Assessing SURF Technologies for Deepwater Oil and Gas Exploration

Gonalo Pedro Martins Rego

Instituto Superior Tcnico, Technical University of Lisbon, Lisbon, Portugal
goncalorego92@gmail.com

Abstract: Subsea umbillicals, risers and flowlines (SURF) technologies are an essential element of any deepwater oil and
gas exploration, with countless associated challenges but immense potential. This work intended to explore the available
solutions existent nowadays in terms of riser systems, as well as possible future technological developments in the area.
Combining specific technical analyses with an overview of the whole oil and gas industry was the key to reach this thesis
objectives.
This thesis was based on IRGCs risk analysis framework, which contemplates interviews with experts and extensive
literature review, and a comparative case-study analysis. The dynamic analysis and comparison of two flexible riser
configurations, namely Free Hanging and Lazy Wave, gives an insight on the systems limitations and the path to follow
towards innovation in SURF engineering.
From the results and investigation throughout this work, the most unanimous solution found for the future of riser systems
consists of changing part of the structures material to composites. Moreover, it is believed that the key to SURF
technologies development is the systemic integration of structural modelling with hydrodynamic and heat transfer analysis
within engineering education, since this collaboration is crucial to the systems global analysis. Therefore, this work is a
helpful tool to understand the correlation between engineering, the intricate global market that the oil and gas industry is
inserted in and the influence an improvement in engineering education can have in such a complex industry as this one.
Keywords: Oil and Gas; Deepwater; SURF Engineering; Riser Systems; Risk Governance; Technological Development.

1. CONTEXT close to the ones found in pre-salt fields in Brazil.

Being able to migrate the highly advanced
The current on-going fluctuations in oil prices
technology used in the North Sea in shallow
generate increased uncertainties in the oil and gas
waters to these deep and ultra-deep locations is
industry, affecting the development of new
not always possible, resulting in the need to
technologies, with potential impact in the
develop specific technology to each location and
sustainable exploration of south Atlantic. These
its own specifications. The industry is being
technological outbreaks, potentiated by the
pushed to reach unprecedented water depths and
economic growth associated with the oil and gas
harsh conditions by a combination of factors from
industry, are converted into a change of paradigm
an increase in worldwide demand to the scarcity of
in the oil exploration. [1]
simple exploration reservoirs. Although the
Technological development in the oil and gas
benefits arising from the deepwater exploration are
industry has been prominent in the exploration of
numerous, the technological risks associated are
the North Sea; however, the conditions are not
immense and sensitive to markets uncertainty.

1
2. RESEARCH PROBLEM AND OUTLINE highly iterative procedure and very dependent of
specific data. [2]
In this thesis it is aimed to open the debate about
It has been stated, with extensive proof and
technological questions of the deepwater oil
support, that this technique can be applied to
exploration challenges. SURF (Subsea Umbillicals,
science related subjects if there is enough data to
Risers and Flowlines) engineering is a major topic
overlap and reach actual conclusions. Once the
within the oil and gas exploration industry,
theory is built, one must guarantee that it is
gathering some of the most complex engineering
evaluated, testable and logically coherent. [3]
design processes. Those challenges are
The reason why technology is such an important
exponentially increased when considering
part of the companies strategy is the fact that it is
deepwater exploration, therefore being relevant to
responsible for providing them with competitive
survey the existent solutions and assess the
advantages within the market. It goes without
viability of an alternative to the current option.
saying that the increases of factors like cost,
A review of the available riser technologies is
complexity and rate of technology change and the
presented, characterizing its benefits and
globalization of technology sources, contribute to
drawbacks, properly accompanied and justified
turning these technological outbreaks into critical
with examples and real applications in a case
issues. [4]
study basis with appropriate bibliographic review
and interviews.
3.2. Risk Governance International Risk
The main focus of the work is to evaluate the
Governance Council
feasibility of using a Free Hanging riser in a simple
There is a primal objective in doing a risk
catenary as a substitute of a Lazy Wave
governance analysis that consists in assisting
configuration in a deepwater field, through
experts to design policies, strategies and
structural dynamic analysis and thorough
regulations to maximize the benefits of a
comparisons.
technological improvement and new approaches to
With the knowledge from the first chapters in mind,
the deep-sea offshore oil and gas industry.
one can analyse in what manners can these riser
Recognizing the existence of risks is the first step
technologies be improved, what are the probable
of a process that leads to working on measures to
paths to future developments and relate to the
comprehend, prevent and solve those same risks.
Portuguese industry and the way it can be a part of
This process includes risk analysis of new
those developments. This discussion and the
technologies projects in the oil and gas industry,
suggested future work are addressed in the end.
and also possibly combining other industries
3. METHODOLOGY developments. Clearly, this thesis aims for these

