Wellstream Flexibles Student

University of Newcastle-upon-Tyne
Subsea Engineering MSc
Module MAR8051
Design and Manufacture of Pipelines, Umbilicals and Risers
Wellstream Flexibles
GE Oil and Gas
8th November 2012
1
Wellstream Growth Playbook 2011
Proprietary and Confidential
Agenda
9.00 am – 9.05 am Welcome Mark Stokes
9.05 am – 9.30 am Introduction to Flexibles Andrew Roberts
9.30 am – 10.30 am Design Michelle Davidson

Break 15 min
10.45 am – 12.15 pm Materials Brendan O’Donnell &

Polymers & Metals Andrew McCormick
Lunch 45 mins
1.00 pm – 2.00 pm Manufacturing

David Watson
1.45 pm – 2.45 pm Plant Tour
Break 15 mins
3.15 pm – 4.45 pm Analysis

Global Dynamic Analysis Garry Kendall &
Local FEA Robert Jones
4.45 pm – 5.00 pm Questions & close
Mark Stokes & George
Karabelas
2
Welcome to Wellstream
Wellstream is pleased to be hosting today’s course and offering the unique opportunity to visit our
state of the art flexible pipe manufacturing facilities
Links with local universities are very important to Wellstream and form part of our strategy for
developing or technology, developing our existing employees, nurturing new talent and giving
something back to the community
Wellstream recognises the importance of developing future talent to support the needs of the local
subsea engineering sector. As Partners in developing the MSc course content Wellstream are
committed to providing a successful and valuable programme
Today’s lectures will be presented by practicing engineers and scientists with over 50years
combined Wellstream experience and significantly greater industry experience.
Topics including design, materials selection, manufacturing and analysis will be covered in detail.
Please feel free to ask questions and make the most of this opportunity to interact with our design
and manufacturing specialists.
3
Housekeeping
As a visitor you will be accompanied at all times whilst on site
Fire
• Fire Alarm Tests – take place on Friday morning, alarm will sound for no more than 10
seconds
• If the Alarm sounds at any other time or for longer than 10 seconds, please remain with your
host and proceed quickly and safely with them to their assembly point at the rear of the car
park. Please hold the hand rails when using stairs
• Fire-warden will check that the area is clear of personnel
• Nearest fire escape routes
Smoking – 2 designated smoking areas

Photographs – prohibited without Wellstream permission
Facilities - toilets and refreshments
4
The Weekly EHS Briefing:
Slips, Trips & Falls - Prevention
Slips, trips & falls frequently occur Safe Procedures & Behaviors
and can lead to major injuries, • Pay attention to uneven or slippery floors.
and a lifetime of disability. In • Walk, don’t run through work areas.
• Be aware of changes in elevation and in walking surfaces.
worst cases fatalities. • Never store items in the aisle or on stairs.
• Always use handrails when going up/down stairs.
The most common causes of slips, trips & falls are: • Make sure cords, hoses or cables do not cross walkways.
• Never stand on a chair, desk, shelf etc, use a stepladder.
• unsafe use of ladders/stairs • obstacles on • When carrying a load, make sure you can see over and around
aisles/walkways it.
• slippery/damaged surfaces • jumping on/off equipment
• bad housekeeping • Clean up your own spills, keep your workspace clean and tidy.
conditions • poor lighting
• unsafe attitude • Report all unsafe conditions and hazards that could result in a
• inappropriate footwear slip, trip or fall (Gensuite Concern Report tool or Help Card)
Watch your step…all the time, everywhere!
Mind the Hazard Signs
Use ladders properly Be aware of cords Always use Mind the sign...stay away from
lying on the floor handrails wet/slippery floors
Slips, trips and falls are one of the top causes of injuries in the workplace. Hazard awareness and
safe behaviors are critical to prevent these type of accidents from happening!
5
GE Oil & Gas
Wellstream Overview
Andrew Roberts
Wellstream Chief Engineer
November 2012
6
GE’s Portfolio
Employees: ~300,000 • ‘10 revenue: ~$150B • Operating 125+ years
Technology Home & Business
Energy Infrastructure GE Capital Solutions
• Power & Water • Aviation • Aviation Financial • Appliances &

• Energy Management • Healthcare • Commercial Finance Lighting
• Oil & Gas • Transportation • Energy Financial • Software &
Services
• GE Money
• Controls
• Treasury
7
GE Energy
25% of GE revenue
Technology partner for customers
Oil & Gas Power & Water Energy Management

• Turbomachinery • Aero • Digital Energy
• Drilling & Surface • Gas Engines • Industrial Solutions
• Global Services • Nuclear − Lineage Power
• Measurement & • Power Generation Services • Converteam
Control Solutions − Parts & Repair Services
− Dresser • Renewables
− Wayne • Thermal
• PII Pipeline Solutions − Environmental Services
• Subsea Systems • Water
Energy is a global scale business

8
GE Oil & Gas today
Employees: ~33,000 Operating in more than 130 countries
Drilling & Surface Subsea Systems Measurement & Control Turbomachinery Global Services
• Drilling risers • Subsea trees & • Asset condition • Gas & steam • Transactional outage
• Blow-out preventers wellheads monitoring, control, turbines services
• Subsea power & sensing & inspection • Axial, centrifugal
• Electric submersible • Contractual services
processing solutions & reciprocating
pumps • Conversions,
• Controls • Optimization & diagnostic compressors
• LWD and wireline modifications, and
tools software • Reactors & heat
• Manifolds upgrades
• Surface wellheads • Control & safety relief exchangers
• Flexible risers • Remote monitoring &
& flow control valves • Turbo-expanders diagnostics
• Logging services • Flexible Flowlines
• Blowers, compressors, • Pumps, valves &
• Specialty flow & NG Pipeline systems
connectors & pipes Solutions • Control panels
• Floating production • Fuel dispensers &
systems • Industrial modules • Pipeline
payment terminals
inspection &
• Fuel control & retail integrity services
systems ... a JV with Al
Shaheen
• CNG compression
We now have a portfolio that spans from upstream to downstream with service & process solutions at
our core
9
Where we now play
Pressure
Control
Gas Storage & Pipeline Compression and
Drilling Inspection
Power Gen
Artificial
lift
Offshore
Liquefaction
of Natural Gas
(LNG)
Refinery & Petrochemical
Subsea
Global Services and Measurement & Control
10
Wellstream Flexibles
Wellstream at a Glance
Wellstream is a leading designer and manufacturer
of high quality bespoke flexible pipeline products,
systems and solutions for fluid transportation
• Pipes primarily used on the seabed and through

the water column for the transport of oil and gas
well fluids
• Global track-record in major theatres of offshore
hydrocarbon development
• Strong focus on R&D and product development
• 1,000+ employees
• One of three players in the industry
12
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 characteristics of the transported fluids
FlexinsulTM
Syntactic Foam
FlextensileTM
Carbon Steel
FlexshieldTM - Polymer
TPE, HDPE, PA11/PA12
FlexlokTM
Carbon Steel
FlexbarrierTM - Polymer
HDPE, PA11/PA12, PVDF
FlexbodyTM
Alloy steel
13
Where are Flexible Pipes Used?
Transfer
Lines
Risers
Jumpers Flowlines
14
Key Wellstream Milestones
Panama City (US)
Newcastle (UK)
Niterói (Brazil)
1983 1988 1989 1995 1996 1997 1998 2003 2004 2005 2006 2007 2008 2009 2010 2011
Investment Acquisition by Startup of Stock Exchange Expansion program

by Hillman Dresser Dresser merger FlexSteel in IPO on London completed
Corporation Industries with Halliburton Panama City 26 April 2007 H1 2009
First commercial Commencement Acquired by Closure of Start production Launch of

Founded 1983 contract – of production Candover & Panama City at Niterói Seastream Installation
Gulf of Mexico in Newcastle Mgm’tTeam offshore facility Facility May 2007 JV with Sea Trucks
Divestment of
FlexSteelTM
Launch of
Integrity
Management
Acquisition
by GE
15
Global Locations
Newcastle upon Tyne
Paris
Panama City
Houston
Kuala Lumpur
Niterói, Rio de Janeiro

