Microsoft PUC WSI 2007_Flexible_Pipe_Extension

Manufacture -1

USP

Course on Flexible Pipes

Introduction to Unbonded Flexible Pipe

Design & Manufacturing

Judimar Clevelario

Technology Manager

Wellstream do Brasil

Manufacture -2

Course Outline

1.What are Flexible Pipes Used For? What is a Flexible Pipe?

I. Flexible Pipe Layers & Construction

II. Key Design Considerations

III. Main Ancillaries

IV. Main Flexible Pipe Standards and Documentation

2.Flexible Pipes Layer Function and Materials

3.Flexible Pipes Design

I. Design Verification Flowcharts (*)

II. Preliminary Design, Fluid Compatibility & Collapse & Local Stress

III. Global FEA analysis

IV. Bird Cage Local Analysis

V. Bending Stiffener and Pipe Fatigue Local Analysis

VI. Pipe and End Fitting Final Local Analysis

4.Flexible Pipes Layers Raw Material Qualification

5.Flexible Pipes Layers Manufacturing Process & Pipe Completion & FAT & Load Out

6.Flexible Pipes Prototype Tests

What are Flexible Pipes Used For?

Designed to have the strength and durability associated with rigid steel pipes,

flexible systems are often the only solution for risers in dynamic environments

What is a Flexible Pipe?

• Unbonded flexible pipes consist of concentric layers of metallic wires,

tapes and extruded polymers designed to form a structure that

addresses the specific environmental requirements and characteristics

of the transported fluids

Flexbarrier - Polymer

HDPE, PA11/PA12, PVDF

Flexlok

Carbon Steel

Flexshield - Polymer

TPE, HDPE, PA11/PA12

Flexinsul

Syntactic Foam

Flexbody

Alloy steel Flextensile

Carbon Steel

End fitting Composition

OUTER SHEATH POLYMER EXTERNAL FLUID BARRIER

TENSILE ARMOR CARBON STEEL TENSILE STRENGTH LAYER

ANTI-WEAR POLYMER ANTI-WEAR LAYER

TENSILE ARMOR CARBON STEEL TENSILE STRENGTH LAYER

ANTI-WEAR POLYMER ANTI-WEAR LAYER

PRESSURE ARMOR CARBON STEEL HOOP STRENGTH LAYER

INTERNAL PRESSURE POLYMER FLUID BARRIER

CARCASS STAINLESS STEEL COLLAPSE RESISTANT LAYER

LAYER MATERIAL FUNCTION

Flexible Pipe Construction

Flexible pipe is a technically challenging, multi-layer structure of

helically wound metallic wires and tapes and extruded

thermoplastics

•Regarding Aplication

– Risers : Static or Dynamic Application

– Flowlines : Static Application

•Regarding the Internal Fluid

– Smooth bore : Water Injection

– Rough Bore : Oil and Gas

•Regarding H2S presence

– Sweet service : with H2S

– Sour service : without H2S

Key Design Considerations

• Gross structural integrity

(tension, pressure)

• Riser interaction (clashing,

interference and

entanglement)

• Fatigue (curvature and tension

ranges)

• Local analysis

– Gap span

– Flexlok stress analysis

– Corrosion fatigue

– Material compatibility

• Touch down point

– Abrasion

– Local armour buckling (bird-caging)

• Collapse

• On-Bottom Stability

• Upheaval Buckling

Main Ancillaries

End Fittings

• End fittings are custom designed for

each flexible pipe structure

• Terminations can be any design –

API/ANSI flanges, hubs, welded, or

other

• Stronger than pipe in burst and failure

tension

• Most common structural material is

AISI 4130 low alloy steel

• Common coatings include electrolysis

nickel plating, and various epoxies.

• Assembly is a manual process

Main Ancillaries

IP - Anode Clamp Design

Installation Sequence

Before the installation,

the ROV clean the

Endfitting surface using

a steel brush to

guarantee a better

electrical contact of the

Anode Clamp.

After that, the

installation process is

illustrated in the figure

aside.

