Carbon Fiber Pipe for Risers

SUT Conference, London, 18/19 April 2012

Technology for the Coming Decade

Presentation
Background and Scene Setting
Carbon Fiber Technology
Riser Applications
Installation
Summary
Strictly confidential. Property of Magma Global Ltd.

Background
Only 15 years ago there was general concern that riser
technology was insufficient to meet the demands of discoveries
beyond 1000m
To accelerate technology Operators were proactive in
supporting JIPs and also actively shared riser experience
Some deep water projects were sanctioned using riser
technology that had very limited track record but achieved
selection through criteria such as local content

Strictly confidential. Property of Magma Global Ltd.

Current Industry Riser Capability

In 2012 we feel confident about riser technology with
successful applications in depths up to 2000m
A range of riser technologies are considered proven with
documented track records spanning 10 years + of production

Flexible risers
SCR - Steel Catenary Risers and PIP SCRs
SLORs Single Line Offset Risers
Hybrid Bundles

Companies capable of riser design, hardware supply and

installation services are established and EPIC contracting is
typical
The riser industry feels mature and ready for the next step
using proven technology
Strictly confidential. Property of Magma Global Ltd.

Validity of Confidence ?
Every project has a different set of issues that makes them
individual and always challenging
Risers are typically the repository for design changes which
further compounds the problem technically and commercially
At the end of a project the feeling is often of:
Relief and pride by the project team
Surprise at how much it has all finally cost
$10-20m per SCR
$30-70m per SLOR

Strictly confidential. Property of Magma Global Ltd.

Whats the Real Status

Whilst we have good riser experience we are not turning the
handle and in fact this will never be the case high EPIC risk
Actual riser costs are much higher than estimated at FEED or
tendered during Execute (Underestimate challenge + Design
changes)
Many risers require rework during the early stages of life and
some require replacement
20 years riser performance is still to be proven feasible and
practical under some conditions
Strictly confidential. Property of Magma Global Ltd.

Future Industry Trends

Depths are increasing (3000m +)
Pressures are increasing (10ksi to 17ksi)
Larger diameters needed to meet project rates - (10-12in)
Process flow issues are more demanding - (Depth and fluids)
Ship shaped FPSOs are preferred with external turrets
Corrosive production fluids - (CO2 and H2S)
Higher temperatures associated with deeper reservoirs
Strictly confidential. Property of Magma Global Ltd.

Conclusion on Industry Status

Were actually struggling with current riser requirements and
future riser requirements are a significant step out
Existing technologies have little head room for further
specification extension
We should not simply assume existing technology has the legs to
meet future requirements
We need to keep pressure on development of riser technology.
Composites are finally an option that could resolve many issues
Strictly confidential. Property of Magma Global Ltd.

Composite Technology is Maturing

80% composite by volume
50% composite by weight
32Te carbon fiber in each aircraft

Strictly confidential. Property of Magma Global Ltd.

Dreamliner Construction - Thermoset

Strictly confidential. Property of Magma Global Ltd.

Polymer Technology
Thermoset
A polymer that irreversibly cures typically through heat or
chemical reaction (epoxy)

Thermoplastic
A polymer that solidifies when cooled. It can then be
reheated and remelted (PP, PE, PA/Nylon)
Thermoplastics can be joined by welding
Offers improvements in manufacturing processes
Offers improvements in material properties/performance

Strictly confidential. Property of Magma Global Ltd.

m-pipe - a high end, high

strength carbon/ thermoplastic
polymer pipe with a monolithic
structure from bore to surface
Differentiated by different:
Material
Manufacturing process
End Fittings
Strictly confidential. Property of Magma Global Ltd.

Material Selection
Victrex PEEK
Extensively used in offshore and subsea applications
Extensively qualified across key performance areas
Exclusive development contract for subsea oil & gas
pipe

T700 Carbon Fibre Toray International

Extensive qualification of T700 to aerospace standards
Worlds largest carbon manufacturer
Supply agreement in place

Strictly confidential. Property of Magma Global Ltd.

mpipe Riser Advantages

Lightweight 10% of the weight in water as steel or flexible

High strain to failure up to 2.5%
Corrosion resistant to seawater and CO2
High fatigue capability unaffected by H2S
High temperature operation
High resistance to permeation
High resistance to rapid gas decompression
Low thermal conductivity
Better erosion and wear resistance compared to steel
Smooth bore reduced pressure drop 20% compared to steel

Strictly confidential. Property of Magma Global Ltd.

