Coflexip 23 avenue de Neuilly 75116 Paris France A GLOSSARY OF FLEXIBLE PIPE TERMINOLOGY Jean-Pierre Sabbagh 1988INTRODUCTION The information contained in this glossary is not defini- tive: itis constantly evolving as the technology behind it follows the increasingly demanding and complex requirements of the Offshore Industry. Numerous pro- ucts and technologies have been developed to respond to the challenges of this industry in areas such as high temperature crudes, production in deep waters, high thermal insulation requirements, dynamic riser systems for floating production in very harsh environments... The high pressure flexible pipe, which ten years ago was considered a new product with promising possibilities, has since been used extensively worldwide inextremely varied conditions and for a broad range of applications. From modest beginnings, its design, manufacture and installation are now common practice and each of these phases is completely covered by a sophisticated quality assurance system, The proven performance of flexible pipe permits its sys- tematic inclusion as a key factor in the development of offshore fields, due to the many technical and economic advantages opened up through its use. A number of terms used in the Petroleum Industry have acquired a specific meaning when refering to flexible pipes. Furthermore, a new terminology has been created to define materials, configurations, applications..., spe- cific to flexible pipe technology. This glossary endeavours to define briefly the terms used most frequently in flexible pipe technology. It is limited to Production applications of flexible pipe. Drilling, Well Servicing and Petrochemical applica- tions are other extensive subjects and are not covered by this document. We trust this glossary will prove helpful for a better understanding of this concept. uw‘Waconia Cc and cy kde. Ay ce pri COFLEXIO Biase In smooth bore flexible pipes, the internal thermoplastic tube is in contact with the trans- ported fluid. This fluid may contain abrasive products and consequently the abrasion resis- tance of the thermoplastic material is of interest. ‘The abrasion resistance of Polyamide 11 and High Density Polyethylene has been tested using a revolving device (6000 RPM) centrifuging a water/solid mixture onto a cylindrical test sample. The mixture consisted of water and siliceous sand with a constant granulometric composition, This test proved the excellent abrasion resistance of both materials and the following comparative table was established : ie | ABRASION | MATERIALS | RESISTANCE, | | (10 basis = semi | | hard steel) Semi hard steel | 10 Steel XC 55P 4 Polyurethane Pelletane 2355-650 39 High Density Polyethylene ‘Marlex 3802 Black 6 Polyamide 11 Rilsan Besno P40 TL 79 Ni Hard Cast Iron 169 | Pelletane 2102-80 208 Pasiita The internal thermoplastic sheath or tube of a flexible pipe reacts to the constant contact with the transported fluid and this results in a modi- ficaton of both its structure and its mechanical characteristics. ‘The speed of this reaction is a determining factor ina flexible pipe’s service life. ‘The main parameters which affect this reaction are - the characteristics ofthe thermoplastic material (crystallinity, amide groupe concentration), the chemical composition and temperature of ‘the fluid with which it is in contact, - the thickness of the thermoplastic layer, - the temperature gradient in the wall of the ther- moplastic layer, - the stresses to which the material is subject. ‘The degradation of the thermoplastic material may be characterized physically by its ultimate elongation and chemically by its viscosity. A significant number of experiments have been performed on thermoplastic test samples and on flexible pipe test sections in order to predict accurately the service life of a flexible pipe in contact with numerous products at various tem- peratures. To guarantee the quality of the ther- ‘moplastic sheath or tube with a satisfactory margin of safety, two requirements have been considered : - maintaining yield elongation higher than 30% (for Polyamide 11) and, - maintaining a plastic deformation capacity, ie. an ultimate elongation at least 1.5 times higher than yield elongation. For each test condition, this dual criterion served to define a maximum time beyond which the material may eventually have a mechanical behaviour that does not fulfill all the guarantees required during its use.COFLEXID As 304 STAINLESS STEEL AISI 304 stainless steel is one of the materials used in the manufacture of a Coflexip inter- locked steel carcass. This grade is equivalent to grade Z6 CN 18.09 in acordance with AFNOR NF A 35-573 standard. Its main characteristics are - Mechanical characteristics of the strip(at 20°C) Ultimate tensile strength min. 540 MPa Elongation at break min. 40 % - Heat chemical analysis, C.& max. 0.030 Mn % max. 2.0 P - 0.040 Ss % max. 0,030 Si % max. 1.0 Ni % min. 8.0 max. 10.0 Cr % min. 17.0 max. 19.0 As 304L STAINLESS STEEL STRIP AISI 304L stainless steel is one of the materials used in the manufacture of a Coflexip inter locked steel carcass. This grade is equivalent to grade Z2CN18.10 in accordance with AFNOR NF A 35-573 standard. Its main characteristics are = Mechanical characteristics of the strip(at 20°C) Ultimate tensile strength min. 490 MPa Elongation at break min. 40 % - Heat chemical analysis, Cc % max. 0.030 Mn % max. 2.0 P % ‘max. 0,040 beta max. 0,030 Si % max. 1.0 Ni % min.9.0 max. 11.0 cr % min. 17.0 max. 19.0 As 316 STAINLESS STEEL STRIP AISI 316 stainless steel is one of the materials used in the manufacture of a Coflexip inter- locked steel carcass. This grade is equivalent to grade Z6 CNDI7.11 or 12 in accordance with AFNOR NF A 35-573 standard. Tis main characteristics are : - Mechanical characteristics of the strip(at 20°C) Ultimate tensile strength min, 360 MPa Elongation at break min. 40 % - Heat chemical analysis (Z6 CND 17-11) Cc % max. 0.07 Mn % max. 2.0 P & max. 0.040 8 % max. 0.030 Si % max. 1.0 Ni % min, 10.0 max. 12.5 cr % min. 16.0 max. 18.0 Mo % min. 2.0 max.2.52 As 316L STAINLESS STEEL STRIP AISI316L stainless steel is one of the materials used in the manufacture of a Coflexip inter- locked steel carcass. This grade is equivalent to grade Z2 CNDIT.12 or 13 in accordance with AFNOR NF A 35-573 standard Its main characteristics are : -Mechanical characteristics of the strip (at 20°C) min. 510 MPa min. 40 % Ultimate tensile strength Elongation at break COPLEXIO - Heat chemical analysis Ce max. 0.030 Mn % max. ee max. Ss % max. 0,030 Si % max. 1.0 Ni % min. 10.5 max. 13.0 (22 CND 17-12) min. 11.5 max. 13.5 (22. CND 17-13) cr % min. 16.0 max. 18.0 Mo % min.2.0 — max.2.5 (22. CND 17-12) min. 2.5 max. 3.0 (22. CND 17-13) As 4130 STEEL This steel is the standard material used to manu- facture Coflexip end fittings : after forging, the steel is submitted to aspecial treatment including both hardening and tempering, in order to reach the required mechanical characteristics. These characteristics are - Mechanical characteristics (on product at 20 °C) + Breaking strength min, 621 MPa + Yield strength min, 415 MPa + Elongation at break (AP 50) min, 18% + Hardness HV 30 max. 248 - Impact Resistance (Charpy V notch impact testing KCV at - 20° C) + Transverse 28 J with a minimum of 18 J on an individual sample + Longitudinal 42 J with a minimum of 27 Jon an individual sample - Heat chemical analysis C % — min, 0.27 max. 0.33 Mn % — min. 0.40 max. 0.90) Si % — min.0.10 max. 0.40 Mo % — min, 0.15 ‘max, 0.25 Cr % ~~ min,0.80 max, 1.20 Sy ‘max. 0,020 Poe max. 0.025COFLEXIO: Avicais Flexible pipes have been used extensively in a number of applications, ‘The main applications and duties are listed here- below : APPLICATIONS DUTY + Flowlines + Crude transport + Spool pieces * Gas transport * Static risers + Dead oil transport + Dynamic risers, + Test + Wellhead jumpers» Water injection + Dynamic jumpers + Chemical /acid + Loading jumpers injection + Gas injection + Gas lift + Service +TFL + Kill annulus control Coftexip welthead jumpers on Esxon's Lena Guyed Tower (Gulf of Mexico) i E Coflexip dynamic risers, flowlines and spael pieces on [vanhoe!Rab Rox fieldCOFLEXIO need MACHINE This fully automatic machine manufactures the double crosswound armours of the flexible pipes. It consists of ~ A spooling section where