Perth
Fast Growth
Offshore Markets
Offshore Systems Manufacturing Sales and Customer Support

Project Management & Engineering R&D Centre
16
EHS & Quality
EHS
• Target to deliver zero incidents Core Culture Curve
• The ‘Journey to Zero’ programme

– Focus on leading metrics 4
– Workforce engagement Start 3.33 92% reduction
INJURY RATES
– Organisational pride 2007 over 3 years
– Brothers keeper 3
Quality 2 0.28
1 March 2012
• Wellstream has an excellent track record in ZERO
the finished quality of its products
MANAGEMENT
DEPENDENT
REACTIV
PERSONAL
E
COMMITMENT
COMMITMENT
TEAM
• Regular auditing of all operations
• Support from One North East and NEPA
• CI at our core
– …..the Wellstream Way (Recordable Incidents/200,000mhrs)
17
Production Facilities
Newcastle, UK
• Operational since 1997
• Capability and experience to manufacture the
full range of offshore products from
2” - 16” ID
• Annual production capacity 300nKm
• Proven track record of operating at highest
standards required by industry
Rio & Niterói, Brazil
• Serving Petrobras since the early 1990’s
• Commenced manufacturing on schedule in
May 2007
• Annual production capacity of 270nKm
• Product range: 2” to 12” ID
• Manufacturing systems replicate Newcastle
18
Flexible Pipes –Old and New !
First Applications
20
GE Title or job number
11/13/2012
Wellstream Today
21
GE Title or job number
11/13/2012
22
Flexible Pipe Design
Michelle Davidson
© Wellstream International Limited. Duplication in full or in part is prohibited.

Content
• General Overview of Flexible Pipes

• Structure Overview
• Layer Overview
• Design Process
– Pipe Loads
– API17J Requirements
– Initial Pipe Design
– Secondary Calculations

General Overview
What is a Flexible Pipe?

• An unbonded multi-layered structure of helically
wound metallic wires and tapes, and extruded
thermoplastics.
In simple terms:
• A spoolable pipe
• Strength is provided through metallic layers
• Fluid sealing is provided through polymer layers
• Suitable for all of the oil/gas/water applications
associated with rigid pipelines.
• Onshore and offshore applications

General Overview
Why Flexibles?
• Allows the use of floating production facilities for the extraction of
hydrocarbons in water depths that prohibit the use of fixed
structures.
• Spoolable - ease of shipping/transport
• Easier and cheaper to install than rigid.
• Reusable
• Provides flexibility in the field architecture (can be critical if field is
already congested)
• Product is fully tested prior to delivery

General Overview - Applications
Topside
Jumpers
Fluid Transfer Offloading Lines

Lines
Risers
Infield Flowlines
Well Jumpers

General Overview
Flexible Pipes can be designed for STATIC or DYNAMIC service
Static Service
• Flexibles connect one fixed termination to another fixed termination (i.e
wellhead manifold to pipeline end manifold)
• No dynamic motion in service
• No fatigue to consider
Dynamic Service
• Flexibles connect between terminations where either one or both are in
motion (i.e vessel to subsea, vessel to rigid tower)
• Flexible is in motion through sea and vessel action throughout service life
• Fatigue service life must be analyzed

General Overview
Risers
• Connect subsea structures to topside vessels or platforms
• Generally dynamic
• In rare circumstances can be static but must be physically located to
prevent motion (i.e strapped to platform, contained for full length in
guide tube)
Flowlines
• Connect between subsea terminations
• Always static
• Any length
• May be buried/trenched for protection or stability
Jumpers
• General term used for short length flexibles
• May be static or dynamic depending upon application.

Structure Overview – Fluid Containment
• Internal Pressure Sheath (Flexbarrier™)

– Acts as the boundary for conveyed fluid
– Fluid seal is afforded through metal seal
ring in endfitting.
– Metallic layers are there to support the
internal pressure sheath against burst or
collapse

Structure Overview - Strength
• Carcass (Flexbody™)
– Prevents collapse under external
hydrostatic pressure
• Interlocked Pressure Armour (Flexlok™)

– Resists internal & external pressure in
the hoop direction
• Inner Layer & Outer Layer of

Tensile Armour (Flextensile™)
– Provides both hoop and axial
strength (according to lay
angle)

Layer Overview – Flexbody™ (Carcass)
Flexbody (Carcass)
The Flexbody is a corrugated
metallic tube with a specified
internal diameter. The
Flexbody supports the
extruded fluid barrier and
prevents collapse from
pressure or crushing loads
applied during pipe
operation. Material Selection
CO2/H2S/Cl/Strength:
Stainless 304 L
Stainless 316 L
Lean Duplex, Al2003
Duplex
Super Duplex
Super Austenitic Al6Xn
Layer Overview Flexbarrier™ (Pressure Sheath)
Flexbarrier -
The Flexbarrier is a
polymer layer extruded
over the Flexbody to
form a boundary for the
conveyed fluid. The
Flexbarrier material is
selected to be
chemically resistant to
the conveyed fluid and
unaffected by its service
conditions.
Material Selection
HDPE
PA11
PA12
PVDF

Plastic Material Selection
Typical Temperature range
20 year service life
PVDF
Date/Slide No as Required
Layer Overview - Flexlok™ / Flexpress™
Flexlok -
The Flexlok is a steel
hoop strength layer
consisting of
circumferentially
wound profiled wire.
The S-shaped wire is
profiled to allow
interlocking of the
edges as they are
formed around the
pipe. Material Selection
Carbon Steel:
suitable for sweet
or sour operating
conditions

Layer Overview - Flextensile™(Armour)
Flextensile (Armour) -
The Flextensile
layer is a helical
steel armour layer
that resists
internal pressure
and axial tension.
Material
Selection
Carbon Steel:
suitable for sweet
or sour operating
conditions

Layer Overview - Flextape™ Flexwear™
Manufacturing Aid:
• Polypropylene over flexlok to resist wire displacement and protect flexlok
during spooling operations
Antiwear:
• PA11 P20, between tensile layers, between lok and tensile for dynamic
service only.
• PTFE used for high interface pressure applications
• PVDF/PA11 or PVDF/PTFE used for high temperature applications
AntiBuckling:
• To resist endcap loads in service, or prevent birdcaging during
manufacture.
Other Functions:
• Fabric tape required under nylon shield and over insulation tapes.

Layer Overview - Flexshield™
Flexshield -
Flexshield is an external
polymer barrier applied
to resist mechanical Material Selection
damage and intrusion of
seawater. HDPE
PA11
PA12

Design Process
Material Data
Manufacturing capability
Design Experience
Rules Secondary Calculations
Pipe Bore Gap Span
Static / dynamic Lower Bound Collapse
Sweet / sour
PipeMaker
™ Gas Permeation
Pressure Birdcaging
Load cases FlexPipe Flexlok Localised Stress Analysis
Utilisation Factors Stress API Criteria
(FPS) Wellstream Criteria

RAOs Orcaflex
Dynamic
Metocean WIL Procedures
Analysis
Number of waves Finite Element Analysis
Fatigue Bend Stiffener Design
Design Life Curvature Analysis
Factor of Safety Analysis SN Curves
Factor of Safety

Pipe Loads
Loading on a flexible pipe is derived from three basic sources:
• Internal Pressure (design pressure)
• External Pressure (water depth)
• Tension/Compression (water depth/weight/dynamic motion)
Associated requirements for structure:

• Pressure Containment (hoop strength)
• Collapse Resistance
• Tensile Strength
Tension
Pipemaker:
• Static, Straight Pipe Model
• Structural Capacity of Pipe
Internal Pressure
Hydrosatic Head
Pipe Loads
Additional Input Parameters:

• Service – static or dynamic (design for movement/wear)
• Fluid - sweet/sour (refers to level of H2S in the fluid, higher H2S
means more corrosive)
• Design and Operating Temperature

Pipe Loads
• Design Pressure
Drive Pipe Design
• Water Depth
• Design Temperature
• Service (Static/Dynamic) Drive Material Selection
• Fluid (Sweet/Sour/Wet/Dry)

