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Lifetime Extension of Flexible Pipe Systems: Extend Operation
Lifetime Extension of Flexible Pipe Systems: Extend Operation
623 2019
Lifetime Extension of
Flexible Pipe Systems
extend operation
Acknowledgements
This document was prepared by the Flexible Pipe Subcommittee of
IOGP’s Subsea Committee.
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Lifetime Extension of
Flexible Pipe Systems
Revision history
Contents
Scope 5
1. Lifetime Extension 6
2. Methodology 8
2.1 System Identification 8
2.2 Failure Mode, Effects and Criticality Assessment (FMECA) 8
2.3 Input Integrity Data 9
2.4 Engineering Analysis 10
2.5 Risk Assessment 11
2.6 Document Work and Implementation Actions 12
2.7 General Recommendations 12
Glossary 19
References 20
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Lifetime Extension of Flexible Pipe Systems
Scope
5
Lifetime Extension of Flexible Pipe Systems
1. Lifetime Extension
The potential for Lifetime Extension is greatly enhanced by ensuring that flexible pipe
system integrity is formally managed and documented during the current operational
lifetime.
Safety
Level
New Degration
Model
Expected
Degration
Acceptance
Level
Time
Lifetime Extension
Installation Evaluation
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Lifetime Extension of Flexible Pipe Systems
The Lifetime Extension should be triggered at a set period before the end of the originally
designed lifespan, to allow sufficient time to perform lifetime studies, implement
mitigations, formulate alternative strategies, and engage regulators. These activities may
take up to three years to perform.
A Lifetime Extension study usually addresses a complete flexible pipe system and can cover
multiple assets. Due to the size of such an extensive study, a systematic methodology is
important. Some of the documents that could be referred to during such exercises are
listed in the references section of this guideline.
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Lifetime Extension of Flexible Pipe Systems
2. Methodology
Additional requirements defined by local agencies should also be identified at this point.
The FMECA should identify the applicable failure modes and mechanisms for each
component and the parameters that affect them. It is recommended to perform the FMECA
based on the state of the art understanding of failure modes and mechanisms that may
have been unknown when the system was designed or last analysed.
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Lifetime Extension of Flexible Pipe Systems
The FMECA should have an associated risk score (based on likelihood, failure detectability,
and consequence) for each failure mode or mechanism identified.
Given the multilayered construction of the flexible pipe, it is recommended to identify the
failure modes and mechanisms based on each layer when considering the pipe tubular
body and end fittings. The prime reference for failure modes is presented in API 17B. This
may be supplemented with references containing a more exhaustive list of failure modes,
such as the one found in the Handbook on Design and Operation of Flexible Pipes (see
references at the end of this document).
The result of the FMECA should be a list of failure modes and mechanisms applicable to
the system with an associated risk score and the list of relevant parameters.
Depending on the result of the FMECA, specific inspection and monitoring tasks or tests
may have to be performed to verify the actual condition of components or obtain key data
for the Lifetime Extension analysis.
The results from the FMECA will decide which engineering studies and checks will be
necessary to be performed during the LTE study.
One should note that while a comprehensive FMECA for a flexible pipe system may include
numerous failure modes and mechanisms, performing such activity from scratch at every
LTE process will be time consuming. Instead, it is recommended to develop a general
FMECA targeting the typical flexible pipe systems and use it as a guide to see what would
be applicable for the identified system given its specific characteristics and operational
data. In other words, during each LTE process the general and comprehensive FMECA
would be mapped onto a more focused case with reclassification of the associated risks.
Another approach would be to perform a series of FMECA with updates reflecting the
latest events related to the system. For example, the first FMECA implementation
reflecting design conservatism and manufacturing non-conformances can be prepared
and reported by flexible pipe OEM and delivered as part of the Flexible Pipe Operation
Manual. The second FMECA implementation can modify the first one by reflecting
Installation irregularities, damages and repairs. The third FMECA implementation can
modify the second one by reflecting incidents, accidents, and exceedance of design
parameters, encountered during operation. A LTE FMECA implementation can modify those
implemented during manufacturing, installation and operation.