the armour wires are quality controlled and reeled onto armouring spools. During this work, the wire is straight- ened, lubricated and the batch numbers. are recorded. The wires are butt-welded if necessary A loading program records the number of spools and the length of wire per spool. - A trolley which transfers the spools between the spooling section and the storage rack - Astorage rack where full spools awa ing onto the machine and empty ones awai their retumn to the spooling section. - Two trolleys which transfer the spools between, the storage rack and the loading devices, - Two loading devices which feed the loaded spools to the spiralling heads, - Two coaxial counter-rotatin for load. spiralling heads, each producing one armour layer. The wires are subject to flexion and torsion while passi through adjustable rollers ensuring that all the wires are tightly applied (US Patent 4.590.752) =A computer which commands spool storage and loading, Armouring machine 0 Coflexip's factory in le Trait ‘Spooling section ranster racks - Acabin with a master control panel, equipped with a flow diagram and video system, which allows direct monitoring of the entire operation. A caterpillar device which draws the flexible pipe through the armouring machine at a con- stant speed: The armoured flexible pipe is stored ona receiver storage reel; The pitch of the wires is set by the movement of the caterpillar device and the rotation speed of the cages. The storage reel is rotated while a roller device on rails ensures that the flexible pipe is evenly coiled. - The armouring process is acontinuous process. When the wire contained on a spool has been completely used, the spool is removed by the loading device dnd replaced by another one. The continuity of the wire alo ensured by butt-weldis Caterpillar device Receiving reo! Delivery reel spiraling head n*2 és Storage acks |COFLEXIO Pcitus Artemis is one of the radio localisation systems used to position a vessel dynamically Artemis is a trade mark of Christian Huygens: laboratorium B.V Itisamicrowave position instrument of the polar type, using FM transmission for range and angle data in the band between 9200 and 9300 MHZ. Its, power is less than 150 mW. By virtue of its two mutually and automatically tracking antennae (one mobile onboard, one fixed on a known location) and its distance measuring circuitry, it provides azimuth and distance between the fixed station and the vessel ‘The Dynamic Positioning program of the vessel integrates these measurements with roll and pitch and the mobile antenna's position to calcu- late the position of dedicated vessel locations. The agility ofthe directional antenna is such that the operating speed of the vessel constitutes no problem. An Artemis has range and azimuth displays of the LED type. One BCD output is used to interface the mobile data unit. The azimuth is correlated to a reference (nor- mally the geographical north). The fixed antenna is lined up by an operator versus a known refer- ence direction by means of a telescope mounted on the antenna itself. The azimuth of this known direction is adjusted on the angular display by means of thumbwheels to the correct azimuth value. The fixed antenna is then locked-on the vessel's mobile antenna and will follow the vessel's course, indicating the proper azimuth direction of the vessel's antenna, In short range (30 to 960 m) accuracy is better than £0.25 m In Long range (300 to 2900 m) accuracy is better than £0.75 m In long range at 10000 m accuracy is £2.6 m in are £0.75 min range In long range at 30000 m accuracy is £7.85 m in are £0.75 m in rai ‘The Artemis system is designed for a maximum range of 32 km, however, both experience and diverse local conditions show that this design value should be reduced to a maximum of 10km prior to site testing. ‘The fixed antenna should preferably be mounted on fixed structures supplying power (either 12V D.C or any other power supply with additional convector equipment to customer's specifica- tion). However, power may be supplied by bat teries charged by any type of generator (solar panels, thermogenerators...). Fixed Artemis antennae on Beatrice A platform during we laying and srenching of a7" 318 L.D., 3175 psi design presure Coflexip water injection line by the DP. ressel Flexservice 3 in December 1984 for Brioil. 6COPLEXIO Pui STIFFNESS Axial stiffness indicates the percentage increase in length of the flexible pipe under an axial tension Some typical axial stiffness values of dynamic production risers (Sweet service, 250 m water depth) are given in the following table: FLEXIBLE PIPE AXIAL STIFFNESS Inside Design Calculation Monitoring and Locating Systems DP. Calculation Unit Logging Unit - Short range radio a ae localisation system | - Medium range radio | localisation system | | = Super short base acoustic | | system : yo y ~ Light weight taut wire | Displays and Operation | | Recording/Plotting/Printing | Acoustic submarine beacon | | Console | | Unit | FLOWCHART OF DYNAMIC POSITIONING AND LAYING / TRENCHING INFORMATION MEASUREMENT AND CALCULATION 25COPLEXIO D YNAMIC RISERS Forseveral r the diminishing number and size of discoveries, the drive towards exploration in deeper waters, advances in subsea technology - the trend in off- shore developments is now very much towards floating production units. Flexible risers are the simplest and most economical means of linking. subséa equipment and floating facilities. From an economic standpoint, the benefits associated with incorporating flexible pipes into production systems are now widely rec sons - greater economic restraints, ized - Simplicity in systems desi -Built-in flexibility : systems ean be easily adap- ted to changing economic objectives as field de- velopment progresses. - Possibility of retrieval for reuse elsewhere. and rapid installation : use of relatively light weight and economical support vessels, and handling equipment means minimum depen- dance on weather and other operational factors. - Dramatic reduction - Existing rigs can be adapted for flexible risers with only a few modifications. - Topside loads can be vastly reduced. ~ Greater floating unit excursions can be accom- ‘modated, permitting simplified anchoring sys- tems. ~ Several separate risers can be positioned at close connection points on the floater. downtime, ‘The dynamic flexible riser concept has served the industry with success for several years in areas of the world where prevailing weather con- ditions are relatively moderate. It is now in ser- vice in one of the harshest environments - the North Sea. Flexible riser systems need to satisfy such a wide range of design criteria that no one solution can be proposed to cover all require- ments. The incorporation of dynamic flexible riser systems in a production scheme results in major advantages for the operator. ~ Generation of early cash flow and minimum estment in equipment y extension of field capability by simple successive upgrading of the riser system. Dynamic flexible riser systems remain fully operational even in 100 year weather conditions, - No down-time is attribuable tothe riser system ~ Marginal impact on overall rig design. - The moonpoo] is left free, enabling re-entry and workover operations without shut-down of other wells. Dynamic riser system in Brazil (Petrobras) - The lightweight engineering of the system eli minates the need for heavy tensioning systems. Routine disconnections during temporary shut- downs for rig maintenance and refurbishing are simple operations. The risers are winched down to the sea bed where they are placed to avoid in- terference with other subsea equipment. Recot nection is a simple operation, the disconnect -dure is performed in reverse. on procj g i : j t t z COFLEXIO DYNAMIC RISERS (Continued) Quick Disconnectors can be used to reduce toa few seconds the duration of disconnection. As with routine disconnections, the risers are easily recovered for rapid reconnection when the emer- gency is over. = Dynamic flexible riser systems require no ‘maintenance other than regular ROV inspection of the flexible lines and subsea equipment, and routine checks of the connectors and their asso- ciated equipment. - Flexible risers have built-in corrosion resis- tance, provided by the external polyamide sheath, In addition, all the metallic components, of