Anode Clamp Design

Used to protect flexible pipe

end fittings against corrosion

• Required for dynamic risers

• Polyurethane cone that moves bending moment from

base of end fitting

• Installed remotely or diver assisted.

Main Ancillaries

Bend Stiffener

• Used at connections to wellhead, PLEM, manifold, etc.

• Prevents overbending. Installation aid when pipe deployed with subsea hardware

• Polyurethane units which can be installed offshore

• Steel solutions also available at lower cost but must be packaged in plant

Main Ancillaries

Bend Restrictor

• Floatation attached to result in

desired riser configuration

• Both concentrated and distributed

• Clamps required for concentrated

buoy to make connection to arch

Main Ancillaries

Buoyancy Modules

Main Ancillaries

Hang Off Clamp

Manufacture -13

Flexible Pipe Standards

•API 17J - Specification for Unbonded Flexible Pipe

•Petrobras NI-2409-A - Flexible Pipe Specification - 2003

–Must be in compliance on all Petrobras Projects.

•ISO 13628 - Petroleum natural gas industries - Drilling and

production equipment - Design and operation of subsea system-

Part 2: Flexible pipe systems for subsea and marine applications.

•Bureau Veritas NI 364 DTO ROO E - Non-bonded Flexible Steel

Pipes used as Flowlines

•DNV Rules for Flexible Pipe

•Other oil company specifications

–- ALL SUPERSEDED BY API 17J

•RP17B - Recommended Practice for Unbonded Flexible Pipe

(sister document to API 17J)

Manufacture -14

Technical Documentation Requirements

for Flexible Pipe

•Design Premise

•Design Load Report

•Design Report (with Riser System / Service Life Analysis)

•Fabrication Specification

•Operation Manual

•Manufacturing Quality Plan

•Data Book

Manufacture -15

Petrobras - Marlim Sul

Pipe ID : 6 inches

Water Depth : 1500m

Pressure Rating : 20.68 Mpa

Design Temperature : 60 Deg. C

Function : Oil / Gas Insulated Flowline

Layer: FLEXBODY TM

Function: Collapse Resistance

Material: Stainless Steel

Thickness: 8,40 mm

Layer: FLEXBARRIER TM

Function: Seal Internal Fluid

Material: Nylon PA-11

Thickness: 7,00 mm Layer: FLEXLOK TM

Function: Provides Hoop Strength

Material: Carbon Steel

Thickness: 6,35 mm

Layer: FLEXTAPE TM

Function: Birdcaging Resistance

Material: High Strength

Glass Filament

Thickness: 0,81 mm

Layer: FLEXTAPE TM

Function: Birdcaging Resistance

Material: High Strength

Glass Filament

Thickness: 0,81 mm

Layer: FLEXTENSILE 1 TM

Function: Provides Hoop

and Axial Strength

Material: Carbon Steel

Thickness: 3,00 mm

Layer: FLEXTENSILE 2 TM

Function: Provides Hoop

and Axial Strength

Material: Carbon Steel

Thickness: 3,00 mm

Layer: FLEXWEAR TM

Function: Limit Steel Layer

Wear, Constrain Flextensile

Wires, Manufacturing Aid

Material: HPDE

Thickness: 5,00 mm

Layer: FLEXINSUL TM

Function: Decrease Heat Loss

Material: Syntetic Foam

PT7000

Thickness: 40,00 mm (total)

Layer: FLEXSHIELD TM

Function: Environmental

Protection

Material: HPDE

PT7000

Thickness: 10,00 mm

Manufacture -16

Flexible Pipe Design Make-up

Flexbody

Flexbody™

™-

-

(Internal Carcass)

The Flexbody is a

corrugated metallic tube

with a specified internal

diameter. The Flexbody

supports the extruded

fluid barrier and

prevents collapse from

hydrostatic pressure or

crushing loads applied

during pipe operation.

•Provides collapse resistance by forming into an interlocking spiral

Manufacture -18

Flexible Pipe Design Make-up

Flexbarrier

Flexbarrier™

™-

-

(Internal Pressure Sheath)

The Flexbarrier is a

polymer layer extruded

over the Flexbody to form

a boundary for the

conveyed fluid. The

Flexbarrier material is

selected to be chemically

resistant to the conveyed

fluid and unaffected by its

service conditions.

