream/handle/11250/182814/Mohammadi%2CKera
mat.pdf?sequence=1&isAllowed=y

Sum, W. S., Leong, K. H., Djukic, L. P., Nguyen, T. K., L., A. Y., & Falzon, P. J. (2016,
Febuary 26). Design, testing and field deployment of a composite clamp for pipeline
repairs. Plastics, Rubber and Composites (Macromolecular Engineering), 45(2), 81-
94. doi:10.1080/14658011.2016.1143082

Thapa, P. B. (2017). DESIGN OF SUBSEA OIL AND GAS PIPELINE REPAIR CLAMP.
Memorial University of Newfoundland. Newfoundland: Research Gate.

Wang, J., & Fan, F. (2012). The hot-plugging clamp design of the petrochemical equipment
pipeline. Advanced Materials Research, 550-553, 3206-3209.
doi:10.4028/www.scientific.net/AMR.550-553.3206

16