See Appendix A of this document for a sample, detailed list of Failure Modes and
Mechanisms.
The input to integrity data should include both the past operating conditions and future
operating conditions envisioned for the system assessed for LTE.
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Lifetime Extension of Flexible Pipe Systems
Historic data for flexible pipe Lifetime Extension analysis may include the following:
• Purchasing documentation (i.e., design reports, material reports, manufacturing
record book inclusive of as built data and drawings, and operation manual)
• Reports describing installation irregularities, damages and repairs
• Operational data (e.g., temperature, pressure, fluid composition, flow velocity)
• External environment data (e.g., metocean data, water depth and temperature)
• Interface data (e.g., floating point unit movements, riser loads, position monitoring)
• Previous integrity assessments reports
• Inspection, monitoring and testing data
• Reports from root cause failure analyses
• Reports from repairs and modifications of the flexible pipe system, including ancillary
items
Where historic input data is assumed, it should be highlighted to ensure that this
uncertainty is adequately bounded in subsequent engineering activities.
The future operating conditions shall be defined based on the parameters identified in the
FMECA. For any new project, conditions shall be defined per operator rules and as per API
17J’s functional and design requirements.
The applicable failure modes or mechanisms identified in the FMECA (2.2) should be
assessed by an appropriate method, e.g., with engineering calculation/analysis or with
engineering judgement. Engineering analysis methods should be verified, and analysis
tools should be validated against test data. The failure modes or mechanisms that cannot
be ruled as not applicable or with negligible risk should be evaluated in line with latest
industry standards.
Annulus composition may affect a great number of failure modes and mechanisms;
therefore, annulus prediction is a key part of the Engineering Analysis. The annulus
environment prediction should be performed through validated tools and account for both
intact and breached external sheath conditions as per API 17J requirements, as applicable.
The flexible pipe system is designed according to applicable design rules and standards at
time of design. A gap analysis between the current industry standard requirements and that
at the time of the previous life extension analysis, and/or initial flexible pipe system design
should be performed to aid in the assessment of the current flexible pipe system status and
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Lifetime Extension of Flexible Pipe Systems
overall risks to operation. It should be noted that updated models may show more rapid
degeneration, reducing design life. LTE may still be possible due to less severe operating
conditions than originally anticipated.
After assessing the current state of degradation of the system components, the
Engineering Analysis should establish the new service life and operating limits based
on the future data expected for the specific system. This analysis shall encompass
calculations, analysis, or engineering judgement regarding the failure modes and
mechanisms identified as applicable and non-negligible in the FMECA.
See Appendix B of this document for a detailed list of analyses and checks that may be
performed in LTE studies.
The Risk Assessment may result in new monitoring, inspection or regular testing
requirements, for example in preparation for consequent LTE and RA, or to maintain safety
level that is adequate for the duration of LTE but lower than the safety level assumed in the
original design. Depending on the analysis, different operational limits may be specified for
critical variables. Examples of this include:
• System derating (pressure, temperature, bore conditions)
• Reduced service life
• Special operating procedures
• Additional monitoring and/or testing
• Specialised inspection
• Modifications and/or partial replacements
• New safety or utilisation factors (shown by reliability analysis)
It is important to ensure that all mitigations and controls can be implemented. For
example, if the Lifetime Extension assessment of a flowline is dependent on inlet
temperature, it is important that an accurate value can be established either by direct
measurement or from system modelling.
The Risk Assessment should be complete after all applicable risk ratings are reviewed
based on the proposed mitigation actions. Acceptance criteria should be based on
demonstrating safety levels that are adequate for the duration of Lifetime Extension, which
in turn should be cross-checked for compliance with local regulations.
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Lifetime Extension of Flexible Pipe Systems
With the conclusion of the Risk Assessment, the Operating Envelope and the Integrity
Management program or strategy should be updated considering the risks and associated
mitigation actions.