Material types

HDPE PA11/PA12 PVDF

Increasing temperature resistance

Increasing chemical compatibility

Manufacture -20

Flexible Pipe Design Make-up

Flexlok

Flexlok™

™-

-

(Pressure Armour)

The Flexlok is a steel hoop

strength layer consisting of

circumferentially wound

profiled wire to resist to

internal pressure and

bending.

The Z-shaped wire is

profiled to allow interlocking

of the edges as they are

formed around the pipe.

Manufacture -22

Flexible Pipe Design Make-up

The Tensile

Armor layer is a

helical steel

armor layer that

resists internal

pressure and

axial tension.

Flextensile

Flextensile™

™-

-

(Tensile Armour)

Manufacture -24

Flexible Pipe Design Make-up

Flexwear

Flexwear™

™-

(Anti-wear Layer)

The Flexwear is a thin

polymer tape layer applied

between any two adjacent

metallic layers, and such

prevents metal-to-metal

contact between the layers

to prevent wear.

Flextape

Flextape™

™-

Tape layers are applied

over the tensile armors

as a manufacturing aid to

prevent “birdcaging”.

Manufacture -26

Flexible Pipe Design Make-up

Flexinsul

Flexinsul™

™-

-

(Insulation)

Flexinsul is a thermal

insulation layer used

to limit heat loss

through the pipe wall

to the surrounding

environment.

Manufacture -28

Flexible Pipe Design Make-up

Flexshield

Flexshield™

™-

-

(External Sheath)

Flexshield is an

external polymer barrier

applied to resist

mechanical damage

and intrusion of

seawater.

Manufacture -30

Pipe Structure Design Verification

Design Criteria

Pipe Wall Design

Stress & Strain,

Anal. Local Analysis

Global Dyn. Analysis

Local FE Analysis

Service Life

Analysis

See Figures

19, 20 API RP 17B

for more detailed

process charts for

static flowlines

and dynamic risers

Flexible Pipe Design Flowchart

Preliminary Design, Fluid Compatibility & Collapse & Local

Stress

The first design step is execute preliminary collapase, gas permeation, creep and

fluid compatibility to define the proposed pipe design

GLOBAL ANALYSIS - STRUCTURAL

• First step is to define the riser

configuration based on:

–Water Depth

–Vessel Type

–Environmental

Conditions

–Flexible ID

–Minimum Service Life

Specification

GLOBAL ANALYSIS – STRUCTURAL

RISER CONFIGURATION EXEMPLES

GLOBAL ANALYSIS - STRUCTURAL

–Installation

–Recurrent Operation

–Extreme Operation

–Abnormal Conditions

• Once the configuration is defined, a non-linear dynamic structural analysis

is performed in order to estimate typical loads experienced by the flexible

pipe during:

• API 17B provides

recommendations on how to

perform the analysis

• Petrobras has its own specification

with mandatory requirements

SIRI_az202_GA-11-1-1.avi

GLOBAL ANALYSIS - STRUCTURAL

• General approach is to run several load

cases (PB spec request aprox. 96 load

cases) in order to determine the most

severe combinations of:

–Wave (10yr or 100yr RP)

–Current (10yr or 100yr RP)

–Offsets (intact or broken mooring

system)

• The environmental conditions must be

supplied by the client

• Petrobras have specific documents

called METOCEANs that provide all

necessary information to perform the

analysis

GLOBAL ANALYSIS - STRUCTURAL

• Vessel behavior are simulated by

a matrix loaded into the

commercial software

(Orcaflex/Flexcom)

• This table specify the vessel

displacement/rotations for all

vessel degrees of freedom in

terms of wave height and period.

• On this way, the environmental

condition influence can be

translated in vessel movements

and rotation that will impose

loads on the riser.

GLOBAL ANALYSIS - STRUCTURAL

–Top Tension

–Tension@Angle Envelop

–Curvature on TDP

–Minimum Tension on TDP

(Birdcaging)

–Suspended length

–Anchoring Loads

• The relevant results often depend on riser configuration.