API17J Requirements
API17J 3rd Edition July 2008 (New Edition Pending)

• Industry Standard for Flexible Pipes
• Design Constraints
– Limits stress in metallic layers
– Limits strain in polymer layers
– Minimum storage/operational bend radii
• Load Cases to be assessed
– Factory Acceptance Test
– Field Hydrotest
– Installation (normal and extreme)
– Operation (normal and extreme)

Pipe Stress Analysis per API17J
• Utilization = Actual stress/Structural capacity (yield stress)
• Different utilizations are specified for different loading conditions
• FPS calculates actual stresses and strains and compares with
allowable values
• Actual loads must be calculated from dynamic analysis (initial
estimates can be made)

Pipe Stress Analysis per API17J
TYPICAL INSTALLATION LOAD CASES
INSTALLATION REEL
TENSIONERS,
TENSION/CLAMPING FORCE
INSTALLATION CHUTE,
TENSION +BENDING
1. Tension/Clamping Force, Straight Pipe

2. Tension + Bending over Chute

Load Cases for Dynamic Pipe
LOAD CASE INTERNAL EXTERNAL TENSION BENT TENSIONER

PRESSURE PRESSURE MODEL
FACTORY 1.5 x 1.04 x - SBR -
HYDROTEST Design
Pressure
FIELD 1.25 x 1.04 x - Weight x water depth x catenary factor OBR -
HYDROTEST Design x dynamic factor
Pressure (Water Filled)
INSTALLATION - - Weight x water depth x catenary factor Chute Chute
CASE 1 x dynamic factor Radius
(May be empty or water filled)
INSTALLATION - - Weight x water depth x catenary factor Straight Tensioner
CASE 2 x dynamic factor
(May be empty or water filled)
OPERATION Operating - Weight x water depth x catenary factor Straight -
CASE 1 Pressure x dynamic factor
(Product filled)
OPERATION Operating - OBR -
CASE 2 Pressure
EXTREME Design - Weight x water depth x catenary factor Straight
OPERATION Pressure x dynamic factor
CASE 1(<10-2) (upset conditions fluid filled)
EXTREME Design - -
OPERATION Pressure
CASE 2(<10-2)
BREACHED Hydrostatic Straight
SHIELD Head

API Allowable Utilisations
LOAD CASE CARCASS FLEXLOK/ FLEXTENSILE POLYMER STRAIN

FLEXPRESS
PA11,HDPE,TPE PVDF
FACTORY 0.91 0.91 0.91 7.7% 3.5%

HYDROTEST 7%*
FIELD HYDROTEST 0.91 0.91 0.91 7.7% 3.5%
INSTALLATION CASE 1 0.67 0.67 0.67
INSTALLATION CASE 2 0.67 0.67 0.67
OPERATION CASE 1 0.55 0.55 0.67
OPERATION CASE 2 0.55 0.55 0.67
EXTREME 0.85 0.85 0.85
OPERATION CASE 1
(<10-2)
EXTREME 0.85 0.85 0.85
OPERATION CASE 2
(<10-2)
BREACHED SHIELD Per API17J
* 7% allowed for storage in static conditions

Design Process
Material Data
Design Experience
Pipe Bore Gap Span
Sweet / sour
PipeMaker Gas Permeation
™
Pressure Birdcaging

RAOs Orcaflex
Dynamic
Analysis
Factor of Safety

Design Process - Secondary Calculations
• Local Flexlok Stress Analysis

– Introduced for assessments of high pressure applications
to give local maximum stresses as against mean stresses
• Gap Span Modelling
– Allows quick assessment for barrier checks under
constant and transient design pressures and temperatures
- also uses minimum wall tolerance
• Upheaval Buckling
– Initial assessment of back fill requirements: simple out of
straightness model
– Detailed assessment from trench surveys and back fill
options
– Pressure and thermal cycle analysis on pipeline stability
– Assessment near sub-sea connections

• Collapse
– Flexible pipe collapse refers to radial
buckling of the internal carcass structure
under external hydrostatic water pressure
loads
External Seawater
• Rough Bore
– Increase Carcass strip thickness, width
and or carcass form thickness
– Consideration of Flexlok support
– Dry Flexlok (Flexseal) layer to increase
External Seawater
collapse capability (Water Injection)
• Smooth Bore
– Use of Flexseal Layer with High Strength
Flexlok

• Compression
• Birdcage phenomena is the local buckling of
tensile armor wires. It is associated with
– High compression loads
– Axial compression
– Bending
– Torsion
• Buckling Models
– In plane – Flextensiles are buckled within
their base cylinder with a ‘Z-shape’ type
profile
– Out of plane – bird-caging when Flextensiles
are buckled out of their base cylinder

Gas Permeation Analysis

• An inner 'annulus' is formed between the two sealed polymer layers
• Gases permeate from the bore fluids to this annulus
• Gases are vented through the endfitting vent ports
Vent
• Gases are vented through non return valves
Shield
Permeated Gases
• CO2, H2S, CH4, H2O
Bore Gases
Annulus Environment Dictates
• Armour wire material selection
• SN curve selection (fatigue service life)
Barrier
Annulus

The Design Process Continues...
Material Data
Design Experience
Pipe Bore Gap Span
Sweet / sour
PipeMaker Gas Permeation
™
Pressure Birdcaging

RAOs Orcaflex
Dynamic
Analysis
Factor of Safety

Polymer Selection
Brendan O’Donnell
Technology Department – Polymer Engineer
54
Materials Selection – Polymers
November 2012
Agenda
Polymer Layer Function and Material Selection Criteria:

• Barrier Layers
- Creep
- Permeation
- Blistering
• Wear Tapes
• Glass Filament Tapes
• Thermal Insulation
• Shield Layers
• End Fitting Epoxy
55
November 2012
Function - Barrier
• Inner seal for containment of bore

fluids.
• Manufacturing Process: melt

extruded onto pipe
56
November 2012
Selection Criteria - Barrier
• Suitability for melt extrusion using WS process.
• 4 polymers qualified for barrier extrusion
– High density polyethylene (HDPE)
– Nylon PA11 or PA12
– Poly vinylidene fluoride (PVDF)
HDPE PA11/PA12 PVDF
Increasing temp. resistance

Increasing chemical resistance
57
November 2012
Material Qualification - Barrier
58
November 2012
Resistance to Creep - Gap Span Testing
•Flexlok Layer
•Barrier Layer
Plastic deformation and creep of the polymer barrier will occur:

• during the factory acceptance test (FAT) where the pipe is subjected to x1.5
of its design pressure
• throughout the lifetime of the pipe once installed.
In order to understand the deformation and creep behaviour we use:

• Mid scale tests to simulate and measure the polymer behaviour under
service conditions.
• Gap span Model to simulate behaviour under different design conditions.
59
November 2012
The test rig uses extruded polymer pipe sections which are located in a pressure
chamber with a breach in the side wall.
• breach simulates the gap in the helically wound Flexlok pressure armour layer.
The internal polymer shell is subjected to temperature and hydraulic pressure to

simulated service conditions.
The extent of the deformation through the breach is measured by displacement
transducer.
60
November 2012
Test sample showing polymer internal and external deformation.
61
November 2012
Fluid Permeation
• Liquid Permeation –
H2O and Ethanol permeation
measured on extruded tubes by
monitoring mass changes.
• Gas Permeation –
• High pressure autoclaves
equipped with a microbalance
Solubility, Diffusion and Permeation coefficient

calculated for CH4, CO2, H2S, H2O and ethanol.
IVA approved Diflex model used predict annulus

environments based on different flexible pipe
operating conditions.
62
November 2012
Blistering
e.g. PVDF
• Gas mixture 90/10 mol% CH4 / CO2.
• 6000psi (414bar) PASS : No slits or
• 130°C blisters
• 20 decompression cycles
• Decompression rate 1000psi/min (70bar/min).
63
November 2012
Multi Layer Barrier: PVDF Only – Wear
Layers
PVDF Barrier:
• Inner wear (PVDF - Dynamic): To act as a sacrificial
layer, i.e. melt flow into the carcass profile in place of PVDF Outer Wear
Layer
the PVDF Barrier (thus preventing notches at the
inner surface of the PVDF Barrier).
• Outer wear (PVDF – High bore pressure, Dynamic &
Static): To act as a sacrificial layer, i.e. to bear the
brunt of compressive creep into hoop strength layer
(Flexlok). PVDF Inner Wear
Layer
Manufacturing Process: melt extruded onto pipe
64
November 2012
Function – Wear Layer (PVDF)
Outer wear
• To act as a sacrificial layer, i.e. to bear the
brunt of compressive creep into hoop
strength layer (Flexlok).
Barrier
• Fluid seal
Inner wear
• To act as a sacrificial layer and prevent
notches at the inner surface of the Barrier
65
November 2012
Selection Criteria – Barrier Wear Layer
Main Property Requirements:
• With respect to PVDF dynamic Barrier

