session 9 - subsea integrity practices in gom - a case study...session 9: hse spe workshop 21st...
TRANSCRIPT
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Session 9: HSE
SPE Workshop
21st October 2011
Shreenaath Natarajan
Subsea Integrity Practices in GoM –A Case Study
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• Integrity Management Philosophy
• Performance Assessment Methods
• Integrity Issues and Mitigation Strategy
• Summary
Shreenaath Natarajan
Objectives
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Shreenaath Natarajan
Integrity Management Philosophy
• Assure fitness-for-purpose of the subsea system• Compliance with regulatory requirements• Effectively manage –
• Risk to personnel safety• Risk to environment• Availability of asset
• Address threats arising from –• Internal (Corrosion, Erosion, Blockage, etc.,)• Extrernal (Corrosion, Impact, Structural Stress/Fatigue, etc.,)• Ageing related problems• Environment uncertainties
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IM in Operations
Peter Falconer
IM Procedure
Inspection Requirements
Risk based IM Plan
MonitoringMitigation
NeedsOperational
Limits
Shreenaath Natarajan
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Performance Assessment Methods
Shreenaath Natarajan
Subsea Integrity Practices in GoM –A Case Study
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Peter Falconer
Performance Assessment Methods
2: Indirect1: Direct
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Integrity Issues and Mitigation Strategy
Shreenaath Natarajan
Subsea Integrity Practices in GoM –A Case Study
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Shreenaath Natarajan
Failure Modes
• Internal• Internal corrosion – SSCC, HIC,
CO2 corrosion• Erosion • Blockage – wax and hydrates• Polymer degradation
• External • Structural overstress• Structural fatigue• External corrosion• Impact• Structural wear-centraliser
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Shreenaath Natarajan
Issue 1 – Environmental Uncertainties
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Issue 1 – Track Environmental Records
• Environment record tracked against design limits• Identify the events that exceed design limits for further investigation
Shreenaath Natarajan
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5 Strain and Motion Sensors Top
11 Strain and Motion Sensors TDZ
Target KPI –
Extreme Loads, Long-term fatigue
Issue 2 – Riser Vortex Induced Vibrations (Failure Mode - Fatigue
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Issue 3 – Flexible Riser Internal & External Corrosion
Issue• Degradation methods difficult to predict or
measure• Few early warnings from external visual
inspections• Annulus volume testing is subjective
Recommendation• Improve reliability and accuracy of volume
tests• Corrosion modeling or methods to predict
onset of corrosion• Embedded fiber optics for monitoring• External inspection/scanning tools• Acoustic monitoring
Shreenaath Natarajan
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• Issue• High surface wellhead bending
moments• Estimated fatigue life reduced to
2 yrs from 20 yrs• Cause
• Missing centraliser during installation
• Recommendation• Retrofit foam centralisers• Continuous monitoring of
wellhead bending moments
Issue 4 – Installation Issues
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• Issue• Flexjoint elastomer deterioration• Increased fatigue and extreme loads at riser-vessel interface
• Source• Prolonged exposure to high temperature/pressure
Issue 5 – Material Degradation
Shreenaath Natarajan
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Shreenaath Natarajan
Issue 5 – Material Degradation
Temperature and Pressure Cumulative Histograms Fatigue Damage Factor
• Recommendation• Develop failure prediction methods based on P&T data • Improve CVI tools and modeling methods• Improved elastomeric materials• Implement learning's from drilling riser elastomers
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Coating damage
Coating breakdown
Shreenaath Natarajan
Issue 6 – Coating Breakdown (External Corrosion)
• Issue:• External corrosion
• Cause:• Installation damage• Coating application procedure
• Recommendation:• Monitor CP readings• Surface preparation is key to effective
long term coatings, which is the barrier to external corrosion
• Design should consider extending the coating to reduce coating transitions
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Anode degradation
Depleted wellhead anodes
Issue 7 – Cathodic Protection Premature Depletion (External Corrosion)
• Issue:• Insufficient cathodic protection
and hence external corrosion• Cause:
• Inadequate CP design• Increased current drawn from
other components that should have been electrically isolated
• Recommendation:• Monitor CP readings (not always
reliable)• Retrofit anodes, if depleted• Guided Wave Ultrasonics• Develop on-line methods for in-
service corrosion prediction
Shreenaath Natarajan
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Missing Strakes
Excessive Marine Growth
Issue 8 – Marine Growth
• Issue:• Loss of VIV suppression
efficiency• Increased drag on the system
• Recommendation:• Regular cleaning of marine
growth• Develop efficient and effective
cleaning tools• Improve anti-fouling treatments• Evaluate fouled fairing
performance
Shreenaath Natarajan
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MAXIMUM CONDUCTOR AND CASING STRAINStress-Strain Curve: Ramberg-Osgood, K=1.13, n=27.13
0.0%
1.0%
2.0%
3.0%
4.0%
5.0%
6.0%
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Tilt Angle of Top of Spool Tree (deg)
Tota
l Str
ain
(El
asti
c +
P
last
ic)
Conductor (Upper Bound Soil Strength) Conductor (Lower Bound Soil Strength)Casing (Upper Bound Soil Strength) Casing (Lower Bound Soil Strength)Max Allowable (API RP 2A)
Yield Strain = 0.2%
Unloading of Lateral Force
Issue 9 – Flowline Snagging
Issue• Remaining strength capacityCause• GoM following a hurricane• Final tilt – 8.8deg• Response suggests 130 to 150te
pull from flowlineRecommendation• Detailed FEA to determine fitness-
for-purpose• Conductor plastic strains ~ 4%
Shreenaath Natarajan
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Issue 9 – Subsea Components
Issue• Visual inspections gives little or no
information on the health statusRecommendation• Hydraulic fluid consumption KPI• Contol valve failure prediction• Subsea communications health• Electrical insulation health• HPU pump cycle monitoring
Shreenaath Natarajan
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Assuring ongoing availability of the subsea systems by:
• Practicing and budgeting integrity management as a compulsory activity instead of being reactive to integrity problems considering opportunity cost of shutdowns
• Ensuring competency of the personnel involved in all stages of IM process and in all disciplines
• KPI tracking through integrity monitoring and inspection thus tracking the performance over time and not just a snapshot in time
• Need to mature the monitoring systems available for deepwater systems
• Need to improve/develop methods for real time assessment of accumulated stress, fatigue, and corrosion
• Designs should include capacity for inspection or long term monitoring methods
• Design consideration for mitigation and/or replacement.
Summary
Shreenaath Natarajan