"Flexible Pipe in Brazilian Ultra-Deep Water Fields – A Proven Solution" by A.Novitsky and S.Sertã, Technip-Coflexip
The developments on Brazil’s offshore segment in the last three years were remarkably important for theoffshore world, due to the important achievements observed in technical areas, more specifically on thedevelopment of pipe solutions for UDW applications. Following the development of two major Petrobrasfields localized in the Campos Basin, Roncador and Marlim South, Technip-Coflexip has designed, tested andinstalled Flexible Pipes, proving the fitness of this kind of product to UDW applications.In order to bring these two fields into production, Petrobras has demanded from Flexible Pipes manufacturersthe development of products able to work within the environment condition related to these applications, tosay, Floating Systems (FPSO or Semi-submersible) anchored up to 1500m WD and wells localized up to2000m WD.The development of Flexible Pipe solutions for this demand was carried out either through TechnicalCooperation Agreements between Technip-Coflexip and Petrobras, or by Technip-Coflexip itself, within projects Roncador Phase I and Marlim South Module I.During this development, the main design aspects related to UDW applications as Collapse, Reverse End-capEffect, Lateral Buckling and Thermal Insulation, have been technically scrutinized and re-validated throughqualification tests, simulating the real field conditions seen by the pipes during installation and operation phases.The objective of this paper is to present an overview of all the work that has been carried out either together with Petrobras, or by Technip-Coflexip Brazil, in order to achieve optimized and safe Flexible Pipe solutionsto be applied on the development of these two major Petrobras fields.The paper will also present current status of development of Flexible solutions for the next goal to be pursuedoff-shore Brazil, Roncador phase II, with a floating unit anchored at 1800m WD. New technologiesdeveloped by Technip-Coflexip aimed at going deeper will be also presented.
MAIN DESIGN ASPECTS IN UDW APPLICATIONSCollapse
In order to resist to differential pressures created by hydrostatic external pressures, a Flexible Pipe bears in itsstructure, collapse resistant layers. These layers can be of the type Interlocked Carcass (internal or intermediate) and/or Pressure Armour (Ex. Zeta, Teta, Psi, Flat spiral). They work together against collapseand their dimensioning is done using a validated collapse model. The current model used by Technip-Coflexiphas been calibrated by over 150 collapse tests carried out on different structures of different diameters andstructure layer compositions( type, thickness and materials).During the qualification process for Roncador Phase I flexible pipes (risers at 1500m WD and flowlines at2000m WD), all the collapse tests carried out to qualify the designs were used as well to re-validate the previous Technip-Coflexip’s collapse model within the correspondent range of aplication. Following to theconclusion of this re-validation work, Technip-Coflexip was given by Bureau Veritas in may/2000, a third