• Inner wear:
– Temperature and chemical ageing resistance as good as
PVDF.
• Outer wear
– Resistance to compressive Creep.
66
November 2012
Function – Anti-wear Tape
To isolate Flextensile and Flexlok

layers and prevent wear / fretting.
• PA11
• PVDF + PTFE
• PEEK
• PEEK + PTFE
67
November 2012
Selection Criteria – Anti-Wear Tape

• High wear resistance, low coefficient of friction (dynamic).
• Resistance to creep.
• Fatigue resistance (dynamic).
• Chemical and temperature resistance (dynamic & static).
68
November 2012
Function – Glass Filament Anti-Buckling
Tape
To constrain the Tensile
Armour sufficiently in order
to prevent radial movement
of the tensile armour wires
which leads to buckling
“bird caging”.
Manufacturing Process:
wrapped onto pipe
69
November 2012
Selection Criteria – Glass Filament Anti-
Buckling Tape
• High Tensile Strength.
• Low Tensile Strain (Strain at break < 2%).
• Wear resistance.
• Ageing performance:
Chemical and temperature
resistance, against annulus
conditions, especially resistance to
saltwater, wrt tensile strength
regression over time (20yrs) &
temperature (70°C).
70
November 2012
Function – Thermal Insulation
• Reduce heat loss from the bore

fluids in order to maintain low
viscosity, hence high flow
rates.
• Manufacturing Process: 1st

layer melt extruded onto pipe
(wear layer), 2nd wrapped onto
pipe
71
November 2012
Function – Thermal Insulation Tapes
Hollow Glass Spheres in a Polypropylene Matrix:
72
November 2012
Selection Criteria – Thermal Insulation
Low Thermal Conductivity Coefficient, K.
• Ageing performance
Chemical and temperature and resistance, against annulus
conditions, especially resistance to saltwater at water-depth
pressures (200bar),
• Suitability for wrapping to pipe :

Tensile strength
Flexural Stiffness/Modulus
73
November 2012
Thermal Insulation - Wear Layer
• Thermal Insulation:
– To provide a level base
upon which Insulation
tape is to sit and also
have a low thermal
conductivity. (HDPE or
TPE)
PE wear layer
74
November 2012
Function – Shield
• Outer seal to prevent seawater

ingress to the pipe.
• Protection of underlying layers.

extruded
– HDPE
75
November 2012
Material Qualification - Shield
76
November 2012
Function – Abrasion
• Sacrificial outer jacket
(unterminated) to protect the
Shield from abrasion damage,
especially at topside of pipe
installation.

extruded
– HDPE
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November 2012
Function – End Fitting Encapsulation
Compound (Epoxy)
• Anchors the ends of the Tensile
Armour wires within the End Fitting,
thus enabling tensile load transfer.
• Manufacturing Process: pump

injection of 2-part mix of liquid
polymer
78
November 2012
Function – End Fitting Encapsulation
Compound (Epoxy)
79
November 2012
Selection Criteria – Epoxy
• Processability
– Low viscosity.
– Gel time >1hour.
– Short cure time:
– Sufficient cure / % crosslink achieved after 2hrs max to enable further
processing.
• Cured/crosslinked properties:
– Chemical Resistance: Chemical compatibility with annulus conditions
(permeated/condensed fluids from the bore, also seawater).
– High compressive strength.
– No porosity.
80
November 2012
Metals
Andrew McCormick
Metals Engineer – Materials Engineering

Materials Engineering - Metals
• Metals in the pipe

– Flexbody (Carcass)
• Stainless strip
– Carcass Material selection and qualification
– Flexlok (Pressure Armour)
• Z-shaped carbon steel wire
– Flextensile (Tensile Armour)
• Rectangular carbon steel wire
– Armour Wire selection and qualification
• End-fittings
– Forged, low-alloy steel

Pipe Structure
Metallic materials in the pipe structure:
4 6
4
4 5
3 5
2
1
1) Stainless Steel Carcass

2) Polymer Fluid Barrier
3) Carbon Steel Pressure Armour
4) Anti wear / Birdcaging / Buckling Tapes
5) Carbon Steel Tensile Armour
6) Polymer External Sheath

Pipe Layers
• Flexbody (Carcass)
– Normally austenitic or duplex stainless steel
COLLAPSE
• Flexlok (Pressure Armour)

EXPANSION
• Flextensile (Tensile Armour)

– Armour wires normally cold rolled carbon steel
STRENGTH

Materials Engineering – Metals
Carcass (Flexbody)

Flexbody Profile
Flexbody (Carcass) is an interlocked tubular structure which supports the

barrier polymer layer
From 0.66mm to 2mm thick
From 24 to 84mm wide

Criteria for Materials Selection / Qualification
Assessment for corrosion resistance:

– Critical Pitting Temperature Testing (CPT)
– Critical Pitting Pressure Testing (CPP)
– Autoclave Exposure Testing (ACE)
– Seawater Exposure
• Assessment for mechanical properties:
– Ultimate Tensile Strength (UTS - MPa)
– Yield Strength (0.2% proof stress - Rp 0.2 - MPa)
– Elongation to failure (%)
• Assessment in pipe:
– Collapse testing of carcass samples (usually manufactured up to pressure
armour)
– Fatigue testing
• Other Characterisation – e.g. Erosion

CPT Testing

• Critical Pitting Temperature Testing (CPT)
• Autoclave Exposure Testing (ACE)
• Seawater Exposure

CPT Testing
• Corrosion testing of CPT results for UNS S32003 in 41 bara CO2, 0 H2S
Carcass:
Temperature (ºC)
Sweet
S32003 CPT [ºC]
2205 CPT [ºC]
0 20 40 60 80 100 120 140 160 180

Chloride Content (000ppm)
Effect of Chloride on CPT of UNS S32003 in 11.5 bara CO2, 0.033 bara H2S
Temperature (ºC)
Sour
0 20 40 60 80 100 120 140 160 180

Chloride Content (000ppm)

Autoclave Exposure


Seawater Exposure


Materials Selection
Carcass Materials:
• Invariably stainless steel (although carbon steel is
permissible for strictly dry conditions)
• Most commonly austenitic stainless steel (304L /
316L / 6Mo AL6XN or 254SMO)
• Alternatively duplex stainless steels (AL2003 / 2205 /
2507)
Material choice is dictated by the application, taking into
consideration:
• Chloride content of water phase
• Corrosive gases (CO2 / H2S)
• Water depth (collapse resistance required)
• Fluid type (water injection, oil production, Gas
production / injection etc)

Austenitic Stainless Steel
Results of Carcass Materials Testing

• 304L is suitable for low chloride
service with limited exposure to
raw seawater. It is unsuitable
for sour service.
• 316L may be used for carcass
in fluid temperatures up to
120°C in some sweet
environments, however
generally its use is limited to
less than 90°C.

Duplex Stainless Steel
Results of Carcass Materials Testing (cont.)

• AL2003 is a lean duplex strip
which falls between 316L and
2205 for corrosion resistance
and cost, and has a similar
strength to 2205 duplex, making
it a good option for enhanced
collapse resistance deep water
pipes.

