FPS 2011 Conference.

FPS 2011 Conference

Composite Pipe For FPSO Risers Presented by Stephen Hatton

FPS 2011 Conference

Agenda

• Riser Options Overview

• Future market requirements

• Carbon / polymer (m-pipe) materials

• m-pipe riser configurations

• Deployment options

• Conclusions

Slide 2

FPS 2011 Conference

Floating Deep Water Production

Dry Tree Wet Tree

Slide 3

FPS 2011 Conference

The Riser Design Challenge

• High stresses due to vessel motions

• Fatigue sensitivity (waves, VIV)

• Mooring offsets up to 25% water depth

• Corrosion (Internal fluid and seawater)

• Vessel payload limitations

• Field lay out congestion

– Mooring line clashing

– Riser and flowline corridors

• Process flow (arrival temps and cool down)

• Installation vessel capability

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FPS 2011 Conference

Riser Options for FPSO Applications

• Flexible Risers (Non Bonded)

• Free Standing (SLOR, Hybrid Bundles)

• Steel Catenary Risers

Slide 5

FPS 2011 Conference

Non Bonded Flexible Risers

Courtesy NKT Slide 6

FPS 2011 Conference

Non Bonded Flexible Pipe

• A FPS ‘workhorse’ for over 30 years

• Used in a range of catenary configurations

• But in deep water:

– Cost / metre

– Weight and vessel payload

– Robustness / damage tolerance

– Sour service capability

– Long Term Reliability

– Market Availability

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FPS 2011 Conference

Free Standing Risers - SLOR

Slide 8

FPS 2011 Conference

Complex Installation Procedures

• SLOR’S typically need heavy lift vessels and complex

fabrication

• High day rates coupled with high equipment costs

make SLOR’S expensive

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FPS 2011 Conference

Steel Catenary Configurations

Courtesy 2H

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FPS 2011 Conference

Steel Catenaries Are Not an Easy or Cheap Solution

• Sensitive to fatigue and need low motion vessels

• Sensitive to H2S without internal cladding

• High vessel payloads (but less than flexible pipe)

• Complex vessel interfaces, the source of much concern in recent years

• Thick pipe walls require:

– Large Installation vessels ($$)

– Long fabrication cycles

– High installation costs

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FPS 2011 Conference

SCR Weld and HAZ Properties A Metallurgical Balancing Act

Required to

accommodate

Loads and pressures

Required for

resistance to crack

growth and impact loads

Resistance to H2S Embrittlement (NACE)

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FPS 2011 Conference

Corrosion and Resistance to H2S Inconel Cladding

• Reduce CO2 corrosion

• Prevent H2S embrittlement

• Avoid fatigue factor knockdown and achieve fatigue life

• Simplify weld procedure requirements

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FPS 2011 Conference

Riser Options Conclusion

• There are many riser configurations built around non bonded flexible pipe and steel pipe for FPSO

• These systems are complex but not withstanding the industry has a good level of experiences with them

• Their installed costs are significant and an important project driver

• In the coming years corrosion and fatigue will be an ‘Achilles heel’ to aged infrastructure and a source of increasing downtime

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FPS 2011 Conference

The Industry is Focussed on Even More Challenging Discoveries

• Deep and Ultra deep water (up to 3500m)

• High Pressures 5-15ksi

• High temperatures (150 deg C +)

• Sour service plus CO2 conditions are typical

• Complex process flow conditions

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FPS 2011 Conference

A New Riser Pipe Material

m-pipe™ is a high quality, high strength carbon / polymer pipe with a monolithic structure from

bore to surface

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FPS 2011 Conference

Key Performance Advantages

• Light weight - 10% of the weight in water of the equivalent steel or un-bonded flexible

• High strain to failure up to 2%

• Corrosion resistant to seawater and CO2

• Extremely high fatigue capacity

• Fatigue performance unaffected by sour service

• High temperature operation up to 390°F, 198°C

• High resistance to permeation (100 x that of pa11, pvdf, pe)