3.1. Case Study Definition analysis, with results on the risks for the
technologies approached in the case studies.
The process of inducting theory from case studies
The International Risk Governance Council, IRGC,
analysis is a validated concept, considered of
provides a risk governance framework that
special importance to new topic areas. This is a

2
consists of an understanding approach to pay help
in the analysis and management of relevant risk
issues for which there is a shortage of structures
and processes in risk governance.
As the sector keeps changing and adapting to the
constant new challenges that emerge everyday,
the analysis to the risks is essential to the
development of state of the art technology. The
IRGCs methodology is important to collect vital Figure 1 - Example of a typical subsea layout with underwater
information to overcome, analyse, govern and equipment, a support vessel and riser systems [8]

manage all the possible phenomena, generating
knowledge around uncertainty.
4. EMERGING FORMS OF SURF
ENGINEERING
Subsea technologies play a vital role in the
hydrocarbon exploration process, where each
pump, sensor or cable has its specific function and
must not fail. Within these range of equipment and
parts, there is one that is widely recognized as the
most critical one, carrying enormous implications
along with its possible failure: the riser.
In a very simplistic way, a riser is basically a pipe
connecting the platform or vessel on the surface
The kind of platform or vessel being used in the
exploration activity is also responsible for the
different shapes and formats that the riser systems
can assume. In terms of deepwater riser concepts,
some have been successfully deployed to FPSO
application, such as classic steel catenary risers
(SCR), flexible risers and hybrid risers. Also,
options like Tension Leg Riser (TLR), Hybrid
Catenary Riser (HCR) and few more, have also
been having positive feedback when applied in
deepwater. [20]
4.1. Riser systems technology
The variables that define the operating conditions

and the wellhead at the seabed, with fluid can take numerous ways and, given that, selecting

transportation as its main function. Obviously, this the type of system adequate to each case is a

is a very reductionist definition, as the level of challenge by itself. Even though the number of

complexity involved in this particular component is options when choosing the adequate riser system

as high as modern technology can go. to an application is quite high, following some

Different kinds of riser systems concepts and simple criteria can make the primary selection

technologies are idealized for dissimilar conditions; much simpler. Emphasis here on the word

water depth and environmental issues are the key primary, since the final choice depends on more

factors responsible for this need of different than this technical issues. Some of the most

approaches. Following the trend of every other influencing technical factors in the selection are:

system in the offshore oil and gas exploration, riser

Inner fluid composition (with or without
design for deepwater fields is far more challenging
gas);
that for shallow waters.

3
 Application (static or dynamic); The most common rigid riser is the SCR, steel
Working conditions; catenary riser, which can be used in applications
Number of lines; with larger diameters, higher pressures and
Crowding of seabed; temperatures and, overall, is cheaper than flexible
Platform displacements and admissible lines. The increased diameter allows for a higher
loads; production flow rate, consequently making a more

Required service life. profitable use of the production vessel.

