t

Evolution and New Design Challenges for Flexible

Pipe in the Offshore Oil and Gas Industry
Pipeline Industries Guild, 21
st
March 2012, Aberdeen
Pipe in the Offshore Oil and Gas Industry
Dr. Patrick OBrien, Wood Group Kenny
Dr. Craig Thomas, MCS Kenny
Experience that Delivers
Presentation Content
Introduction to flexible pipes
Unbonded flexible design and construction
Bonded flexible design and construction
Sureflex J IP
Recent industry findings Recent industry findings
Current challenges in the flexible pipe industry
Flexible Riser Fatigue
Analysis of birdcaging in flexible risers
Smooth bore flexible pipe technology Smooth bore flexible pipe technology
Anti H2S layer for flexible pipes
Composite Armours in Flexible Pipe
1 Experience that Delivers
Unbonded Flexible Pipe
Applications
Risers, Flowlines, & J umpers
Used mostly in high pressure Used mostly in high pressure
applications
F ti Functions
Production, Injection, & Export
Suppliers
Technip (Coflexip), NKT Flexibles,
Wellstream Prysmian Wellstream, Prysmian
Deepflex, Airborne, Magma
2 Experience that Delivers
Unbonded Flexible Pipe - Structure
Multi-layer construction: Multi layer construction:
Steel & thermoplastic layers
Each has its own specific function
C l i t 19 l Complex pipes up to 19 layers
Simple applications as low as 4 layers
Main components include:
Leak-proof thermoplastics
Corrosion-resistant steel Corrosion resistant steel
Insulation, anti-wear, structural tapes
Unbonded layers
Free to slide relative to each other
Annulus venting
3 Experience that Delivers
Unbonded Flexible Pipe
Layer Function Layer Function
Carcass (Stainless Steel) Carcass (Stainless Steel)
External Pressure Resistance
Carcass Profile:
Internal Sheath (Polymer)
Internal Fluid Containment Barrier
Pressure Armour (Carbon Steel)
Hoop Load Resistance
Armour Profile:
Tensile Armour (Carbon Steel) ( )
Tensile Load Resistance
External Sheath (Polymer)
4 Experience that Delivers
( y )
External Fluid Barrier
Carcass
Typically stainless steel Typically stainless steel
Corrosion resistant
AISI grades 304, 304L, 316, 316L
D l S D l (25%C ) Duplex or Super Duplex (25% Cr)
Selection criteria
Bore fluid chemistry (i.e. O2, H2S, CO2,
Chlorides, injection & well service fluids)
Water Depth
Continuous Manufacturing Process
Interlocking profile is formed fromflat strip Interlocking profile is formed from flat strip
during manufacture
5 Experience that Delivers
Pressure & Tensile Armour Wires
Typically high strength carbon steel
Selection criteria impacted by service
Sweet wire UTS 1400MPa (200ksi)
Sour wire UTS 750MPa (105ksi) ( )
Tensile armours cross wound in pairs
Flat wire with chamfered edges Flat wire with chamfered edges
30-55 to longitudinal axis
Support weight of all layers
Deepwater Multiple Pairs for higher Tensions
6 Experience that Delivers
Polymer Materials y
Internal & external sheaths
Provides fluid integrity
Applied by extrusion
Internal sheath exposed to bore fluid p
Carcass layer permeable
Key drivers for selection: Key drivers for selection:
Temperature
Water Content
Typical materials: PA-11, HDPE, XLPE, PVDF
7 Experience that Delivers
Bonded Flexible Pipe
Applications
Mainly J umpers
Functions
Production (no gas), Injection, & Export
Low pressure dead oil/water service
Suppliers Suppliers
Dunlop Oil & Marine, ContiTech Beattie,
Taurus Emerge, Airborne
8 Experience that Delivers
Bonded Flexible Pipe - Structure
Composite of several layers Composite of several layers
Each has its own specific function
Main components include:
Vulcanized rubber/wire matrix layer
Armouring layers g y
Bonded layers
La ers bonded and encaps lated Layers bonded and encapsulated
No annulus venting system
No gas in bore fluid
blistering
9 Experience that Delivers
SureFlex JIP Deliverables
Completedat end of 2010 Completed at end of 2010
State of the Art Report on Flexible Pipe Integrity
Gathered data on flexible pipe population statistics, damage, degradation and failure
The JIP has produced two deliverables:
pp p p , g , g
mechanisms worldwide
Reviewed current integrity management practice
Reviewed developments in monitoring and inspection methods for flexible pipe p g p pp
Guidance Note on Monitoring Methods and Integrity Assurance for Flexible Pipe
Life cycle flexible pipe integrity assurance
Sources of flexible pipe degradation damage and failure Sources of flexible pipe degradation, damage and failure
Guidance on Inspection and Monitoring Techniques
www.ukoilandgasuk.co.uk
Click on Publications
Code: OP010; Category: Operations: Keyword: Flexible Pipe
Cost: 50 for Members O&GUK, 100 for Non-Members