Carcass Materials Selection
Results of Carcass Materials Testing (cont.)

• 2205 Duplex is resistant to both pitting corrosion general and crevice
corrosion and stress corrosion cracking (due to the 22% chromium
content). Corrosion resistance may still not be good enough for very
high chloride content applications.
• 2507 “Super Duplex” is good for deepwater applications and aggressive
environments provided H2S is not too high.
• 6Mo “Superaustenitic” grades (e.g. AL6XN & 254SMO) are a very high
molybdenum content stainless steel – the composition giving the alloy
excellent pitting corrosion resistance as well as good general corrosion
and cracking resistances in lower chloride containing environments.

Erosion Testing
Material Characterisation - Erosion Testing

• DNV test to calibrate ERBEND

ERBEND
• Carcass erosion
modelling:
– Use of tools like
ERBEND* is
common.
Comparison of erosion rates (N2) - 30m/s gas velocity,

350 GLR, 20 degC
Erosion rate (mg material loss
316L
2003
2205
/kg sand)
*ERBEND is the DNV erosion model (ref.

DNV RP 0501)
0 20 40 60 80 100
Position around 1m radius, 90 degree bend

Materials Engineering – Metals – Wires
Pressure Armour (Flexlok)

Flexlok (Pressure Armour)
• Carbon steel Z-shaped wire manufactured by hot and cold rolling or

purely cold rolling, with a final stress relief operation.
From 4.8mm to
12mm thick (16mm
in development)
• Shaped wire interlocks with its

neighbour to ensure that there is a
limited area of unsupported
barrier beneath the wire layer.
Materials Engineering – Metals – Wires
Tensile Armour (Flextensile)

Flextensile (Tensile Armour)
• Carbon steel wire usually manufactured by cold rolling, cold rolling

followed by stress relief heat treatment, hot and cold rolling followed by
stress relief heat treatment, or cold rolling followed by final lead
patenting.
From 5mm to 12mm wide

From 2mm to 7mm thick

Criteria for Armour Wire Materials Selection /
Qualification
• Mechanical Properties
• Sour Service
– HIC testing
– SSC testing
• Corrosion Resistance Testing (allows material selection decisions)
• Fatigue Resistance

Sweet and Sour Service
• Sweet service is any service which does not contain significant

quantities of H2S (the partial pressure of CO2 is not relevant when
establishing if a field is sweet or sour).
• Sour service is defined by NACE MR0175 / ISO 15156 as an
environment with partial pressure of H2S exceeding 3mbar. It should be
noted however that materials can fail in sour service failure modes
below this level of H2S.
• Sour service qualification of wires must be considered for any
design with H2S in the annulus. 1mbar or more of H2S requires the
use of mid / low strength / full sour wires.
• A reduction in fatigue performance is noted from between 1mbar and
10mbar of H2S.

Sour Service Testing
• Sour service tests (from NACE)

– Hydrogen Induced Cracking (HIC) test (NACE TM 0284)
• 4 day test (Wellstream require 30 day tests on any environments saturated
with <0.5 bar H2S) with the samples in the environment but under no load.
– Sulphide Stress Corrosion Cracking SSCC test (NACE TM-0177)
• 30 day test with samples in the environment either loaded in tensile to 90%
of their actual yield or loaded in four point bending to 0.5% strain in the
outer fibres .
– Wellstream has derived its own testing procedures from these and
European Federation of Corrosion (EFC) guidelines. These are:
• R112E001-Ethd for Threshold Testing
• R112E001-Eenv for Environment Testing

SSC and HIC Testing
SSC testing:
– Tensile load applied to wire (90% of YS) or
0.5% strain in outer fibres using deflection
applied in 4PB.
– Cell filled with seawater solution EFC
solution / NACE solution
– H2S gas mixture bubbled through
– pH maintained throughout test (typically 3.5-
3.8 although can be higher for slightly sour
applications with higher strength wires)
through acid additions.
• HIC testing:
– Same as SSC, but no load applied
– Samples are all sectioned to see if
cracking has occurred inside the wire

HIC Mechanism
• Hydrogen attack principles:
As 2H+ combine to form H2 there is a volume expansion:

Blistering / Hydrogen Cracking
• Blisters are sometimes

visible on the surface
of a wire / strip:
• Cross section of a
blister clearly shows
the cracking from
hydrogen attack on this
thin strip:

Armour Wire HIC
• Centreline cracking is common Crack

in armour wires which are not
sour service compatible:
• Pressure Armour wires can

show cracking at locations of Nub
high cold deformation: Valley
Crack

Corrosion Resistant Testing
• Corrosion of Armour Wires:
CO2 Saturated Deionised Water at 50°C

(Annulus Corrosion Rate From Weight Loss Measurements)
1
Corrosion Rate (mm/yr)
0.1
0.01
0.001
0 5 10 15 20 25
Weeks

Simulated Annulus Environment
• Corrosion of Armour Wires Corrosion Rate vs Volume to Surface Area Ratio
– Lloyds Register approved 3

2.75
calculation for long term 2.5

2.25
corrosion rate – generated 2

1.75
from published data and 1.5

1.25
verified through simulated 1

0.75
annulus environment testing. 0.5
Log(Corr. Rate) [log(mm/yr)]

0.25
0
– Paper #1292 published at -0.25 -5 -4 -3 -2 -1 0 1 2 3 4 5
-0.5
Eurocorr 2008 on the -0.75
-1
subject. -1.25
-1.5
-1.75 Combined data - CSO (blue), NKT
-2 (green), Norsok (pink)
-2.25 Annulus confinement
-2.5
-2.75
Capcis 07 actual - tensile
-3
-3.25
Capcis 07 actual - Flexlok
-3.5
-3.75
Capcis 07 actual - Average
-4
-4.25
-4.5
Fitted Curve
-4.75
2
Log(V/S) [Log(ml/cm )]

Fatigue Resistance
• Lloyds Register Approved Fatigue Testing and Analysis Methodology:

– Detailed document on
• Minimum number of test samples (as a minimum in accordance with ASTM E739,
preferably 20-24 samples minimum)
• The reliability and repeatability of the testing is assessed through the percentage
replication used in the testing.
• The spread of stress ranges used in the testing is maximised to improve reliability
in the regression of the slope of the s-n curve.
• The requirements of API 17J / ISO 13628-2:

– Tests in the following environments:
• Air
• Predicted Annulus Environment
• Seawater

Fatigue testing of armour wires
• 4-point bend set-up:

Fatigue Report
• Generation of S-N curves
– Data from testing is used

to generate a design s-n
curve which is then
approved by Lloyds
Register;
– Curves are used in pipe
service life analysis.

Materials Engineering – Metals
End Fitting

End Fitting Components
Body
Seal ring
Jacket
Seal ring
Inner Collar
Flexlok Collar
Sleeve
Outer Collar

Body forging
Internally clad with Inconel 625

Forging Materials
End Fitting Materials:

Pressure containing components (these include Body, Jacket and internal
collars) – typically low alloy steels:
• 4130 steel (70ksi MYS) - The Wellstream standard forged end fitting
material – Specification at the top end of the capability of 4130 ; Design
performed on the basis of 65ksi on all welded components allowing 5ksi
for reduction in properties as a result of PWHT.
• ASTM A182 F22 – An 85ksi minimum yield strength steel which can
consistently achieve excellent Charpy impact requirements without risk
of quench cracking. Design performed on the basis of 75ksi on all
welded components allowing 10ksi for reduction in properties as a result
of PWHT. 100ksi MYS option also available for ultra high pressure
applications.
• F65 carbon steel – on customer request.

Forging Materials
End Fitting Materials (cont.):

Pressure containing components – Stainless steels:
• 2205 Duplex (65ksi MYS) – Forged duplex steel. Good corrosion
resistance but processing large forgings of 2205 can be risky.
Specification includes detailed testing requirements drawn from Norsok
standards and ensures compliance with ISO 15156.
• 2507 Superduplex (75ksi MYS) – High strength forged duplex steel.
Very high corrosion resistance but processing large forgings of 2507 can
be risky. Specification includes detailed testing requirements drawn
from Norsok standards and ensures compliance with ISO 15156.

