Course of Flexible Pipes
Course of Flexible Pipes
Course of Flexible Pipes
USP Course on Flexible Pipes Introduction to Unbonded Flexible Pipe Design & Manufacturing
Judimar Clevelario Technology Manager Wellstream do Brasil
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
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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
Designed to have the strength and durability associated with rigid steel pipes, flexible systems are often the only solution for risers in dynamic environments
Flextensile Carbon Steel Flexbarrier - Polymer HDPE, PA11/PA12, PVDF End fitting Composition
Flexible Pipe Construction Flexible pipe is a technically challenging, multi-layer structure of helically wound metallic wires and tapes and extruded thermoplastics
LAYER
OUTER SHEATH TENSILE ARMOR ANTI-WEAR TENSILE ARMOR ANTI-WEAR PRESSURE ARMOR INTERNAL PRESSURE CARCASS
MATERIAL
POLYMER CARBON STEEL POLYMER CARBON STEEL POLYMER CARBON STEEL POLYMER
FUNCTION
EXTERNAL FLUID BARRIER TENSILE STRENGTH LAYER ANTI-WEAR LAYER TENSILE STRENGTH LAYER ANTI-WEAR LAYER HOOP STRENGTH LAYER FLUID BARRIER COLLAPSE RESISTANT LAYER
STAINLESS STEEL
Regarding Aplication
Risers : Static or Dynamic Application Flowlines : Static Application
Main Ancillaries IP - Anode Clamp Design Anode Clamp Design Used to protect flexible pipe end fittings against corrosion
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.
Main Ancillaries
Bend Stiffener
Required for dynamic risers Polyurethane cone that moves bending moment from base of end fitting Installed remotely or diver assisted.
Main Ancillaries
Bend Restrictor
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
Buoyancy Modules
Floatation attached to result in desired riser configuration Both concentrated and distributed Clamps required for concentrated buoy to make connection to arch
Main Ancillaries
Hang Off Clamp
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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: FLEXBARRIER Function: Seal Internal Fluid Material: Nylon PA-11 Thickness: 7,00 mm
TM
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Layer: FLEXBODY TM Function: Collapse Resistance Material: Stainless Steel Thickness: 8,40 mm Layer: FLEXLOK TM Function: Provides Hoop Strength Material: Carbon Steel Thickness: 6,35 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: FLEXINSUL TM Function: Decrease Heat Loss Material: Syntetic Foam PT7000 Thickness: 40,00 mm (total)
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: FLEXWEAR TM Function: Limit Steel Layer Wear, Constrain Flextensile Wires, Manufacturing Aid Material: HPDE Thickness: 5,00 mm Layer: FLEXSHIELD TM Function: Environmental Protection Material: HPDE PT7000 Thickness: 10,00 mm
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Material types
HDPE
PA11/PA12
PVDF
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Flextape Tape layers are applied over the tensile armors as a manufacturing aid to prevent birdcaging.
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Flexinsul (Insulation)
Flexinsul is a thermal insulation layer used to limit heat loss through the pipe wall to the surrounding environment.
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Design Criteria
See Figures 19, 20 API RP 17B for more detailed process charts for static flowlines and dynamic risers
Water Depth Vessel Type Environmental Conditions Flexible ID Minimum Service Life Specification
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
Wellstream International Limited. Duplication in full or in part is prohibited.
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
Wellstream International Limited. Duplication in full or in part is prohibited.