The Risk Assessment should also establish the period for which the current assessment
is valid and after which the Lifetime Extension analysis should be restarted. The validity
period of the risk analysis may be based on previous experiences and engineering
judgement and should not exceed the new service life.
See Appendix C of this document for examples of Recommended Assessment Process for
the LTE.
The report should contain the historic data and predicted future data used to evaluate the
degradation of the system components. The report should also contain, or reference, all the
necessary evidence that supported the Lifetime Extension process, such as the engineering
analysis and risk assessment, as well as the mitigation actions.
The asset control and integrity management system, including any asset registers and
maintenance/operational documentation, should then be updated with the revised limits
of operational conditions, consistent with the basis of the Lifetime Extension. Flexible Pipe
Operating Manuals and Design Reports may need amendments based on the Lifetime
Extension Report.
The flexible pipe cross section and system is complex, with interacting degradation
processes. This has to be duly considered in the LTE process.
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Lifetime Extension of Flexible Pipe Systems
Erosion:
• Erosion of carcass
• Erosion of internal cladding in the top and bottom end fitting areas
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Lifetime Extension of Flexible Pipe Systems
Dynamic behaviour:
• Global load increase
• Wear of outer sheath
• On bottom stability/thermal expansion
• Condition of vertical anchoring arrangement
• Condition of horizontal anchoring arrangement
• Changes in riser number or arrangements over MWAs
• Condition of buoyancy section (reduced total buoyancy)
Structural:
• Pull-out of pressure barrier from end fitting
• Collapse of pressure barrier in smooth bore pipes
• Crack growth of pressure barrier at end fitting
• Mechanical wear, pressure barrier
• Environmental stress cracking (ESC), outer sheath
• Carcass tear due to hydrate plug
• Carcass failure due to collapse (due to hydrostatic pressure)
• Carcass failure due to collapse (due to hydrate in carcass structure)
• Carcass failure due to rapid depressurisation
• Lack of annulus vent
• Bird caging (compressive failure)
• Lateral buckling
• Over bending failures (sheaths, carcass, pressure vault)
Third party:
• Mechanical impact, damage outer sheath
• Mechanical impact, armouring layers
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Lifetime Extension of Flexible Pipe Systems
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Lifetime Extension of Flexible Pipe Systems
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Lifetime Extension of Flexible Pipe Systems
Example:
Allowable
Case Operating Temp [C] pH Actual Duration % Utilization
Duration
Design 65 6 1 20 5.0
Total 18 31.3
Expected
39.6 years
Remaining Life
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Lifetime Extension of Flexible Pipe Systems
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Lifetime Extension of Flexible Pipe Systems
Glossary
Design Life
Period of time during which the flexible pipe is designed to fulfil all specified performance
requirements. Design Life can be longer than Service Life, for example when the required
fatigue life is 10 times the duration of the service life.
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Lifetime Extension of Flexible Pipe Systems
References
[1] American Petroleum Institute. API Spec 17J - Specification for Unbonded Flexible Pipe, Fourth Edition.
[2] American Petroleum Institute. API RP 17B - Recommended Practice for Flexible Pipe, Fifth Edition.
[3] American Petroleum Institute. API Spec 17L1 - Specification for Unbonded Flexible Pipe Ancillary
Equipment, First Edition.
[4] American Petroleum Institute. API RP 17L2 - Recommended Practice for Flexible Pipe Ancillary
Equipment, First Edition.
[5] Norsok Y-002, Life Extension For Transportation Systems
[6] Norsok U-009, Life Extension For Subsea Systems
[7] Handbook on Design and Operation of Flexible Pipe. Fergestad D and Løtveit SA, eds. Trondheim:
Marintek, 2014.
[8] Wood Group. “Flexible Pipe Integrity Management Guidelines and Good Practices”. Prepared for the
Sureflex JIP. 2017.
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