the subsea part of the system are cathodically protected. ‘The same flexible riser, normally working as a production riser, can be designed to be as well used for re-entry and work-over operations (US Patent 4.570.716). Fax ‘This computer program calculates the stresses ‘on each layer of a flexible pipe when submitted to internal pressure and extemal forces. Itis used systematically in the design phase of a flexible pipe. Input - Layer by layer description of the flexible pipe: Geometrical data and mechanical properties of the materials - Loadings : intemal and/or external pressure, axial force, torque. ~ Boundary conditions may be taken into account Free or restrained elongation of the pipe. Free or restrained rotation of the pipe. Output : - For each layer : - Stresses - Part of the external load sustained by the layers (tensile force, contact pressure with adjacent layers, torque) Radius and thickness variations. - For the pipe : Elongation - Rotation Eisace CONTINUITY The steel armours of a flexible pipe are in contact with the end fittings and provide electrical con- tinuity. In the case of a rough bore structure, the inner layer, the interlocked carcass, (first inner layer), is isolated from the end fittings by a technil joint in order to avoid any elecrochemical corrosion due to the difference in steel material used (stain- less steel for the interlocked carcass, alloy steel for the end fitting).<— Termination Baan Flexible pipe generally elongates when submit- ted to an internal pressure. The thickness and angle of the double crosswound armours are major factors in this elongation. Acomputer program has been developed and ca- librated against actual tests in order to calculate accurately the elongation of a buried flexible pipe under its “on site” test pressure, and the ma- ximum height of the arches of the flexible pipe COFLEXIP inside the trench. This calculation is essential when designing a flexible pipe which is to be butied, in order to guarantee the requested minimum cover, However, the design of a flexible pipe which doesnot elongate under pressure has been devel- oped for a specific range of pressures. This flexible pipe can therefore be trenched without any requirements conceming a minimum trench depth, Eo FITTING All flexible pipes are terminated by an end fitting at each end, The end fittings are mounted by hand. Firstly, cach separate layer of the flexible pipe is laid back, and is then re-anchored individually onto the end fitting by means of the steel parts incor~ porated in the end fitting structure itself. Numerous burst tests have been performed which prove that the end fitting is stronger than the flexible pipe itself and is never a weak point in the line, Housing Technl ing —Epory oa Different parts of an end firing Inner locking ring Outer locking ring ‘Thotmoplastic sheath Pouble crosswound Reinforcing spiral Zeta spiral ‘Thermoplastic sheath Interlocked steel carcass Flexible pipe Z inner seal assem End fiting ii Typical End Fitting 28COPLEXIP END FITTINGS (Continued) The standard material used to manufacture the end fittings is AISI4130, However, other mate- suis Sp rials may be used if requested. The end fittings are Ni-Kanigen treated against corrosion. Alter- native protection such as painting may also be provided. B ‘The end fittings may be fitted with any type of 7 4 termination. The most common terminations are either fixed or rotating flanges, Grayloc, eee cee a Cameron or Weco. a | Flexible Pipe | End Fitting | | eel jute | tgs! | | | Diam, | Press. | HS ‘Type A Bieeec D E F |Weight Gnches)| (pst) |” | dexm) | mm) | (ram) | (om | (omy) eam), ke) oar ee ealiel allel. fi | 2000 | yes | etme pipe nate wo | 170} 80 | 35 | 25] 2} 10/ | 3000 | yes. Flange 2° 1/16 API 20 | ao) us | 16s | 30] 50) 60] || 68 2000 psi RX23 | [2 [18000 no | Cameron ob2"iné 375 | 30 200 | a | 50 | 50) 90) | APB 5000 psi RX24 | lee 4 ftoo0 | no | Fangs" IGAPIOB | 455 590) 65.| att”) sor | 101 | 150, | 5000 psi RX33 | | | | 4 | amp | no | Gvieinbscn se | 390 | 480 | 250 | 0 | io) 101 | 50] 4 5000 | no | Cameron hub 4” 1/16. 425 510 230 193 TOL | 101 90 | 5000 psi BX155 | i fees | |6 | 3000 | yes | Swivelfange6" ANSI | 400 | 70 | 280 | 381 | 182) 140 | 150 | B165 RT! 900 Ibs R&S | | | fer | [6 | s000 | no | GrolocaboaRs2 | 425 | s2s | 280 | 235 | 12 | 130 | 120] |S | 3909/ ves |Cameronnae7*1ns | ao | sao | 280 | 206 | 152] 152 | 130] | | 5000 psi AX | | | iE ioe | Cameron hub 71/16 390°) 415 |.-370-| 216° | 203°} 180%} "460 5000 psi RXAS | Js | aso0 | no | Swivel Mange 8” 410 | 840 | 335 | 4s2 | 203 | 203 | 280! || ANstBIes | i) 1500 Ibs RT R50 | 8 3500 | no | Graylochub&GR82 | 410 | 495. | 340 | 295 | 203 | 203 | 135 10 | 2800 | no | Swivelftange 1" | deo | 80S | 405 | S45 | 234 | 234 | 352 | ANSI BI6;5 900 ts | i | RTIRS3 | | 10 3000 | no | Graylochub 10M 102 | 440 | sss | 440 | 410 | 254 254 | 267 | 12 | 1400 | yes | Flange 12" anstpies | 455 | 705°] 500 | 558° | 298 | 298 | 480 | (600 tbs RTI RST | | je | 2100 | yes | Graylochub 12M 120 | 425 | 770 | -435 | 406 309 | 308 | 300 | 1s | 750 | “no | Flange 16"34 apr | 620 | 1050 | 640 | 872 | 406 | 406 | 1100 | | ‘6BX 10000 psi BX 162 | | | | | etnies | Dimensions and Weight of some typical End Fittings : 29" COFLEXIO a RESIN Epoxy is a resin injected into the end fitting to fill-in all the empty spaces. A hardener is mixed with the epoxy just before injection. Complete polymerisation time at_ ambient temperature is 12 hours. The epoxy used by Coflexip is manufactured by Ciba Geigy and specially designed for high shear and compres- sive resistance Eariscr MACHINE This machine manufactures the thermoplastic tubes or sheaths, It consists of ~ A container in which the thermoplastic pellets are stored, - An extruding screw with a special profile designed to move forward, mix, pressurize and homogenize the thermoplastic material while heated. - Aheati control. Screens and filters which 1g device with an accurate temperature way be placed between the screw and the extrusion head for filtration and perfect homogenization. - Anextrusion head, When extruding a tube, the The thermoplastic material emerges from the extrusion head in a tubular shape, is cooled by g, calibrated and cooled again by immersion in a grading tank.When extruding a sheath, the extrusion heads perpendicular tothe The thermoplastic is “distributed uni- formly around the flexible pipe which passes through the centre of the extrusion head. The extrusion head is in line with the screw water spray’ Container “Outside Caliper Receving Reel Flexible Pip Extrusion c ~Caterpillar Device ‘ Tank “Banusion Head Motor CFolier Device Extrusion machine (tube) 30 Exorusion of High sheath Density Polyethylene thermoplastic Extrusion of Polyamide 1 thermoplastic sheath flexible pipe is cooled by water spraying, and then by immersion in a grading tank. -A caterpillar device which draws the tube/ flexible pipe through the machine, The relative speed of the screw and of the caterpillar device determines the thickness of the tube/sheath. The tube/fiexible pipe is stored on a receiver i i i‘ikdonram's esa Callnp and sional Ary ce id, COFLEXIO EXTRUSION MACHINE (Continued) Receiving Ree! Roller Device Flonible Pipe { "e a ® Roller Device iEstrusion Screw epee oe ws So Le pene ies -Caterpilar Device storage reel, with a roller device on rails which coils the tube/flexible pipe evenly. The extrusion process is a continuous process ‘When the container in which the thermoplastic pellets are stored is empty, itis replaced by anew one. Faia The steel wires of adynamic riser are designedso that stresses encountered during operation remain well below their endurance limit. It means that for intact wires fatigue should not ‘occur. However, wear induced alteration of the wires can occur as follows : - Variations of curvature induce sliding of the steel wires and relative displacements of adja- cent layers. - This movement, combined with the contact pressure between layers (due to the different forces acting on the flexible pipe) creates local ‘wear which reduces the thickness of the wires. ~ Because of this reduction, stresses in the steel wires are increased. It means that as time passes, the endurance limit may be reached. Fatigue can then lead to failure. ~ Furthermore, there is obviously a limit on the admissible thickness