• For a free hanging catenary systems (most common configuration

in Brazil), the most important results are:

GLOBAL ANALYSIS – Service Life

• Once the riser is proven to resist to the most severe

environmental conditions, a service life analysis is performed in

order to verify the suitability of the riser against a specified service

life

• Petrobras has its own specification that drives the fatigue analysis.

On this specification, the global analysis load cases are related

with a number of incidences

• This way, the tension extracted from the load cases can be

associated to a number of cycles and an accumulated fatigue

damage and life can be calculated based on Palmgreen-Miner

rule

• The load cases are based on annual environmental conditions

• Petrobras normally specify 20 years of service life with a safety

factor of 10

LOCAL ANALYSIS BIRD CAGE

Local BirdCage Analysis FEA & STRAIN ENERGY

Lateral Deflection (Amplified )

0.015 0.01 0.005 0 0.005 0.01 0.015

110 8

210 8

310 8

410 8

510 8

StraightHlex

StraightHelix

BentHelix

BentHelix(Calib)

ApplCompression

StraightHlex

StraightHelix

BentHelix

BentHelix(Calib)

ApplCompression

Equilibrium Path

Deflection

Axial Compression

End Fitting Outer Sheath Holding System FEA Model

Material Qualification

To specified environmentsChemical resistance

only armor wires with yeild stress >= 700 Mpa and/or ultimate stress >= 900

Mpa and exposed to cathodic protectionAPI 17J Sect. 6.2.4.6Hydrogen embrittlement

Pressure and tensile armors in dynamic applications onlyAPI 17J Sect. 6.2.4.5Fatigue resistance

Carcass onlyAPI 17J Sect. 6.2.4.4Erosion resistance

To specified environments (Armor wires only)API 17J Sect. 6.2.4.3Corrosion resistance

To specified environments (Armor wires only)API 17J Sect. 6.2.4.2SSC and HIC

Sour service applications only (Armor wires only)ASTM E92Hardness

ASTM A370Ultimate strength/elongation

ASTM A370Yield strength/elongation

Or ISO 8457-2ASTM A751Chemical composition

CommentsTest ProcedureTests

Test Procedures for Metallic Materials

Material Qualification

Insulation material onlyASTM D570Water absorption Effectiveness to the UV stabilizerWeathering resistance Method C. PE only.ASTM D1693Environmental stress cracking API 17J Sect. 6.2.3.4Aging tests API 17J Sect. 6.2.3.3Fluid compatibilityCompatibility and aging

At design conditionsAPI 17J Sect. 6.2.3.2Blistering resistance

As a minimum to CH4, CO2, H2O and

methane, at design temp and pressAPI 17J Sect. 6.2.3.1Fluid permeabilityPermeation characteristics

Or glass transition temp (ASTM E1356)ASTM D746Brittleness temperature ASTM E1269Heat capacity ASTM D1525Softening point Method AASTM D648Heat distortion temperatures ASTM E831Coefficient of thermal expansion ASTM C177Coefficient of thermal conductivityThermal properties

ASTM D256Notch sensitivity Dynamic applications onlyASTM D671Fatigue

Or ASTM D1505ASTM D792Density Or ASTM D1044 or D1242ASTM D4060Abrasion resistance At design minimum temperatureASTM D256Impact strength

Hydrostatic pressure resistance ASTM D695Compression strength Or ASTM D2583ASTM D2240Hardness ASTM D638Modulus of elasticity ASTM E328Stress relaxation properties

ASTM D638Ultimate strength/elongation

ASTM D638Yield strength/elongation

Due to temperature and pressureASTM D2990Resistance to CreepMechanical/physical properties

CommentsTest ProcedureTestsCharacteristic

Test Procedures for Extruded Polymer Materials

Offshore Facilities

• Newcastle, UK

– Operational since 1997

– Capability and experience to manufacture

the full range of offshore products from

2” - 16” diameters

– Annual production capacity of 260nkm

– Proven track record of operating at highest

standards required by industry

– In 9 years of manufacturing there have been

zero in-service failures

• Niterói, Brazil

– Commenced manufacturing on schedule in

May 2007

– Annual production capacity of 150nkm

– Expected product range: inside diameter of

2” to 12”

