The Banyu Urip Onshore/Offshore Crude Oil Export Pipeline is 20 inch carbon steel extending for +/- 96 km. As the pipeline is the key facility to transport Banyu Urip crude for export, the integrity management of the pipeline is vitally important. There are several aspects of the integrity management program; two will be focused on in this paper: Right of Way (ROW) maintenance and as-built capacity analysis to support potential varying production profiles.
Pipeline ROW maintenance is challenging due to several reasons: (1) the agreement made to give access to local communities who previously owned the land to enable farming, now creates access challenges for inspection and surveillance. (2) Managing ongoing local government and 3rd party infrastructure projects above the pipeline. (3) Geographical andweather conditions impacting accessibility. (4) Boat surveillance limitations on the offshore section of the pipeline. Proactive external engagements and new technology applications are considered key to a successful ROW maintenance program.
Proactive community engagements include effective socialization to local communities about the importance of pipeline integrity and the hazards asscoated with buried/submerged pressurized hyrdrocarbon pipelines. Additionally, establishing and maintaining strong government relations are also important to ensure potential infrastructure development around the pipeline ROW will not harm the pipeline or impede implementation of the pipeline integrity management program. Government alignment is also a key enbler for successful community engagement.
Utilization of new technology has enabled the operator to tackle some ROW accessibility challenges. The use of drones has resulted in patrol cost optimization compared with using helicopters.
Following pipeline construction and commissioning, various as built studies have been performed to test the pipeline across a range of production profiles and to determine if a higher operating envelope than original design basis could be established. These studies included detailed surge and stress analysis. Surge analysis was performed to calculate maximum pressure expected in pipeline; while stress analysis was performed to ensure pipeline integrity at higher production rates. The result shows the pressure in the pipeline could increase to 78 bar (26% increase), and flow rate increase to 374m3/hr (9% increase). Stress analysis confirmed that pipeline is capable of operating at a higher envelope (MAOP 83 bar at 78 degC, relieving capacity at 688 m3/hr – a 34% increase vs design basis).
This engineering assessment of the existing as-built facility can supporting Indonesia through enabling increased production without additional pipeline infrastructure cost.