OTC 23931

Qualification of Flexible Fiber-Reinforced Pipe for Ultra-deepwater Applications M. Kalman, L. Yu, A. Salimi, J. Liu, DeepFlex, Inc.

Copyright 2013, Offshore Technology Conference This paper was prepared for presentation at the Offshore Technology Conference held in Houston, Texas, USA, 6–9 May 2013. This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material does not necessarily reflect any position of the Offshore Technology Conference, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Offshore Technology Conference is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of OTC copyright.

Abstract

This paper presents the initial work and remaining scope of a RPSEA sponsored project to develop, qualify, and field deploy flexible fiber reinforced pipe (FFRP®) for ultra-deepwater applications. FFRP is unbonded flexible pipe with composite reinforcement layers which has the advantages of light weight, high flexibility, and corrosion resistance. Due to these advantages, a simple, low top tension riser configuration is enabled. The initial design basis is a 7-inch ID, 690 barg design pressure, 120°C design temperature, 3000 meter design water depth production riser for a Gulf of Mexico application. The Phase 1 Engineering Study will confirm the product and system design to be employed in the subsequent phases. In Phase 2, a prototype pipe will be manufactured, and qualification testing will be conducted in accordance with API RP 17B recommendations. With successful testing, and subject to approval via a Phase 2 decision stage gate, Phase 3 will be an actual field deployment of the riser system with six months of performance monitoring. The paper includes a summary of the project plan for Phase 1, the product technology, the design basis, and presents the initial pipe concept. Engineering analysis to confirm the suitability of the pipe concept, and the riser configuration are underway in accordance with the project plan. The top tension reduction offered by FFRP enables light weight and small footprint installation vessels and production platforms. FFRP enables installation vessels and floating production systems which previously had water depth limits of 1500 m to be used in ultra-deepwater of up to 3000 m, expanding the number of existing installation vessels and FPSO’s that can be used in deepwater, substantially reducing overall project cost and risk. Introduction In April 2011 the Research Partnership to Secure Energy for America (RPSEA) ultra-deepwater (UDW) program issued a request for proposal for Need 4: Dry Trees and Risers in 10,000 Feet (3000 m) Water Depth. The RFP [1] included Technical Area of Interest 4402 – Qualification of Flexible Fiber Reinforced Pipe for 10,000-Foot Water Depths. In June 2011, DeepFlex submitted a proposal responsive to the RFP and was awarded the project in October 2012. The project has been started and is being conducted in three phases:

Phase 1 – Engineering Study Phase 2 – Prototype manufacturing and qualification testing Phase 3 – Field deployment supply

The Phase 1 Engineering Study consists of the design premise and design report, riser system configuration & analysis report, Failure Mode, Effects and Criticality Analysis (FMECA) report, manufacturing documentation for prototype, and Phase 2 qualification plan and proposal. Phase 2 consists of prototype manufacture, static and dynamic testing, documentation of qualification

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Phase 3 consists of supply of an FFRP riser system for field deployment and results of a six month field trial. As the work is just underway, this paper presents a summary of the scope of work and approach for Phase 1 and progress to date on the initial tasks. To guide the project, a Working Project Group has been established with representatives of the Operator Participants TOTAL, BP, and Shell. TOTAL is championing the project. Subcontractors include DNV, ETA International, and MCSKenny. DeepFlex Flexible Fiber Reinforced Pipe (FFRP) is unbonded flexible pipe employing composite reinforcement materials for the pressure armor and tensile armor. Unbonded flexible pipe with steel reinforcement materials has been employed for dynamic risers for offshore oil and gas production for over 35 years. Reference [2] provides an excellent overview of the service history of unbonded flexible pipes employing metallic materials for the pressure and tensile armor that were in service in 2010. The flexible pipe industry has been developing composite materials for the structural layers for more than 20 years [3] – [13], with manufacturers mainly focusing on composite tensile armor layers employing pultruded thermoset and thermoplastic tapes. Benefits of FFRP Risers Risers are a necessity for conveying produced fluids from the seabed to production platforms as well as injecting fluids from the platform to the seabed. Some of the advantages of FFRP over other riser concepts being considered for ultra-deepwater applications are stated below, based on criteria provided by RPSEA in the RFP [1]. Design/Engineering (Mechanical Complexity) – The multilayer structure of unbonded flexible pipe, with or without composite reinforcement, is indeed complex in cross-sectional design and manufacture relative to other riser structures. However, the benefits of FFRP, such as high pressure and tensile capacity, spoolability, and fatigue and corrosion resistance, substantially reduce system design complexity. Free hanging and/or lightweight catenary riser systems can be employed, reducing the installation time, cost, and risk. Extreme storm and fatigue response – Since FFRP is unbonded, fatigue is substantially reduced. The pipe weight and riser configuration can be optimized to assure that hydrodynamic loading does not result in clashing with neighboring risers or mooring lines. Impact of water depth – It is expected that FFRP has lower top tensions than most other riser systems being considered for 10,000-foot water depths. Field architecture and layout – With tighter allowable minimum bend radius than steel catenary risers, or composite pipes employing bonded reinforcement layers, and the ability to use free hanging or lightweight catenary structures, FFRP offers more flexibility for field layout options. Flow assurance – FFRP is naturally insulating due to the multiple polymer and composite layers. More insulation layers can be added, if required, to achieve a specified overall heat transfer requirement. Future FFRP designs may incorporate active heating systems. Ability to accommodate regular pigging – The internal layer of the FFRP design concept is identical to that of steel armored unbonded flexible pipe. Therefore, with proper pig selection, FFRP can be effectively pigged as necessary over the service life. Suitability to high pressure/high temperature – Material and small scale tests have demonstrated that the FFRP structure is suitable for high pressure/high temperature applications. Suitability will be confirmed through the Phase 2 qualification testing process. Impact to host structure – Lower top tension means that existing host structure designs for shallower water depths can be employed, or a host structure designed for higher top tension requirements can accommodate more FFRP risers than other types of risers. High bending fatigue resistance in combination with the tighter minimum operating bend radius of FFRP lowers the requirements on host platform dynamic motions. Interface with flowlines and pipelines – The light weight and flexibility of FFRP simplifies tie in of risers and reduces the dynamic loads at pipeline end terminations and subsea structures. Thus, anchoring devices may be avoided.

