Course of Flexible Pipes

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USP Course on Flexible Pipes Introduction to Unbonded Flexible Pipe Design & Manufacturing
Judimar Clevelario Technology Manager Wellstream do Brasil

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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

Manufacture -2

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

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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

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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 Flexshield - Polymer
TPE, HDPE, PA11/PA12 Flexinsul Syntactic Foam

Flexlok Carbon Steel

Flexbody Alloy steel

Flextensile Carbon Steel Flexbarrier - Polymer HDPE, PA11/PA12, PVDF End fitting Composition

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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

Regarding the Internal Fluid


Smooth bore : Water Injection Rough Bore : Oil and Gas

Regarding H2S presence


Sweet service : with H2S Sour service : without H2S
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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

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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

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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.

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Main Ancillaries
Bend Stiffener
Required for dynamic risers Polyurethane cone that moves bending moment from base of end fitting Installed remotely or diver assisted.

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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

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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

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Main Ancillaries
Hang Off Clamp

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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 systemPart 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)

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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

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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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Manufacture -16

Flexible Pipe Design Make-up


Provides collapse resistance by forming into an interlocking spiral

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.

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Flexible Pipe Design Make-up


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

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Flexible Pipe Design Make-up

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.

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Flexible Pipe Design Make-up

Flextensile (Tensile Armour)


The Tensile Armor layer is a helical steel armor layer that resists internal pressure and axial tension.

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Manufacture -24

Flexible Pipe Design Make-up


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 Tape layers are applied over the tensile armors as a manufacturing aid to prevent birdcaging.

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Flexible Pipe Design Make-up

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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Manufacture -28

Flexible Pipe Design Make-up

Flexshield (External Sheath)


Flexshield is an external polymer barrier applied to resist mechanical damage and intrusion of seawater.

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Pipe Structure Design Verification

Manufacture -30

Design Criteria

Pipe Wall Design

Stress & Strain, Anal. Local Analysis

Global Dyn. Analysis Local FE Analysis

See Figures 19, 20 API RP 17B for more detailed process charts for static flowlines and dynamic risers

Service Life Analysis

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Flexible Pipe Design Flowchart

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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

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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

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GLOBAL ANALYSIS STRUCTURAL


RISER CONFIGURATION EXEMPLES

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GLOBAL ANALYSIS - STRUCTURAL


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:

Installation Recurrent Operation Extreme Operation Abnormal Conditions

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
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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
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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.

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GLOBAL ANALYSIS - STRUCTURAL


The relevant results often depend on riser configuration. For a free hanging catenary systems (most common configuration in Brazil), the most important results are: Top Tension Tension@Angle Envelop Curvature on TDP Minimum Tension on TDP (Birdcaging) Suspended length Anchoring Loads

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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

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LOCAL ANALYSIS BIRD CAGE


Local BirdCage Analysis FEA & STRAIN ENERGY

Lateral Deflection (Amplified )

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

Deflection StraightHlex StraightHelix BentHelix BentHelix(Calib) ApplCompression

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End Fitting Outer Sheath Holding System FEA Model

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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

Hydrogen embrittlement Chemical resistance

API 17J Sect. 6.2.4.6

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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

Compatibility and aging

Method C. PE only. Effectiveness to the UV stabilizer Insulation material only

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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

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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

FlexbodyTM R Provides collapse resistance

2 machines maximise production output

FlexlinerTM may replace the carcass and FlexbarrierTM for smoothbore applications

Increases burst strength by enhancing hoop strength of FlexlokTM

Helical wrapping of single or multiple layers of insulation tape onto the pipe

Supports tensile armour wires against buckling outwards

R = Rotating equipment work centre

E = Extrusion work centre

T = Taping work centre

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Flexible Pipe Construction 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

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Manufacture -63

Carcass take up Reel

The carcass is taken upon a reel, ready for the extrusion operation.

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Flexible Pipe Construction Flexbarrier

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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Manufacture -70

Production Reels & Carousel


The product is stored on reels or in a carousel as it is processed through each work centre. The reels are also used to transport the product to the customer. Carousels are used when the length of product exceeds the capacity of the production reels or where the SBR is large. Transportation to the customer takes place by loading the product on to the vessel either on reels or in to the vessels own carousel.

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Manufacture -71

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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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

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Manufacture -77

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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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 preform tooling heads which twist the wire so it lays flat against the pipes surface.

Material Selection
Sweet & Sour Service
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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)

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Flexible Pipe Construction

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

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Pipe Completion / Logistic Base in Brazil

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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

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Manufacture -95

Factory Acceptance Tests

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

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Factory Acceptance Testing (FAT)

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

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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

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

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Factory Acceptance Testing (FAT)

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

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Flexible Pipe Construction

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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Flexible Pipe and Umbilical loud-out at Wellstream Base

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Load-out

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Load-out

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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 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 of previous test results can be used


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.

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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

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Classification of Prototype Testing


Class I
Burst Tension Collapse

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

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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

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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

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Wellstream Golfinho C240/C272 Field Product Tests


Deep Immersion Performance Test, DIP test (OFFSHORE)

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