The Life-Cycle of Flexible Risers and Flowlines

(a design and operations awareness course)

Society for Underwater Technology

Damage, Defects, Degradation and Failure Modes

Society for Underwater Technology

Objectives / Overview
Link between Design & Failure
Potential Failure Modes by Layer Industry Examples

Experience of Use, Damage and Failure

SureFlex JIP, Oil & Gas UK Publications Failure Mechanisms & Causes in Practice

Life Cycle Integrity Assurance

Technical Integrity Assurance Checks

Meeting the Challenges Link between Degradation & Integrity Management Case Studies

Link Between Design & Failure

Risk Assessment & Integrity Management

Link Between Design & Failure

Carcass (Stainless / Duplex Steel)
External Pressure Resistance
Carcass Profile:

Internal Sheath (Polymer)

Internal Fluid Containment Barrier

Pressure Armour (Carbon Steel)

Hoop Load Resistance
Armor Profile:

Tensile Armour (Carbon Steel)

Tensile Load Resistance

External Sheath (Polymer)

External Fluid Barrier

Link Between Design & Failure

Potential Failure Modes : Layer by Layer
Carcass Internal Pressure Sheath Pressure Armour Backup Pressure Armour Tensile Armour Layours Insulation Layers Outer Sheath Corrosion Considerations

Additional Reference Material

API Recommended Practice 17B / ISO 13628-11:2007
Tables 30-32 : Potential defects (static/dynamic/system)

Link Between Design & Failure

Carcass
Hole, Crevice, Pitting or Thinning Unlocking Deformation Collapse or Ovalisation Circumferential Cracking / Wear / Fatigue Pigging

Link Between Design & Failure

Internal Pressure Sheath
Hole or crack Rupture Collapse Ageing Embrittlement Excess Creep of Polymer into Metallic Layer Crazing leading to cracking Wear / Nibbling / Fatigue Multi Layer PVDF Physical Property PA-11 Blistering
Maximum Temperature (C) Allowable strain (%) Modulus of Elasticity (MPa) Tensile strength (MPa) Thermal Conductivity (W/mK) 65
[150F]

Pint

HDPE
60 7.0 700 30 0.35

XLPE
90 7.0 800 30 0.35

PVDF
130 [265F] 3.5 950 40 0.17

7.7 350 55 0.33

Link Between Design & Failure

Pressure Armour Layer
Rupture Unlocking Collapse or Ovalisation Longitudinal Wire Crack

Backup Pressure Armour Layer

Rupture Ovality Clustering

Link Between Design & Failure

Tensile Armour Layers
Multiple Wire Rupture Birdcaging or Clustering Kinking Individual Wire Rupture

Insulation Layer
Crushed Layer Flooded Layer

Link Between Design & Failure

Outer Sheath
Hole, tear, rupture, cracking Wear / abrasion
FPSO / FPU interfaces Ancillary components Touch Down Point

Leads to seawater ingress, and potential corrosion / fatigue effects

Link Between Design & Failure

Corrosion Considerations [1]
Armour wires carbon steel
General corrosion and pitting Stress corrosion cracking Hydrogen cracking Sour service (SSC) Corrosion fatigue

Inner carcass stainless steel

Pitting and crevice corrosion Stress corrosion cracking Sour service (SSC)

Link Between Design & Failure

Corrosion Considerations [2]
Sheath damage Oxygen corrosion
Steel wires exposed to seawater with oxygen replenishment in damaged area leads to general corrosion Further away from damaged area, oxygen is consumed and corrosion rate falls Can be prevented by cathodic protection, but not effective in all instances Underneath coating Splash zone Inside guide tubes and bend stiffeners

Link Between Design & Failure

Corrosion Considerations [3]
Sheath damage Oxygen corrosion

Link Between Design & Failure

Corrosion Considerations [4]
CO2 corrosion in the pipe annulus
Diffusion of CO2 and H2O through pressure sheath, or annulus flooding / liquid ingress Condensation of wet gas on armour wires Localised pitting, gradual loss of section Environmental conditions : Distilled water CO2 (and H2S) Super-saturated with Fe (large steel area / solution volume) pH 5.5 to 6.5 Low oxygen (< 5 ppb)

Link Between Design & Failure

Corrosion Considerations [5]
Stress Corrosion Cracking (SCC)
Found in underground transmission pipelines, but believed possible in flexibles