• Virtually indestructible from effects of rapid gas decompression

• Low thermal conductivity, 10x better than steel

• Better erosion resistance compared to steel

• Excellent wear resistance

………….. a good riser material

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FPS 2011 Conference

Fully Automated Process

• A single repetitive process that integrates only two materials

• exceptional process control (parameter control, monitoring, documentation and repeatability)

• Continuous length production capability

• Dimension flexibility 2-24” diameter and wall thickness

• At the point of pipe construction a simpler process with greater control than typical either a steel pipe or non bonded flexible

Single Process

Multiple Processes

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FPS 2011 Conference

End Fitting Development and Qualification

• m-pipe to any steel interface resolved

• Flange, hub or threaded connections

• As ‘strong as the pipe’

• Preloaded with bore seal

• Compact and light weight

• External pressure test ports

19

Slide 19

FPS 2011 Conference

Typical Pipe Products for 2000m Water Depth

Nominal Diameter

Depth Rating

Pressure Rating

ID

WT

OD

Weight in Air

Spoolable Diameter

(in) (m) (ksi) (mm) (mm) (mm) (kg/m) (m)

2 2000 5K 47 7 61 1.75 7

3 2000 5K 72 9.5 91 3.64 10.5

6 2000 5K 148 17 182 13.4 21

8 2000 5K 199 22 243 23.3 28

10 2000 5K 250 27 304 35.9 35

2 2000 15K 47 8.5 64 2.2 7.5

3 2000 15K 72 12 96 4.78 11.5

6 2000 15K 148 23 194 18.9 23

8 2000 15K 199 31 261 34.3 30

10 2000 15K 250 38 326 52.7 38

WT Equivalent to a 70ksi Steel Pipe

Light Weight

Small Spool Diameter Slide 20

FPS 2011 Conference

Status and Questions

• We have access to a new material, pipe and end

fitting

• BUT

– Question 1 – How do we best configure the riser

– Question 2 – How do we install the riser

m-pipe

Risers Catenary

Free Standing

Slide 21

FPS 2011 Conference

M-pipe as a Simple Catenary

Static Configuration and with ‘Near’ Current

Current

8in Diameter, 1000m Water Depth, 10 Deg Top Angle

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FPS 2011 Conference

Min Bend Radius 13.6m (Near)

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FPS 2011 Conference

Chain Tethered Simple Catenary

Iin Chain

Current

8in Diameter, 1000m Water Depth, 10 Deg Top Angle, 1in Chain, Attached 20% WD

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FPS 2011 Conference

Min Bend Radius 26.6m (Far)

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FPS 2011 Conference

Chain Tethered Catenary Conclusion

• Simple configuration based on the proven flexible

riser pliant wave

• Low payloads and high motion tolerance

• Low fatigue and high corrosion resistance

• Will facilitate use of FPSOs in deep and ultra deep

• Will enable critical service conditions HTHP and

UHTHP

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FPS 2011 Conference.

What about Deployment ?

FPS 2011 Conference

• Smaller, lower specification vessels

• Shorter installation durations

• Reduced overall installation risk

• Lower maximum lift weights

• Higher permissible deflections at lower loads

• Simplified riser mechanical complexity

(URA/LRA/Foundations)

• Reduced offshore personnel

• Shorter installation durations

• Increased operational windows

• Reduced corrosion coating damage

• Offshore re-spooling

• Increased tow feasibility

m-pipe Installation

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FPS 2011 Conference

Barge or Construction Vessel Installation

Hub Diameter 26-30m for 8-12in diameter pipe

Small payload (100’s Te rather than 1000’s Te)

Potential for offshore respooling

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FPS 2011 Conference

Summary

• Despite advances in riser technologies they remain complex and costly

• FPSOs are the most challenging host due to riser motions and offsets

• Ultra deep applications and more stringent service conditions are forecast

• Carbon fibre / polymer technology is coming of age and this and other industries

• It offers the potential for cost savings and simplification of the riser challenge

• In some instances it is an enabler

Slide 30