Victrex

.an ideal riser material

Why PEEK?
5 = Good
0 = Poor

Polymer Comparative Properties - Victrex PEEK

Temperature
Resistance

Chemical
Resistance

Abrasion
Resistance

Mechanical
Strength

Victrex
PEEK

PTFE

PFA

PVDF

PPS

2 (unreinforced)
4 (reinforced)

PA11

3/4

Strictly confidential. Property of Magma Global Ltd.

Typical PEEK Applications

Application Examples

Electrical connectors
Umbilicals and industrial
hoses
Tubulars and pipes
Seals and back-up rings

Strictly confidential. Property of Magma Global Ltd.

Electronic sensors
Wireline and data
logging
Communication and
power cables
Plugs and packers
Thrust washers

Bearings and brushings

(as above: 200C, water
cooled, high load)
Motor and pump
components
Adhesive tapes

Testing Four Point Bending & Axial

Compression

Strictly confidential. Property of Magma Global Ltd.

Testing Compression Ring

Strictly confidential. Property of Magma Global Ltd.

Testing - Collapse

Strictly confidential. Property of Magma Global Ltd.

Testing Inter Laminar Shear

Strictly confidential. Property of Magma Global Ltd.

Testing High Strain Bending

Strictly confidential. Property of Magma Global Ltd.

Testing Impact and Tensile

Strictly confidential. Property of Magma Global Ltd.

Test Over 1000 Test Specimens

Strictly confidential. Property of Magma Global Ltd.

Ultrasonic C-Scan NDT

Bonding
Porosity
De-lamination

Strictly confidential. Property of Magma Global Ltd.

Cracking
Foreign bodies
Impact damage

End Fitting
Collar

m-pipe
Locking
Nut

Strictly confidential. Property of Magma Global Ltd.

End Fitting Resonant Rig

Strictly confidential. Property of Magma Global Ltd.

4in ID 10ksi Spool Piece

Strictly confidential. Property of Magma Global Ltd.

End Fitting Design Features

Flush bore seal with proven AX gasket

Load capacity greater than pipe strength

Smooth structural transition to standard pipe

Compact and low profile

Standard plain end steel pipe interface

Fully preloaded for good fatigue performance

External seal pressure test facility

Strictly confidential. Property of Magma Global Ltd.

Applications Weighted Catenary

Strictly confidential. Property of Magma Global Ltd.

Applications Chain Weighted SCR

Strictly confidential. Property of Magma Global Ltd.

Applications SLOR or Bundle

Strictly confidential. Property of Magma Global Ltd.

Applications TTRs (Spar and TLP)

Strictly confidential. Property of Magma Global Ltd.

Applications Offloading line

Strictly confidential. Property of Magma Global Ltd.

Applications Floating Hose

Strictly confidential. Property of Magma Global Ltd.

Applications Other Applications

SCR TDP high fatigue zones

Taper Joints to replace Flex Joints

Marine Drilling riser Kill and Choke lines

CWOR joints (tapered and cased wear)

Flowline Upheaval Buckling

Rigid Jumper Spool

Strictly confidential. Property of Magma Global Ltd.

Installation
Reel, J lay or Tow out
Lower specification vessels
Shorter installation durations
Reduced overall risk

Lower maximum lift weights

Higher permissible deflections at lower loads
Shorter installation durations
Increased operational windows
Reduced coating damage
Offshore re-spooling
Increased tow feasibility

Strictly confidential. Property of Magma Global Ltd.

Unique Manufacturing Process

Fully automated robotic manufacturing

Single repetitive process
High degree of process control and documentation
Diameter capability 2-24
Wall thickness unlimited by process or materials pressures >20ksi
Wall thickness variation along pipe and riser length
Discrete (80ft) and continuous length (km) production

Strictly confidential. Property of Magma Global Ltd.

Summary
A step change in riser technology to
Enable future subsea discoveries
Thermoplastic technology provides
manufacturing, quality and
performance benefits
High end polymers and fibers ensures
pipes with appropriate performance
Underpinning engineering and design
validation is largely completed
Volume manufacturing is being
established ready for end 2013
Strictly confidential. Property of Magma Global Ltd.