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Flexible Riser Installation PDF
Flexible Riser Installation PDF
Douglas R. A. Johnston
Comex 0dK) Ltd, Bucksburn House, Howes Road, Bucksbum, Aberdeen AB2 9RQ, UK
ABSTRACT
The purpose of the paper is to define the primary considerations affecting
flexible riser installation and to determine further and highlight which areas
of product specification may be addressed with a view to improving the
economics of installation operations. The paper first defines flexible riser
characteristics and identifies the necessary installation hardware prior to
providing commentary on the methods of installation. A basic cost model is
introduced to illustrate the major cost elements of the installation process.
Areas of potential hazard and risk are briefly highlighted and a summary of
conclusions is provided.
Key words: flexible riser installation, installation methods, bending
stiffness, installation economics.
1 INTRODUCTION
The installation of flexible risers presents a series of practical problems,
some of which are of sufficient note to be of importance to the designer
and to the end user. Their flexibility may easily be brought into question
as soon as the installation contractor begins to handle the end product.
Without the benefits of the manufacturing plant, machinery and
conditions it soon becomes obvious that the material is often far from
flexible and that what flexibility it possesses only creates problems for
the contractor.
Present address: Comex Norway A/S, Norsea Base, Dusavik, PO Box 549, 4001 Stavanger,
Norway.
151
Marine Structures 0951-8339/92/$05.00 1992 Elsevier Science Publishers Ltd, England.
Printed in Great Britain.
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D. R. A. Johnston
2 CHARACTERISTICS
The detailed specifics of materials and the methods of construction of a
flexible riser are not in themselves relevant to the installation operation.
They do, however, determine the riser characteristics which govern the
methods of installation. Some of these are so basic that the main reason
to mention them here is to ensure they are not ignored.
2.1 Length
The continuous length of the riser product is a characteristic of obvious
importance. The length required is an outcome of the riser system design
for its specific application and will depend intrinsically on the water
depth, the motion characteristics of the permanent topside vessel and the
design's weather criteria for the site. The length required is therefore
normally a physical necessity which is independent of any installation
considerations.
The riser length affects the overall riser weight and the dimensions of
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2.2 Diameter
The internal diameter of a riser is effectively a feature of the flow requirements. The external diameter is a design and manufacturing feature
necessary for the specified internal diameter and flow requirement.
The external diameter is a characteristic which impacts installation in
several ways. The riser diameter affects the overall riser weight and the
dimensions of reels and winches: this has a bearing on vessel selection.
The diameter also affects the weight/unit length, the minimum bending
radius and the bending stiffness, all of which are of primary concern to
the installation contractor as they dictate the handling characteristics of
the riser. Generally, experience indicates that whilst a 6 in (1 in =
25.4 mm) diameter riser is relatively easy to handle, an 8 in may be
difficult.
2.3 Weight
The weight/unit length of a flexible riser is determined by the design,
materials and construction and is dependent on the diameter required
and the service application. The greater the weight/unit length, the more
difficult the handling problems associated with overboarding, laydown
and pull-in.
The overall weight of the complete riser affects deck loading,
seafastening and craneage requirements. Generally, any weight-saving
possible, either overall or per unit length, will have a consequent benefit
towards ease of handling and vessel requirements during installation.
Table 1 presents typical weight/unit length values for various diameter
risers. The values are dependent on design factors such as service
conditions and operating pressures.
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D. R. A. Johnston
TABLE 1
Typical Values for Flexible Risers Used in Production Systems
External diameter (in-)
Weight/unit length (kg/m)
MBR (m)
4
15
0.70
6
22
1.00
8
75
1.75
10
150
2.10
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TABLE 2
Riser diameter
(in)
Tensile strength
(tonnes)
Max. allowable
(tonnes)
4
6
8
55
79
90
27.5
39-5
45.0
3 INSTALLATION EQUIPMENT
The equipment requirements for the installation of a flexible riser are
dictated by the riser characteristics.
3.1 Winches
A suitable main winch is required to safely deploy a flexible riser. It is
possible that this may take the form of a base and motor which engages
into a separate and removable drum, thus allowing the change out of a
whole drum complete with the individual riser stored on that drum. If
this is not possible then it is necessary to transfer the riser from a delivery
or storage drum on to the main installation winch.
A complete riser length will be a considerable weight which will be
dependent on its characteristics and the weight of its ancillary end
fittings. For a Lazy-S system in a 120 m water depth this will be in the
region of 40 tonnes for a 4 in riser and up to 80 tonnes for an 8 in riser.
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D. R. A. Johnston
With the MBR of a riser being of the order of 1-75 m, and this governing
the drum diameter, it can be appreciated that this necessitates a
dimensionally large a n d powerful winch.