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Ability for future expansions/additions – Lower top tension with FFRP enables host platforms to support additional risers without substantial modifications to the vessel structures. Accommodation of FPSO removal and replacement – FFRP is readily re-spoolable using essentially a reversal of the installation process, and it can be re-used in other fields for the remaining service life. Scope of Work Phase 1, the Engineering Study, consists of the tasks in Table 1. A brief description of the work to be conducted for each task follows.

Table 1. Phase 1 Scope of Work

Task No. Description

1 Project Management Plan

2 Technology Status Assessment

3 Technology Transfer Approach

4 Routine Reports & Activities

5 Design Premise

6 Design – FFRP Structure and System

7 FMECA

8 Mfg Documents for Prototype

9 Qualification Test Plan

10 Field Development Cost Estimate

11 Proposal Update for Phase 2

 Tasks 1 through 4 are common to all RPSEA projects. As of this writing, Tasks 1 through 3 are completed with the documents submitted to RPSEA. Task 5 Design Premise – The design premise, which confirms agreement of the design parameters for the project is in process at this writing. A summary of the design parameters is provided in Table 2. The full design premise document is in accordance with Section 5 and Annex A of API 17J [14]. As the DeepFlex FFRP under development for this project is for a future application, DeepFlex is using draft revisions of API 17J [14] and API 17B [15] under review by the API 17 Flexible Pipe Task Group as the governing standards for the project. API 17B includes Annex H which defines requirements for composite armor in unbonded flexible pipe, with reference to DNV OS-C501, Composite Components [16].

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Table 2. Project Design Parameters

Parameter Value

Internal Diameter 7-inch

Design Pressure 690 barg

Design Temperature 120 C

Maximum Operating Temperature 110 C

Design Water Depth 3000 meters

Internal Fluid Multiphase Production – Fluid compositional data pending

Location Gulf of Mexico

Vessel Disconnectable turret moored FPSO

Task 6 Design FFRP Structure and System - This task encompasses the largest body of work to be conducted in Phase 1. Task 6 consists of the six subtasks per Table 3. This work is conducted in accordance with DeepFlex Engineering procedures, following the recommended practices in API 17B [15], Section 5.2.3 and Figure 20.

Table 3. Task 6 Subtasks

SubTask No. Description

6.1 Materials Selection and Pipe Cross Section Design

6.2 System Configuration Selection

6.3 Dynamic Analysis

6.4 Detail and Service Life Design

6.5 Design Report

6.6 Dynamic, Service Life and Installation Analysis Report

As of this writing, the initial pipe cross section has been completed and riser configuration analysis is underway.

Key design challenges being addressed in design include:

Designing against hydrostatic collapse, burst and tensile failure of the pipe structure over the service life. Assuring that the pipe thermoplastic and composite armor layer materials have sufficient resistance to degradation

over the service life at the relatively high design and operating temperature. Some material qualification testing which is relevant has already been conducted, as discussed in [12], however additional testing to envelope the expected operational fluid composition and temperatures will be executed, once this design premise has been confirmed.

Designing against radial and lateral buckling of tensile reinforcement layers due to the reverse end cap load resulting from external hydrostatic pressure, in particular at or near the touchdown point of the riser system.

