Flexible Pipe Systems Configurations for the Pre-Salt Area

2010 ◽  
Author(s):  
Judimar Clevelario ◽  
Fabio Pires ◽  
Claudio Barros ◽  
Terry Sheldrake
Keyword(s):  
Water Injection ◽  
High Strength Steels ◽  
High Strength ◽  
Pilot Project ◽  
Local Analysis ◽  
Flexible Pipe ◽  
Pipe System ◽  
Flexible Pipes ◽  
Unbonded Flexible Pipes ◽  
Global And Local

Unbonded flexible pipes are being considered as an actual solution for the following developments for the Brazilian Pre-Salt area. This technology is already being successfully used in the first EWT installed in the Brazilian Pre-salt and being qualified for the first Pre-salt Pilot Project development. However, unlikely the current project developments in water depths around 1500m, the free catenary configuration is not always an applicable option not only due to the 2500m water depth but also to the presence of contaminants such as CO2 and H2S in the conveyed fluids which in certain applications make the use of conventional high strength steels unfeasible, making the use of sour service armour wires mandatory. This paper presents the result of the global and local analysis performed for different applications such as 4″ gas lift, 6″ water injection, 6″ production and 9.13″ Gas export structures designed specifically for the ultra deep water in Brazilian Pre-Salt area. The aim of this study was to verify the feasibility of the free hanging catenary configuration and determine the most suitable flexible pipe system configuration for different applications, confirming that the flexible pipes are an adequate solution for the Pre-Salt even when the service life requirements exceeds 20 years and associated safety factors.

Optimization of Flexible Pipes Dynamic Analysis Using Artificial Neural Networks

2016 ◽  
Author(s):  
Victor Chaves ◽  
Luis V. S. Sagrilo ◽  
Vinícius Ribeiro Machado da Silva
Keyword(s):  
Dynamic Analysis ◽  
Fem Simulation ◽  
Training Data ◽  
Local Analysis ◽  
Flexible Pipe ◽  
Nonlinear Fem ◽  
Irregular Wave ◽  
Flexible Pipes ◽  
Artificial Neural ◽  
Hybrid Methodology

Irregular wave dynamic analysis is an extremely computational expensive process on flexible pipes design. One emerging method that aims to reduce these computational costs is the hybrid methodology that combines Finite Element Analyses (FEA) and Artificial Neural Network (ANN). The proposed hybrid methodology aims to predict flexible pipe tension and curvatures in the bend stiffener region. Firstly using short FEA simulations to train the ANN, and then using only the ANN and the prescribed floater motions to get the rest of the response histories. Two approaches are developed with respect to the training data. One uses an ANN for each sea state in the wave scatter diagram and the other develops an ANN for each wave incidence direction. In order to evaluate the accuracy of the proposed approaches, a local analysis is applied, based on the predicted tension and curvatures, to calculate stresses in tension armour wires and the corresponding flexible pipe fatigue lifes. The results are compared to those from full nonlinear FEM simulation.

An Analytical Model to Predict the Bending Behavior of Unbonded Flexible Pipes

2013 ◽  
Vol 57 (03) ◽  
pp. 171-177
Author(s):  
Leilei Dong ◽  
Yi Huang ◽  
Qi Zhang ◽  
Gang Liu
Keyword(s):  
Bending Moment ◽  
Bending Stiffness ◽  
Nonlinear Formulation ◽  
Flexible Pipe ◽  
Flexible Pipes ◽  
Bending Behavior ◽  
Interlayer Slip ◽  
Unbonded Flexible Pipes ◽  
Relationship Of ◽  
Theoretical Results

Analytical formulations are presented to determine the bending moment-curvature relationship of a helical layer in unbonded flexible pipes. Explicit expressions describing the variation of both bending stiffness and moment as a function of the applied curvature are given. The approach takes into account the nonlinearity of the response caused by the interlayer slip. The contribution of local bending and torsion of individual helical elements to the bending behavior of helical layers is included. Theoretical results for a typical unbonded flexible pipe using the nonlinear formulation for helical layers are compared with experimental data from the available literature. Encouraging correlations are found and the importance of the initial interlayer pressures is seen. The influence of local bending and torsion of individual helical elements on the bending behavior of the entire pipe is also evaluated. The results show that the inclusion of this local behavior significantly influences the full-slip bending stiffness.

