45869978 Introduction to Unbounded Flexible Pipe

7/22/2019 45869978 Introduction to Unbounded Flexible Pipe

1/91

Wellstream International Limited. Duplication in full or in part is prohibited.

Manufacture -1

PUC / CCE / Prominp

Course on Flexible Pipes

Introduction to Unbonded Flexible PipeDesign & Manufacturing

13th of December 2007

Judimar Clevelario

Technology Manager

Wellstream do Brasil

[email protected]


2/91


Manufacture -2Course Outline1.What are Flexible Pipes Used For? What is a Flexible Pipe?

I. Flexible Pipe Layers & ConstructionII. Key Design Considerations

III. Main Ancillaries

IV. Main Flexible Pipe Standards and Documentation

2.Flexible Pipes Layer Function and Materials

3.Flexible Pipes DesignI. 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 AnalysisVI. 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


3/91


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


4/91


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 characteristicsof the transported fluids

Flexbarrier - PolymerHDPE, PA11/PA12, PVDF

FlexlokCarbon Steel

Flexshield - Polymer

TPE, HDPE, PA11/PA12

FlexinsulSyntactic Foam

FlexbodyAlloy steel FlextensileCarbon Steel

End fitting Composition


5/91


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 ofhelically 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


6/91


Key Design Considerations

Gross structural integrity(tension, pressure)

Riser interaction (clashing,

interference andentanglement)

Fatigue (curvature and tensionranges)

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


7/91


Main AncillariesEnd Fittings

End fittings are custom designed for

each flexible pipe structure Terminations can be any design

API/ANSI flanges, hubs, welded, orother

Stronger than pipe in burst and failuretension

Most common structural material isAISI 4130 low alloy steel

Common coatings include electrolysis

nickel plating, and various epoxies. Assembly is a manual process


8/91


Main Ancillaries

IP - Anode Clamp Design

Installation Sequence

Before the installation,the ROV clean theEndfitting surface using

a steel brush toguarantee a betterelectrical contact of theAnode Clamp.

After that, the

installation process isillustrated in the figureaside.

Anode Clamp Design

Used to protect flexible pipe

end fittings against corrosion


9/91


Required for dynamic risers

Polyurethane cone that moves bending moment frombase of end fitting

Installed remotely or diver assisted.

Main AncillariesBend Stiffener


10/91


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 AncillariesBend Restrictor


11/91


Floatation attached to result in

desired riser configuration Both concentrated and distributed

Clamps required for concentratedbuoy to make connection to arch

Main AncillariesBuoyancy Modules


12/91


Main Ancillaries

Hang Off Clamp


13/91


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 andproduction 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)


14/91


Manufacture -14

Technical Documentation Requirementsfor Flexible Pipe

Design Premise Design Load Report

Design Report (with Riser System / Service Life Analysis)

Fabrication Specification

Operation Manual

Manufacturing Quality Plan

Data Book


15/91


Manufacture -15Petrobras - Marlim SulPipe ID : 6 inchesWater Depth : 1500mPressure Rating : 20.68 MpaDesign Temperature : 60 Deg. CFunction : Oil / Gas Insulated Flowline

!" ##

$%

% &

' ($)**+"" ##

,

(-& . /

0

123 ##

$(

&//

./ /

4 #

"*##

$(

&//

./ /

4 #

"* ##

'% *

(-& .

& $5 /

0

2"" ##

'% 6

(-& .

& $5 /

0

2"" ##7$

#

7 5

7 8/ $&

.(

3"" ##

%'9

.

#

(+"""

!""" ## :;.%

-#

(

.(

(+"""

*""" ##


16/91


Manufacture -16

Flexible Pipe Design Make-up

FlexbodyFlexbody --

(Internal Carcass)(Internal Carcass)The Flexbody is acorrugated metallic tubewith a specified internaldiameter. The Flexbodysupports the extrudedfluid barrier andprevents collapse fromhydrostatic pressure orcrushing loads applied

during pipe operation.

Provides collapse resistance by forming into an interlocking spiral


17/91


Carcass Materials

In corrosive well conditions stainless steels are utilized due to:

Excellent corrosion resistance

Good mechanical strength

Good formability

Subjected to severe conditions:

High temperatures

Corrosion forming gases(hydrogen sulfide and carbondioxide)

Seawater

Acids

Sand erosion

Material types

Carbon steel 304L 316L 2205 Duplex AL6XN Lean Duplex

Increasing corrosion resistanceIncreasing corrosion resistance

Increasing tensile strengthIncreasing tensile strength

Improved resistance to temperatureImproved resistance to temperature

Corrosion and erosion testing is carried out to ensure suitability in accordance withthe requirements of API 17J

Exposure to installation conditions such as seawater flooding and inhibitor injection isalso assessed


18/91


Manufacture -18


FlexbarrierFlexbarrier --

(Internal Pressure Sheath)(Internal Pressure Sheath)

The Flexbarrier is apolymer layer extrudedover the Flexbody to forma boundary for theconveyed fluid. TheFlexbarrier material is

selected to be chemicallyresistant to the conveyedfluid and unaffected by itsservice conditions.

