Next Generation Bulkheads for Pipe-In-Pipes: Story of a Fast-Track Technology Development from Inception to Offshore Operational Testing

Abstract

This paper discusses the development of next-generation bulkheads for Pipe-in-Pipe, aiming to replace forged bulkheads with cheaper and safer mechanical stoppers. The process started with an innovative mechanical design based on wedges, utilizing alternate plastic materials instead of steel for enhanced safety and improved thermal performance. The development included the selection and qualification of the supply chain, prototype production, mechanical testing, and design improvement for the final Scale 1 production. The versatile and agile development process allowed for quick testing and pivoting of use cases, resulting in a fast-track development completed in less than three years. The wedges demonstrated excellent mechanical resistance, exceeding expectations. Operational benefits included a much safer and hands-free setup methodology, a 6-fold reduction in bulkhead setup time, and a 20% increase in overall productivity for laying Pipe-in-Pipe flowlines. The use of polymeric bulkheads also addresses thermal conduction issues associated with steel, reducing thermal losses, and enhancing the overall thermal performance of Pipe-in-Pipe. The paper emphasizes the novelty of using plastic-based wedges, with a patent published in 2020, marking the first qualification of such a system for offshore installation. The results and observations presented contribute valuable information to the petroleum industry, offering a safer, more efficient, and thermally optimized solution for Pipe-in-Pipe applications.