Hydrogen Cracking - High strength armours susceptible

Breach of external sheath allows seawater ingress CP leads to generation of hydrogen on steel surface Localised plastic deformation from impact damage renders material more susceptible High operating stresses approaching yield Avoid impact damage Repair and seal off areas of sheath failure Do not overprotect CP potential Inspect

Link Between Design & Failure

Corrosion Considerations [6]
Carbon Steel - Sour Service Issues
Aqueous corrosion produces hydrogen as product of reduction reaction Atomic hydrogen diffuses into material Hydrogen Induced Cracking (HIC) H recombines at inclusions or bands of segregation, continued diffusion leads to pressure increase Cracking parallel to plate surface, blistering HIC

Link Between Design & Failure

Corrosion Considerations [7]
Sulphide Stress Cracking (SSC)
H remains in solid solution and cracking occurs under critical combinations of stress, microstructure and H concentration

Selection of steel grade for sour service Qualification testing to demonstrate suitability to service conditions

SSC

Link Between Design & Failure

Corrosion Considerations [8]
Carbon Steel Corrosion Fatigue
A significant driver predominantly in determining remaining life in the event of annulus flooding Fatigue performance of armour wires degraded if corrosive species reach annulus Surface corrosion/pitting provides initiation site Growth of flaw accelerated by the presence of CO2/H2S Annulus environment prediction critical Qualification testing to determine appropriate S-N curve Marintek/SINTEF JIP Design criteria for sweet or sour operating conditions Effect of flushing with inhibitor fluid to mitigate?

Link Between Design & Failure

Corrosion Considerations [9]
Carbon Steel Corrosion Fatigue

Link Between Design & Failure

Corrosion Considerations [10]
Stainless Steel
Can be susceptible to pitting and crevice corrosion in aggressive (Cl-, H+) environments SCC can occur when all of the following are present: Chlorides in environment Dissolved oxygen in environment Locally high tensile stress Sour service conditions Sulphide stress cracking, hydrogen embrittlement (low T) Influence on chloride SCC (high T)

Link Between Design & Failure

Corrosion Considerations [11]
Number of potential mechanisms of corrosion
Type of material Environmental conditions Applied stresses

Detailed materials selection is the first step

Strength limits on armour wires Influence of sour service Grade of CRA for carcass

Qualification testing for project Monitoring and / or control of environmental conditions

Link Between Design & Failure, Example : WI Riser Systems

Water Injection Riser
Vent ports historically not included in design
Low fluid aeration => no permeation => no design requirement to vent the annulus

Valuable access to annulus to allow annulus testing, and displacement of seawater if required Industry experience shows care required to prevent annulus flooding of other risers through common manifolds

Link Between Design & Failure , Example : PVDF History

Plasticised Polymer
Loss of plasticiser during operations leading to:
End Fitting Failures Embrittlement

Unplasticised Polymer
Stiffer, more brittle and notch sensitive Solution - Multi-layer PVDF
Industry failures relating to carcass collapse Careful sealing between layers and stringent operational limitations to avoid carcass collapse during depressurisation

Experience of Use, SureFlex JIP

Update on previous UKOOA JIP reports (2001/2002) SureFlex JIP Output Reports (2010):
State of the Art Report on Flexible Pipe Integrity
Gathered data on flexible pipe population statistics, damage, degradation and failure mechanisms worldwide Reviewed current integrity management practice Reviewed developments in monitoring and inspection methods for flexible pipe

Guidance Note on Monitoring Methods and Integrity Assurance for Flexible Pipe
Life cycle flexible pipe integrity assurance Sources of flexible pipe degradation, damage and failure Guidance on Inspection and Monitoring Techniques

Experience of Use, SureFlex JIP

Participation / input to the JIP from
14 global operators, HSE, 4 engineering consultancies Manufacturers (Technip FlexiFrance, Wellstream, NKT)

Data gathered from industry; questionnaires and interviews conducted on an international basis Additional database statistics based on;
in-house projects database industry data gathering public domain sources

Database results:
Population statistics based on 1,900 risers, 1,400 static lines and over 130 production facilities worldwide 315 individual damage / failure incidents