Material types

HDPE PA11/PA12 PVDFIncreasing temperature resistanceIncreasing temperature resistance

Increasing chemical compatibilityIncreasing chemical compatibility


19/91


Internal Pressure SheathMaterial Selection

Static Service

130C

120C

110C

100C

90C80C

70C

60C

50C40C

266F

248F

230F

212F

194F166F

158F

140F

122F104F

HDPE Nylon PVDF Nylon PVDF

Dynamic Service

Service Life

Assessment RequiredBased on

conveyed fluid

oil or water

Service Life

Assessment Required


20/91


Manufacture -20


FlexlokFlexlok --

(Pressure Armour)(Pressure Armour)The Flexlok is a steel hoopstrength layer consisting ofcircumferentially woundprofiled wire to resist tointernal pressure and

bending.The Z-shaped wire isprofiled to allow interlockingof the edges as they are

formed around the pipe.


21/91


Provide hoop strength

Depending on sweet or sour service, medium carbon steels range fromminimum UTS 110ksi to 155ksi are used due to:

Excellent formability to produce high tensile strengths

Steel rod is a readily available commodity

Good fatigue resistance

Designed to withstand pipe annulus conditions:

High hoop and bending loads including fatigue Corrosion forming gases (hydrogen sulphide and carbon dioxide)

Permeated water

Pressure Armor Materials


22/91


Manufacture -22


The TensileArmor layer is ahelical steelarmor layer thatresists internalpressure andaxial tension.

FlextensileFlextensile --

(Tensile Armour)(Tensile Armour)


23/91


Tensile Armor Wire

Manufactured from carbon steel wire rod to specified strength(ranging from minimum UTS 110ksi to 190ksi, depending on

sweet or sour service) and cross-sectional area Good fatigue resistance Designed to withstand pipe annulus gas permeated conditions


24/91


Manufacture -24


FlexwearFlexwear -

(Anti-wear Layer)

The Flexwear is a thinpolymer tape layer appliedbetween any two adjacentmetallic layers, and such

prevents metal-to-metalcontact between the layersto prevent wear.

FlextapeFlextape -

Tape layers are appliedover the tensile armorsas a manufacturing aid toprevent birdcaging.


25/91


Anti-Wear Layers

Nylon Tape -

Excellent wear resistancewith high temperature performance

Nylon Tape with Additive -

Superior wear resistance, best hightemperature performance, required inlarge diameter pipes in high wear areas

The Anti-Wear layer is a thin polymer tape layer applied betweenany two adjacent metallic layers, and such prevents metal-to-metalcontact between the layers to prevent wear.


26/91


Manufacture -26


FlexinsulFlexinsul --(Insulation)(Insulation)

Flexinsul is a thermalinsulation layer used

to limit heat lossthrough the pipe wallto the surroundingenvironment.


27/91


Insulation Layer

Wrapped versions arepreferred due to the low

cost of production

(Application: 1st layermelt extruded onto pipe,2nd wrapped onto pipe)

Deepwater syntacticfoam insulationmaterials rated for1,000m, 2,000m and

3,000m.


28/91


Manufacture -28


FlexshieldFlexshield --

(External Sheath)(External Sheath)Flexshield is anexternal polymer barrierapplied to resistmechanical damage

and intrusion ofseawater.


29/91


Outer Sheath Materials

Static Applications

The preferred material isHDPE

Dynamic Applications

Nylon PA-11/PA-12

UV resistance Stabilizer package in standard

shield added for UV exposure

Carbon black added to prevent

UV degradation for risers closeto top section


30/91


Manufacture -30

Pipe Structure Design Verification

Design Criteria

Pipe Wall Design

Stress & Strain,Anal. Local Analysis

Global Dyn. AnalysisLocal FE Analysis

Service LifeAnalysis

See Figures19, 20 API RP 17B

for more detailedprocess charts forstatic flowlinesand dynamic risers


31/91


Flexible Pipe Design Flowchart


32/91


Preliminary Design, Fluid Compatibility & Collapse & LocalStress

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

fluid compatibility to define the proposed pipe design


33/91


GLOBAL ANALYSIS - STRUCTURAL

First step is to define the riserconfiguration based on:

