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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
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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
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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
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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
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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
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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
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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
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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
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Required for dynamic risers
Polyurethane cone that moves bending moment frombase of end fitting
Installed remotely or diver assisted.
Main AncillariesBend Stiffener
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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
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Floatation attached to result in
desired riser configuration Both concentrated and distributed
Clamps required for concentratedbuoy to make connection to arch
Main AncillariesBuoyancy Modules
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Main Ancillaries
Hang Off Clamp
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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)
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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
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Manufacture -15Petrobras - Marlim SulPipe ID : 6 inchesWater Depth : 1500mPressure Rating : 20.68 MpaDesign Temperature : 60 Deg. CFunction : Oil / Gas Insulated Flowline
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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
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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
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Manufacture -18
Flexible Pipe Design Make-up
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
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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
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Manufacture -20
Flexible Pipe Design Make-up
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.
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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
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Manufacture -22
Flexible Pipe Design Make-up
The TensileArmor layer is ahelical steelarmor layer thatresists internalpressure andaxial tension.
FlextensileFlextensile --
(Tensile Armour)(Tensile Armour)
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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
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Manufacture -24
Flexible Pipe Design Make-up
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.
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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.
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Manufacture -26
Flexible Pipe Design Make-up
FlexinsulFlexinsul --(Insulation)(Insulation)
Flexinsul is a thermalinsulation layer used
to limit heat lossthrough the pipe wallto the surroundingenvironment.
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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.
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Manufacture -28
Flexible Pipe Design Make-up
FlexshieldFlexshield --
(External Sheath)(External Sheath)Flexshield is anexternal polymer barrierapplied to resistmechanical damage
and intrusion ofseawater.
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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
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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
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Flexible Pipe Design Flowchart
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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
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GLOBAL ANALYSIS - STRUCTURAL
First step is to define the riserconfiguration based on:
Water Depth
Vessel Type
EnvironmentalConditions
Flexible ID
Minimum Service Life
Specification
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GLOBAL ANALYSIS STRUCTURAL
RISER CONFIGURATION EXEMPLES
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GLOBAL ANALYSIS - STRUCTURAL
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
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GLOBAL ANALYSIS - STRUCTURAL
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
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GLOBAL ANALYSIS - STRUCTURAL
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.
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GLOBAL ANALYSIS - STRUCTURAL
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:
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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
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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
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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
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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
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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
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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
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Manufacturing Process
Carousel
End FittingTesting and
Packing
Insulation
Carcass
Carcass
Barrier Extrusion
Flexlok
RewindRewind
Armour
Flexwear / Shield Extrusion
Carousel
Carousel
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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
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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
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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
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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
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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
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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
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Quality Inspection
Critical parameters which are
checked for tolerances (every 10
meters).
External diameter
Wall thickness - beginningand end
Ovality
Manufacture -54
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Carcass take up Reel
The carcass is taken upon a reel,ready for the extrusion operation.
Manufacture -55
Extrusion Process
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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
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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
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Transfer Stations and Silos
The material is loaded intoa silo.
Unique silos for
each polymer
Driers integrated
with silos
Manufacture -58
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The Extruder loader and Hopper
From the silo the material is
vacuum transferred to the
extruder hopper.
Manufacture -59
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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
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Wellstream International Limited. Duplication in full or in part is prohibited.
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
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Wellstream International Limited. Duplication in full or in part is prohibited.
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
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Wellstream International Limited. Duplication in full or in part is prohibited.
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
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Wellstream International Limited. Duplication in full or in part is prohibited.
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.
Material SelectionMaterial Selection
Sweet & Sour Service
Manufacture -64
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Wellstream International Limited. Duplication in full or in part is prohibited.
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
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Wellstream International Limited. Duplication in full or in part is prohibited.
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
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Wellstream International Limited. Duplication in full or in part is prohibited.
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
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Wellstream International Limited. Duplication in full or in part is prohibited.
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.
Material SelectionMaterial Selection
Sweet & Sour Service
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Wellstream International Limited. Duplication in full or in part is prohibited.
Materials The armour
wire is supplied
from the stores
in various coil
weights.
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Wellstream International Limited. Duplication in full or in part is prohibited.
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.
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Wellstream International Limited. Duplication in full or in part is prohibited.
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.
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Wellstream International Limited. Duplication in full or in part is prohibited.
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.
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Wellstream International Limited. Duplication in full or in part is prohibited.
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
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Wellstream International Limited. Duplication in full or in part is prohibited.
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
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Wellstream International Limited. Duplication in full or in part is prohibited.
Quality Inspections
Critical Dimensions -
ODDiametral gap,
flatness (prevent
fishscaling)
Gap betweenadjacent wires
Pitch
Lay angle
InsulationManufacture -75
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Wellstream International Limited. Duplication in full or in part is prohibited.
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)
Flexible Pipe Construction
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Wellstream International Limited. Duplication in full or in part is prohibited.
Outer SheathOuter Sheath --The Outer Sheath is anexternal polymer barrier
applied to resist mechanicaldamage and intrusion ofseawater.
Material SelectionMaterial Selection
HDPE, & PA-11/PA-12
Pipe Completion / Logistic Base in Brazil
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Wellstream International Limited. Duplication in full or in part is prohibited.
Manufacture -78
End Fittings
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Wellstream International Limited. Duplication in full or in part is prohibited.
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)
Flexible Pipe Construction
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Wellstream International Limited. Duplication in full or in part is prohibited.
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
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Wellstream International Limited. Duplication in full or in part is prohibited.
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
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Wellstream International Limited. Duplication in full or in part is prohibited.
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)
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Wellstream International Limited. Duplication in full or in part is prohibited.
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
Factory Acceptance Testing (FAT)
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
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Wellstream International Limited. Duplication in full or in part is prohibited.
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
Factory Acceptance Testing (FAT)
Manufacture -84
Load-out
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Wellstream International Limited. Duplication in full or in part is prohibited.
Once the pipe iscompleted it is
secured to a reelor installed in to acarousel.
Manufacture -85
Load-out
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Wellstream International Limited. Duplication in full or in part is prohibited.
Flexible Pipe and Umbilical loud-out at WellstreamBase
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Wellstream International Limited. Duplication in full or in part is prohibited.
Manufacture -87
Load-out
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Wellstream International Limited. Duplication in full or in part is prohibited.
Manufacture -88
Load-out
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Wellstream International Limited. Duplication in full or in part is prohibited.
Qualification Criteria & Scaling Limitations
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Wellstream International Limited. Duplication in full or in part is prohibited.
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
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Wellstream International Limited. Duplication in full or in part is prohibited.
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
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Wellstream International Limited. Duplication in full or in part is prohibited.
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