10 Experience that Delivers
,
SureFlex Data Gatheringg
Gathering data from industry
188 questionnaires sent out to industry
16 were comprehensively responded to
20 additional follow-up interviews conducted on an international basis
B d Based on:
MCS Kenny in-house projects database
Industry data gathering Industry data gathering
Public domain sources
The results are:
Population statistics based on 1,900 risers, 1,400 static lines and over
130 production facilities worldwide
11 Experience that Delivers
315 individual damage / failure incidents
SureFlex Findings:
Some Key Statistics Some Key Statistics
58% of flexible pipes installed are risers
76% of all flexible pipe have design pressure below 345 bar (5000psi) pp g p ( p )
90% of all flexible pipe is below 10-inch
Majority of flexible pipes have P x ID less than 50,000 psi-inch
Current P x ID limit is 80,000 psi-inch
70% pipes are used for design temperature less than 80 deg C
70% of all flexible risers in water depths less than 1,000 m water depth
12 Experience that Delivers
SureFlex Findings:
Design Pressure Statistics Design Pressure Statistics
50%
Design Pressure for Operating Flexible Pipe
D t t f 2 521 Fl i bl Pi
35%
40%
45%
Dataset of 2,521 Fl exi bl e Pi pes
20%
25%
30%
46%
5%
10%
15%
30%
18%
8%
0%
5%
0-3,000 3,000-5,000 5,000-7,000 7,000-15,000
8%
Pressure Range (psi)
13 Experience that Delivers
SureFlex Findings:
DesignTemperature Statistics Design Temperature Statistics
Design Temperature for Operating Flexible Pipe
35%
40%
45%
Dataset of 1,566 Fl exi bl e Pi pes
20%
25%
30%
42%
5%
10%
15%
26%
27%
5%
0%
0-60 60-80 80-120 120+
Temperature Range (deg C)
14 Experience that Delivers
SureFlex Findings:
Water Depth Statistics for Risers Water Depth Statistics for Risers
Water Depth of Operating Flexible Risers
50%
60%
Dataset of 1,885 Fl exi bl e Ri sers
30%
40%
57%
0%
10%
20%
13%
23%
7%
0 to 500m 500m to 1000m 1000m to 1500m 1500m +
Water Depth Range (m)
15 Experience that Delivers
SureFlex Findings:
Water Depth vs Internal Diameter Water Depth vs Internal Diameter
16 Experience that Delivers
SureFlex Findings:
Pressure vs Internal Diameter Pressure vs Internal Diameter
17 Experience that Delivers
SureFlex Findings:
Failure / Damage Statistics Failure / Damage Statistics
18 Experience that Delivers
SureFlex Findings:
Damage / Failure Conclusions Damage / Failure Conclusions
External sheath damage / flooded annulus remains most common damage
Some key conclusions on damage and failure:
External sheath damage / flooded annulus remains most common damage
mechanism
Detection driven in part by increased uptake of annulus monitoring
General wire corrosion due to intermittent exposure in splash zone or
where shielded by vessel structures is a key concern
Aged internal pressure sheath and PVDF end fitting pull out are driven by Aged internal pressure sheath and PVDF end fitting pull out are driven by
pre-2002 failure data
Vent system anomalies show significant increase
Carcass collapse failure show significant increase over 2002 data
19 Experience that Delivers
General Armour Wire Corrosion
20 Experience that Delivers
SureFlex Findings:
Feedback on Inspection / MonitoringTechniques Feedback on Inspection / Monitoring Techniques
Method / Technique Take-up
(1) Limited, specific applications
(5) Common practice
Industry JIP Feedback
(1) Under development, unproven
(5) Highly reliable
Proof Pressure Testing Some examples (2) Short term assurance only / Ad-hoc method (3)
Visual Inspection (5) Anomaly tracking / Gross defects (4)
Ultrasonic Techniques Some examples to detect annulus flooding
(2)
Unproven at detecting wire defects, access to critical
region may be problematic (3)
MAPS Offshore trials ongoing (1) (2)
Polymer Coupons Commonly used for high temperature
applications (3)
Limited implementation but can provide assurance
for PA11 (4)
Annulus Monitoring (various
techniques)
Significant increase in recent years (4) Various methods can detect flooding, though
dependent on access (3) / (4)
Eddy Current (1) New tool under development (2)
Radiographics Historically limited to topsides (2) Digital method under development (3)
Intelligent Pigging (1) (1)
Torsion Monitoring Focused on deepwater applications (1) Alternative systems under development (1)
Curvature Monitoring Focused on fatigue (1) No operational feedback (2)
Acoustic Emission (1) Not field proven (2)
Sonar Monitoring (RAMS) Limited use to date (1) Has detected bend stiffener loss (4)
FPU Excursion/ Environment
Monitoring
(4) Several systems have failed to properly record and