– Facility designed to allow future expansion

Manufacturing Process

•The manufacturing of flexible pipes consists of 7 main stages, followed by assembly of end

fittings, testing and packaging

– Work stations are laid out to optimize the sequential manufacturing process

– Maximum flexibility in manufacturing to reel or carousel

– Equipment parameters are computer monitored and controlled throughout the process ensuring

consistency

– Quality control teams operate at each work station, throughout the length of the production run

– Continuous Improvement teams operate at each work station

Shield

Extrusion

Stage

Flexwear

TM

Stage

Insulation

Stage

Armour

Stage

Flexlok

TM

Stage

Barrier

Extrusion

Stage

Carcass Stage

Flexbody

TM

Flexbarrier

TM

Flexlok

TM

Flextensile

TM

Flexinsul

TM

Flexwear

TM

Flexshield

TM

Provides

collapse

resistance

Forms the fluid-

conveying

conduit

Provides

pressure

retention

capacity of pipe

structure

Provides axial

tension

strength

Enhances

thermal

properties

Reduces friction

between

metallic armour

wires

Protects

structural layers

from mechanical

damage and

ingress from sea

water

RERRTT or EE

R = Rotating equipment work centre E = Extrusion work centre

2 machines

maximise

production

output

Flexliner

TM

may

replace the

carcass and

Flexbarrier

TM

for smoothbore

applications

Flexpress

TM

used when

Flexlok

TM

alone

cannot provide

sufficient

strength

Increases burst

strength by

enhancing

hoop strength

of Flexlok

TM

Helical wrapping

of single or

multiple layers

of insulation

tape onto the

pipe

Supports tensile

armour wires

against buckling

outwards

Additional

external

protection can be

given by a

Flexgard

TM

T = Taping work centre

Shield

Extrusion

Stage

Flexwear

TM

Stage

Insulation

Stage

Armour

Stage

Flexlok

TM

Stage

Barrier

Extrusion

Stage

Carcass Stage Shield

Extrusion

Stage

Flexwear

TM

Stage

Insulation

Stage

Armour

Stage

Flexlok

TM

Stage

Barrier

Extrusion

Stage

Carcass Stage

Flexbody

TM

Flexbarrier

TM

Flexlok

TM

Flextensile

TM

Flexinsul

TM

Flexwear

TM

Flexshield

TM

Provides

collapse

resistance

Forms the fluid-

conveying

conduit

Provides

pressure

retention

capacity of pipe

structure

Provides axial

tension

strength

Enhances

thermal

properties

Reduces friction

between

metallic armour

wires

Protects

structural layers

from mechanical

damage and

ingress from sea

water

RERRTT or EE

R = Rotating equipment work centre E = Extrusion work centre

2 machines

maximise

production

output

Flexliner

TM

may

replace the

carcass and

Flexbarrier

TM

for smoothbore

applications

Flexpress

TM

used when

Flexlok

TM

alone

cannot provide

sufficient

strength

Increases burst

strength by

enhancing

hoop strength

of Flexlok

TM

Helical wrapping

of single or

multiple layers

of insulation

tape onto the

pipe

Supports tensile

armour wires

against buckling

outwards

Additional

external

protection can be

given by a

Flexgard

TM

T = Taping work centre

Flexible Pipe Construction Carcass

Carcass

Carcass -

-

The Carcass is a corrugated

metallic tube with a specified

internal diameter. The

Carcass supports the

extruded fluid barrier and

prevents collapse from

pressure or crushing loads

applied during pipe operation

Material Selection

Stainless 304L, 316 L

Duplex & AL6XN

Manufacture -63

Carcass take up Reel

¾The carcass is taken upon a reel,

ready for the extrusion operation.