reduction, independent of the endurance limit. This is called the maximum allowable wear. This brief description shows that the combina- tion of wear and fatigue may lead to the failure of a dynamic flexible riser. In order to minimize wear the design of a dyna- mic riser incorporates a special lubrication and, depending on working conditions and required lifetime, a thermoplastic friction layer between the layers where the contact pressure is the high- est. The Flexlife program, which has been calibrated against test results, predicts the service life of a dynamic riser, based on this approach. HAIGH'S DIAGRAM ‘4c(MPa) Fatigue Region Slate siress Point A shows the alternating and static stresses in the wire under operating conditions atthe beginning of the service of the flexible riser. Point B shows the alternat- {ing and static stresses in the wire under operating Conditions at the end of the service life of the flexible riser. Movement from point A to poin B is due to wear accumulated during the service life of the flexible rise. 31COFLEXIO Piraie BENCHES Fatigue benches are used in order to assess the resistance of flexible pipes operating in dynamic conditions. Some of the benches are designed in order to submit samples to a series of tests which reproduce various actual configurations. Others are designed for the comparison of different flex- ible pipe structures. Four of these benches are described hereafter The Jumper Tower duplicates the movement of a jumper which is sus- pended between two pointshavinga variable vertical distance. The jumper has one fixed end, the other one being submitted to an alter- nate move The adjustable parame- tersare: horizontal dis- Bac betivenss ents, Eee stroke of vertical move ment, pressure and temperature of the internal fluid, period of movement. = The Oscillating Tower duplicates the move teat ofl a Gyre configuration between the bottom of an artic lated column and a fixed point on the base. One vertical riser in a catenary end of the line is mobile and secured inside a trumpet which functions as the lower end of an I tube. The other end of the line is stationary and rests overa spout which represents the base of the articulated column. Three movements are possible : single plane bending, by an oscillatory movement of the trumpet within the vertical plane of the line, torque, by pivoti the trumpets around their axes, combination bending/torque, as in the case of an articulated column mounted on a universal Joint. ‘The adjustable parameters are : amplitude of oscillation, amplitude of torque, period of move- ‘ment, pressure and temperature of the internal fluid. ~ The Bending/Rotation bench submits a flexible pipe to a uniform rotation around its axis, the pipe itself being bent with a given bending ra- dius, Itmay also be used for single plane bending tests, in which case the sample is placed, taut, between two trumpets. ‘The adjustable parameters are : bending radius, subaxial load, inner fluid pressure, rotation speed. - The Single Plane Bending bench simulates down-point motions within the vertical piane of a catenary. The bench includes mobile trolleys, one of which is operated by a hydraulic jack, a heat exchanger and a measuring station. The ends of the tested lines can thus be either free or blocked in rotation. asFe Aa nye cst ree semi aces aaa COPLEXIO INATHENE 3802 BLACK - Finathene is the trademark of Petrofina to desi- gnate a high density polyethylene. ~ 3802 Black designates the grade. Finathene 3802 Black is one of the thermoplastic materials used by Coflexip in the manufacture of the tube or sheath of flexible pipes. Fz RESISTANCE There is sometimes a requirement to provide a certificate of resis- tance to fire, this normally applies only to wellhead jumpers on fixed platforms. The main wellhead jumpers range of 4" to 8" is cov- ered by a Lloyd's certificate based ‘on an actual fire test. The certifi- cate allows use of the 4" to 8" flexible pipes in arange of applica- tions. Currently lines outside this range may be required to have additional fire protection added to the line and end fittings. Cover End fitting Fire resistant material Fire protection of the End Fiting Fos ce This computer program analyses the static and dynamic behaviour of flexible pipes. Flexible pipes may be submitted to concentrated forces, time varying forces, current, waves and user-defined motions of arbitrary nodes, espe- cially vessel-induced motions of the riser top. Flexan C is a tridimensional finite-element pro- ‘gram, The basic element is a catenary, which is well adapted to the simulation of flexible risers. Drag and inertia forces are computed through the MORISON equation. Static equilibrium is found through an iterative method which minimizes the unbalanced forces at every node. Dynamic analysis is carried out in the time- domain. Masses are lumped at nodes and the equation of motion is written as : K=fQx, %0) 33COFLEXIO FLEXAN C (Continued) where xis the vector of displacements, & and Xits first and second-order derivative. This second- order non-linear differential system is integrated using a generalized Adams multistep algorithm, with a variable time-step. ‘The main simplifying assumption of Flexan Cis toneglect the flexural (and torsional) stiffness of flexible lines. It may easily be shown that this, assumption is valid for long flexible lines hang- ing between two points, as the effect of bending stiffness sharply decreases as the distance with respect to an end increases, Accordingly, it is, possible to use Flexan C in orderto analyse most flexible riser systems. The ability of Flexan C to predict the static and dynamic behaviour of flexible risers has been confirmed by number of model tank tests and by the results of the full-scale test of a flexible pipe hanging in a double catenary configuration on Frigg field (Flexible Arch experiment). Input : - original coordinates of nodes - element characteristics (weight, length, diame- ter, drag and inertia coefficients) - concentrated forces - data for convergence of static analysis algo- rithm ~ data for dynamic analysis - total simulation time and time step wave characteristics (regular airy wave) . current (varying with depth) vessel motions (in the case of a flexible riser) additional concentrated masses output requirements Output = static analysis : coordinates of every node - tensions at both ends of each element . gTaphic configuration of system - dynamic analysis : output is optional and is in- put defined. It is possible to obtain x,y and z motions of any node tensions at both ends of any element - angles at both ends of any element - radius of curvature at any node These results may also be obtained graphically, as time-dependent curves. Graphic output also includes system configura- tion at user-defined time intervals, Fin Due to its low bending stiffness, a flexible flowline conforms to the seabottom contours. Itcan accommodate free spans, seafloor instabi- lities and obstacles. The problem of thermal expansion/contraction is eliminated. Stresses, originating from the self-burial of the line or from the platform settlement are not trans- mitted, This flexibility constitutes the basis of the flexible riser concept which enables the riser to adapt itself to the movements of the floaterandto remain connected in any weather conditions. seit cre, Ny done 4 he TW documant priyaay cork, dy or ps COFLEXIO Fioae ARCH = Data recording station “ s = 7 Telemety system copa "| Recording of Measurement of) EAE Moored suriace buoy | environmental motions by a peice \ rh i, ~s-— Distance measured Frigg field eae / a a OP platform Bese ee Inclination by accelerometers | i | | Floxible ‘Measurement of motions by accelerometers. and vertical displacement by pressure sensors >\ Subsurface buoy Measurement of motion’ © ‘ey accelerometers anc tension by three load cells Flexible Arch Experiment From October 1982 to July 1983, a test on a 9" 3/4 inside diameter, 4500 psi design pressure flexible pipe was performed on Frigg field in the Norwegian Sector of the North Sea in a water depth of 106 meters. The test configuration con- ted of a 135 meter length of flexible pipe han- ging in a double catenary between a subsurface buoy and a surface buoy, designed to respond in seas of ten meters, this being similar to the res- ponse of a large tanker in survival