log excursion data (3)
Fibre Optic Monitoring Embedded in tensile armours to detect
strain cycling (2)
No operational feedback (2)
21 Experience that Delivers
strain cycling (2)
SureFlex Findings:
EmergingTechniques 1 Emerging Techniques - 1
Vent Gas
Ultrasonics
Monitoring
MAPS
22 Experience that Delivers
SureFlex Findings:
EmergingTechniques 2 Emerging Techniques - 2
Magnetic Torsion
Monitoring
RAMS
23 Experience that Delivers
SureFlex Outcomes:
Guidance Note Document 1 Guidance Note Document - 1
Life Cycle Flexible Pipe Integrity Assurance
The layout of the document is:
Lists what should be done from an integrity perspective at each stage of the
life cycle
Sets context with historical damage / failure data g
Sources of Potential Damage / Failure
Failure drivers
A ill i t i t ll ti d i l d id t l d Ancillary equipment, installation and service loads, accidental damage,
manufacturing defects
Guidance on Inspection & Monitoring Techniques
Procedure
Industry Practice
Guidance
24 Experience that Delivers
Guidance
SureFlex Outcomes:
Guidance Note Document 2 Guidance Note Document - 2
General visual inspection
The monitoring and inspection techniques include:
General visual inspection
Pressure, temperature and bore fluid monitoring
In-line coupon monitoring p g
Riser annulus integrity monitoring
Radiography, eddy current, ultrasonics
Non-intrusive stress monitoring
Armour wire fibre optic monitoring
Load, configuration and external environment monitoring
25 Experience that Delivers
SureFlex Conclusions - 1
Significant database of population statistics and failure damage incidents
Some key conclusions from the work are:
Significant database of population statistics and failure damage incidents
1,400 static lines, 1,900 risers and 315 reported damage / failure
incidents
Integrity Management Practice
Lack of coherent strategy which details all design and operational data to
be monitored and recorded Follow-up on recording and assessing still be monitored and recorded. Follow-up on recording and assessing still
found wanting.
Handover from project execution to operations has improved since 2002,
but still needs to be better
Numerous failures to correctly commission gas venting systems
26 Experience that Delivers
SureFlex Conclusions - 2
Significant Uptake inAnnulus Testing since 2002
Further conclusions .....
Significant Uptake in Annulus Testing since 2002
Improvement in procedures and assessment capability
New techniques developing q p g
Initial testing at FAT followed by annual testing is now accepted practice
Retired Risers due to Corrosion Fatigue
Limited number of retired riser dissections imply predictions are too
conservative
Corrosion fatigue assessments needs improvement Corrosion fatigue assessments needs improvement
Principal cause of damage remains external sheath breach
Focus nowon global corrosion in the splash zone
27 Experience that Delivers
Focus now on global corrosion in the splash zone
SureFlex Recommendations
Create a joined-up approach to S-N curve definition for corrosion fatigue and
Main recommendations from SureFlex are:
j p pp g
improve our methodology for corrosion fatigue assessment.
Put more focus on and significantly improve our practice on annulus vent
systemdesign commissioning and maintenance system design, commissioning and maintenance.
Establish an industry consensus on failure mechanisms involved in tensile
armour birdcaging and lateral buckling through discussion and information
sharing between relevant stakeholders sharing between relevant stakeholders.
Establish a mechanism for annual update of the Guidance Note document:
Procedure Industry Practice Guidance Note format is well established Procedure Industry Practice Guidance Note format is well established
Inspection and monitoring techniques are developing quickly now in
response to demand
N d t t l t t i d t i d ti
28 Experience that Delivers
Need to capture latest industry experience and practice
Flexible Riser Fatigue g
Numerical / Analytical Wire Stress Calculations
Upcoming Slides on Flexible Pipe Fatigue:
Numerical / Analytical Wire Stress Calculations
Finite Element Wire Stress Calculations
Full Finite Element Model of Pipe Cross Section p
Summary of Current Status on Flexible Riser Fatigue
Recent Flexible Pipe Dissection Experience
29 Experience that Delivers
Flexible Pipe Fatigue
Flexible Pipe Bending Hysteresis Flexible Pipe Bending - Hysteresis
StickSlip Bending StickSlipBending
TensileArmour initiallysticksonreversebending
Slipisinline withandtransversetolaydirection p y
Hystereticfatiguestress
150
50
100
s