Flexible Pipe Construction Flexbarrier

Material Selection

PVDF, HDPE & PA-11/PA-12

Internal Pressure

Sheath

Sheath -

-

•For Flexbarrier (polymer fluid barrier)

the carcass is passed through the

extruder cross-head, where the resin

melt is applied over the carcass.

•Control of extruder volume and line

speed, coupled with use of specially

sized dies, determine the thickness of

the wall around the carcass.

•High Density Polyethylene (HDPE),

Nylon (PA11 or PA12), and

polyvinylidene fluoride (PVDF) as well

as other polymers are applied in this

process.

Manufacture -70

Production Reels & Carousel

¾The product is stored on reels or in a

carousel as it is processed through

each work centre.

¾The reels are also used to transport

the product to the customer.

¾Carousels are used when the length of

product exceeds the capacity of the

production reels or where the SBR is

large.

¾Transportation to the customer takes

place by loading the product on to the

vessel either on reels or in to the

vessels own carousel.

Manufacture -71

Caterpullers

¾There are two caterpullers

on each extrusion line, one

is used to pull the pipe

from the pay-off Rim drive

and feed it down the line at

a constant speed.

¾The other one is used to

pull the product through

the line at a constant speed

dictated by UT the catenary

setting. The catenary is a

necessary function of the

extrusion line.

Manufacture -73

Pressure Armor

•The Flexlok machine applies a

shaped, rolled, carbon steel wire

which is preformed and

interlocked as it is wound around

the pipe, providing a smooth,

flexible, continuous layer to

support the barrier and increase

pipe burst pressure.

•When design and pressure

requirements demand higher burst

strengths, Flexpress, a wide flat

wire, may be wound over the

Flexlok layer.

•Machines that apply from 1 to 4

wires simultaneously are used.

Material Selection

Sweet & Sour Service

Manufacture -77

Taping Head

¾The tape heads are

suitable for the

application of either two

or four tapes. A

fabricated steel frame

supports the rotating

head.

¾The following tapes are

applied -

–Manufacturing aids

–Anti-birdcaging

(Deepwater)

–Anti-wear

(Dynamic Risers)

–Thermal Insulation

Manufacture -78

Tensile Armour

• The Armour machine applies

a layer of helical steel armour

wires to the pipe.

• The flat wires increase burst

strength and give the pipe

axial strength. There are two

machines that apply the flat

wire contra-helically.

• The flat wire can be of

various sizes and tensile

strengths depending on the

pipe design. As the wire is

applied, it runs through pre-

form tooling heads which

twist the wire so it lays flat

against the pipe’s surface.

Material Selection

Sweet & Sour Service

Manufacture -83

Armour Line

¾The armour line consists of two Armoring machines which

rotate in opposite directions from one another.

¾Stationed throughout the line are tape machines which

apply the tape layers.

Insulation

¾Reduce heat loss

from the bore fluids

(in order to

maintain low

viscosity bore fluids

hence high flow

rates).

¾(Application: 1st

layer melt extruded

onto pipe, 2nd

wrapped onto pipe)

Manufacture -89

Outer Sheath

Outer Sheath -

-

The Outer Sheath is an

external polymer barrier

applied to resist mechanical

damage and intrusion of

seawater.

Material Selection

HDPE, & PA-11/PA-12

Flexible Pipe Construction

Pipe Completion / Logistic Base in Brazil

End Fitting Technology

• End fittings are critical components of any flexible pipe system

– Custom designed for each flexible pipe structure

– Each layer of the pipe individually terminated

• Designed to:

– Assure a leak tight transition between subsea and surface facilities

– Withstand severe environmental loads and thermal cycling

– Stronger than pipe in burst and failure tension

– Allow for the venting of permeated gases

• Terminations can be any design - API/ANSI flanges, hubs, welded, or other

• Most common structural material is AISI 4130 low alloy steel

Manufacture -95

Factory Acceptance Tests

•The FAT requirements are specified in the

Fabrication Specification and Quality Plan.