Water Depth

Vessel Type

EnvironmentalConditions

Flexible ID

Minimum Service Life

Specification


34/91


GLOBAL ANALYSIS STRUCTURAL

RISER CONFIGURATION EXEMPLES


35/91



Installation

Recurrent Operation Extreme Operation

Abnormal Conditions

Once the configuration is defined, a non-linear dynamic structural analysisis performed in order to estimate typical loads experienced by the flexiblepipe during:

API 17B provides

recommendations on how toperform the analysis

Petrobras has its own specificationwith mandatory requirements

SIRI_az202_GA-11-1-1.avi


36/91



General approach is to run several loadcases (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 besupplied by the client

Petrobras have specific documentscalled METOCEANs that provide all

necessary information to perform the

analysis


37/91



Vessel behavior are simulated bya matrix loaded into the

commercial software

(Orcaflex/Flexcom) This table specify the vessel

displacement/rotations for allvessel degrees of freedom in

terms of wave height and period.

On this way, the environmentalcondition influence can betranslated in vessel movementsand rotation that will impose

loads on the riser.


38/91



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 configurationin Brazil), the most important results are:


39/91


GLOBAL ANALYSIS Service Life

Once the riser is proven to resist to the most severeenvironmental 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 relatedwith a number of incidences

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

associated to a number of cycles and an accumulated fatiguedamage and life can be calculated based on Palmgreen-Minerrule

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


40/91


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 . 108

2 . 108

3 . 108

4 . 108

5 . 108

StraightHlexStraightHelix

BentHelix

BentHelix(Calib)

ApplCompression

StraightHlexStraightHelix

BentHelix

BentHelix(Calib)

ApplCompression

Equilibrium Path

Deflection

AxialCompression


41/91


Local AnalysisBending Stiffener Design FEA Modeling

3D Model Beam Model Performance Curve Prediction

Tip Region [USP Test]Tip Region [FEA Model]

Performance Curve Development

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

0 10 20 30 40 50 60

Angle (degress)

Tension(KN)

CRP 0 C CRP 50 C WS 50 C WS 0 C


42/91


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


43/91


Material Qualification

Insulation material onlyASTM D570Water absorptionEffectiveness to the UV stabilizerWeathering resistance

Method C. PE only.ASTM D1693Environmental stress crackingAPI 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 andmethane, at design temp and pressAPI 17J Sect. 6.2.3.1Fluid permeabilityPermeation characteristics

Or glass transition temp (ASTM E1356)ASTM D746Brittleness temperatureASTM E1269Heat capacity

ASTM D1525Softening point

Method AASTM D648Heat distortion temperaturesASTM E831Coefficient of thermal expansionASTM C177Coefficient of thermal conductivityThermal properties

ASTM D256Notch sensitivityDynamic applications onlyASTM D671Fatigue

Or ASTM D1505ASTM D792Density

Or ASTM D1044 or D1242ASTM D4060Abrasion resistanceAt design minimum temperatureASTM D256Impact strength

Hydrostatic pressure resistanceASTM D695Compression strength Or ASTM D2583ASTM D2240Hardness

ASTM D638Modulus of elasticityASTM 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


44/91


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 270nkm

(based on 8in ID structure)

Expected product range: inside diameter of2 to 12

Facility designed to allow future expansion


45/91


46/91


Manufacturing Process

Carousel

End FittingTesting and

Packing

Insulation

Carcass

Carcass

Barrier Extrusion

Flexlok

RewindRewind

Armour

Flexwear / Shield Extrusion

Carousel

Carousel


47/91


Flexible Pipe Construction Carcass

CarcassCarcass --The Carcass is a corrugatedmetallic tube with a specifiedinternal diameter. TheCarcass supports theextruded fluid barrier andprevents collapse frompressure or crushing loadsapplied during pipe operation

Material SelectionMaterial Selection

Stainless 304L, 316 L

Duplex & AL6XN

Manufacture -48


48/91


Storage of pancakes The material is verified for

compliance with specifications

in accordance with the

Manufacturing Quality Plan

The rolls of strip are calledpancakes and the weight ofeach depends on the size ofthe strip thats being used.

The approximate weight is

440kg.

Th P b d R ll


49/91


The Pre-bend Roll

The strip passes through a

flyer head, an entry guide, aprogressive die and then

forming rollers to shape thestrip.

Manufacture -50


50/91


Butt Welding Strip

The pancakes are joined

using an automatic

welding machine, this

enables the drum to be

loaded with one

continuous length of

strip and allows the

production of a

continuously formed

carcass length.