(
M
P
a
)
Regular Stress
Cycle -50
0
W
i
r
e

S
t
r
e
s
s
-150
-100
-0.1 -0.05 0 0.05 0.1
W
30 Experience that Delivers
Pipe Dynamic-Curvature (rad/m)
Wire Equations of Equilibrium
LayercomStress Methodology LayercomStress Methodology
d
0
, 12
11

tot
t
ds
d

Tangential
2
0
, 22 11

diff n
t
Surface Normal
1
3
0
, 32 11

tot t
t
Transverse
3
MethodofSolution
Incrementalcurvaturedeterminesincrementalnonslipaxialstress
Incremental nonslip axial stress determines incremental tangential shear Incrementalnon slipaxialstressdeterminesincrementaltangentialshear,
normalinterfaceandtranverseshearstresses
CheckCoulomblawandgraduallyrelaxstresseswhileretainingequilibrium
Wirecurvaturesfromloxidromic/geodesicequations
31 Experience that Delivers
Friction-Induced Stress
LayercomMethodology LayercomMethodology
Structural Model for Friction Irregular Loading StructuralModelforFriction IrregularLoading
Wire Stress
60
80
100
)
Pipe Bending Curvature
0 01
0.015
0.02
0.025
d
/
s
)
60
-40
-20
0
20
40
S
t
r
e
s
s

(
M
P
a
)
0 02
-0.015
-0.01
-0.005
0
0.005
0.01
C
u
r
v
a
t
u
r
e

(
r
a
d
-80
-60
0 10 20 30 40 50 60
Time
-0.025
-0.02
0 10 20 30 40 50 60
Time (s) Hysteresis Loop
100
0
20
40
60
80
s
s