Experience of Use, SureFlex JIP

JIP Reports available online through O&G UK
http://www.oilandgasuk.co.uk/publications/viewpub.cfm?frmPubID=152

Experience of Use, SureFlex JIP,

Key Conclusions [1]
Significant database of population statistics and failure damage incidents Integrity Management Practice
Lack of coherent strategy across the industry which details all design and operational data to be monitored and recorded Follow-up on recording and assessing still found lacking

Handover (project execution to operations) has improved since 2002, but could improve further
e.g. multiple failures to correctly commission gas vent systems

Massive growth in experience

Exponential growth in operational experience (riser-yrs) from early 1990s to present There still remains relatively limited operational experience of risers over 15 to 20yrs service in harsh environment Longer-term failure modes not experienced to date e.g. fatigue

Experience of Use, SureFlex JIP,

Key Conclusions [2]
Significant Uptake in Annulus Testing since 2002
Improvement in procedures and assessment capability New techniques developing Initial testing at FAT followed by annual testing is now accepted practice

Retired Risers due to Corrosion Fatigue

Limited number of retired riser dissections imply predictions are conservative Corrosion fatigue assessments need improvement

Principal cause of damage remains external sheath breach

Focus now on global corrosion in the splash zone

No single method of monitoring / inspection provides all the answers

Range of measures/techniques are usually required to demonstrate integrity

Experience of Use, SureFlex JIP,

Population Statistics [1]
Pressure vs. ID

Experience of Use, SureFlex JIP,

Population Statistics [2]
Water Depth vs. ID

Experience of Use, SureFlex JIP,

Damage/Degradation Statistics [1]

Data collected over all global regions, all configurations, and all operational phases

Steep Wave

Steep S

Free Hanging Catenary

Lazy Wave

Lazy S

Tethered Wave

Experience of Use, SureFlex JIP,

Damage/Degradation Statistics [2]

Experience of Use, SureFlex JIP,

Damage/Degradation Statistics [3]

Experience of Use, SureFlex JIP,

Inspection/Monitoring Techniques
SOTAR report gathers current operational & practical experience of inspection / monitoring techniques for flexible pipe
Established and evolving techniques Reviews relative take-up / usage, and effectiveness of individual techniques, based on JIP feedback

Techniques / methodologies are evolving, and this is an area of significant industry development

Experience of Use, SureFlex JIP,

Life Cycle Integrity Assurance [1]
Guidance Note provides list of technical integrity assurance checks through the pipe life cycle:
Concept Definition / FEED Detail Design Manufacture Storage Installation & Commissioning Project Handover to Operations Operation

Key items summarised as follows

Experience of Use, SureFlex JIP,

Life Cycle Integrity Assurance [2]
Concept Definition / FEED
Is system within industry experience, or does system represent a technology stretch? Define key risks & mitigating integrity measures
Assess spare riser philosophy for system life-cycle

Assess appropriate riser configuration FPSO / FPU interface assessment / turret layout
Ease of installation, inspection / monitoring requirements Requirement for i-tube inspection, pigging requirements

Consider process monitoring requirements to address:

Bore pressure / temperature, annulus monitoring, coupon monitoring, bore fluid composition / sampling points

Consider redundancy of subsea monitoring equipment

e.g. backup sensors

Experience of Use, SureFlex JIP,

Life Cycle Integrity Assurance [3]
Detail Design [1]
Define detailed Statement of Requirements, and applicable Codes & Standards Design Basis to detail life cycle integrity requirements Establish operating envelopes / anomaly limits Define operational requirements for monitoring systems, and ensure compliance with relevant topsides specs. Ensure best in class annulus vent system e.g. avoid common annulus vent header Assess corrosion-fatigue in seawater flooded annulus
Feeds into integrity management strategy Aid to development of operational spares philosophy

Experience of Use, SureFlex JIP,

Life Cycle Integrity Assurance [4]
Detail Design [2]
Consider small scale fatigue testing of armour material in project-specific environment to define S-N curve Complete prototype testing (if design stretch) Ensure structural dynamic analysis accounts for frequency effects (and includes all life-cycle scenarios) Assess effect of large buoyancy elements for localised curvature effects Define depressurisation procedures and ensure compliance with topsides system specifications
Particularly relevant for multilayer pressure sheathes, or smooth bore risers used to mitigate FLIP