Concerning hybrid risers, they are typically
The various options within the range of riser
characterized by being able to accommodate large
systems available cover different functions, which
vessel motions, having a good fatigue
can be arranged in two groups: drilling and
performance and not being very sensitive to
production. In this work, the spotlight is on
environmental loading. On the other hand, the
production risers, which can be applied with
large spatial requirements, the clearance
various functions: transport of crude, gas or dead
challenges, the complex design and, most of all,
oil, injection of water, chemical or gas, and gas lift.
the high CAPEX constitute some major drawbacks
Within the production riser category, there are few
to this arrangement. In terms of installation,
factors that can be used to differentiate the risers
despite the positive aspect of being pre-installable,
from one another, none as critical as the stiffness
a few installation challenges appear with the need
or flexibility of the pipes. This results in three main
for long and heavy components. [6] Also, although
categories: flexible, rigid and hybrid pipes.
it requires diverless subsea tie-in between the riser
As far as flexible solutions are concerned, their
base and the flowline, constant monitoring
numerous advantages cover:
associated with assistance, assurance and

Ability to be retrieved and reused; verification is key in this case. [7]

Ease and speed of installation, performed All things considered, the main challenge in the

by a lightweight and economical vessel; riser systems is to find a compromise between the
cost, including development and installation costs,
High reliability due to its complete
and every factor linked to costs afterwards, like
manufacture onshore;
maintenance, operability, and risk of damage.
Functions separation (leakproofness and
There is no denying of the fact that the major factor
mechanical resistance) which increases its
is the economical one.
reliability;
Ability to adapt to all sorts of seabeds 4.2. Flexible riser configurations
without buckling problems;
High corrosion resistance. The flexible riser solutions, which are the focus
here, can have different configurations. The most
Brazilian exploration is the best example of flexible
common solution is designated Free Hanging,
riser usage, given the fact this concept is widely
consisting of a pipe that runs in a catenary shape
spread over their deepwater fields, commonly used
from the upper connection point (on the floating
in applications with FPSOs.

4
unit) to the seabed. The fact that all the weight is
suspended and supported by the sole connection
with the vessel makes it difficult to bear when
higher depths are attained. Also, the dynamic
motions caused by the hydrodynamic loads on the
riser and vessel constitute a major problem in
terms of fatigue in the top connection.
The Lazy Wave configuration shows a sort of
loop formed between the upper connection and
the seabed caused by the attachment of buoyancy
modules along a given section of the riser. The
major difference to the Free Hanging solution is
the distributed buoyancy section that allows for
greater vessel motion: these motions are partially
dissipated by the buoyed sections flexibility and
only the rest affects the riser. This constitutes a
great advantage, although not the biggest, since
that is considered to be the ease of installation.
The Lazy S configuration displays a riser in a
double catenary with the help of a subsurface buoy
and a mid-water arch. Both the mid-water arch and
the buoy are tensioned through a sling (that
consists of a wire rope loop commonly used for
heavy equipment lifting) and dead weight. Usually,
the risers are clamped at the top of the buoy and
guided over gutters to avoid overbending issues.
Figure 2 - Flexible pipe riser systems configurations: a) Free
Hanging; b) Lazy Wave; c) Lazy S [8]
Other solutions can be found, as the patented
Pliant Wave and Pliant S, the classical Steep
Wave and Steep S, the Free Standing Riser or
the recent Double Camel Wave type.
Accounting for all the flexible solutions presented,
it is safe to say that the starting point of any
flexible riser analysis should be the Free Hanging
configuration, considering the fact that it is the
most economical (both in hardware requirements
and installability terms). Its dynamic limitations,
however, put it aside very soon in many situations.
If the first option fails, the next most economical
comes with the wave configurations: typically with
the Lazy Wave, which is the simplest of the bunch,
but also Steep Wave and Pliant Wave. All require
more hardware than the Free Hanging
configuration and have sluggish installation
processes, yet not more complex. The constraints
in the number of risers appear as a major
drawback and force these configurations to be
abandoned in some cases. The S configurations,
namely Lazy S and Steep S, have more complex
installation procedures due to the large (and
somewhat cumbersome) equipment needed.
Despite this, they constitute very good solutions,
with great technical robustness and permitting
multiline systems with a large number of risers.
The Pliant S system should only be considered for
shallow water applications, where it has been
demonstrated that vessel excursion cannot be
accommodated by a Lazy S configuration. It is very
costly to implement this solution, both time
consuming and in terms of complexity, requiring
many additional hardware.
All in all, Free Hanging and Lazy Wave are both
the most common and cost-effective solutions
within the ones presented, being logical to deepen
its study in the context of a practical real life case.
5
5. DYNAMIC ANALYSIS OF A DEEPWATER Figure 3 shows the typical configuration of a
flexible risers layered structure. Within that
FLEXIBLE PIPE RISER SYSTEM
structure one can include the following layers:
The case study here presented is part of a real
Inner interlocked carcass a crushing
project, currently in the design phase; therefore
resistant layer that is optional on the structure,
some of the information is sensible and will be
depending on the need for external radial forces
carefully dealt with. The project is included in the
resistance;
exploration of pre-salt oil field, in the Santos basin,
Thermal screen a thermal barrier with
about 300 kilometres off the coasts of Rio de
the purpose of decreasing the pressure sheaths
Janeiro and Sao Paulo states. The vessel/platform
temperature beneath its maximum allowable
to be used is an FPSO, as usual in the Brazilian
temperature;
fields, spread moored type, and will operate at a
Pressure plastic sheath included to
water depth of 2150 meters. The purposes of the
guarantee internal leakproofness;
project cover many areas like producing, storing
Zeta spiral used to complement the
and offloading oil, also producing, re-injecting and
carcasss function of resisting collapse and radial
exporting gas, injecting water and re-injecting CO2.
mechanical compression and also add the
5.1. Flexible Pipe Design resistance to internal pressure;
Psi spiral similar to the previous;
Whatever the option taken in terms of configuration
Flat steel spiral a pressure backup
is, some basic considerations are common and will
layer used to reinforce the radial resistance;
always be respected: the structure consists of
Anti-collapse plastic sheath a layer
several layers, which are limited in types, although
that it is not necessarily always used but whose
in each case one can detail specific parameters
function is to transmit the external hydrostatic
according to the requirements; the kind of physical
pressure to the pressure armours, preventing
tests that must be performed, some of them in the
collapse;
factory and others on-site.
Anti-wear plastic layer a layer used to
suppress the wear between metallic layers;
Tensile armours intended to resist axial
forces;
Intermediate plastic sheath optional,
above the pressure sheath, or the anti-collapse
sheath, and under the external sheath;