(
M
P
a
)
-80
-60
-40
-20
0
0 02 0 02 0 01 0 01 0 00 0 01 0 01 0 02 0 02
S
t
r
e
s
32 Experience that Delivers
-0.02 -0.02 -0.01 -0.01 0.00 0.01 0.01 0.02 0.02
Pipe Curvature (rad/m)
3D (out-of-plane) Irregular Seas
L M th d l LayercomMethodology
3D Pipe Bending in Irregular Seas
2 13 1 ff Hs = 2m, Tp = 13s, 15deg off-bow
Global Tension (left) and Curvature (right) Responses
1.70E+06 0.008
1.60E+06
1.65E+06
0.004
0.006
)
1.55E+06
T
e
n
s
i
o
n

(
N
)
0
0.002
C
u
r
v
a
t
u
r
e

(
r
a
d
/
m
)
1.45E+06
1.50E+06
-0.004
-0.002
1.40E+06
15 35 55 75 95 115
Time (s)
-0.006
33 Experience that Delivers
Tension Local-y Pipe Curvature Local-z Pipe Curvature
3D (out-of-plane) Irregular Seas
L M th d l LayercomMethodology
3D Pipe Bending in Irregular Seas
H 2 T 13 15d ff b Hs = 2m, Tp = 13s, 15deg off-bow
Armour Total Stress at 8 Equally Spaced Positions on the Cross Section
750E+06
800E+06
700E+06
750E+06
600E+06
650E+06
S
t
r
e
s
s

(
P
a
)
500E+06
550E+06
450E+06
15 35 55 75 95 115
Time (s)
34 Experience that Delivers
0deg 45deg 90deg 135deg 180deg 225deg 270deg 315deg
FE Model Single Armour Wire g
Single tensile armour wire in
isolation
Wire constrained between
cylindrical surfaces
Apply curvature to cylindrical Apply curvature to cylindrical
surfaces
Compare FE results with: p
Theoretical wire-curvature
models
Analytical Tools
Layercom
35 Experience that Delivers
Wire Deformation Path under
Bending Fatigue Stress Bending Fatigue Stress
Vi 1
View 2
Frictionless Contact
Original Wire Position
Applied end
rotation (both
ends)
View 1
Pipe
View 1 View 2
Neutral
Axis
Resultant Axial Displacement of Wire -
Principle Wire Stress for Fatigue Calculation
36 Experience that Delivers
Comparison of Results - 1
0 02
0.015
0.02
0.005
0.01
e

[
1
/
m
]
0
0 50 100 150 200 250 300 350 400
e
r
s
e

C
u
r
v
a
t
u
r
e
0.01
0.005
T
r
a
n
s
v
e
MCSLoxodrome
Saevik
0 02
0.015
Witz&Tan
Abaqus/Standard
37 Experience that Delivers
0.02
AngularPosition [degrees]
Comparison of Results - 2
80
Abaqus
60
70
M
P
a
]
Abaqus
LayercomW&T
LayercomSaevik
30
40
50
A
x
i
a
l

