2011 - hpht subsea design - john mcgrail 2h

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HPHT – SubseaDesign Challenges

John McGrail

2H Offshore Engineering Ltd

20th January 2011

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Overview

What is HPHT

The subsea design problem Solutions

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Courtesy: Dave Turner BP

129 Deg C 149 Deg C 177 Deg C 260 Deg C 260 Deg C

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Where is the HPHT?

North Sea,

Norway,

GOM Brazil (Sub Salt/Presalt)

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Deep Water

HPHT – The Design Problem ?

Corrosiveconditions

HP>10,000psi

Internal

Shut-in

HT>121 Deg C MaxOperating Temp

   P  r  o   b   l  e  m    R

  e   l  a   t   i  v  e   M  a

  g  n   i   t  u   d  e

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How to Design for HPHT

Bigger

Standard technology, just bigger

Stronger

Higher strength materials

More resistant

Improved corrosion resistance

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OPT USA 2003

12-3/4 INCH OD Nominal Wall Thickness Comparison for API 1111 & 2RD Codes10,000ft Water Depth, 300kg/m3 Fluid, 135 Deg C Design Temp

X65 Grade Pipe, 3mm Corrosion Al lowance, 12 Deg Top Angle

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

5,000 10,000 15,000Design Pressue at Mudline (psi)

   W   a   l   l    T   h   i   c   k   n   e   s   s

   (   m   m   )

 API-1111 API 2RD

Pipe Manufacturing Limit?

Bigger - Pipe Wall Sizing

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Bigger – The Knock-on Effects

Extreme self-weight loads compound wallthickness requirements

Results in loads at the limit of:

Installation vessels

Host production vessels

Introduces fatigue issues from fluctuatingaxial loads

Thicker walls Impact pipe weldability

Increased cycle times

Reduced fatigue performance

Reduced pipe availability

Reduced flow area

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Stronger:Increased Material Grade

Stronger materials essential to maintain line pipe size feasibilityfor standard line pipe manufacturing processes

 Alternative is forged pipe – expensive and lack of availability But – weldability is a problem…….

Example HP deepwater drilling riser sizing data below:

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Stronger Flexible Pipe:Design Limits?

Flexible Pipe Present Range of Application

(Adapted from TECHNIP’s Presentation at Dry Tree & Riser Forum)

• The 7.5-inch ID flexible pipedeveloped for water injection on

Thunder Horse is a landmark as it

established important records:Design Pressure (shut-in) = 10,000psiDesign Water Depth = 6300ft (1920m) Allowable lifetime= 16.5 years (limited

by sour service)

• More recently, Telemark 4-inch IDoil production flexible pipe has been

developed for installation on:Design Pressure (shut-in) = 12,500psiDesign Water Depth = 4500ft (1372m)

 Allowable lifetime= 20 years

Telemark 

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More Resistance:Corrosive Conditions

HPHT = Internal corrosion problems

HPHT wells often associated with corrosive / sour conditions:

CO2

H2S

Sour service performance sensitive to: Partial pressures of H2S present, and pH of the production fluid

Stresses in the pipe

Material properties of the pipe – flaws/grain structure

Hardness of the steel

Problem for high pressure, high strength steel, high loadapplications (i.e. HPHT scenarios)

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CO2 Corrosion (Sweet Corrosion)Corrosion Rate vs Partial Pressure and Temp

Partial pressure of CO2 (MPa)

Temperature of 25°C

   C

  o  r  r  o  s   i  o  n  r  a   t  e

   (  m  m   /  y  e  a  r   )

Temperature (°C)

   C  o

  r  r  o  s   i  o  n  r  a   t  e   (

  m  m   /  y  e  a  r   )

Heavy Pitting and General Wall Loss

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H2S Fatigue Life:Reduction Factor 10-100

Source: High pressure riser designs for ultra deepwater; J. Murray et al,

In air

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1

100

0.01 0.1 1 10

H2S Partial Pressure (psi)

   C  a

  r   b  o  n

   D   i  o  x   i   d  e   P

  a  r   t   i  a   l    P  r  e  s  s  u  r  e

   (  p  s   i

Material Selection

NACE

Low alloy steels

Non

NACE

13% Cr

(410, F6NM)Super Duplex Inconel 625

Source : Oilfield Metallurgy – Lloyd-Thomas Consultancy

7  I n c r e a

 s i n g  C o s t

HPHT

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Clad Pipe – Inconel 625 – Metallurgical orMechanically Lined

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Installation:Large Wall Thickness / Cladding

Time / Cost:

Installation is Majority of Pipeline /Riser CAPEX

12-3/4” OD x 12.7 mm wt pipe joint

45 minutes to weld, inspect and applyinsulation field joint on

12-3/4” OD x 40.0 mm wt pipe joint

100 minutes

Clad pipe a further impact

Loads:

Heavy pipe = large lay tensions

Demanding vessel specifications

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The HPHT Solutions - Materials?

Materials Technology – key requirement:

Higher strength steels

70-80ksi offshore weldable 125ksi for use with mechanical connectors

Cost effective base material cladding

Development of alternative materials: Titanium / Aluminium alloys

Composites

Image: Composites World

Image: Timet

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The HPHT Solutions - Installation?

More efficient offshore weldingprocesses

Higher speed Higher strength materials

Improved AUT and ECAcapability for thick walled / clad

pipe

Friction welding?

Electron beam welding?

Laser welding?

Image: TWI

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The HPHT Solutions?

Installation

Greater lift / lay capacity for heavier pipelines and risers

Other Equipment

HPHT qualification required for:

Flexible pipe – HT qualification program ongoing (150ºC target)

Flexible joints (HPHT containing)

Connection system & sealing technology (flanges, connectors)

Image: Oil StatesImage: SRP

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Summary

HPHT is not a linear extrapolation, ‘bigger’ wont work just on its own –Technology changes are necessary

Material and welding technology is critical to success

 Alternatives to conventional welding are needed that are faster and canwork with higher strength steel

 Alternative materials – lightness, strength and corrosion resistance Composites

Titanium / Aluminium

 Alternatively…………Subsea HIPPS / subsea processing? Solve some ofthe problems away from long pipeline / riser sections

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Questions?

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