Equilibrium Path
5 10
8
Axial Compression
4 10
3 10
2 10
1 10
0.015
0.01
0.005
0.005
0.01
0.015
Material Qualification
Test Procedures for Metallic Materials Tests Chemical composition Yield strength/elongation Ultimate strength/elongation Hardness SSC and HIC Corrosion resistance Erosion resistance Fatigue resistance Test Procedure ASTM A751 ASTM A370 ASTM A370 ASTM E92 API 17J Sect. 6.2.4.2 API 17J Sect. 6.2.4.3 API 17J Sect. 6.2.4.4 API 17J Sect. 6.2.4.5 Sour service applications only (Armor wires only) To specified environments (Armor wires only) To specified environments (Armor wires only) Carcass only Pressure and tensile armors in dynamic applications only only armor wires with yeild stress >= 700 Mpa and/or ultimate stress >= 900 Mpa and exposed to cathodic protection To specified environments Or ISO 8457-2 Comments
Material Qualification
Test Procedures for Extruded Polymer Materials Characteristic Mechanical/physical properties Tests Resistance to Creep Yield strength/elongation Ultimate strength/elongation Stress relaxation properties Modulus of elasticity Hardness Compression strength Hydrostatic pressure resistance Impact strength Abrasion resistance Density Fatigue Notch sensitivity Coefficient of thermal conductivity Coefficient of thermal expansion Heat distortion temperatures Softening point Heat capacity Brittleness temperature Test Procedure ASTM D2990 ASTM D638 ASTM D638 ASTM E328 ASTM D638 ASTM D2240 ASTM D695 ASTM D256 ASTM D4060 ASTM D792 ASTM D671 ASTM D256 ASTM C177 ASTM E831 ASTM D648 ASTM D1525 ASTM E1269 ASTM D746 Comments Due to temperature and pressure
Or ASTM D2583
At design minimum temperature Or ASTM D1044 or D1242 Or ASTM D1505 Dynamic applications only
Thermal properties
Method A
Or glass transition temp (ASTM E1356) As a minimum to CH4, CO2, H2O and methane, at design temp and press At design conditions
Permeation characteristics
Fluid permeability Blistering resistance Fluid compatibility Aging tests Environmental stress cracking Weathering resistance Water absorption
API 17J Sect. 6.2.3.1 API 17J Sect. 6.2.3.2 API 17J Sect. 6.2.3.3 API 17J Sect. 6.2.3.4 ASTM D1693 ASTM D570
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
Niteri, 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
Carcass Stage Barrier Extrusion Stage FlexbarrierTM E Forms the fluidconveying conduit FlexlokTM Stage FlexlokTM R Provides pressure retention capacity of pipe structure FlexpressTM used when FlexlokTM alone cannot provide sufficient strength Armour Stage FlextensileTM R Provides axial tension strength Insulation Stage FlexinsulTM T Enhances thermal properties FlexwearTM Stage FlexwearTM T or E Reduces friction between metallic armour wires Shield Extrusion Stage FlexshieldTM E Protects structural layers from mechanical damage and ingress from sea water Additional external protection can be given by a FlexgardTM
FlexlinerTM may replace the carcass and FlexbarrierTM for smoothbore applications
Helical wrapping of single or multiple layers of insulation tape onto the pipe
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
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The carcass is taken upon a reel, ready for the extrusion operation.
Internal Pressure 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.
Material Selection
PVDF, HDPE & PA-11/PA-12
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Caterpullers
There 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. The 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.
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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
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Taping Head
The tape heads are suitable for the application of either two or four tapes. A fabricated steel frame supports the rotating head. The following tapes are applied Manufacturing aids Anti-birdcaging (Deepwater) Anti-wear (Dynamic Risers) Thermal Insulation
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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 preform tooling heads which twist the wire so it lays flat against the pipes surface.
Material Selection
Sweet & Sour Service
Wellstream International Limited. Duplication in full or in part is prohibited.
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Armour Line
The armour line consists of two Armoring machines which rotate in opposite directions from one another. Stationed throughout the line are tape machines which apply the tape layers.
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Insulation
Reduce heat loss from the bore fluids (in order to maintain low viscosity bore fluids hence high flow rates). (Application: 1st layer melt extruded onto pipe, 2nd wrapped onto pipe)
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
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
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The FAT requirements are specified in the Fabrication Specification and Quality Plan. API 17 J FAT section
9.2 9.3 9.4 9.5 Gauge Test Hydro Test Electrical Continuity/Resistance 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
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
Storage
Reel diameters are from 26ft to 35ft, typical way of handling flexible pipe Carousels used for very long lengths
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Load-out
Once the pipe is completed it is secured to a reel or installed in to a carousel.
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Load-out
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Load-out
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Load-out
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
Class II
Dynamic Fatigue Crush Strength Combined Bending & Tension Sour Service Fire Erosion DIP TEST (Bird Cage Test)
Class III
Bending Stiffness Axial Stiffness Abrasion Rapid Decompression Axial Compression Thermal Characteristics Thermal Cycling Artic, Weathering Structural Damping
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
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