Assuring that the end fitting design meets all of the pipe structure design requirements. In particular, with regard to anchoring the composite tensile armor in the end fitting.

Task 7.0 Failure Mode, Effects and Criticality Analysis (FMECA) - The FMECA is conducted in accordance with Section 7 of DNV RP A203 [17]. DNV has been subcontracted for the project to facilitate a FMECA workshop using their Failure Mode Identification and Risk Ranking (FMIRR) process. The FMECA identifies all known failure modes and mechanisms that should be addressed to result in a successful FFRP and riser system design. Each pipe layer, the overall structure, the riser system and ancillary equipment associated with the riser system are addressed in the FMECA. The RPSEA Working Project Group, Operator Participants, and subcontractor representatives will be invited to attend the workshop to assure that all known failure modes and mechanisms are addressed considering broad based knowledge from previous qualification programs and field experiences. For each failure mode/mechanism listed in the FMECA, the following aspects are addressed:

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Consequence of Failure – see Figure 2 for rankings Probability of Failure – see Figure 2 for rankings Risk Ranking – The product of consequence and probability of failure, per Figure 1 Related Design Parameters or Drivers – Aspects of the design and loads that may result in occurrence of the failure

mode/mechanism Applicable Design Methods – The design or analysis conducted to design against occurrence of the failure

mode/mechanism Related prototype or material tests – Identifies tests which will validate the design against occurrence of the failure

mode/mechanism A summary of the action plan to address the failure mode/mechanism. Upon completion of the action plan, the probability of occurrence is re-evaluated to confirm that the risk has been

reduced to an acceptable level.

    INCREASING PROBABILITY OF OCCURRENCE OF THE FAILURE MECHANISM

RISK RANKING IMPROBABLE RARE FREQUENT VERY FREQUENT

INC

RE

AS

ING

CO

NS

EQ

UE

NC

E O

F

FA

IUR

E O

CC

UR

EN

CE

 

LOW  LESS IMPORTANT LESS IMPORTANT NORMAL NORMAL

MEDIUM LESS IMPORTANT NORMAL NORMAL NORMAL

HIGH NORMAL NORMAL CRITICAL CRITICAL

VERY HIGH NORMAL CRITICAL CRITICAL CRITICAL

Figure 1. FMECA Risk Ranking

Task 8.0 Manufacturing Documentation for Phase 2 Prototype – Task 8 consists of three subtasks per Table 4.

Table 4. Task 8 Subtasks SubTask

No. Description

8.1 Pipe Construction Report

8.2 Plant Upgrades Evaluation

8.3 Quality Plan

8.4 Manufacturing Documentation Report

The Pipe Construction Report provides the instructions from Engineering to Operations to manufacture the pipe, including layer by layer dimensions, materials, and tolerances. In the plant upgrades evaluation, an evaluation of the product design relative to current manufacturing process capabilities on a layer by layer and overall pipe structure is conducted to define plant upgrade requirements and timing.

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The Quality Plan defines the operational procedures to be followed, so that the accountability for assuring procedures are followed and the hold and witness points for each process are employed in pipe manufacture. Task 9.0 Phase 2 Qualification Test Plan – The Qualification Test Plan will be developed based on the recommendations in Chapter 6 of API 17B, Prototype Testing, and the results of Task 7.0, the FMECA. The tests necessary to reduce risk rankings to an acceptable level will be conducted. As a minimum, based on this pipe being a new design, the tests identified in Table 5 will be conducted.

Table 5. Preliminary Prototype Test Plan API 17B

Class Description

No. of Replicates

Notes

SHORT TERM/STATIC TESTS

I Burst 1

I Axial tension 1

I Collapse 3 After crush strength test on same samples in straight configuration

II Crush strength 3

III Bending-stiffness 1 To MBR (non-destructive)

III Axial compression 1

LONG TERM/DYNAMIC TESTS

I Thermal Cycling 2

II Bending with External Pressure

1 Curved collapse tests will also be conducted for comparison with the Type I straight pipe collapse tests.

II Dynamic Fatigue 1

Task 10.0 Field Development Cost Estimates – Task 10 is conducted to prepare for Phase 3, Field Deployment Supply, and consists of three subtasks per Table 6. Table 6. Task 10 Subtasks

SubTask No.

Description

10.1 Packaging, Shipping and Installation Plan

10.2 Integrity Management and Data Gathering Plan

10.3 Field Development Concept Report with Cost Estimates

Subtask 10.1 is common to any flexible pipe supply contract. Due to the pipe length and diameter, carousel packaging or packaging on reels with mid-line end fittings is expected. In Subtask 10.2 a plan will be prepared to ensure that the necessary valuable data will be obtained during field trials, including definition of instrumentation, and passive and active measurements to be made with clear responsibilities. The Integrity Management Plan will define the instruments and measurements to be made over the service life on a permanent installation basis. Task 11 Proposal for Phase 2 – Phase 2 will consist of the prototype pipe manufacture and qualification testing. With successful completion of Phase 2, a proposal for Phase 3 - Field Deployment Supply, will be prepared based on the Engineering work conducted in Phase 1.

