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OTC 23931Qualification of
Flexible Fiber-Reinforced Pipe (FFRP®)for Ultra-deepwater Applicationsfor Ultra-deepwater Applications
Mark Kalman, Liang Yu, Amir Salimi, Jing Liu
PRESENTATION OUTLINE
• Project Scope and Management• Design Premise• Pipe Design – Layers & Features• Riser System and Global Analysis Summary• Results from critical pipe structure analyses• FMECA• Qualification Plan
Slide 2
• Qualification Plano Materialso Layerso Full scale tests
• Conclusions/Discussion
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
PROJECT SCOPE & MANAGEMENT
To field qualify a single Flexible Fiber Reinforced Pipe (FFRP) riser solution in three phases of work:
• Phase 1 – Engineering Study
• Phase 2 – Prototype Manufacturing and Qualification Testing
Slide 3
RPSEA
Working
Committee
RPSEA
TOTAL
SHELL
US DOE/NETL
Qualification Testing
• Phase 3 – Field Deployment Supply
Key Objective: Develop a pipe design and riser system which safely conveys hydrocarbons from ultradeep wells to an FPSO without leakage to the environment
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
SHELL
CHEVRON
DEEPFLEX
Project Team
Subcontractors
DNV
MCSK
SWRI
ETA
STATOIL
PHASE I ENGINEERING STUDY SCOPE & SCHEDULE
Slide 4
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
PROJECT DESIGN PREMISE
Slide 5
Parameter Value
Internal Diameter 7-inch
Design Pressure 68.9 MPa (10,000 psi)
Design Temperature 120 °C
Maximum Operating
Temperature110 °C
Design Water Depth 3048 meters
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
Internal Fluid Multiphase Sour Production Fluid
Location Gulf of Mexico
Vessel Disconnectable turret moored FPSO
GOVERNING STANDARDS
Slide 6
Standard Applicability
API 17J Draft Fourth Edition
Specification for Unbonded
Flexible Pipe, June 2012 and
FPTG Comments & Resolution
November 2012
• Polymer layers
• Metallic layers
• Pipe and end fitting assembly
• Riser system
DNV-OS-C501• Composite armor layer design,
testing and qualification.
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
DNV-OS-C501
Composite Components
October 2010
testing and qualification.
• LRFD methodology applies to
composite armor utilization
API 17B Draft Fifth Edition
Recommended Practice for
Unbonded Flexible Pipe, June
2012 and FPTG Comments &
Resolution November 2012
• Guidelines for design, analysis,
manufacture, testing, installation and
operation
• Annex H provides guidelines in
applying DNV-OS-C501 to composite
armor design
PIPE DESIGN PROPERTIES
Slide 7
Parameter Value
Inner Diameter 177.8 mm (7 inch)
Design Temperature 120 °C
Design Pressure68.9 Mpa
(10,000 psig)
Outer Diameter356.8 mm
(14.05 inch)
167.5 kg/m
A single pipe structure with required:
• tensile strength at riser hang off• internal pressure capacity• collapse resistance• axial compression capacity at
touch down
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
Weight Empty in Air 167.5 kg/m
Weight Empty in
Seawater65.0 kg/m
Storage Bend Radius 2.87 m
Operating Bend Radius 4.04 m
Burst/Design Ratio 2.0
Collapse/Design Ratio 2.1
Failure Tension 22,328 kN
PIPE DESIGN – LAYERS & UNIQUE FEATURES
• Hybrid pressure armor
o R1 metallic + R2 composite
• Anti-collapse sheath
o R0 + R1 provide collapse
resistance
Slide 8
resistance
• Dual annulus
o Permeated gas flow to surface
via inner annulus flow path
o Outer annulus flooded during
installation
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
RISER CONFIGURATION - LOW LAZY WAVE
Slide 9
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
� 4174 m riser length
� 1930 m horizontal offset
GLOBAL ANALYSIS LOAD CASES
Slide 10
• The FPSO is fully weathervaning
• Head seas are considered
• 10 year hurricane and 100 Year
winter storm environment analysis
• 210 load cases
o 2 environment conditions
o 3 wave/current directions
Anchor point
22.5°
Static mean position
Offset
Far Cross 1
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
o 3 wave/current directions
o 7 wave periods/direction
o 5 vessel positions
� Near Case
� Far Case
� 3 Cross Cases
Cross 2 Cross 3
Near
RISER SYSTEM ANALYSIS – RESULTS SUMMARY
Slide 11
• Worst Case scenario regarding top
tension:
o Near Case
o Wave period = 14 s
o Wave direction = 157.5 deg 3000.0
3100.0
3200.0
3300.0
3400.0
3500.0
3600.0
3700.0
3800.0
3900.0
4000.0
12 13 14 15 16 17
To
p E
ffe
ctiv
e T
en
sio
n
Near Case - 157.5 deg
Near Case - !80 deg
Far Case - 157.7 deg
Far Case - 180 deg
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
12 13 14 15 16 17
Wave Period (s)
ANCILLARY EQUIPMENT
Slide 12
Buoyancy ModulesBend Stiffener
