Integrity Management for Steel Catenary Risers With Design Life of 30 Years

Abstract The objective of this paper is to demonstrate the best practices of Topside Structural Integrity Management for an aging fleet of more than 200 platforms with about 60% of which has exceeded the design life. PETRONAS as the operator, has established a Topside Structural Integrity Management (SIM) strategy to demonstrate fitness of the offshore topside structures through a hybrid philosophy of time-based inspection with risk-based maintenance, which is in compliance to API RP2SIM (2014) inspection requirements. This paper shares the data management, methodology, challenges and value creation of this strategy. The SIM process adopted in this work is in compliance with industry standards API RP2SIM, focusing on Data-Evaluation-Strategy-Program processes. The operator HSE Risk Matrix is adopted in risk ranking of the topside structures. The main elements considered in developing the risk ranking of the topside structures are the design and assessment compliance, inspection compliance and maintenance compliance. Effective methodology to register asset and inspection data capture was developed to expedite the readiness of Topside SIM for a large aging fleet. The Topside SIM is being codified in the operator web-based tool, Structural Integrity Compliance System (SICS). Identifying major hazards for topside structures were primarily achieved via data trending post implementation of Topside SIM. It was then concluded that metal loss as the major threat. Further study on effect of metal loss provides a strong basis to move from time-based maintenance towards risk-based maintenance. Risk ranking of the assets allow the operator to prioritize resources while managing the risk within ALARP level. Current technologies such as drone and mobile inspection tools are deployed to expedite inspection findings and reporting processes. The data from the mobile inspection tool is directly fed into the web based SICS to allow reclassification of asset risk and anomalies management.

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Alternative Framework for Structural Integrity Management of Jacket Platform Beyond its Design Life

10.2118/188518-ms ◽

2017 ◽

Author(s):

A. Kongchang ◽

A. Danthainum ◽

T. Chattratichart ◽

P. Sonachai ◽

T. Thavornsuk ◽

...

Keyword(s):

Structural Integrity ◽

Jacket Platform ◽

Alternative Framework ◽

Design Life ◽

Integrity Management

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Comprehensive Qualification Program for the Browse 24 Inch High Temperature Flexible Joint Prototype

Volume 6A: Pipeline and Riser Technology ◽

10.1115/omae2014-23201 ◽

2014 ◽

Cited By ~ 2

Author(s):

Basim Mekha ◽

Ben Hawkey ◽

James Patrick ◽

Todd Pottorff

Keyword(s):

High Temperature ◽

Joint Venture ◽

Lessons Learned ◽

Flexible Joints ◽

Test Program ◽

Flexible Joint ◽

Design Life ◽

Wet Gas ◽

Comprehensive Test ◽

Steel Catenary Risers

Flexible Joints have been an essential part of many steel catenary risers (SCRs) as one of the main means for connecting SCRs to the floating facilities in deep water. Since 1994 when the first Flexible Joints were installed on the Augur Tension Leg Platform (TLP), many Flexible Joints have been designed and installed for 6 inch to 24 inch SCRs on all kinds of floating production facilities and in a range of water depths. Woodside Energy Limited (Woodside), as operator of the Browse LNG Development on behalf of the Browse Joint Venture participants for their original Browse LNG Development concept (Browse to Kimberley subsea development and onshore processing concept), had contemplated using Flexible Joints as top termination units for the high temperature 24 inch Wet Gas Export SCRs. Woodside contracted Oil States Industries, Inc. (OSI) to design, manufacture and test a prototype 24 inch Flexible Joint that would meet the project’s stringent operational and fatigue requirements for 40 years design life. This high temperature 24 inch Flexible Joint was the largest Flexible Joint ever manufactured since its design required bellows and a thermal barrier. A state-of-the-art qualification program for the high temperature 24 inch Flexible Joint was undertaken to demonstrate its feasibility for use on the 24 inch wet gas export SCRs for the Browse project in approximately 600m water depth. The Flexible Joint prototype was subjected to a comprehensive test program, including axial and rotational tests, hydrotests and a fatigue test, which was developed to cover all aspects of the Flexible Joint design and its components. In this paper, the details of the high temperature 24 inch Flexible Joint qualification program will be presented with emphasis on the steps taken to successfully complete the program and the lessons learned from the challenges that were encountered. The paper will also provide a summary of the challenges and steps taken to complete the program which presented a unique opportunity to expand on the capability of the industry to go beyond what has been previously accomplished. The program was very challenging in all aspects but succeeded in achieving all of its goals.