S
t
r
e
s
s

[
M
LayercomMCSLoxodrome
10
20
30
W
i
r
e

A
0
10
0 0.05 0.1 0.15 0.2 0.25
Pipe C r at re [1/m]
38 Experience that Delivers
PipeCurvature[1/m]
Each Layer Modelled Explicitly
Contact Friction Lock in Contact, Friction, Lock-in
39 Experience that Delivers
Flexible Pipe Fatigue
Current Status Current Status
Ongoing Industry Efforts
Continue to improve analysis models Continue to improve analysis models
Set standard methodology for armour wire testing and S-N curve
development
M i t k J IP Marintek J IP
Step towards transparency
Manufacturers further evaluating annulus environment g
Most likely we are conservative in our fatigue predictions
Recent OTC Brazil 2011 paper by Charlesworth, DAll, et al
P f d f ti t ti f i i b d tiff i Performed fatigue testing of armour wires in bend stiffener region
10 years operation West of Shetlands
40 Experience that Delivers
Recent developments in Flexible Pipe
Fatigue (OTC 22398)
BP West of Shetland
Fatigue (OTC 22398)
BP West of Shetland
Foinaven & Schiehallion fields
Flooded annuli due to sheath damage
d i i t ll ti (1997) during installation (1997)
Increasing H
2
S levels
Fatigue of armour wires an issue
Integrity managment process
implemented
OTC-22398-2011
Sheath Damage
implemented
Breaches sealed
Annulus flushed with corroson inhibtor
Regular fatigue life reassessments Regular fatigue life reassessments
41 Experience that Delivers
Replacement of High Pressure
Flexible Gas Riser Flexible Gas Riser
High Pressure Gas Riser
Higher fatigue sensitivity - compared to water
injection and production risers
Integrity management process Integrity management process
HP gas riser predicted to be approaching end
of fatigue life
2008 - decision taken to replace gas riser 2008 - decision taken to replace gas riser
Decommissioned riser taken to Technip for
dissection and inspection.
42 Experience that Delivers
OTC-22398-2011
Dissection and Inspection of
Decommissioned Gas Riser Decommissioned Gas Riser
Dissection of Gas Riser
Two samples taken: Bend stiffener and topside
(high and low dynamic loading)
Dissection showed:
Signifcant degradation of outer wear tape in
bend stiffener region but RECE effects not an
issue close to sea surface.
Majority of pipe layers in good condition for 10-
year service
43 Experience that Delivers
Armour wires in near pristine condition
Fatigue Testing of Armour Wires g g
Fatigue analysis of bend stiffner sample
Armour wires supplied to Marintek
Commissioning fatigue analysis also performed by g g y p y
Marintek
Comparison between predicted and actual fatigue damage
possible
H
2
S and CO
2
environments considered.
Results of Fatigue Testing Results of Fatigue Testing
Armour wires have been shown to have received very little
fatigue damage over 10-year service.
True for H S and CO environments True for H
2
S and CO
2
environments
Armour wires of decommissioned riser have fatigue lives
which are comparable to as-built wire
Far too conservative in our fatigue predictions
44 Experience that Delivers
Far too conservative in our fatigue predictions
Birdcaging & Armour Wire
Disorganisation Disorganisation
Radial buckling mode of the tensile wires
Hi h i l d
Birdcaging
High compression loads
Bending
Reverse End Cap Reverse End Cap
Local deformation of individual wires about wire weaker axis
45 Experience that Delivers
Birdcaging & Armour Wire
Disorganisation Disorganisation
Armour Wire Disorganisation & FE Models
46 Experience that Delivers
Armour Wire Disorganisation g
47 Experience that Delivers
Birdcaging Modelling & Validation g g g
Finite Element Model
Good comparison with
experimental results
48 Experience that Delivers
Looking Ahead for Flexibles g
Some Forward Developments & Challenges
Singing Risers & Smooth Bore Flexible Pipe
Sour Annulus &Anti-H2S Layer Sour Annulus & Anti H2S Layer
Composite Armour Wires in Flexible Pipe
49 Experience that Delivers
Traditional Rough Bore Flexible Pipes g
Inner carcass
shackle construction corrugated profile
Induces vortex shedding from carcass in dry
gas flow
OTC 18895 - 2007
50 Experience that Delivers
Statoil Asgard B Platform
(OTC 18703) (OTC 18703)
Serious noise and vibration phenomenon
Accompanied by pressure losses in system
Cause: Vortex induced pulsations in bore
Amplified by resonance with topside piping
Premature fatigue failure