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
OrcaFlex 9.4g: case-NS8.sim (modified 4:29 PM on 2/27/2013 by OrcaFlex 9.4g)
catenaryriser End Force at End A vs catenaryriser End Force Ez-Angle at End A
catenaryriser End Force Ez-Angle (deg) at End A, t = 145.000 to 160.000s201816141210864
ca
ten
ary
ris
er E
nd
Fo
rc
e (
kN
) a
t E
nd
A,
t =
14
5.0
00
to
16
0.0
00
s
4000
3500
3000
2500
2000
1500
1000
• Module Upthrust: 827 kg
• Outer Diameter: 1.5 m
• Module Length: 1.79 m
GAS PERMEATION ANALYSIS
Slide 13
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
Carcass + liner collapse depth
• 2380 m (78 % of water depth)
With 1.15 Safety Factor
• 2070 m (68% of water depth)
Two cases considered
• Wet Annulus – with condensed water
filling inner annulus
•Dry Annulus – no condensation
GAS PERMEATION ANALYSIS – DRY ANNULUS
Slide 14
Maximum pressure at subsea end vs. flow path restriction
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
GAS PERMEATION ANALYSIS – WET ANNULUS
Slide 15
Liquid water buildup rate vs. pipe length available for water permeation
0.25
0.3
0.35
0.4
Wa
ter
bu
ild
up
ra
te (
m p
ipe
/da
y)
Shielding Factor 70%
Shielding Factor 80%
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
0
0.05
0.1
0.15
0.2
0.25
200025003000350040004500
Wa
ter
bu
ild
up
ra
te (
m p
ipe
/da
y)
Pipe Length for water permeation (m)
Water build up rate to collapse
carcass in 200 years
FMECA
Slide 16
� In accordance with DNV-RP-A203: Qualification of New Technology
� Qualification Basis: Design Premise + Design Report per API 17J
� Technology Status Assessment and Risk Ranking conducted for Riser System,
Pipe Structure, Layers, End Fitting, Ancillary Equipment
� Workshop conducted at DNV with Working Committee/Test Subcontractors
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
� Qualification plan based on mitigating risk for failure modes ranked “Critical”
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
1 - Proven
2 - Limited field
history or not
used by company
3 - New or
Unproven
1 - Known 1 2 3
2 - Limited
Knowledge2 3 4
3 - New 3 4 4
1 = No new technical uncertainties
2 = New technical uncertainties
3 = New technical challenges
4 = Demanding new technical challenges
Application Area
Technology Maturity
QUALIFICATION PLAN
Slide 17
� Material/Layer Qualification underway
o Composite Layers
o Metallic Layers
o Polymer Layers
o End Fitting
API 17B TEST
API 17B
PROTOTYPE
TESTS/CLASS
RECOMMENDED PER
FMIRR
Burst I X
Axial Tension I X
Collapse I X
Thermal Cycling (High Temp
Only)
I X
Dynamic Fatigue II X
Crush Strength II X
Combined Bending + Tension II X
Sour Service Test II
Fire Test II
Erosion Test II
Combined pressure + tension II X
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
� Full Scale Qualification Plan per
API 17B Draft Chapter 6
Combined pressure + tension II X
Outer sheath holding system II X
External sealing system II X
Dynamic tension/tension II X
Curved collapse II X
Vent Valve Test X
Bending stiffness III X
Torsional stiffness III X
Abrasion test III
Rapid decompression test III
Axial compression III X
Thermal characteristic test III
Arctic test III
Weathering test III
Structural damping test III
Internal pressure cycling III
Lateral buckling test III X
Impact III X
PLANNED GOM MANUFACTURING FACILITY
Slide 18
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
CONCLUSIONS
• A single pipe design has been developed which meets the
specified conditions in the design premise (7-inch ID, 690 barg
design temp, 120 °C design temperature, 3048 m water depth, GOM, turret moored FPSO installation)
• Critical analyses have been completed to confirm the pipe
design and riser configuration meet requirements
• A FMECA has been completed which provides input to defining
Slide 19
• A FMECA has been completed which provides input to defining
the system and product qualification plan to mitigate risk
• Ongoing work to complete Phase 1:o Complete detailed Engineering – End fitting design, thermal
analysis at bend stiffener, service life analysiso Manufacturing & Qualification Plano Field development cost estimate –
Installation, Integrity Management Plano Proposal for Phase 2
OTC 23931• Qualification of FFRP for UDW Applications• Mark Kalman
Acknowledgements / Thank You / Questions
Special thanks to:
U.S. Department of Energy National Energy Technology Laboratory
Slide 20
Paper # • Paper Title • Presenter Name
U.S. Department of Energy National Energy Technology Laboratory
Working Committee: RPSEA, TOTAL, SHELL, CHEVRON, STATOIL
DEEPFLEX: Investors, Executive Team and Co-Authors
Contact: [email protected]