Cladding & Butt welding
End Fitting Materials (cont.):

Corrosion resistant weld cladding:
• Weld cladding of bore and / or seal surfaces can be used on low alloy
steel materials to increase corrosion resistance:
– Inconel 625 – excellent corrosion resistance
• Qualified with both G48 pitting and G28 intergranular corrosion tests.
– 316L, 2205 duplex, 904L weld inlay are possible but rare.
Butt welding:
• Qualification is performed in accordance with BS4515.
– Dissimilar weld joints are avoided where possible through material selection.
– Weld buttering is avoided where possible (and is only required for dissimilar
joint preparations).

Coatings
End Fitting Materials – Coating Systems:

• CeramKote 54 – MTL-5007
– Ceramic epoxy coating – two part, three coat system meeting NORSOK
requirements;
– Very high ceramic particle content in the system makes this system more
durable than standard two part epoxy systems;
– Fast curing;
– Can be easily repaired.
• ENP (electroless nickel plating) – MTL-5212
– Usually only required by Petrobras for Brazil
– Extremely damage intolerant and not easily repaired (SIFCO brush
plating)
– Detailed qualification requirements in Petrobras specificiation N2409

Bolting
Fasteners, studs, nuts and capscrews:

• Alloy steel (Wellstream standard)
– Subsea bolts restricted to 22 HRc to eliminate HISC
– Topside bolts may be up to 30 HRc
• Inconel 718 (difficult to source)
– Microstructure control iaw API 6A-718
– Hardness restricted to <40 HRc
• Inconel 625+ (difficult to obtain)

Bolting Risks & Mitigation
Fasteners Risk Factors:

• Hydrogen embrittlement / Hydrogen Induced Stress Cracking (HISC)
• Over-torquing / stressing;
– Excessive stress has a big influence on HISC failure;
• Excessive CP action;
• High hardness (mitigated through MTL and tight QC controls).
Fastener coatings
– Xylan 1424 - default
– Zinc plating and passivation
– Sheradising (Subsea 7 requirement)
– Hot dip / dip spun galvanising

MSc Subsea Engineering - Manufacturing
124

Structural Composition
Carcass
Prevents collapse under external
hydrostatic pressure
Fluid Barrier
Acts as the boundary for conveyed
fluid
Interlocked Pressure Armour
Resists internal & external pressure in
the hoop direction
Inner Layer & Outer Layer of Tensile
Armour
Provides both hoop and axial strength
Insulating Layer
Protects against heat loss
Outer Sheath
Protects against seawater ingress and
other mechanical damage
125
Manufacturing Process - Newcastle
Carousel
End Fitting
Testing and
Packing
Carousel Carousel
Insulation
Flexwear / Shield Extrusion
Armour
Rewind
Rewind
Flexlok
Barrier Extrusion
Material Stores Carcass
Carcass
Offices
126
Main Functions & Layers – Inner Carcass
Rough Bore
Carcass
Interlocked Carcass = Collapse Resistance

127
Main Functions & Layers – Inner Carcass
The carcass is a corrugated metallic tube with a

specified internal diameter. The carcass
supports the extruded fluid barrier and prevents
collapse from pressure or crushing loads applied Material Selection
during pipe operation. Stainless 304 L
Stainless 316 L
Duplex
Super Austenitic
Design Considerations
Fluid compatibility
(temperature, chlorides,
H2S, CO2)
Collapse resistance
Erosion
Pigging
Cost
128
Main Functions & Layers – Inner Carcass Profiling
Process
Cold-Forming a Flat Strip Through a Set of Profiling Tools to Reach a Specified Profile
Winding & interlocking of profile into a carcass
129
Fluid Barrier
Barrier
130
Fluid Barrier
The fluid barrier is a polymer layer extruded
over the carcass to form a boundary for the
conveyed fluid. The barrier material is
selected to be chemically resistant to the
conveyed fluid and unaffected by its service Material Selection
conditions Polyethylene
Cross-linked Polyethylene
Polyamide-11 (Nylon) /
Polyamide-12
Polyvinylidine Fluoride (PVDF)
Fluid compatibility
Temperature
Fatigue Performance
Cost
131
Armour Wires
Tensile
Tensile
Pressure
132
Pressure Armour
The pressure armour is a steel hoop strength

layer consisting of circumferentially wound
profiled wire. The shaped wire is profiled to
allow interlocking of the edges as they are
formed around the pipe
Sulfide Stress Cracking /
Hydrogen Induced
Cracking (H2S pp)
Fatigue
Internal Pressure
Collapse Resistance
Material Selection
Carbon Steel:
suitable for sweet or
sour operating
conditions
133
Main Functions & Layers – Pressure Armour
Different Pressure Armour Wire Shape / Name
Zeta (Technip) Teta (Technip)

Flexlock (Wellstream)
C-LiNKT (NKT) Te (Technip) Steel tape (NKT)
134
Tensile Armour Wire
The Flextensile layer is a helical steel armour

layer that resists internal pressure and axial
tension. Two or four layers counter wound for
torsional balance
Material Selection
Carbon Steel: suitable
for sweet or sour
operating conditions
Sulfide Stress Cracking /
Hydrogen Induced Cracking
(H2S pp)
Fatigue
Internal Pressure
135
Anti Friction Tapes
Tape
Tape
136
Anti Friction Tapes
The Flexwear is a thin polymer tape layer

applied between any two adjacent metallic
layers, and such prevents metal-to-metal
contact between the layers to prevent wear
Material Selection
Nylon Based
Compounds with
additives to enhance
temperature and
wear performance
Wear
Fluid Compatibility
Compression Resistance
137
Insulation
138
Outer Sheath
Outer Sheath
139
Outer Sheath
The outer sheath is an external
polymer barrier applied to resist
mechanical damage and intrusion of
seawater Material Selection
Polyethylene
Cross-linked Polyethylene
Polyamide-11 (Nylon) /
Polyamide-12
Environmental compatibility
Fatigue Performance (static
/dynamic)
Cost
140
Main Functions & Layers – Variations around the
same theme …
Additional Possible Layers

• 4 Armour Layers for Greater
Tensile Resistance – Deep
Water / High Pressure
• Flat Spiral to Reinforce
Pressure Vault
• Insulation Layers on Top of
External Sheath to Improve U
Value
• Fire resistant Layers for Topside
Application
• External Carcass for Protection
for Topside Application
141
same theme …
• No Pressure armour
• Armour Laid Directly on Pressure
Sheath
• Lay angle selected to provide
equilibrium between radial and
axial load
• Maximum Pressure Limited
– Armour layers only take pressure
– Gap control between armour
• Cost effective
• Can be optimised against UHB
142
same theme …
Smooth Bore with Anti-Collapse

Sheath
• Anti-Collapse Sheath Transfer
Hydrostatic Loading onto Pressure
Vault if External Sheath is Damaged
• Pipe Bore can be Empty without
Risking Tube Collapse
• Tube can be Sized to Take Full
Vacuum
143
Main Functions and Layers – End Fitting
Body
Isolating ring
Outer seal ring
Outer
sleeve
Inner seal ring
Jacket
144
Ancillary Equipment – End Fitting
• Each layer secured within the end-fitting to preserve mechanical characteristics

of the structure with a safety margin
Internal
Parts • Seal produced fluid in bore
Neck • Prevent seawater ingress
• Withstand bore pressure
• Transfer tensile armour loads
Termination • Connect flexible to rest of subsea
Any type: system
API / ANSI
Jacket
Grayloc
Welded …
145
Epoxy
Pressure sheath
casting
crimping
arrangement
Neck
146
• Raw Materials:
– From Standard API6A 60K Steel (4130) up to Duplex
– Grade Adapted to Fluid Properties and Pressure/Temperature
– Comply with NACE MR 01-75
– Corrosion Protection with Electroless Nickel (ENP), Painting or 316L/Inconel
Cladding
• Equipment that can be Connected to or Mounted on the End Fittings:
– Anodes
– Gas Relief Valves
– Bending Limiters: Stiffener (dynamic) or Vertebrae (static).
147
Ancillary Equipment – Stiffener
• Function:
– Accommodate curvature variations in a built in
connection of a dynamic riser : behind end-fitting or
along the line at the bottom end of a I tube
• Construction
– Cone of polyurethane to create a continuous
stiffness variation
– Cone dimensions defined to satisfy Bending Radius
(1.5 MBR) and service life criteria
148
Ancillary Equipment – Restrictor
• 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
149
Ancillary Equipment – Buoyancy Modules
150
OTHER ANCILLARY EQUIPMENT
– Anodes
– Friction Anchor Collar
– Pullheads
– Swivel Lift Rings
– End fitting Collar
151 Date/Slide No as Required

Factory Tour
Carousel
End Fitting
Testing and
Packing
Carousel Carousel
Insulation
Flexwear / Shield Extrusion
Armour
Rewind
Rewind
Flexlok
Barrier Extrusion
Material Stores Carcass
Carcass
Offices
152
Global Dynamic Analysis
&
Structural Analysis
Overview
Garry Kendall

Dynamic Riser Systems
• What is a dynamic riser system?