Manufacture -51


51/91


The Pre-bend Roll

The strip passesthrough a flyer head, an

entry guide, a

progressive die and

then forming rollers toshape the strip.

Manufacture -52

M d l / Wi di R ll


52/91


Mandrel / Winding Rollers

The formed strip is wound

around a mandrel using

winding rolls.

The size of the mandreldictates the internal

diameter of the carcass.

This can range from 2 up

to 16.6.

The winding rolls rotate

around the mandrel as the

strip is closed to its final

interlocked shape.

Manufacture -53


53/91


Quality Inspection

Critical parameters which are

checked for tolerances (every 10

meters).

External diameter

Wall thickness - beginningand end

Ovality

Manufacture -54


54/91


Carcass take up Reel

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

Manufacture -55

Extrusion Process


55/91


Extrusion Process

The required wall thickness is

determined by the basic pipedesign, material type and / orlayer function.

Wall thickness and pipe

diameter are constantlymonitored and checked forvoids.

The process is computer

controlled ensuring a uniform

stress-free extrusion bycarefully monitoring andcontrolling extrusionparameters, including resinmoisture content, temperature,pressure, line speed, andquench tank pressure.

Manufacture -56


56/91


Materials and Storage

Raw materials are delivered to

the plant in Octabins/boxes, in

the form of granules. Materials are verified for

compliance with specifications.

The material is protected against

contamination by a plastic or foillined bag.

Manufacture -57


57/91


Transfer Stations and Silos

The material is loaded intoa silo.

Unique silos for

each polymer

Driers integrated

with silos

Manufacture -58


58/91


The Extruder loader and Hopper

From the silo the material is

vacuum transferred to the

extruder hopper.

Manufacture -59


59/91


The Crosshead The polymer material passes

through the extruder

(auger/barrel) and filters, theninto the crosshead.

Each type of material run

through the extruder has its

own heat profile. This is due to

individual polymers being

processed differently because

of mechanical properties.

Manufacture -60


60/91


Production Reels & Carousel The product is stored on reels or in a

carousel as it is processed througheach work centre.

The reels are also used to transportthe product to the customer.

Carousels are used when the length ofproduct exceeds the capacity of theproduction reels or where the SBR islarge.

Transportation to the customer takesplace by loading the product on to thevessel either on reels or in to the

vessels own carousel.

Manufacture -61


61/91


Caterpullers There are two caterpullerson each extrusion line, one

is used to pull the pipe

from the pay-off Rim driveand feed it down the line at

a constant speed.

The other one is used to

pull the product throughthe line at a constant speed

dictated by UT the catenary

setting. The catenary is a

necessary function of theextrusion line.

Manufacture -62


62/91


Quality Inspections

Critical dimensions - OD

and wall thickness. Wall

thickness measuredcontinuously by UT

Visual checks are also

carried out, and monitoring

the manufacturingtolerances are also part of

the Operators inspection

process.

Manufacture -63

Pressure Armor


63/91


Pressure Armor

The Flexlok machine applies ashaped, rolled, carbon steel wirewhich is preformed andinterlocked as it is wound aroundthe pipe, providing a smooth,flexible, continuous layer to

support the barrier and increasepipe burst pressure.

When design and pressurerequirements demand higher burststrengths, Flexpress, a wide flatwire, may be wound over the

Flexlok layer. Machines that apply from 1 to 4

wires simultaneously are used.


Sweet & Sour Service

Manufacture -64


64/91


Bobbin Rewind Flexlok/Flexpress wire is

supplied in coils. These haveto be loaded onto the Flexlokmachine bobbins.

The coils are loaded on to thepayoff and the wire is strungthrough the pinch rolls and

casting rollers and secured tothe bobbin.

The wire is then taken up onthe bobbin as the rewind

rotates and traverses fromside to side.

Manufacture -65


65/91


Quality Inspection Critical dimensions -

OD, Pitch, Gap,

Diametral gap from barrier

Dimensions are recorded every

10 metres and 100% visual

inspection of the wire is

conducted.

The Flexlok welds and the

materials used are tracked. The

welds and material are

recorded on the material

traceability record sheet.

Manufacture -66

Taping Head


66/91


p g

The tape heads are

suitable for the

application of either two

or four tapes. Afabricated steel frame

supports the rotating

head.

The following tapes are

applied - Manufacturing aidsAnti-birdcaging

(Deepwater)

Anti-wear(Dynamic Risers)

Thermal Insulation

Manufacture -67

Tensile Armour


67/91


The Armour machine appliesa layer of helical steel armourwires to the pipe.