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Integrity Management for Steel Catenary Risers With Design Life of 30 Years

Volume 4: Pipelines, Risers, and Subsea Systems ◽

10.1115/omae2020-18065 ◽

2020 ◽

Author(s):

Hao Song ◽

Chenteh Alan Yu ◽

Yongming Cheng ◽

Jing Hou

Keyword(s):

Measurement Data ◽

Management Program ◽

Gas Production ◽

Digital Model ◽

Life Extension ◽

Critical Element ◽

Steel Catenary Riser ◽

Integrity Assessment ◽

Design Life ◽

Integrity Management

Abstract The riser is a critical element in a subsea production system for transporting hydrocarbons from the seafloor to the surface. The track record of existing riser systems worldwide has shown that risers tend to be designed conservatively to accommodate dynamic loads, strength and fatigue requirements, and corrosion/erosion provision needs. Among all the riser types, the steel catenary riser (SCR) is the most installed riser configuration for deepwater oil and gas production worldwide in the last two decades. This is mainly because of their simple configuration and relatively low manufacturing and installation cost. As riser technology advances, SCRs are designed to tackle more challenging environments and longer service lives. For the riser life extension applications, regulatory bodies prefer riser operations to be managed through an integrity management program, demonstrating that a robust framework with detailed records on the conditions of the risers is in place. This paper studies an integrity management program for SCRs with a 30-year design life in a harsh environment. The planned riser integrity management program is based on successful industry practice and the newly published riser integrity management standard API RP 2RIM [4]. It starts with a review of the riser design basis and as-built data, continuing with key field data measurement and production fluid sampling. A digital model, continuously calibrated with the measured data, is established to assess the integrity of the riser system. Key physical quantities are selected to monitor the structural health of the SCRs, including vessel motion measurement, measurement of SCR top hang-off angles and tensions, and full water column current measurement. The relationship between the measurement data and the riser strength and fatigue performance is established. Details of the riser integrity assessment in a digital model utilizing the measurement data are presented. The implemented proposed riser integrity management program is expected to provide a more focused and efficient method with a higher level of confidence in operating the SCRs during the design life and potentially beyond.

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Integrity Management and Life Extension for a CALM Buoy Oil Export Terminal

Volume 3: Operations, Monitoring and Maintenance; Materials and Joining ◽

10.1115/ipc2016-64495 ◽

2016 ◽

Author(s):

Robert B. Gordon ◽

Juan Carlos Ruiz-Rico ◽

Michiel Peter Hein Brongers ◽

Julian Gomez

Keyword(s):

Failure Modes ◽

State Of The Art ◽

Life Extension ◽

Remaining Life ◽

Integrity Assessment ◽

Design Life ◽

Oil Export ◽

Integrity Management ◽

Inspection And Maintenance ◽

Future Risk

This paper applies state-of-the-art integrity management and life extension methodologies to address degradation and failure modes specific to CALM buoy export terminals. The main objectives are to (1) classify the components of the export terminal according to their criticality, (2) establish risk-based inspection and maintenance plans to reduce or mitigate risk to acceptable levels and (3) assess remaining life. The method is applied to a CALM buoy operating off the coast of Colombia. This buoy serves as the oil export terminal for all crude oil transmitted by the Ocensa pipeline, which has a capacity of 560 kBPD or around 60% of total Colombia oil production. The buoy is nearing the end of its design life, and options for life extension have been investigated based on an integrity assessment of the current condition of the equipment. As part of the assessment, detailed plans for future Risk Based Inspections (RBI) and Mitigation, Intervention, and Repair (MIR) have been developed.

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Life Extension Issues for Ageing Offshore Installations

Volume 5: Materials Technology; CFD and VIV ◽

10.1115/omae2008-57411 ◽

2008 ◽

Cited By ~ 11

Author(s):

A. Stacey ◽

M. Birkinshaw ◽

J. V. Sharp

Keyword(s):

Structural Integrity ◽

Life Extension ◽

Original Design ◽

The North ◽

Design Life ◽

Offshore Installations ◽

Need To Evaluate ◽

Integrity Management ◽

The North Sea ◽

The Uk

With many offshore installations in the UK sector of the North Sea now reaching or being in excess of their original anticipated design life, there is a particular need to evaluate approaches to structural integrity management by offshore operators. Ageing processes can affect the structural integrity of the installation and demonstration of adequate performance beyond its original design life is thus a necessary requirement. This paper addresses the issues relevant to the life extension of ageing installations.

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Managing Ageing Flexible Pipe Assets

Volume 3: Pipeline and Riser Technology; Ocean Space Utilization ◽

10.1115/omae2008-57811 ◽

2008 ◽

Author(s):

Adriana Botto ◽

Enda O’Sullivan ◽

Ce´line Banti

Keyword(s):

Management Strategy ◽

Assessment Tools ◽

Life Extension ◽

Flexible Pipe ◽

Detailed Understanding ◽

Operational Conditions ◽

Design Life ◽

Flexible Pipes ◽

Integrity Management ◽

Manufacturing History

The population of flexible pipes is increasing exponentially and by definition it is ageing. Over the coming years an increasing number of flexible pipes will reach the end of their design life, therefore prudent operators should focus on understanding the integrity status of their flexible pipes. Understanding and effectively managing the integrity of flexible pipes is necessary to prevent, predict, or detect the presence of any loss of integrity. A detailed understanding of the manufacturing history, operational conditions, any previous repairs and inspection or test history are all required to gain a full insight of the flexible pipe fitness and assess its suitability for continued operation and for any potential life extension beyond the initially intended service life. This paper presents guidelines for developing and implementing an integrity management strategy, which utilises the correct mix of inspection and assessment tools (degradation of internal pressure sheath, fatigue assessment, corrosion and annulus condition monitoring etc.) and operating procedures that will allow the operator to assess the opportunity for life extension of flexible pipes.

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