• Overview of dynamic riser system considerations
• Riser ancillaries
• Riser system configuration options
• Structural Analysis Overview

• Flexible pipe ideally suited to link subsea infrastructure to floating

production unit.
• Can accommodate large deflection without affecting pipe performance /

pressure holding capacity
– Wave and current loading
– Floating Unit offset dynamic movement – 1st order motion
– Floating Unit offset variation – 2nd order motion
• Different system configurations can be used depending on

– Water depth
– Environmental conditions – North Sea vs West Of Africa
– Field layout

Riser Configurations
• There are two key considerations which influence

system complexity and overall cost:
– System Compliance, determined by:
• Vessel motions
– System Control, determined by:
• High level of variation in contents density
• Strong currents
• Restrictions in spatial arrangement

Riser Configurations
• Vessel/Mooring Design versus System

Compliance
– An increase in the softness of the mooring requires
an increase in system compliance
• Spread moored FPSO  free hanging catenary
• Turret moored FPSO  lazy wave
• System Control versus Ancillary Costs
– An increase in the control requirements results in an
increase in ancillary components required
• Deep water FPSO  free hanging catenary
• Shallow water FPSO  lazy wave/lazy S

Riser Configurations (Vertical control)
Increased compliance Increased vertical control
Free Hanging Lazy Wave Weighted Lazy Wave

Catenary

Riser Configurations (Lateral control)
Cost effective for

spatial restrictions
Lateral Control
Steep Wave / S
Lazy S
Cost effective for a

high volume of risers
Fixed S
RISER SYSTEM
CONFIGURATIONS

Free Hanging Catenary
Benefits
– Simple configuration, combining easy
installation with a simple pipeline end
connection on seabed
– Low ancillary costs
– Generally lowest cost solution
– High static loads at hang-off

– Requires a low level of compliance in
the vessel motions (benign conditions,
hard mooring system, etc.)
• Seabed riser interaction (abrasion) Examples

• Compression (bird-caging) – Matrix Oil Langsa,
Indonesia
• Over bending in extreme near conditions
– Petrobras Barracuda
/ Caratinga, Brazil

Lazy Wave
Benefits
– Compliant configuration, accommodates
significant offsets, vessel motions damped
– Relatively simple configuration, combining easy
installation with a simple pipeline end connection
on seabed
– Reduces compression at the touchdown point
Example
– Shell
• Buoyancy requirement – Teal/Guillemot, UK
• Lateral and vertical stability North Sea
• Riser on riser
interaction (clashing)

Weighted Lazy Wave
Benefits
– Compliant configuration, accommodates significant offsets,
vessel motions damped
– Relatively easy to install, simple pipeline end connection at
seabed
– Controlled touchdown point minimising riser pick up and
transverse motion
– Can be proposed as alternative to pliant wave
– Ancillary requirements (buoyancy &
ballast) to control vertical stability and
reduce riser on riser interaction
– Potential for riser clashing is less than for
lazy wave

Lazy S / Fixed S
Benefits
– Compliant, accommodates reasonable vessel offsets
– Vessel motions damped
– Multiple risers installed on same mid-water arch
• Sizing
• Riser – gutter interaction
• Hydrodynamic loading on the buoy
• Over bending at the

touch down point in Examples
• Snatch loading extreme conditions – CNR International
• Compression (lazy-s) West Espoir (Lazy S)
• Riser on riser – Norsk Hydro Troll C
interaction (Fixed S)

Steep Wave
Benefits
– Compliant configuration able to accommodate
significant vessel offsets and motions
– No sea bed riser interaction
– Small step out distance
Examples
– Amerada Hess
Fife, UK North
Sea
– ConocoPhilips Su
Tu Den, Vietnam
– Kerr-McGee
• Riser on riser • Dynamic loading upon Leadon, UK North
interaction riser base Sea
• Bend stiffener design

Steep S
Benefits
– Compliant configuration able to accommodate significant
vessel offsets and motions with a restricted footprint
– Multiple risers installed on same arch structure
– No touchdown curvature or sea bed interaction issues
– More stable arch due to flexible pipe restraining loads
• Complex system interaction

• Potential for complex installation leading to
high costs
• Damped dynamic loading

• Riser on riser upon riser base
interaction
• Bend stiffener design

Restrained Wave
Developed as an hybrid Buoyancy

between lazy wave and modules
steep wave.
Retains advantages of
lazy wave and dynamic
behaviour of steep
wave. Vertical clamp
(Hold down)
Horizontal Clamp
(Hold back)
In the UK :
Pierce,
Curlew,
Tethers & Foinaven,
Anchors Schiehallion
RISER SYSTEM ANALYSIS
CONSIDERATIONS

• Key Drivers for Riser System Design
– Water Depth
– Environmental Data
• Current
• Design wave conditions (maximum wave height / associated period range)
• Wave Spectrum for Fatigue assessment
– Floating Unit Characteristics

• Response Amplitude Operators (RAO)
• Mooring system
– Range of offset to be accommodated
– Sector spacing for riser layout
• Riser connection location – distance to COG
– Field layout

• Riser System Optimised Through Extensive Detailed Dynamic FE

Analysis
– Use of specific FE softwares (Flexcom, Deeplines, Orcaflex …)
– Time domain analysis of riser configuration
• Detailed model of flexible pipe characteristics
• Configuration details (length, buoyancy section, mid water arch hydrodynamic
characteristics …)
• Floating Unit characteristics: Offset (intact or damaged), Draft (loaded or
ballasted), RAOs, heading …
• Environmental conditions (current, wave height & periods)
• Marine growth consideration
– Generally leads to an extensive load cases matrix
– Iterative process

• Results Extracted from Design Cases Dynamic Analysis

– Maximum loads along riser, particularly at topside and subsea connection
– Minimum bending radius obtained along riser
– Maximum loads combination to design ancillary equipment
• Tethers
• Clump weight
• Clamp
• Stiffener
• Stiffener connection …
– Riser movements to ensure no clashing with sea bed, floating unit, mooring
lines and other risers …

Local Fatigue Analysis
CONTENTS
Fatigue Analysis:
Design Rules
1. Riser Local Fatigue

PipeMaker™
2. Finite Element Analysis (FEA) Applications FlexPipe
– Hang Off Arrangements

Stress (FPS)
– Subsea Clamps Dynamic

Analysis
– Reels
Fatigue
– Other Examples Analysis
173
November 2012
FATIGUE ANALYSIS
The extent of fatigue analysis undertaken is
limited to the two governing functional layers of
the pipe:
• Tensile Armour (FlexTensile)
• Pressure Armour (Flexlok)
To date WIL have performed fatigue analyses in

accordance with API 17J on 600+ risers since 1997.
174
November 2012
FATIGUE ANALYSIS
• Hang Off Region

– Bend Stiffener (BS) or Bell mouth
– Free length of riser above BS
• Sag & Hog Bend Region