conditions. As faras the number of cycles and amplitude of mo- tions are concemed, this ten month test was equi- valent to 6 year operation for a large tanker. ‘The test was financed by Mobil Exploration Norway, Inc.,the Institut Francais du Pétrole, Elf Aquitaine Norge A/S and Total Marine Norsk A/S, with funding support from the European Economic Community. ‘The objective of this test was to provide techni- cal data on the behaviour of a large diameter, high pressure flexible pipe for a dynamic riser application. The flexible pipe maintained its pressure (4500 psi) over the duration of the test. (For further details, see OTC paper n° 4739- 1984.) After retrieval, the flexible pipe was dissected and carefully analyzed. This analysis demonstra- ted its excellent dynamic behaviour.The differ- ent data collected have been used to correlate the computer program that predicts the response of a flexible pipe in such a configuration,COFLEXIP Fee PIPE Flexible pipes are composite products made up of several concentric steel and thermoplastic layers. Flexibility is provided by the intrinsic properties of the thermoplastic layers and is not reduced by the steel layers which are helicoidly wound wires. Both internal and extemal leakproof functions are provided by the thermoplastic layers, where- as the mechanical resistance to both internal and external loadsis provided by the steel layers. The interest in the use of the flexible pipe is due to a number of factors such as ~ Ease and speed of installation by a light weight and economical vessel. - Tie-in simplicity. - Ability to be retrieved and reused, - High reliability due to its complete manufac- ture onshore, guaranteed by a sophisticated qua- lity assurance system. - Separation of the leakproof and mechanical re- sistance functions which increase its reliability - Ability to adapt to all sorts of sea beds without kinking, buckling or free span problems. - Ability to follow accurate and complex tracks. - High corrosion resistance. Feu Flexlife has been developed to analyse the service life of flexible risers, and is specifically adapted to Coflexip pipes and the differentlayers, they incorporate. Three different problems are dealt with Flex- life - Steel wire fatigue, due to cyclic stress vari- ations. Stress variations are small and fatigue is, usually not the limiting factor due to the heli- coidal configuration, - Wear due to friction between steel layers. This is generally the limiting factor. - Combination between fatigue and wear. As wear increases, stresses in the steel wires in- crease and fatigue may become the ultimate ruin factor. Flexlife consists of two parts (1) - Static and dynamic internal stresses in each layer are computed for maximum and minimum extemal loads (inner pressure, axial tension, bending radius). It is thus possible to check that maximum admissible stresses and the endurance limit are not exceeded. 36 (IL) - Relative displacements between adjacent steel wire layers are computed. They are mainly due to variations of the bending radius, Pressure between the two layers is also calculated, The ‘main parameters here are inner pressure, and ten- sion. ‘The above analysis is run for different load cases corresponding to the loading history of the pipe. Input data is generally obtained from Flexan C, which has to be run for each class of wave his- togram. Fora given wear coefficient, itis then possible to calculate the annual wear rate. Using this value, the program calculates : - the time necessary to reach the maximum allo- wable wear (Ty), - the time necessary for stresses to reach the en- durance limit (T,)- The calculated service life is the lower of these two values Fleslifé has been developed and calibrated using the results of bench tests. Gott aes. fry doar piCOPLEXIP FLEXLIFE (Continued) Input : layer-by-layer pipe description inner pressure number of load cases number of eycles in each load ca maximum and minimum se - maximum tension, bending radii for each load case. Output - static and cyclic stresses in each layer - time to reach the endurance limit - time to reach the maximum allowable wear - predicted service life Foo 1 (FS 1) MJV Flexservice | isa former bulk carrier which has been converted to lay and bury Coflexip flowlines and other flexible lines such as electri- cal and/or umbilical cables. She is equipped with a Thomson-CSF dynamic positioning system. The location equipment in- cludes the following systems : Artemis radio lo- cation, Argo radio location, Simrad HPR 309 hydroacoustic, and two Géomécanique taut wire inclinometers. The storage capacity is made up of four rotating baskets and two laying winches which give a total capacity of 2725 tons of flexible lines. The vessel is equipped to lay simultaneously up to four flexible lines along a predetermined laying track with great accuracy, Due to her four point mooring system and varied deck facilities, the vessel can carry out other works such as installation of mooring buoys. The presence of saturation diving station rated to, 450 m permits a wide range of subsea work with up to four divers at any time. An RCV 225 is available for subsea surveys. Main features of Flexservice 1 - Up to 4 flexible lines of varying diameter (2 flowlines +2.control lines/electric cables) can be laid simultaneously along complex. predeter- mined laying tracks. 3 ~ Simultaneous laying and burying of flowline/ control line bundles. - Large storage capacity a typical load of flexible lines might consist of 31,000 m of 1" ID hydraulic line 31,000 m of 2.5" ID gas lift line 31,000 m of 4 "ID oil gathering line 3,500 m of 10 "ID oil export line 31,000 m of electric cable.COFLEXIP FLEXSERVICE 1 (Continued) additional space is available in the hold for 2,000 tons of cargo. - The dynamic positioning system permits accurate tracking of laying routes, ensures optimum station keeping, enables a close approach to fixed or floating platforms, enables layi in deep water, eliminates the risks of damage by anchors in perations in confined areas and pipeline congested areas. - Sizeable deck equipment 2 heavy lift cranes, 2 powerful tugger winches and a 60 tons launching ramp give the vessel added ability to perform various types of off- shore works. ~ The saturation diving station, combined with the DP, system, makes Flexservice | an ideal support vessel fora wide variety of subsea opera- tions. Foe 3 (FS 3) Flexservice 3 is a dynamically positioned flexible pipe and cable laying vessel specially designed and built to carry out a comprehensive range of offshore work worldwide, and more particularly in deep waters and difficult sea conditions. Based on the new Ugland-Nordvestkonsult 350 design, Flexservice 3 is @ relatively light-weight but powerful vessel offering optimum manoeu- vrability and versatility combined with a large flexible pipe and cable storage capacity. Ample deck space and handling equipment provide a well-equipped platform for a variety of offshore construction and underwater works. ‘Complete dynamic positioning equipment con- sisting of Kongsberg Albatros 503 systems, an Artemis mono-beacon radio location, a Syledis 38 multi-bescon radio location, a Simrad ultra shortbase hydroacoustic system and a Kor berg taut wire system, enable the vessel to per- form simultaneous laying of up to4 flexible lines, (2 flowlines + 2 control lines or electric cables) with the greatest accuracy along predetermined laying tracks. A burying platform situated aftis equipped to ac- commodate the Coflexip trenching machine for simultaneous laying and trenching of flexible pipes and electric cables, even in consolidated clays. The vessel is fully equipped to accommodate a saturation diving system, with a4m x4m central moon pool to facilitate immersion of the diving bell. Fully DNV classified, she is prepared for DSV class and complies with the most stringent diving regulations. A helideck situated at the bow can accommodate either Bell 212, Puma or similar type helicopters, Main features of Flexservice 3 - Simultaneous laying and burying of flowline/ control line bundles with Coflexip trenching machine. = The dynamic positioning system permits accurate tracking of laying routes, - optimum station keeping. i 8 | i iCOFLEXID FLEXSERVICE 3 (Continued) -close approach to fixed or floating platforms . flexible pipe laying and recovery