Define clashing / interference criteria, and assess impact testing requirement Consider range of chemical treatments through life-cycle of flexible pipe system

Experience of Use, SureFlex JIP,

Life Cycle Integrity Assurance [5]
Manufacture
Establish a company approved manufacturing spec. Record / track / close-out / document non-conformances Define any critical areas which should be free from welds Consider retention of material samples / pipe section for future fatigue tests, integration testing, inspection trials Recommend annulus volume test in FAT programme Ancillary equipment assessed for fatigue, and sufficient attention to welding / coating / finishing / CP systems
Particularly an issue where components may be supplied by 3rd party / company, to ensure system integration

Consider over-sheathing in areas of high abrasion / contract loads predicted

Experience of Use, SureFlex JIP,

Life Cycle Integrity Assurance [6]
Storage
In accordance with manufacturer recommendations Define storage / packaging requirements (e.g. UV protection)
Attention to ancillary components handling & protection, which have potential to damage pipe

Define treatment requirements for bore & annulus (short term vs long term strategies) Define periodic inspection & testing requirements Wet-parking in advance of FPSO / FPU hookup is sometimes dictated by project:
Consider integrity threats from internal / external corrosion, physical damage, dynamic stability, external protection requirements

Experience of Use, SureFlex JIP,

Life Cycle Integrity Assurance [7]
Installation & Commissioning [1]
Interface management is critical, particularly when installation contractor is not the pipe supplier Installation analysis performed to define limiting seastates for each stage to reduce risk of damage Installation equipment should be suitably rated / matched to mitigate pipe damage Installation operations must be to procedures which are Approved for Construction As alternative to oversheathing, consider localised application of abrasion resistant products to protect pipe Ensure manufacture Non Conformances are highlighted to installation / operations teams e.g. sheath repairs

Experience of Use, SureFlex JIP,

Life Cycle Integrity Assurance [8]
Installation & Commissioning [2]
Record non-conformances / concessions / procedure deviations for future integrity assessment All operatives vigilant for evidence of outer sheath damage and understand implications of damage Qualified technicians & approved procedures to cover plastic weld repair should be present on the vessel Ensure adequate reel packing to mitigate damage Ensure vent ports are plugged prior to deployment
vent system must not be obstructed in operation

Conduct thorough as-built survey to form a baseline for all future integrity management assessments Conduct annulus testing as part of commissioning phase Conduct anode continuity checks prior to deployment

Experience of Use, SureFlex JIP,

Life Cycle Integrity Assurance [9]
Project Handover to Operations
Project transfer of integrity management strategy which is supported and implemented by operations Consider seconding operations / integrity engineer to the design project Supply completed as-built documentation
design, manufacture, photographic records, installation, baseline inspection

System verification assurance & legislative compliance Verify operational envelopes adopted in the design and compliance with operations & maintenance manual Operators are increasingly requiring annulus integrity test results as part of formal handover to operations

Experience of Use, SureFlex JIP,

Operation

Life Cycle Integrity Assurance [10]

Implement, maintain, review, and regularly audit a flexible pipe integrity management strategy Monitor annulus for potential flooding (all risers) Ensure annulus vent system remains fit for purpose Monitor / log / assess bore bore fluid characteristics (pressure, temperature, gas composition, treatment fluids, methanol) Establish alarm limits / criteria for key parameters Verify use of any annulus treatment fluids Assess integrity threat to any intervention on system Employ coupon sampling program for higher risk lines Record environmental data and verify against design Repair any outer sheath damage on dynamic riser
If not complete already, complete C-F assessment

Flexible Pipe Failure Modes

Carcass (Stainless / Duplex Steel)
External Pressure Resistance

Internal Sheath (Polymer)

Internal Fluid Containment Barrier

Pressure Armour (Carbon Steel)

Hoop Load Resistance

Tensile Armour (Carbon Steel)

Tensile Load Resistance

External Sheath (Polymer)

External Fluid Barrier

Flexible Pipe Failure Modes

Carcass
Hole, Crevice, Pitting or Thinning Unlocking Deformation Collapse or Ovalisation Circumferential Cracking / Wear Fatigue Pigging
Carcass Profile:

Flexible Pipe Failure Modes

Internal Pressure Sheath
Hole or crack Rupture Collapse Ageing Embrittlement Excess Creep of Polymer into Metallic Layer Crazing leading to cracking Wear / Nibbling / Fatigue Multi Layer PVDF Blistering
Internal Sheath crack