Generally, hydraulic winches are utilised offshore and they will be
capable of providing upwards of 15 tonnes line pull at variable speeds up
to 25 m/min. Actual laying speeds will be in the region 10-15 m/min.
As the flexible riser and pipe market is relatively small, there is a very
limited element of choice in the selection of winches. Whilst there may be
a requirement to optimise winch design, it is not viewed as economically
justified.
For safe deployment, it is necessary that the winch be provided with a
positive braking mechanism.
3.2 Gutters
In order to deploy safely a flexible riser over the side of a vessel deck it is
necessary to utilise a gutter or chute arrangement to lead the riser safely
and ensure that a safe bending radius is maintained both over the deck
edge and at either side on entry and exit. Depending on the vessel shape,
an angle in excess of 90 may be required to be radiused to ensure that the
riser does not contact any sharp or sudden edge in the event of the vessel
backing up on the catenary.
4 INSTALLATION VESSELS
The minimum vessel requirements are dictated by the necessary
installation equipment and the riser characteristics.
4.1 Deck space
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4.3 Craneage
Vessel craneage requirements vary greatly and it is often possible, though
not advantageous, to proceed with limited capacity craneage. For an
operation requiring installation ofa Lazy-S riser system in a water depth
of 120 m or more, a relatively large capacity crane is required.
An anticipated rating would be 100 tonnes or more, capable of a single
fall operation to the seabed depth and maintaining in excess of 50 tonnes
at a radius of 10-15 m from the vessels side. An adequate hoisting speed
would be in the order of 10 m/min. Slewing and topping speeds are not
critical. Vessel cranes will be used for handling and overboarding
operations. It may be necessary to use the crane for lifting and handling
drums complete with their spooled riser and this could easily require
larger capacity craneage, dependent on available deck space and crane
positions.
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D. R. A. Johnston
5 INSTALLATION ANALYSIS
A sequential analysis of the riser during critical periods of the installation
is necessary to confirm that basic criteria determined from the riser
characteristics are being met.
5.1 Criteria
The use of standard catenary static analysis is the current practice for
determination of geometry and forces during installation.
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D R. A. Johnston
moving of the end termination and riser lifted length cause mud
movement which may reduce visibility to nil. For Lazy-Wave and Lazy-S
riser systems, use of the vessel crane attached to the end fitting is the most
commonly used method. Further pull-in wires will be attached to the
seabed structure close to the fixed tie-in location, incorporating tirfors, or
if necessary run to a surface constant tension winch. Lifting bags may be
attached at intervals along the riser length to assist in reducing pull-in
tensions and frictional resistance.
For the Steep-Wave and Steep-S riser configurations, the riser end
connection is required to be pulled down into its seabed riser base
connector (RBC). The methods for carrying out this operation have yet to
be optimised and have a tendency to exceed the pull-in times for Lazy
riser configurations.
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D R. A. Johnston
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TABLE 3
Relative Costs for Riser System Installation
Free hanging Lazy-S
Relative vessel days
Relative vessel cost/day
Relative cost of installation
0-40
0.75
0-30
Lazy-Wave
0-80
1-00
0.80
0-60
1.00
0-60
Steep-S Steep-Wave
1.00
1.00
1.00
0-80
1-00
0-80
To allow the designer and operator to put this into perspective against
design and manufacturing costs:
(1) Assume overall engineering costs as equivalent to 50% of the vessel
cost per installation day.
(2) Assume additional equipment costs as equivalent to one-third of
the vessel cost per installation day.
(3) Assume that installation of a free hanging catenary riser takes two
days which is a realistic starting base.
(4) Assume that an installation vessel capable of installing a free
hanging riser system costs 35 000 per day (approximately 1990
cost).
Relative installation costs would then be as detailed in Table 4. It is
important to note that these are orders of magnitude only.
The illustrated costs are for a single riser but costs would not be pro
rata for multiple or group installation.
Certain costs are not included, notably mob and demob costs. It is
obviously of importance to review the uplifts for engineering and
additional equipment as these are subject to prevailing market conditions.
The model should only be used for indicative purposes. The model
TABLE 4
Relative Installation Costs for Riser
Systems
Riser system
Installation cost
(order of magnitude)
if)
Free Hanging
Lazy-S
Lazy-Wave
Steep-S
Steep-Wave
127 500
340 000
255 000
425 000
340 000
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D. R. A. Johnston
BIBLIOGRAPHY
American Petrolium Institute (API), Recommended Practice for Flexible
Pipes API-RP 17B, API, Washington DC, USA, 1988.
Cocks, P. J., Testing and Structural Integrity of Flexible Pipes. Engineering Structures, Oct 1989, Butterworth and Co.
Veritec, Guidelinesfor Flexible Pipes, Rev. 2, Veritec A/S, Oslo, Norway, 1987.