Lead to 2 Gas leakage incidents topside
Not expected - Wet gas/ liquid hydrocarbons not
affected Only arises in dry gas export affected. Only arises in dry gas export
Liquid - damping effect on the acoustic waves
51 Experience that Delivers
Smooth Bore Flexible
Riser Technology Riser Technology
Implemented by Technip into Asgard B
No vortex shedding
Noise & vibration eliminated
Pressure Loses reduced
Preventative measures required to avoid
inner Tube Collapse
OTC 18703 2007
52 Experience that Delivers
p
OTC 18703 - 2007
Smooth Bore Wire Carcass
(OTC 21777) (OTC 21777)
Helically wound wires with K-armour carcass
Replaces rough bore folded strip armour
Implemented by NKT
No vortex induced pulsations
Noise &vibration eliminated Noise & vibration eliminated
Similar reduction in pressure loss as smooth bore
K-Armour
Increased collapse capacity
High radial stiffness g
Deepwater & Ultra Deepwater applications
Offers axial support absorbs compression
Prevents bird caging of tensile armour in Deepwater
OTC 2177 - 2011
53 Experience that Delivers
Prevents bird caging of tensile armour in Deepwater
Sulphide Stress Cracking (SSC) &
Hydrogen Induced Cracking (HIC) Hydrogen Induced Cracking (HIC)
High strength steels are cured or strain hardened
Increases yield stress
Disadvantage: Highly susceptible to SSC & HIC
Presence of H
2
S gas and water -> weak acid
Acts as a cataylist in metal embrittlement
Due to H
2
penetration in metal
54 Experience that Delivers
2
p
Sulphide Stress Cracking (SSC) &
Hydrogen Induced Cracking (HIC) Hydrogen Induced Cracking (HIC)
SSC & HIC corrosion phenomena induced in the pipe annulus
B Hi h P H S (S ) Fl id OTC 21371 2011
High bore pressure - corrosive gases diffuse through pressure sheath
Bore - High Pressure, H
2
S (Sour) Fluid OTC-21371-2011
Water vapour (from bore/external breach) - combines with H
2
S or CO
2
gas
Acidic condensate on armour wires leads to failure
SSC and HIC can appear within weeks ceasing production
55 Experience that Delivers
SSC and HIC can appear within weeks ceasing production
Sulphide Stress Cracking (SSC) &
Hydrogen Induced Cracking (HIC) Hydrogen Induced Cracking (HIC)
Sour service pipes require low grade steel
Not as susceptible to SSC & HIC
Low yield stress y
Increased thickness required for strength
Increased number of armour layers
Limitations of use in deep and ultra deep water
Increased weight
Limitations of use in deep and ultra deep water
56 Experience that Delivers
OTC-21371-2011
New Anti H
2
S Layer for Flexible Pipes
(OTC 21371) (OTC 21371)
Additional thermoplastic sheath
Developed by Technip
Anti-H
2
S sheath placed above pressure
2
p p
sheath - Dubbed PEZnO
Thermoplastic (PE) matrix compounded
with zinc oxide (ZnO) ( )
Components in sheath chemically react
with H
2
S that has pervaded the pressure
sheath:
H
2
S free enviroment maintained in
annulus
OTC-21371-2011
57 Experience that Delivers
annulus
New Anti H
2
S Layer for Flexible Pipes
(OTC 21371) (OTC 21371)
High reactivity of ZnO gives a very small reaction zone
OTC-21371-2011
Initial thickness of PEZnO selected to ensure that Anti-H
2
S layer is not totally
transformed to PEZnS before end of service life
58 Experience that Delivers
New Anti H
2
S Layer for Flexible Pipes
(OTC 21371) (OTC 21371)
Benificial impacts on flexible pipe design:
OTC-21371-2011
Anti-H
2
S layer : No diffusion of H
2
S from the bore to the annulus
No risk of SSC or HIC of armour wires
Sweet service armour can be used
Decrease in manufactoring costs & up to 25% decrease in weight
OMAE2010-20383: - Flexibles for Ultra Deep Water in the Brazilian Pre-Salt Area
59 Experience that Delivers
Thermoplastic Composite Pipe
Technology Technology
Reinforcing a thermoplastic liner
with melt-fused fibre-tapes
One Material Concept
with melt fused fibre tapes
Same thermoplastic compound
in liner, tapes and coating
F ll b d d lid ll t b l Fully bonded, solid wall tubular
Developed by Airborne
60 Experience that Delivers
Conclusions
Key Conclusions are:
Flexible Pipe has had a long and successful history
A major contribution to floating production developments
It is a complex product
Alot of fun to engineer!! A lot of fun to engineer!!
New Challenges ahead for Flexible Pipe
Continuous evolution and growth likely
61 Experience that Delivers
Thank you
A ti ? Any questions?
Experience that Delivers