Figure 3 - Typical structure layers of a riser systems flexible External plastic sheath designed to
pipe [8] keep the armours in position, protect them against
environmental corrosion and protect the insulation
layers against water ingress;

6
 Outerwrap interlocked steel carcass
optional, helps preventing the transfer of crushing
loads to the tensile armours.
Based on the conditions verified and the properties
of the layers constituting materials, one can define
the appropriate structure for each application.
5.2. Design methodology
As any other engineering design project, there is
not just a single correct approach to it, methods
vary according to many factors. Therefore, the
methodology here presented is just one among
many, although it is believed to be the most
adequate, and also it follows the guidelines used
by the most renowned companies in flexible pipe
design. Figure 4 illustrates a typical project
flowchart for this application.
Figure 4 - Typical project flowchart, from preliminary structure
to finish
When designing flexible pipes for riser applications
there are a number of major failure modes to
account for, here considered throughout the
analysis. Some of those issues are addressed
through the structure design itself, meaning the
layers and their properties, whereas others require
an exhausting and iterative approach posterior to
the structures definition during the configuration
studies and dynamic global analysis.
Bursting pressure is defined as the lowest
internal pressure for which the structural capacity
is reached in one of two cases: all the layers of the
pressure vault, if they exist; or one armour layer.
The software chosen to address this issue
calculates the stress in all layers due to an internal
pressure, performing those steps iteratively
through increments of the internal pressure until
the criterion previously defined is met. Damaging
pull is defined as the axial force for which the
structural capacity is reached in one layer, whether
it is the interlocked carcass, the pressure vault or
the tensile armours. The internal pressure is also
responsible for the designated end-cap effect, by
means of the axial tension generated; on the
opposite, the external pressure and the
consequent axial compression are responsible for
the reverse end-cap effect. These issues can be
verified in the tape layers. Lateral buckling is a
problem that contemplates the disorganization of
armour wires when subjected to compressive
stresses and lateral displacements, if submitted to
cyclic bending under differential external pressure.
Collapse is a critical issue represented by the
collapse pressure, the external pressure that
generates a collapse of at least one crushing
resistant layer.
7
Another possible source of problems is related to
the vessels supports of each riser; each line,
according to its function and location on the
balcony, has a specific support associated and a
correspondent support limit. The critical situation
is during the installation process, when all the
lines weight is being supported there, and the
worst case happens if the installation is performed
with the line full of water. The limits are usually
pretty high, but the supports design has a lazy
wave configuration in mind, where the buoyancy
modules relieve the top connection from much of
the weight, and not a free hanging one. Then, this
calculation is particularly necessary in the Free
Hanging case, disregarding it in the Lazy Wave.
Although all these problems are relevant, the
biggest issues are related to fatigue, as the cyclic
loadings cause much more damage than simple
one-time loadings. Clearly, when talking about
underwater applications there are always cyclic
loadings, given the fact that currents and waves
act on the structures causing them to move in
different directions. In this particular case of a
flexible riser, the critical sections are located on
the top connection and on the TDP, both for the
Lazy Wave and Free Hanging. The fatigue
problems are prone to be less in the Lazy Wave
configuration, as that is one of the reasons that
lead to the configuration choice in the first place.
The buoyed segment helps to isolate some of the
movement and releases some tension from the
critical fatigue points. As far as the Free Hanging
configuration is concerned, the worst point is on
the top connection, right next to the bend stiffener,
