Qualification of Flexible Fiber-Reinforced Pipe for Ultra-deepwater Applications - Update on Phase 1 Engineering and Phase 2 Prototype Testing

Abstract

This paper presents the result of the Phase 1 engineering study for a RPSEA sponsored project to develop, qualify, and field deploy flexible fiber reinforced pipe (FFRP®) for ultra-deepwater applications. In addition, the Phase 2 qualification testing scope of work is presented. FFRP is unbonded flexible pipe with composite reinforcement layers which has the advantages of light weight, high flexibility, and corrosion resistance. Due to these advantages, a simple, low top tension riser configuration is enabled. The design basis is a 7-inch ID, 690 barg design pressure, 120°C design temperature, 3048 meter design water depth production riser for a Gulf of Mexico application. The Phase 1 Engineering Study confirmed the product and system design to be employed in the subsequent phases. In Phase 2, a prototype pipe will be manufactured, and qualification testing will be conducted in accordance with API RP 17B recommendations. With successful testing, and subject to approval via a Phase 2 decision stage gate, Phase 3 will be an actual field deployment of the riser system with six months of performance monitoring. Included in the paper is a summary of the Phase 1achievements and task deliverables. Due to its high level of importance, a relatively large portion of the paper is dedicated to the design of the FFRP structure and system, covering final pipe cross section arrangement, the riser system configuration and the results of analyses to provide a reliable prediction of the product's behavior in various working conditions. In addition, a review of the Phase 2 plan is presented. The outcome of the on-going phase 2 qualification testing will be utilized to calibrate the design models and to confirm the suitability of the pipe design, and the riser configuration.

Qualification of Unbonded Flexible Pipe to API and DNV Standards

“…For the pipe structure family in Figure 3, a design premise and design report for a generic design basis was prepared as part of a RPSEA Project and submitted to DNV, and a Qualification Basis Summary was prepared so that the basis could be reviewed in a workshop setting. The design basis and the design report for the RPSEA project are summarized in [3] and [4].…”

“…Several qualification projects are underway to expand the DeepFlex FFRP and FHRP operating envelope [1][2][3][4]. The technology behind flexible pipe has continued to evolve over that duration to larger diameter, higher temperature, higher pressure and deeper water depth and as a result of lessons learned in offshore applications.…”