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Conclusions A project to develop FFRP, an unbonded composite armored flexible pipe for high temperature, high pressure, ultra-deepwater applications is started. The project consists of three phases, an engineering study, prototype manufacture and qualification testing, and a field deployment trial. The design basis is ultra-deepwater Gulf of Mexico. With project success, the FFRP riser system offers a lower cost, lower risk riser system for offshore production in global ultra-deepwater basins. Several design challenges based on worldwide flexible pipe operational experience are being addressed in the project. Acknowledgements The authors wish to thank RPSEA, TOTAL, BP, Shell, BG Group, and Chevron for funding the project. We also wish to thank the National Energy technology Laboratory and the US Department of Energy for their funding and support. References [1] Request for Proposal (RFP) UDW Need 4 Technical Areas of Interest RFP2010UDW004 Ultra-deepwater program, Research

Partnership to Secure Energy for America (RPSEA), April 21, 2011

[2] P. O’Brien, C. Overton, J. Picksley, K. Anderson, I. MacLeod, E. Meldrum. Outcomes from the SureFlex Joint Industry Project – An International Initiative on Flexible Pipe Integrity Assurance. Presented at Offshore Technology Conference, Houston, Texas, May 2-5, 2011

[3] G.A. Chaperon, H.P. Boccaccio, M.J. Bouvard. A New Generation of Flexible Pipe. Presented at Offshore Technology Conference, Houston, Texas, May 6-9, 1991. DOI: 6584-MS

[4] Y. Makino, K. Ishii, T. Fuku, and S. Morimoto. Development of Light-Weight Flexible Riser Pipe. Presented at Offshore Technology Conference, Houston, Texas, May 3-6, 1993. DOI: 7262-MS

[5] M. Kalman, T. Blair, M. Hill, P. Lewicki, C. Mungall and B. Russell. Composite Armored Flexible Riser System for Oil Export Service. Presented at Offshore Technology Conference, Houston, Texas, May 3-6, 1999. DOI: 11010-MS

[6] M. Kalman and J. Belcher, “Flexible risers with Composite Armor for Deep Water Oil and Gas Production,” Composite Materials for Offshore Operations - , S.S. Wang, J. G. Williams, and K.H. Lo, Eds., American Bureau of Shipping, 1999, pp. 151-165

[7] M. Megel, L. Kumosa, T. Ely, D. Armentrout and M. Kumosa. “Initiation of Stress Corrosion Cracking in Unidirectional Glass/Polymer Composite Materials”, Composites Science & Technology, Vol. 61, No. 2 (2001) pp. 231-246

[8] Composites in Offshore Oil: A Design and Application Guide, 2002. Wheat Ridge, Colorado: Ray Publishing Inc.

[9] J. Rytter. Qualification Approach to Unbonded Flexible Pipes with Fibre Reinforced Armour Layer. Presented at the 23rd International Conference on Offshore Mechanics and Arctic Engineering, Vancouver, British Columbia, Canada, June 20-25, 2004. DOI: OMAE2004-51175

[10] M. Bryant, S. Bhat, and B. Chen. Non-metallic Unbonded Flexible Pipes for Deepwater. Presented at Offshore Europe, Aberdeen Scotland, U.K., September 4-7, 2007. DOI: 108457-MS

[11] M. Kalman, L. Yu, D. Moosberg, D. Johnson. Development and Testing of a Non-interlocked Hoop Strength Layer for Unbonded Flexible Pipe. Presented at Offshore Technology Conference, Houston, Texas, May 2-5, 2011. DOI: 21128-MS

[12] M. Kalman, L. Yu, M. Seymour, J. Erni. “Qualification of Composite Armor Materials for Unbonded Flexible Pipe. Presented at Offshore Technology Conference, Houston, Texas, April 30 - May 3, 2012.

[13] A. Do, A. Lambert. “Qualification of Unbonded Dynamic Flexible Riser with Carbon Fibre Composite Armors. Presented at Offshore Technology Conference, Houston, Texas, April 30 - May 3, 2012.

[14] API 17J Draft Fourth Edition, Specification for Unbonded Flexible Pipe, June 2012 and Flexible Pipe Task Group Comments & Resolution November 2012

[15] API 17B Draft Fifth Edition, Recommended Practice for Unbonded Flexible Pipe, June 2012 and Flexible Pipe Task Group Comments & Resolution November 2012

[16] DNV OS C501 Composite Components, October 2010

[17] DNV RP A203 Qualification of New Technology, July 2011