– Proximity to MWA or buoyancy
• Seabed Region
– Touchdown on seabed, or:
– Bend Stiffener at PLEM
175
November 2012
FATIGUE ANALYSIS - SERLIFE SOFTWARE
The package can perform local fatigue analyses

for:
1. Riser top end with bend stiffener.
2. Riser top end with bellmouth
3. Riser Sag or Hog bend
4. Simple touchdown or subsea end with bend stiffener
This presentation describes the basic case of

Riser top end with a bend stiffener.
176
November 2012
The package utilises the following information

to undertake the analysis:-
1. Dynamic Analysis Results (from Global Analysis Fatigue load cases,

which exclude the Bend Stiffener)
2. Pipe Structure Design
3. Bend Stiffener or Bellmouth information (from suppliers)
4. Operational Pressure & Service Life Requirements (from Client)
5. S-N Curves (developed in-house from extensive testwork)
177
November 2012
Global Analysis supplies extreme end force angles with associated tensions or vice-
versa.
If the global analysis considers regular wave

analysis then a unit length of pipe will
draw a closed loop in 3D space during a
wave period.
178
November 2012
Tensile Fatigue Analysis Components
(in common with Flexlok analysis)
Inter-Layer Selected
Curvatures from
Pressures material-specific
Ansys Analysis
from FPS S-N Curve
“Torus” analysis of
bent helix at pressure
Components of
Total damage
Alternating Stress,
and location
Mean stress and Damage
of maximum damage
for each Load Case
179
November 2012
TORUS analysis using the generated data, plus the selected S/N curve, calculates
stress range and damage in the Tensile wires, using curvatures from Ansys Curvature
analysis, and tensions and squeeze pressures from FPS.
Tensile damage output sheet receives formatted damage data & creates graph.
Tensile Layer Damage Profile
0.045
0.04 Tensile 1
0.035 Tensile 2
0.03
Fatigue Damage
0.025
0.02
0.015
0.01
0.005
0
0 1 2 3 4 5 6 7 8 9 10
Pipe Arc Length (m)
180
November 2012
Flexlok Fatigue Analysis Components
Inter-Layer Selected
Curvatures from
Pressures material-specific
Ansys Analysis
from FPS S-N Curve
2-D Ansys analysis of

Flexlok profiles
Alternating Stress Total damage

at eight key locations and location
for each Load Case of maximum damage
181
November 2012
• The Flexlok input sheet receives primary & secondary radii from 7 (Ansys Curvature
analysis) above and internal & external pressures from 4 (FPS) and creates input
data files for Ansys.
• Ansys analysis calculates Flexlok stress at 8 critical locations.
• After the selection of the S/N curve, Flexlok damage and life is output.
F G
E H
A
D
B C
182
November 2012
The accumulated damage in each layer should

be < 0.1, giving us a factor of 10 safety margin,
as required by API 17J
183
November 2012
Finite Element Analysis
Application Overview
Garry Kendall

GENERAL FE APPLICATION
• There are numerous applications for Finite Element (FE) software within the pipe
and ancillary component design process.
• WIL have a number of FE packages available including ANSYS, ABAQUS and

Solidworks Simulation.
• The majority of the work undertaken by the Local and Structural Analysis team
utilises ANSYS (Classic & Workbench)

HANG OFF DESIGN

HANG OFF DESIGN
• Hang off arrangements are used to secure the topside of the riser in
position for attachment to the topside pipework.
• There are a number of variations tailored to the specific requirements of
each system, but the basic principle involves securing the riser via a split
plate attached to a groove on the external surface of the end fitting

HANG OFF DESIGN
• Standard design includes a C-plate arrangement fitted into a hang off
groove to support the end fitting.
• For this configuration simply split plate theory can be used to assess:-
– Extreme loads (strength assessment)
– Operational loads (fatigue assessment)

HANG OFF DESIGN
• Designs can vary significantly if the bend stiffener and end fitting are in close proximity or if
additional functionality is required.
• Example of Hang Off Design including Bend Stiffener Attachment
• End Fitting
• Hang Off Plate
• Moment Transfer Collar
• Bend Stiffener
• Pedestal

HANG OFF DESIGN
• Load derived from Global Analysis applied at model boundaries

HANG OFF DESIGN
• The assembly design varies
from project to project.
• This example includes a
‘diverless latching mechanism’
which adds an additional
complexity to the hang off
design and required the use of
multiple split plates.

HANG OFF DESIGN
Main Components
• Gusseted Hang off Plate (split)
• I Tube Plate (split)
• M42 eyebolts

HANG OFF DESIGN
SOLIDWORKS MODEL
• Gusseted Hang Off Plate
• I Tube Plate (split)
• M42 eyebolts

HANG OFF DESIGN
LOAD APPLICATION
- Bolt Preload applied - Tensile load in M42 Eyebolts.

Vertical Clamp Analysis

• Pliant wave system configuration requires a vertical and horizontal clamp

configuration as part of the system design.
• Vertical clamp includes bellmouths at both ends and tether attachment point.
Vertical clamp
(Hold down)
Tethers &
Anchors
• Clamping requirements (length, bolt preload) defined through in-house

standard calculations, however combined effects of tether, bell mouth and
system induced loads require full FE analysis to assess.

• Separate model produced to examine bellmouth to clamp interface for

extreme and fatigue loading

TENSIONER PAD TESTS

TENSIONER PAD TESTS
• Off shore installation can often

make use of a tensioner
arrangement to control the speed
of the unspooling of the product.
• The tensioner pad profiles can

vary between installers.

TENSIONER PAD TESTS
• Tensioner tests conducted to examine the effect of various pad profiles on

specific pipe designs.
• Considered a variety of pad designs.
• Test undertaken by duplicating the tension loads on a static pipe (i.e. not
travelling)

TENSIONER PAD TESTS
• Results showed that for some pipe designs, the tensioner application resulted in
deformation and indentation of the shield layer.

TENSIONER PAD TESTS
• FE analysis undertaken to quantify if bulging and plastic deformation of the

shield affected the underlying syntactic foam insulation layers.
• Tension pad
• Shield layer
• Insulation layers
• Flexlok layer

TENSIONER PAD TESTS
• Results showed no excessive

deformation of underlying insulation
and extent of shield plastic
deformation was localised.


Wellstream Flexibles Student

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University of Newcastle-upon-Tyne

Subsea Engineering MSc

9.30 am – 10.30 am Design Michelle Davidson

10.45 am – 12.15 pm Materials Brendan O’Donnell &

1.00 pm – 2.00 pm Manufacturing

3.15 pm – 4.45 pm Analysis

Smoking – 2 designated smoking areas

• Power & Water • Aviation • Aviation Financial • Appliances &

Oil & Gas Power & Water Energy Management

Energy is a global scale business

Global Services and Measurement & Control

• Pipes primarily used on the seabed and through

Investment Acquisition by Startup of Stock Exchange Expansion program

First commercial Commencement Acquired by Closure of Start production Launch of

Newcastle upon Tyne

Niterói, Rio de Janeiro

Offshore Systems Manufacturing Sales and Customer Support

• The ‘Journey to Zero’ programme

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

• General Overview of Flexible Pipes

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What is a Flexible Pipe?

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

Fluid Transfer Offloading Lines

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Flexible Pipes can be designed for STATIC or DYNAMIC service

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• Internal Pressure Sheath (Flexbarrier™)

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• Interlocked Pressure Armour (Flexlok™)

• Inner Layer & Outer Layer of

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

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

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

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

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(FPS) Wellstream Criteria

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Associated requirements for structure:

Additional Input Parameters:

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API17J 3rd Edition July 2008 (New Edition Pending)

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1. Tension/Clamping Force, Straight Pipe

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LOAD CASE INTERNAL EXTERNAL TENSION BENT TENSIONER

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LOAD CASE CARCASS FLEXLOK/ FLEXTENSILE POLYMER STRAIN

FACTORY 0.91 0.91 0.91 7.7% 3.5%

* 7% allowed for storage in static conditions

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(FPS) Wellstream Criteria

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• Local Flexlok Stress Analysis

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Gas Permeation Analysis