Failure initiation region of PDVF

Flexible Pipe Failure Modes

Ageing of PA-11 in Flexible Pipes
Time to reach Initial Acceptance Criterion of 1.2 dl/g

Flexible Pipe Failure Modes

Pressure Armour Layer
Rupture Unlocking Collapse or Ovalisation Longitudinal Wire Crack
Armor Profile:

Backup Pressure Armour Layer

Rupture Ovality Clustering

Pressure Armour Unlocking

Flexible Pipe Failure Modes

Tensile Armour Layers
Multiple Wire Rupture Birdcaging or Clustering Kinking Individual Wire Rupture

Insulation Layer
Crushed Layer Flooded Layer

Flexible Pipe Failure Modes

Outer Sheath
Hole, Tear, Rupture, Crack Ingress of Sea Water
Outer Sheath Damage

ROV installation of riser repair clamp. Outer sheath was damaged during riser deployment

Repair Clips on riser Section

Flexible Pipe Failure Modes

End Fitting
Internal Pressure Sheath Pull-out Tensile armour Pull-out Outer Sheath Pull-out Vent Valve Blockage / Leakage Failure of Sealing System Crack or Rupture of Tensile Armour Structural Failure of End Fitting body or Flange

From OMAE2004-51431, outer sheath failure due to blocked riser vent valve.

Ancillary Failure Modes

Bend Limiters

Stiffener Crack / Rupture Stiffener Support Structure Failure Bellmouth Deformation or Inadequate Size Stiffener Design

Bend Restrictors

Unlocking Dynamic Loading Mechanical Failure

Ancillary Failure Modes

Buoyancy Modules
Module Slippage Loss of Buoyancy Module Reduced Buoyancy

Subsea Buoys
Clamp Slippage Loss of Buoy Reduced Buoyancy Tether Failure

Ancillary Failure Modes

Clamps
Slippage Damage / Mechanical Failure Degradation

Riser Bases
Damage to Riser Connection Displacement

Ancillary Failure Modes

Riser Base Ancillary Equipment Failure Example Example riser hold-down top-hat swivel fixed to top of base pile Connection Failure, riser displaced 75 metres vertically upwards

Ancillary Failure Modes

Riser Support Structures
Structural Failure or Displacement of Support Structure

Cathodic Protection
Electrical Discontinuity Anode Exhaustion

Mattresses or Sand Bags

Instability

Ancillary Failure Modes

Dumped Rock or Trench Backfill
Loss of cover

Flexible Pipe Layout

Upheaval, Buckling or Creep Pipe Loop Pipe Disarrangement Pipe Free Spans Riser Interference

Meeting the Industry Challenges, JIPs and Industry R&D Focus [1]
Flexible Pipe JIPs
Flexible Pipe Technology JIP (first major update of API Spec 17J & RP 17B since mid-90s, and development of ISO equivalents) Polymer ageing JIPs (PA-11 RUG 2003 API 17TR2, ongoing PA11 & XLPE) Permeation modelling JIP Marintek / Sintek Corrosion Fatigue JIP, started 2001 Real Life JIP Ancillary Equipment JIP (API Spec 17L1 / RP 17L2) Hois JIP (focus on increased reliability / cost effectiveness of NDT technology across O&G industry) Riser End of Life JIP (investigation of residual fatigue life in post-service armour wire samples from retired risers) Flow induced pulsation studies (Singing Risers JIP by Marintek, FLIP JIP by OTM Consulting)

Meeting the Industry Challenges, JIPs and Industry R&D Focus [2]
Manufacturer R&D Efforts
Ultra deepwater; qualification of carbon / composite armours, pressure armour profile to increase external resistance Increasingly aggressive corrosion testing conditions to define degradation rates Sacrificial layers to chemically inert H2S prior to permeation into annulus Polymer development; pressure / temperature / fatigue (including thermal barrier layers) Condition monitoring & inspection e.g. fibre optics / BS monitoring Drive for more cost effective materials Smooth bore gas risers to mitigate FLIP Cryogenic pipe for very low temperature Flow assurance improved insulation / active heating / temperature monitoring Gas permeation models Local cross section modelling (external parties also)