having all the structures length influencing the
dynamic loading. So, in order to assess if the total
damage is within the acceptable value range
(which comes from safety factors and is highly
influenced by the service life) one needs to
consider a vast list of currents coming from all
directions, combined with waves that come in
different periods and heights, as well as the draft
coming from the vessels load, resulting in
thousands of cases to analyse.
5.3. Configuration Comparison and Results
Table 1 shows the chosen structure for the
practical case studied in this thesis. Defining this
structure in the adequate software, one could
assure that all the criteria associated with the
bursting pressure, damaging pull, end-cap effect,
lateral buckling and collapse failure modes were
met. The top connection also endured the total
weight of the riser, even in the event of installation,
where it is full of water.
Layer number Type of layer
1 Interlocked carcass
2 Pressure sheath
3 Teta clip
4 Spiral
5, 7, 10, 12 Anti-wear tape
6, 11 First armour
8, 13 Second armour
9 Fabric tape
14 High strength tape
15 Leakproofness sheath
16 Fabric tape
17 External sheath
Table 1 Structure used
Deeplines was the tool used to model the whole
system and perform the dynamic global analysis.
The result of several configuration studies, which
had to ensure conditions like the top angle
requirement (9 in this case), is presented in
8
Figure 5, where the two configurations can be 6. DISCUSSION AND CONCLUSIONS
compared.
6.1. Future of the Oil and Gas industry and

SURF technologies

One critical part of the upcoming developments in

the oil and gas industry relates to SURF
engineering, as there is margin for improvement
both for the kind of sites currently being explored
and the increasing water depths locations.
Discovering reserves in such locations is just the
Figure 5 - Comparison of the resulting configurations
determined and modelled first step towards a sustainable exploration; in the
end, if it is not technically viable, then everything
The service life of a flexible riser can be dictated
will sink. Therefore, the main purpose of this thesis
by the fatigue characteristics of the steel layers
was to single out and understand SURF
and by the fatigue characteristics of the polymers;
technologies, performing a comparative case-
in this case, the critical fatigue problem is in the
study analysis focused on the deepwater
traction armours. The term damage, here
exploration. The future of the oil and gas industry
mentioned, is nothing else than a ratio between
is full of uncertainties, covering a wide range of
the projected life and the actual life the part can
topics from technical issues to global energetic
sustain. It is the reason between fatigue life and
scenarios. Whether it is verified that oil
service life; there is also a safety factor, which,
dependency is diminishing or that its dominance is
rearranging a simple equation, results in the
stronger than ever, the need for improvements in
maximum allowable damage, which is 0.1 here.
the oil exploration technology is essential. For one,
The final results show that the Lazy Wave
these developments are key to lower the costs of
configuration meets the criterion, whereas with the
extraction and maintain oil as a competitive source
Free Hanging solution there is a colossal increase
in relation to alternative sources. On the other
in the total damage. Extrapolating from the 60% of
hand, the developments may be vital to overcome
damage significant cases, the total damage stands
current impossibilities and reach new milestones to
at 7.223! It leaves no margin for doubts;
increase the global production, in order to keep up
considering that these kind of equipment are
with the demand. It is easy to relate to the offshore
designed for a service life of 25 years, the result
oil exploration, since the milestones mentioned
obtained for the Free Hanging configuration
consist of, in this case, reaching greater water
corresponds to a lifetime of less than 3,5 years.
depths, unexplored this far.
Needless to say that this is definitely critical,
From this problem-based learning and research, it
impractical and, in the end, unfeasible.
was possible to find an almost unanimous solution
for the future of riser systems, within the group of
experts contacted, which consists of changing part