operations in confined field conditions and deep waters - Good manoeuvrability is provided by two 3700 BHP diesel main engines, two bi-mode electric bow thrusters, 800 BHP/1200 BHP and two 700 BHP stern thrusters, all with joystick control. - Good handling capacity : one 100 ton A-Frame, one 15 ton x 12 m crane, two 5 ton x 12m cranes, rotating storage basket, motorized sheaves and spooling equipment for handling flexible pipe. - Storage capacity for flowlines : up to ten 78 x 44 x 50 Coflexip reels with 1400 ton total capacity. - Storage capacity for electric cable : fixed baskets with 3600 ton capacity. = Large deck area (52.m x 17m), with possibility of either closed shelter or open shelter working. - Provision for full saturation diving system with immersion of the diving bell through a central 4m x 4m moon pool. Fae | FLEXDYN This set of computer programs has been deve- oped to analyse the behaviour of a flexible pipe, either hanging between two points or partly laid on the sea bed. ‘The main feature of these programs is that they take into account the pipe bending stiffness. Flexsta is a three-dimensional finite-element program which performs the static and dynamic analysis of the pipe. The basic element is a cubic hermite polynomial. Static analysis is based ‘upon an iterative algorithm which minimizes the total potential energy of the system. Mini- mization is carried out using an augmented Lagrangian method. Flexsta results have been checked against tests, carried out by Coflexip with short jumpers for which the effect of bending stiffness is significant, It has also been noted that, for long catenaries, Flexsta and Flexan C give similar results, Flexsta is most useful when bending stiffness cannot be neglected. It can also be used during the static part of the analysis of systems with distributed buoyancy, especially to select buoy- ancy modules and their location. Input = pipe di 39 = pipe characteristics ( weight in air, stiffness, diameter) - end conditions (hinged or built-in) ~concentrated forces (vertical, positive or nega- tive) ~ current (varying = water depth - load case : coordinates of both ends of the pipe, code for the consideration of current, code for initialization of the configuration. Different load cases may be chained in the same input file. Pipe configuration may be initialized by a straight ine, ahalf-circle, or the result of the preceeding load case. Output : - coordinates of every node - angles, radius of curvature, moment, axial and shear force at center of each element depth) Graphic output is also available. Flexdyn is the dynamic version of Flexsta. However, Flexdyn is purely bi-dimensional. As Flexan-C, it takes into account wave, current and vessel motions. Output is optional and user-defined : motions, tension, moment, angle and bending radius at any node, These values are also avail- able as time-dependent curves ; . system configuration at given time intervals.COFLEXIO: Fiowane ‘This is the main flexible pipe application,The hundred meters to several kilometers. Some length of a flowline can vary from several typical configurations are summarized below: 1, Wellhead to steel plasform - Flexible pipe 3. Wellhead to concrete platform. 5. Wellhead 10 manifold through J tube Flexible pipe either through J tube or 6, Platform toriser base 2, Wellhead to steel platform - Flexible pipe connected to bottom of rigid riser. 7. Plagform to shore ‘clamped along plasform 4. Platform 10 plasform 8. Riser base to riser base 40 ‘Wa documenta pepe Caen a ety coo, Ay ck pohCOFLEXIO Fiz HANGING CONFIGURATION This is the configuration ofa flexible riser which runs in a catenary shape from the upper connec- tion point on the floater straight down to the sea bed where it can be connected to any type of sub- sea equipment H ANGING DEVICE A hanging device is used to maintain the top of ariser on a support, for example at the top of aJ or I tube. \ [| Purin wie Le é : Le ee er p Pestle poe r Tepatlorsiee p) y ji Hancing ae Device lat Vy DS Hanging device Flexible pipe 41COFLEXID H EAT TRACING ‘The principle of the heat tracing method is the release of heat, by Joule effect, through a con- ductor through which an electric current passes. These electric heating elements are embedded at regular intervals in the steel wires of the double crosswound armours. Each wire is isolated by a thermoplastic sheath. The pairs of insulated wires are placed inside a Coflexip patented (US Patent 4.364.418) stain- less steel rectangular tube, the outer dimensions of which are the same as those of the steel armour wires. This tube protects the electric heating elements against stress, so that they retain all their properties. Power is regulated by an electric control box. Heat tracing flexible pipes are used when the physical characteristics of the crude pose Double crosswound {Flexible pine | armours AD Stainless stool sates ON Ne aie \ 7 8"LD., 1700 psi design pressure heat racing (and heat Insulated) export dynamic flexible riser installed in 1978 berween a PLEM and a SPM on Conoco's Udang field. problems, such as hydrate or wax formation, asphaltene crystallization, pour point temperature... which cannot be solved by a thermally insulated flexible pipe. Furthermore, heat tracing gives the possibility of re-heating the fluidto the desired flowing temperature inthe event of pump shut-down, etc. This technique is, generally used in addition to thermal insulation. Hos CARBON STEEL WIRES Several high carbon steels are used for the flat steel wires which make up the reinforcing spiral and double crosswound armours. These range mainly from FM 62 to FM 78 (Afnor NFA 35- 51 standard) according to the requested ulti- mate tensile strength and to the dimensions of the 2 wire (which have an effect on the strain harden- ing ratio). The flat steel wires are submitted to a special treatment in order to obtain the required characteristics. ‘The main characteristics of a FM 72 wire (which is the most common) are i i j ' i 2j 2 | i H : t ; | 3 COPLEXIP HIGH CARBON STEEL WIRES (Continued) - Heat chemi ~ Mechanical characteristics (at 20°C) Si % min. 0.10 max. 0.35 Ultimate tensile strength min. 1400 MPa Mn. % min. 0.60 max. 0.90 Elongation at break (AP 100)min. 1 % s % max, 0.025 analysis % max. 0.025 c % min. 0.70 max. 0.75 H IGH DENSITY POLYETHYLENE High density polyethylene is one of the thermo- Stress, (MPa) plastic materials used in Coflexip flexible pipes. It is obtained by polymerizing ethylene in the presence of transition metal catalysts. HDPE is supplied in pellets and is transformed into a tubular shape, either an intemal tube or an intermediate or external sheath, by means of an extrusion machine. Its main advantages are : - High ageing characteristics and chemical rsis- tance to acids and sea water (up to 65°C). - Good ageing characteristics and chemical re- sistance to dead oil (up to 50°C). - Excellent resistance to wear, abrasion and cor- rosion ~ High impact and tensile resistance at low tem- perature (- 50°C). - High resistance to stress cracking, - High elongation at yield point. - Large working temperature range : - 50°C to +65°C. - Good flexibility. - Good creep resistance. - Low cost. Shear mods 6 MPa) 2a oo 0 doo Temperature 0 COCO 30 20 19} YIELD ELONGATION ‘average) 30 700 Strain ¢ (96) The characteristics of the HDPE used by Coflexip are as follows : Physical properties = density : 0.940, - melting temperature range : 125°C/130°C, - thermal conductivity : 0.35 keal/m.