•API 17 J FAT section

–9.2 Gauge Test

–9.3 Hydro Test

–9.4 Electrical Continuity/Resistance

–9.5 Gas Venting Test

•Hydrostatic

– Minimum hydrotest pressure is 1.5 times the design pressure and

the maximum pressure is 1.04 times the minimum hydrotest

pressure

– After the 24 hour period if the pressure has not dropped more than

4% the pipe is considered to have passed hydrotest

Factory Acceptance Testing (FAT)

• Outer Sheath Integrity

– By pressurizing the annulus of the pipe to 30psi maximum for a period of 30

minutes

– The pressure must remain above 20psi during the test period and should

not reduce by more than 1psi during the last 15 minutes of the 30 minute

hold period

Factory Acceptance Testing (FAT)

• Pressure relief system test (Annulus gas venting)

– To verify the flow of air through the annulus, over the full length of the pipe

– Hoses are attached to the vent holes at the in-board endfitting then pressure is

introduced slowly to a maximum of 90psi

– Hoses are then attached at the out-board endfitting and the pressure and flow

rate are recorded. A show of air bubbles are also required

• Endfitting testing

– Electrical Resistance - To confirm the insulation from the Barrier

layer/Insulation ring between the Carcass and the Endfitting by

measurement of resistance

– Electrical continuity test – To measure that the resistance between

both endfittings is less than the omhs (:) advised on the

MWO/PWO for the length of pipe tested

Factory Acceptance Testing (FAT)

Storage

Flexible Pipe Construction

• Reel diameters are from 26ft to 35ft, typical way of handling flexible pipe

• Carousels used for very long lengths

Manufacture -99

Load-out

¾Once the pipe is

completed it is

secured to a reel

or installed in to a

carousel.

Manufacture -100

Load-out

Flexible Pipe and Umbilical loud-out at Wellstream

Base

Manufacture -102

Load-out

Manufacture -103

Load-out

Qualification Criteria & Scaling Limitations

• Two Objectives to Prototype testing:

– Prove or validate new or unproven pipe designs

– Validate the manufacturers’ design methodology for a new

pipe design

• Scaling of previous test results can be used

– Pressure – the test pipe may be used to qualify pipes of the

same family having equal or lower pressure rating

– Internal Diameter – testing of one pipe of a product family

should verify products two inches larger or smaller than the

size tested

• Scaling comparisons also based on pressure and internal

diameter (P x ID), with the test pipe qualifying pipes with a

lower P x ID value.

Testing Classes

• All Unbonded Flexible Pipe testing is executed in accordance with API Recommended

Practice 17B

• API RP 17B categorizes test types into three classes:

– Class I – basic tests identifying ultimate capacity under simple loading

– Class II – tests verifying specific aspects of a flexible pipes performance

– Class III – tests characterizing the flexible pipe behaviour

– Petrobras NI-2409 A additional Tests as Tension-Tension, DIP Test, etc…

Classification of Prototype Testing

Class II Class III

•Burst

• Tension

•Collapse

•Dynamic Fatigue

•Crush Strength

• Combined Bending & Tension

• Sour Service

•Fire

• Erosion

•DIP TEST – (Bird Cage Test)

• Bending Stiffness

• Axial Stiffness

• Abrasion

• Rapid Decompression

• Axial Compression

•Thermal Characteristics

•Thermal Cycling

• Artic, Weathering

• Structural Damping

Class I

Thermal Cycling

Mid-Scale Thermal Cycle Tests evaluate the

swaging and sealing arrangements under thermal

loading during start-up, shutdowns and changing

properties of the intermediate sheath material over

the service life

Full-Scale Thermal Cycle Test As a minimum 50

thermal cycles at specified max / min temperature for

two samples. Following completion, pipe is dissected for

evidence of barrier slippage

Full-scale Dynamic Fatigue Tests

2M Cycles representing the most

severe operating load cases. Also

the total test fatigue damage is

equivalent to in service fatigue

damage. Bore pressure = MAOP

Wellstream Golfinho C240/C272 Field Product Tests

• Deep Immersion Performance Test,

“DIP” test (OFFSHORE)

Microsoft PUC WSI 2007_Flexible_Pipe_Extension_Course PT7000 Wellstream

Navigation menu

Versions of this User Manual:

Views

Navigation