9
of the structures material to composites, instead of
keeping the metallic alloys. The composites
industry is fast-growing and spreading to
diversified areas of application, including some of
the most challenging; the aerospace industry must
be quoted as a reference. Adapting the knowledge
gained through years of development of aerospace
equipment to the demanding world of deep and
ultra-deepwater oil and gas exploration is a
challenge. But starting from zero is an even bigger
challenge, so it is believed that experience based
breakthroughs are the correct path to follow.
Industrial policies are crucial to major paradigm
shifts in terms of technological development. In
this case, it is believed that the relations between
industry and universities should be promoted, not
only with respect to the actual students during their
formation, but also considering the scientific
investigations. For one, the level of qualification
and experience of the investigators is very high,
difficult to find within the industry; on the other
hand, the industry has a more practical sense of
knowledge, which sometimes lacks within the
academic stratum.
6.2. Future Work
This thesis was done based on extensive literature
review, accompanied by interviews with experts
and complemented by a case-study analysis. The
number of interviews constitutes a limitation, which
can straightforwardly be overcome. It could have
been interesting to analyse more flexible
configurations, as well as some types of rigid and
hybrid riser systems; one could also deepen the
iterative process of defining the structure, here
partially discarded. There are also a number of
components of the riser system that contemplate a
sufficient degree of complexity to justify an
analysis of this specificity. Finally, from a not so
technical perspective, it would be interesting to
expand the investigation on the impact of
engineers education in the industry and the
opposite. The repercussion of possible future
changes in the system should be evaluated.
7. ACKNOWLEDGMENTS
I would like to thank specially to Professor Manuel
Valsassina Heitor for his guidance and availability
all through this work, for opening my in mind to
such different areas of interest and for the
opportunity to work with him.
To my parents and my brother, eternal
gratefulness for their unconditional support.
To all the interviewed experts I want to thank for
their availability and valuable contributes.
8. REFERENCES
[1] E. Ekmekcioglu, The Macroeconomic Effects of
World Crude Oil Price Changes, International Journal of
Business and Social Science, Vol. 3, No. 6, 2007.
[2] K. M. Eisenhardt, Building Theories from Case Study
Research, Academy of Management Review, Vol. 14, No. 4,
1989.
[3] J. Pfeffer, Organizations and Organization Theory,
1982.
[4] R. Phaal, C. J. Farrukh, D. R. Probert, Technology
roadmapping - A planning framework for evolution and
revolution, Technological Forecasting and Social Change, vol.
71, no. 1-2, 2004.
[5] IRGC, An introduction to the IRGC Risk Governance
Framework, International Risk Gover- nance Council, Geneva,
Tech. Rep., 2008.
[6] S. A. Hatton, H. Howells, Catenary and Hybrid
Risers for Deepwater Locations Worldwide, Advances in Riser
Technologies, Aberdeen, 1996.
[7] R. Song, K. Uppu, Assessment of Riser System
Selection, Deepwater Technology Asia 2012, Jakarta, 2012.
[8] Technip, Flexible Pipe basic course, 2014.
10