°C at 20°C. Mechanical properties (at 20°C and 65 % RH) - bending modulus : 7000 bars, - torsional modulus : 7300 bars, = tensile modulus : 8000 bars, - tearing resistance ; 1500 N/om, - hardness : 54 shore D. 4BCcOFLEXIO YDROSTATIC PRESSURE TEST IN SHOP All Coflexip flexible pipes are tested in shop at the nominal test pressure (1.5 times the design pressure) for 24 hours. -Filling of the line The line is filled with water by means of filling pump and a pig (each end of the line is equipped with a blind flange and valve). The line is pressurized at 50 to 150 bars from the filling end and the air is bled by the valve of the opposite end. When air bleeding is satisfactorily completed, the bleed valve is closed and the test started. - Pressure build-up : The pressure is gradually raised to 1.1 times the nominal test pressure (1.65 times the design pressure) and the inlet valve closed. The internal pressure and the ambient temperature are con- tinuously recorded for 24 hours on a chart with a calibrated recorder. - Pressure release After completion of the test, the pressure is re leased by opening the inlet valve and the water is, discharged. ‘The remaining water is drained by compressed air, pushing the pig through the line. Retrieval of the pig : After full deconipression of the pipe, the pig is, retrieved and visually inspected. The acceptance criteria are as follows During the 24 hour test, the pressure within the line must be greater that the nominal test pres: sure, assuming that the temperature is constant during the test period. - If duri he first half hour, the pressure de- creases beneath the nominal test pressure, the Every Coflexip flexible pipe is hydrostatically tésted for 2M hours at 1.5 times design pressure before shipment pipe is subject to close examination, Should the pressure drop below the minimum test pressure at any time during the test, the pressure is in- creased to its original value and the records set back to zero with new charts, -For each hour, the pressure drop must be lower than the previous one, assuming that the tem- perature is constant for the same period. ~ The temperature recorded during the 24 hours test can be a basis for accepting the pressure variations,Cae an iy cine fy tee poe, COPLEXIO YDROSTATIC PRESSURE TEST ON SITE ~ The procedure for hydrostatic pressure testing on site is summarized hereafter ing and Pigging of the flowline : Flexible flowlines are generally installed full of water, so that pigging is not required after instal- lation, In such cases, precautions are taken to complete the filling at the end of the installation operation, before launching the end fitting, toen- sure that the air trapped in the line is reduced to a minimum, If, however, a pigging operation is required for any reason, such as laying of an ‘empty line or injection of chemicals, itis perfor- med according to a procedure which ensures that any air is satisfactorily removed from the line. ~Test instruments and connection pressure test Prior to starting the pressurization of the line, a pressure test is performed on the test equipment and flexible connections, at a pressure determi- ned by the pressure rating of the equipment, but not less than 110 % of the nominal test pressure of the pipe. The duration of this test is half an hour. - Pressurization of the line Pressurization of the line is carried out ina steady and controlled manner. During this pressuriza- tion, a P/V (pressure/volume) plot is carried out using the volume of water injected. The air con- tent of the line, measured by extrapolating back to the axis, is compared with the flowline fill volume. The air content must not exceed 0.5 % of the pipeline fill volume if the line is smooth bore, or 1 9 if the line is rough bore. Ifthe air content is found to exceed this figure, venting is performed from the end(s) of the line, and pressurization recommenced. Should the air content remain in excess of an ac- ceptable figure, the line is refilled. The pressure to be reached before stopping the pumps is achieved according to one of the two following stabilization methods. 45 - Constant volume stabilization : The pressure is raised to 110 % of the nominal test pressure, as corrected from the L.A.T. of the test instruments, and the filling valve is closed at this stage. ‘A pressure drop will occur, due to the flexible line's stabilization process. However, during the stabilization period, the pressure should not fall below the test pressure, so repressurization should not usually be required during the test. - Constant pressure stabilization upon reaching the nominal test pressure, the pump is stopped and the filling valve close . during the first half hour of the stabilization period, no repressurization is carried out ; after the first half hour, and during the stabili- zation period, if pressure drop occurs, the pres- sure is raised back to the test pressure and the amount of injected water recorded, ‘The pressure versus time curve is recorded on a chart during the pressurization of the line. - Stabilization period : Pressure drop during the first half hour : should the pressure drop be more than 10 % of the actual, test pressure during the first half hour of the sta- bilization period, the possibility of a defect exists and the line is inspected if the leakage is not found in the test equipment. The stabilization period lasts for a minimum of 10 hours before starting the hold period. The stabilization period may be extended, if significant pressure drops are still occuring after the first 10 hours due to the stabilization process or to the thermal stabilization of the line. In sucha case, the pressure drops should be con- tinuously decreasing, thus. providing evidence that stabilization is occurring During the stabilization period, the pressure curve is recorded on a chart and a log of pressure and subsea temperature readings are maintained, every half hour for pressure readings and every two hours for temperature readings.COFLEXIO HYDROSTATIC PRESSURE TEST ON SITE (Continued) - Instrumentation of the test ‘A deadweight tester (DWT) is the primary source of pressure measurements throughout the test period, except if the test is carried out from a ship ora floating vessel where a large diameter standard test gauge is used. ‘A standard test gauge and apressure recorder are used throughout the test. Ambient and subsea temperature measurements are made during the stabilization and the hold pe- riod, to allow the pressure versus temperature correction to be made. A calculation note for the flexible line is issued prior to test commence- ment. . Ambient temperature is measured from an am- bient temperature recorder. . Subsea temperature measurements are taken with a reversing thermometer. - Hold period When the stabilization period is completed, the hold period (minimum 24 hours) may start. ‘A new pressure chart is fitted on the pressure recorder. A log of pressure and subsea temperature read- ings is maintained at half hourly intervals during the hold period. During the 24 hours test period, the pressure must be greater than or equal to the nominal test pressure. There must be no unaccountable pres- sure drop during the 24 hour test period. The ‘maximum pressure drop during the hold period, resulting from final stabilization of the ine, shall not exceed 1 % of the nominal test pressure, after ‘making an allowance for temperature variation during the test. Once the test has commenced, should the pres- sure fall below the test pressure, the line is re- pressurized. In such a case, the hold period is considered as recommencing from this point. - Pressure release ‘The line is depressurized to a previously agreed pressure. - Documentation of the test When the test is completed, the following records are signed by all parties attending the test and are part of the test documentation. . Log of deadweight tester readings or master gauge readings. Subsea temperature readings. . Ambient temperature charts. Pressure charts during pressurization, stabilisa~ tion and hold periods. - PV plot of pressurization. - Record of pigging if any. Copies of calibration certificates approved as ‘ue copies" by all parties attending the test upon checking the original certificates, ‘Test acceptance certificate. lice DIAMETER The Inside Diameter (L.D.) of a Coflexip flexible pipe is its actual inside diameter. For example, a 4" LD. flexible pipe has an inside diameter of 4", 46 i.e. 101.6 mm, Flexible pipes with inside diame- ters ranging from 1" to 20” can be manufactured. ‘Wisden it orn fo Ce ae ical ci eedbeer STEEL CARCASS ‘The interlocked steel carcass is manufactured by cold forming a trip by means of a spiralling ma chine (US Patent 4.597.276). The basic function of this carcass is to give mechanical support to the intemal thermoplastic leakproof sheath in order to resist collapse due to gas diffusion or external hydrostatic pressure. Furthermore, the interlocked steel carcass al- lows the use of TFL tools and practically all types. of pigs. It does not perform any sealing function and is therefore only submitted to the external compressive forces of the intemal fluid For low pressure flexible pipes, the carcass may be used as