The flat wires increase burststrength and give the pipeaxial strength. There are twomachines that apply the flatwire contra-helically.

The flat wire can be of

various sizes and tensilestrengths depending on thepipe design. As the wire isapplied, it runs through pre-form tooling heads whichtwist the wire so it lays flatagainst the pipes surface.


Sweet & Sour Service

Manufacture -68


68/91


Materials The armour

wire is supplied

from the stores

in various coil

weights.

Manufacture -69


69/91


Bobbins The armour wire is

wound from coils

onto bobbins.

The number of

bobbins and

amount of wire

used are

determined by the

pipe

specifications.

Manufacture -70


70/91


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.

Manufacture -71


71/91


Armour Bobbin Loading

Bobbins are loaded on

to the machine with a

loading system.

The loader can load up

to 4 bobbins at once.

Each armour machine iscapable of holding up to

96 bobbins.

Manufacture -72


72/91


Start up Once all the wires are

pulled down and secured

to the pipe the line isstarted.

The pipe is pulled forward

and the machine rotates

allowing the wire to be

wrapped on to the pipe.

Manufacture -73


73/91


Armour Running The second layer of armour

wires are then applied and

wrapped with tape.

The pipe is pulled through

the line by caterpullers and

take-up on a reel or

carousel.

Manufacture -74


74/91


Quality Inspections

Critical Dimensions -

ODDiametral gap,

flatness (prevent

fishscaling)

Gap betweenadjacent wires

Pitch

Lay angle

InsulationManufacture -75


75/91


Reduce heat loss

from the bore fluids(in order to

maintain lowviscosity bore fluidshence high flow

rates).

(Application: 1st

layer melt extrudedonto pipe, 2nd

wrapped onto pipe)



76/91


Outer SheathOuter Sheath --The Outer Sheath is anexternal polymer barrier

applied to resist mechanicaldamage and intrusion ofseawater.


HDPE, & PA-11/PA-12

Pipe Completion / Logistic Base in Brazil


77/91


Manufacture -78

End Fittings


78/91


g End fittings are custom designedfor each flexible pipe structure Terminations can be any design -API/ANSI flanges, hubs, welded, orother

Stronger than pipe in burst andfailure tension Most common structural materialis AISI 4130 low alloy steel Common coatings includeelectroless nickel plating, Inconel

Overlay and various epoxies. Installation is a manual process

Anchors the ends of the TensileArmour wires within the End Fitting,

thus enabling tensile load transfer.

(Application: pump injection of

viscous 2-part mix of liquid polymer)



79/91


StorageStorage

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

Carousels used for very long lengths

Manufacture -80

Factory Acceptance Tests


80/91


The FAT requirements are specified in theFabrication 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


81/91


Hydrostatic Minimum hydrotest pressure is 1.5 times the design pressure and

the maximum pressure is 1.04 times the minimum hydrotestpressure

After the 24 hour period if the pressure has not dropped more than4% the pipe is considered to have passed hydrotest

Factory Acceptance Testing (FAT)


82/91


Outer Sheath Integrity

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

The pressure must remain above 20psi during the test period and shouldnot reduce by more than 1psi during the last 15 minutes of the 30 minutehold 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 isintroduced slowly to a maximum of 90psi

Hoses are then attached at the out-board endfitting and the pressure and flowrate are recorded. A show of air bubbles are also required


83/91


Endfitting testing

Electrical Resistance - To confirm the insulation from the Barrierlayer/Insulation ring between the Carcass and the Endfitting bymeasurement of resistance

Electrical continuity test To measure that the resistance betweenboth endfittings is less than the omhs () advised on theMWO/PWO for the length of pipe tested


Manufacture -84

Load-out


84/91


Once the pipe iscompleted it is

secured to a reelor installed in to acarousel.

Manufacture -85

Load-out


85/91


Flexible Pipe and Umbilical loud-out at WellstreamBase


86/91


Manufacture -87

Load-out


87/91


Manufacture -88

Load-out


88/91


Qualification Criteria & Scaling Limitations


89/91


Two Objectives to Prototype testing: Prove or validate new or unproven pipe designs

Validate the manufacturers design methodology for a newpipe 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 familyshould verify products two inches larger or smaller than the

size tested

Scaling comparisons also based on pressure and internaldiameter (P x ID), with the test pipe qualifying pipes with alower P x IDvalue.

Testing Classes


90/91


All Unbonded Flexible Pipe testing is executed in accordance with API RecommendedPractice 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


91/91


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

Documents

45869978 Introduction to Unbounded Flexible Pipe