Meeting the Industry Challenges, JIPs and Industry R&D Focus [3]
Current Challenges
Flow Induced Pulsation / Vibrations (following slides) High Temperature (polymer developments / thermal barrier layers) Deep Water (collapse / tensile / TDP fatigue / birdcaging / lateral buckling considerations)

Experience of Use, Flow Induced Vibrations [1]

Phenomenon in Gas Export & Gas Injection Risers Internal flow causes eddies to shed on corrugated carcass Causes pressure fluctuations and flexible pipe vibrations High frequency vibrations in connected topside and subsea rigid pipe works Potential for fatigue damage to connected rigid pipe works Controlled by limiting flow rates and/or suppression devices Various industry efforts to further understand the phenomenon and how to design for it (2 ongoing JIPs)

Experience of Use, Flow Induced Vibrations [2]

Experienced by a number of operators Worldwide
Significant production losses Significant investigation costs Significant remedial work costs Particular experience by Norsk Hydro

Troll C Platform Gas Export Riser, 15 inch ID, 203 bar pressure Paper No. OMAE2003-37194

Experience of Use, Flow Induced Vibrations [3]

Excitation Frequency

167 Hz 117 Hz 84 Hz 137 Hz

191 Hz

208 Hz

Gas Flowrate Increasing

Problem only becomes apparent above a certain onset velocity Excitation force builds as flowrate increases Higher flowrates result in higher frequencies Harmonic excitation at multiple frequencies up 2kHz First vibration frequency can occur below 100 Hz

Experience of Use, Flow Induced Vibrations [4]

Significant research carried out by certain operators / JIPs Measurement of both topside and subsea structural responses Fatigue of associated topside and subsea SBCs possible in hours

Link Between Failure and Integrity Management

Risk Based Integrity Management
Risk
failure modes and consequences

Mapping risk to integrity strategy

Available Integrity Measures

Examples

Link Between Failure and Integrity Management

Example 1 - Corrosion Fatigue
Failure Mode
Risk
Corrosion fatigue of armours External sheath damage Reduced Service Life, Failure if Undetected. ROV Inspection Annulus Testing

Possible mitigation / inspection

Refer to separate case study

Link Between Failure and Integrity Management

Example 2 - Nylon Ageing
Failure Mode
Risk
Pressure sheath failure Excessive temperature, pH, water cut

Possible mitigation / inspection

Loss of containment

Temperature Monitoring Degradation Calculations / Predictions Coupon Sampling Fluid Sampling/Analysis

Damage & Degradation, Case Studies

Case Studies
1. Corrosion Fatigue Case Study 2. In-Service Riser Repair (Galley)

Corrosion Fatigue Case Study [1]

Initial riser design in early to mid 1990s
Dry fatigue indicated acceptable service life
Loadcases very limited (<10 in 3 directions) No account for frequency effects

No corrosion fatigue assessments

Outer sheath breach / annulus flooding on installation

Annulus treatment / inhibition program Program of outer sheath clamp repairs to re-seal annulus Corrosion fatigue assessment performed based on early life conditions (no H2S), and same limited loadcases

Corrosion Fatigue Case Study [2]

After ~10yrs operation, re-assessment required
Significant H2S levels developed (not accounted for in original S-N curves / fatigue assessments) Industry methodology standardising to SN curve defined by the mean less two standard deviations, in combination with a safety factor of 10 for fatigue life Improved understanding of the frequency effects of the structural dynamic response of risers, and computing power to assess more representative wave class / bins
In a number of cases this has concluded the basic / coarse analysis can be non-conservative as nominated frequency may be at a trough of response

Corrosion Fatigue Case Study [3]

Fatigue Re-assessment Program Initiated
Updated permeation models
New models allowed more representative

Selection of wire samples for fatigue testing

Selected from dissection of original batch material section

Local wire fatigue testing to define SN curves

Using appropriate inhibited fluids & H2S / CO2

Global riser dynamic analysis

Accounting for all directional wave bins (~1000 seastates)

Local cross section analysis / fatigue assessment

Bringing together the global loads and the local SN curves

Reliability based assessment for critical lines

Was used in this case to justify short term extension of operations, with additional mitigations, until earliest feasible riser changeout

Corrosion Fatigue Case Study [4]