an internal pressure resistant layer. The interlocked steel carcass may also be used extemally to add protection to the flexible pipe, to increase its weight. The main materials used for this carcass, chosen according to the chemical composition and tem- perature of the fluids in contact are galvanized AISI 304, AISI 304L, AISI 316, AISI 316L. More sophisticated stainless steels may al- sobe used such as Duplex, Incolloy, Inconel. etc. steel, cortexie The inner interlocked carcass is electrically iso- lated from both the steel armours (by the thermo: plastic sheath) and the end-fittings (by a Technil ring). |-tnterlosked. Steel Carcass Taermoplsie Sheath Zeta Spat i - Reinforcing Spica B Double Cros: Thermoplastic ‘Sheath Interlocked steel carcass during its manufactureCOFLEXIP J TUBE PULL-IN J tube pull-in is common pro- cedure when installing flex- ible pipes. Its main advantage is the avoidance of a subsea tie- in, The typical steps of such a pro- cedure are : ~ preinstalled messenger line fol- lowed by a pulling wire is trans- ferred from the platform to the ves- sel; ~ the end of the pull-in wire is connected to the flexible pipe’s end fitting and the pull-in operation begins; -when the end of the flexible pipe reaches the top of the J tube, a hanging device is attached to the end fitting in order to support the weight of the flexible pipe ; - the installation of the flexible flowline is then performed in the ordinary way. The pull-in procedure is similar for an I tube pull-in, When studying the feasibility of a pull-in, several points should be checked : - The passage of the end fitting and pulling head inside the tube (particularly the bent parts) with an admissible clearance. Should the outside dia- meter of the end fitting be too large, one possibil- ity isto adapt a temporary end fitting intended to be used solely for the pull-in operation, and to cut the pipe and mount a new end fitting after the pull-in operation. ~The Land J tube's internal surface should be smooth, exempt from edges, etc. - The pulling tension should re- ‘main within the limits acceptable for the pipe. A sealing plug may be pre-installed on the flexible pipe at the bellmouth loca- tion in order to keep the corro- sion inhibitors inside the J tube. Lees The flexible pipe is made up of several concen- tric layers which are separately manufactured. Each layer has specific functions. The steel layers give mechanical resistance to intemal pressure and to external loads whereas the ther- 48 moplastic sheaths provide internal and external leakproof characteristics. ‘The main layers used in Coflexip flexible pipes are outlined in the following table:2 COPLEXIO TAYER (Continued) ‘Thermoplastic tube Polyamide 11, High Density Polyethylene, | Cofion | Galvanised steel, | AIST 304, | AISI 304L, | AISI 316, | AISI 316L, | | Duplex, etc. Interlocked steel! carcass ‘Thermoplastic sheath | Polyamide 11, High Density | Polyethylene, Coflon | Designation of Material used the layer Low or medium carbon steel Zeta spiral Reinforcing spiral | Low, medium or high carbon | steel ‘Thermoplastic | Polyamide 11, friction sheath | High Density Polyethylene | Double crosswound | Low, medium or | armours high carbon steel Insulation foam, Cofoam ae Laying flexible pipe is a simple and quick opera- tion. The flexible pipe is stored on tumtables or on reels on the deck of the laying vessel and is paid out of the turntable or the laying reel which is rotated by means of a winch (US Patent 4.284.249). When the pipe has been entirely paid out of reel or turntable n°I, its end fitting is con- nected on the deck of the vessel to the end fitting of the pipe stored on reel or turntable n°2 and the laying operation is resumed. The same operation is performed for the remaining tumtables or reels. Flexible pipe hangs in a free hanging catenary from the vessel to the sea bed. The 4 rotative speed of the turntable or reel and the speed of the vessel are adjusted together accord- ing to the shape of the catenary which is con- trolled by an ROV by determining the distance between the stem of the vessel and the touch down point of the catenary and/or by the angle at the top of the catenary. With Flexservice D.P. vessels, the laying speed can be as high as 600 meters/hour, and can be performed in sea conditions up to Beaufort 6 to 7 according to different parameters such as ac- tual heading, currents, wind, wave height, etc.COFLEXIPD | S CONFIGURATION ‘This isa configuration where a dynamic flexible nary from the upperconnection on the floater: riser runs downto the sea bed in adouble-cate- a subsurface buoy, and mid-water arch. The lower part of the flexible riser lies on the sea bed. ‘The mid-water arch and buoy are tensioned by means of a sling and dead weight. 1. A messenger line is passed from the floating produc tion facility tothe installation vessel. 2) The upper end of the riser (QCDC or QDC or end 4) The reiaining swivel is disconnected from the mid: fitsing only) is sransfered with the upper section of the water arch and the lower end of the riser is laid on the riser sea bed. tcatant sich cn 3) The mid-water arch is launched and positioned at 5) The flowline is laid in the direction of ts final ‘mid.depth by means of the deal weight while paying destination out ofthe riser continues.COFLEXIO Fa; WAVE CONFIGURATION This is a configuration where a loop is formed tion of the dynamic flexible riser. The lower part between the upper connection and the seabed by _ of the riser lies horizontally on the seabed, clamping buoyaney modules along a given sec- Thelazy wave configurations astraight forward extension of the classic Lazy $ configuration where the mid-water arch, associated subsurface buoy, sling and dead weight are replaced by a i number of buoyancy modules 1) Amessenger line is passed from the floating produc tion facility 10 the installation vessel. 2) The upper end of the riser (QCDC or QDC or end 4) The installation ofthe riser continues by the paying [fusing only) is transfered with the upper section of the out of the viser. 3) The buoyancy modules are launched 5) The flowtine is laid in the rection ofits final destination 31 i i i Zbesa CARBON STEEL FM 15 (AFNOR NFA 35-051 standard) is the low carbon steel used for the armour wires of Coflexip flexible pipes. The Z shaped wires are usually manufactured from FM 15 steel or other similar medium or low carbon steels. These materials are suitable for all the steel armours when the pipe is designed for sour service. The steel wires are submitted to a special treatment in order to obtain the required characteristics. ‘The main characteristics of these wires (FM 15) are cortexie WIRES Mechanical characteristics (at 20°C) Ultimate tensile strength Flat steel wires, Zeta 4.8, Zeta 6.2 min. 784 MPa Zeta8 min. 736MPa Elongation at break (AP 100)min. 1.5 % Hardness HV 30 max, 22 Re - Heat chemical analysis c % min. 0.12 max, 0.17 Si % min.0.10 max. 0.35 Mn % min. 0.40 max, 0.70 s % max, 0.025 3 % ‘max, 0.025 Mite All Coflexip flexible pipes, and particularly their cathodic protection, are designed for the service life of the field and require no maintenance other than regular (yearly) ROV inspection. rs FOR DIVERLESS CONNECTIONS(MDC) ‘The"Manipulator for Diverless Connections (MDC)" is a connecting device specifically in- tended for flexible lines, that can be operated from a conventional support vessel, and capable of making diverless connections or disconnec- tions to a conventional wellhead or any other subsea structure in water depth up to 1000 meters. This remote controlled system is developed by Coflexip, with IFP (Institut Frangais du Pétrole) and Alsthom ACB (Ateliers et Chantiers de Bretagne), for the performance of the following operations, - First and second end connection/disconnection of a flexible line to a subsea structure (wellhead, template, manifold). Connection/disconnection of a flexible line to another flexible line on the seabed. - Connection/disconnection of a flexible line toa id pipe on the seabed. - Disconnection, recovery, on site repair or re- placement and reinstallation of a flexible line. Installation of flexible spool pieces. The system could also perform other tasks such a: intervention/maintenance of Christmas trees /manifolds (replacement of control pods, chokes,...), obstacle detection and positioning,