Bu Hasa field is located 200 kilometres southwest of Abu Dhabi. It is ADNOC ONSHORE’s most western-producing field. It was discovered in 1962 and was put into production in May 1965. Bu Hasa currently has three Remote Degassing Stations (RDS-1/2/3) and two satellite stations, BQ & HW.

Production from oil wells completed in Shuaiba, Thamama B, Thamama F, BQ & HW is routed through individual flow lines to three Gathering stations (RDS-1, RDS-2, RDS-3), BQ and HW stations in various parts of the field. The combined production from the wells at each station is routed to Central Degassing Stations (CDS) via transfer lines ranging in sizes from 16” to 24”.

Mechartes conducted a comprehensive scope involving nonlinear finite element analysis to evaluate manufacturing residual stresses on carbon steel mother pipes post-completion of the manufacturing process. This included analyzing mechanically lined pipes with temperature-dependent material properties for the mother pipe and internal lining. The manufacturing process steps analyzed included hydroforming, induction heating, cooling to ambient temperature, and induction heating for 3LPP coating.

Transient heat transfer analysis was performed to calculate temperature distributions during induction heating and 3LPP coating processes. Static analysis was conducted in multiple steps: applying hydroforming pressure initially, followed by temperature loading due to induction heating and induction heating for 3LPP coating.

The analysis evaluated residual stresses from hydroforming, induction heating, and 3LPP coating using ANSYS Mechanical software. This comprehensive study aimed to ensure structural integrity and performance reliability of the mechanically lined pipes under operational conditions, providing insights for optimizing manufacturing processes and materials used in pipeline construction.