Increasing H2S levels

Time

Corrosion Fatigue Case Study [5]

Reliability based assessment results
Riser change out date Limit Criteria based on accepted operations safety case probability for a large release from gas riser

Time

In-Service Riser Repair [1] History & Background

Galley Field, Northern Producer FPF
Approx 120miles NE of Aberdeen Installed September 1997 10yr design life

Talisman owned, Petrofac operated

Chevron (Texaco) original owner 1997-2004

Flexible Riser System

Lazy-S Configuration 3xProd., Oil Exp., Gas Exp., Water Inj., Umbilical

Reference OMAE2007-29382

In-Service Riser Repair [2] History & Background

UPPER DECK Riser tie in platform

MWL

8 - inch Gas Export Inverted Bellmouth I - tube

Damage

PONTOON Bellmouth

In-Service Riser Repair [3] History & Background

INVERTED BELLMOUTH

In-Service Riser Repair [4] History & Background

Bubbles identified from inverted bellmouth
Routine GVI Checks indicate permeated gas levels of leakage
Annulus flooded, confirmed by vacuum test

Assumed breach within lower bellmouth Borescope inspection inconclusive

In-Service Riser Repair [5] Riser Pull Test

Potential restriction at bellmouth
Confirm riser not jammed at lower bellmouth Confirm tension not supported at pontoon

Riser Pull Test Lateral Displacement

Lateral mid-span displacement associated with vertical lift at bellmouth Riser de-pressurised & isolated before test

Conclusions
Test results a good overall comparison with analysis Riser tension not supported at pontoon Riser can be lifted for inspection

In-Service Riser Repair [6] Riser Pull Test

UPPER DECK Riser tie in platform

Winch Pulley arrangement Pulling wire

8-inch Gas Export Webbing Sling

Tension Meter

I-tube PONTOON Bellmouth

In-Service Riser Repair [7] Riser Pull Test

0.00 Te

0.75 Te

1.50 Te

In-Service Riser Repair [8] Riser Pull Test

In-Service Riser Repair [9] Riser Lift & Inspection

At transit draft Inspection basket deployed Prior to lift

In-Service Riser Repair [10] Riser Lift & Inspection

Small damage area identified with debris embedded in outer sheath

In-Service Riser Repair [11] Riser Lift & Inspection

Larger section removed to assess armours

In-Service Riser Repair [12] Consequence of Damage

Gas Export Operations Halted
Severity of damage & failure consequences Loss of Gas Export revenue Reduced Production Consent to flare

Temporary Mitigation
Gas Export swapped with Water Injection Service
Early restart of Gas Export operations

Technical integrity assessment

Supported riser service swap Justification for in-service use of damaged riser Economic consequences of Water Injection failure Water Injection repair before full winter season

In-Service Riser Repair [13] Remedial Actions & Repair

Permanent Repair
Cut out damaged section and re-terminate Riser lift to hang-off deck to effect repair Weather window assessed for each stage Critical maximum lifts to +30m and +40m Vessel actively winched towards MWA Analysis predicted weather windows
Hsig = 5m to 9m (+40m lift) Hsig = 12m (+30m lift)

In-Service Riser Repair [14] Remedial Actions & Repair

Initial Crane Lift on End Fitting 40metre Lifts : Dual Clamps & Strand Jacks

In-Service Riser Repair [15] Remedial Actions & Repair

In-Service Riser Repair [16] Remedial Actions & Repair

Riser repair completed successfully Riser brought back into WI service
0.3m (scaled) Riser Tie-in Platform +32.29m TOS Bottom of C-Clamp on Riser End Fitting at Tie-in Deck

Conclusions / Key Lessons Damage worse than expected from minor sheath breach
Subsequent similar cases on other assets have lead to full bore failures

Water Line, Operating Draft, 21.35m Water Line, Survival Draft, 18.29m
3.4m 6.5m

Vacuum testing and integrity management allowed timely repair Successful riser repair Inverted bellmouths and similar devices require debris protection

3.0095m

0.3m Top of Lower Inverted Bellmouth (pontoon level)

Min. 0.7m

Bend Stiffener

NOT TO SCALE

21.4 metres (measured by divers, refer to e-mail, 20/11/05, 09:16 from Galley OIM)

Maximum Cut Length = 18.9 metres (21.4 - 2.5)

Questions ?