Qualification of Flexible Fiber-Reinforced Pipe for Ultradeepwater Applications

Abstract

Abstract This paper presents the initial work and remaining scope of a RPSEA sponsored project to develop, qualify, and field deploy flexible fiber reinforced pipe (FFRP®) for ultra-deepwater applications. FFRP is unbonded flexible pipe with composite reinforcement layers which has the advantages of light weight, high flexibility, and corrosion resistance. Due to these advantages, a simple, low top tension riser configuration is enabled. The initial design basis is a 7-inch ID, 690 barg design pressure, 120°C design temperature, 3000 meter design water depth production riser for a Gulf of Mexico application. The Phase 1 Engineering Study will confirm the product and system design to be employed in the subsequent phases. In Phase 2, a prototype pipe will be manufactured, and qualification testing will be conducted in accordance with API RP 17B recommendations. With successful testing, and subject to approval via a Phase 2 decision stage gate, Phase 3 will be an actual field deployment of the riser system with six months of performance monitoring. The paper includes a summary of the project plan for Phase 1, the product technology, the design basis, and presents the initial pipe concept. Engineering analysis to confirm the suitability of the pipe concept, and the riser configuration are underway in accordance with the project plan. The top tension reduction offered by FFRP enables light weight and small footprint installation vessels and production platforms. FFRP enables installation vessels and floating production systems which previously had water depth limits of 1500 m to be used in ultra-deepwater of up to 3000 m, expanding the number of existing installation vessels and FPSO's that can be used in deepwater, substantially reducing overall project cost and risk. Introduction In April 2011 the Research Partnership to Secure Energy for America (RPSEA) ultra-deepwater (UDW) program issued a request for proposal for Need 4: Dry Trees and Risers in 10,000 Feet (3000 m) Water Depth. The RFP [1] included Technical Area of Interest 4402 - Qualification of Flexible Fiber Reinforced Pipe for 10,000-Foot Water Depths. In June 2011, DeepFlex submitted a proposal responsive to the RFP and was awarded the project in October 2012. The project has been started and is being conducted in three phases:Phase 1 - Engineering StudyPhase 2 - Prototype manufacturing and qualification testingPhase 3 - Field deployment supply The Phase 1 Engineering Study consists of the design premise and design report, riser system configuration & analysis report, Failure Mode, Effects and Criticality Analysis (FMECA) report, manufacturing documentation for prototype, and Phase 2 qualification plan and proposal.