Qualification Approach to Unbonded Flexible Pipes With Fibre Reinforced Armour Layer

2004 ◽  
Author(s):  
Jan Rytter
Keyword(s):  
Offshore Structure ◽  
Flexible Pipe ◽  
Load Bearing ◽  
Compression Load ◽  
Metal Parts ◽  
Analysis Tools ◽  
Industry Standards ◽  
Flexible Pipes ◽  
Unbonded Flexible Pipes ◽  
Load And Resistance Factor

The future water depth capabilities for unbonded flexible pipes is being pushed by NKT Flexibles I/S through the development of an innovative flexible pipe structure, taking full advantage of the material characteristics of metallic, polymeric and fibre reinforced materials. The fluid tight liner and possible insulation of this pipe structure are supported by an inner armour, capable of carrying the external hydrostatic pressure, clamp and crushing loads, as well as axial compression load, and an outer armour, consisting of two cross wound layers of carbon/epoxy composites, carrying the internal pressure as well as end cap forces and applied tension. A permeable and radially flexible outer layer protects the composite armour. Combining known and well-proven flexible pipe technologies and new solutions for materials, structure and functionality of the flexible pipe, positions this future product outside the present industry standards for flexible pipes, e.g. API-17J. The analysis tools used for the conventional flexible pipes are validated by NKT according to the API-17J specification. The API-17J describes load cases and corresponding allowable utilization ratios, stated as design criteria. However, this approach is not directly applicable to the composite pipe, where the same analysis tools will be used, but the material in one of the two primary load bearing layers is made of fibre reinforced polymer, a material class not covered by the API allowable utilization factors. The DNV offshore standard DNV-OS-C501 considers any offshore structure in which the load bearing material is a composite. An accompanying Recommended Practice DNV-RP-F202 for composite risers has also been issued, but is not applicable to the composite flexible pipe. The design equations of the DNV standard are formulated in the so-called Load and Resistance Factor Design (LRFD) format, where partial safety factors are applied to the load effects and to the resistance variables that enter the design equations. The DNV standard DNV-OS-C501 covers composite materials and composite metal interfaces of a structure, metal parts should be designed according to other relevant standards. The API standard can therefore be used for the metal parts. One of the challenges in using this combined approach is the different ways loads are defined in the two standards. In short, this will result in a conventional API design check of the inner armour, the polymer layers, and the secondary layers, whereas the composite tensile armour, special intermediate layers and the interfaces will be analyzed with composite specific tools based on the criteria derived from the DNV standard. The qualification procedure is described and exemplified in the following.

Finite Element Analysis of Flexible Pipes Under Compression

2014 ◽  
Author(s):  
Eduardo Ribeiro Malta ◽  
Clóvis de Arruda Martins
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
High Strength ◽  
Element Model ◽  
Large Displacements ◽  
Flexible Pipe ◽  
Element Analysis ◽  
Flexible Pipes ◽  
Compressive Loads ◽  
Surface Vessel

Axial compressive loads can appear in several situations during the service life of a flexible pipe, due to pressure variations during installation or due to surface vessel heave. The tensile armor withstands well tension loads, but under compression, instability may occur. A Finite Element model is constructed using Abaqus in order to study a flexible pipe compound by external sheath, two layers of tensile armor, a high strength tape and a rigid nucleus. This model is fully tridimensional and takes into account all kinds of nonlinearities involved in this phenomenon, including contacts, gaps, friction, plasticity and large displacements. It also has no symmetry or periodical limitations, thus permitting each individual wire of the tensile armor do displace in any direction. Case studies were performed and their results discussed.

Parallelized Element-by-Element Architecture for Structural Analysis of Flexible Pipes Using Macro Finite Elements

2017 ◽  
Author(s):  
Fernando Geremias Toni ◽  
Clóvis de Arruda Martins
Keyword(s):  
Structural Analysis ◽  
Finite Elements ◽  
Degrees Of Freedom ◽  
Local Analysis ◽  
Present Moment ◽  
Flexible Pipe ◽  
Computational Performance ◽  
Flexible Pipes ◽  
Oil And Natural Gas ◽  
Global Stiffness Matrix

Flexible pipes are employed to transport oil and natural gas from the seabed to the floating units, and vice versa. These pipes are made of concentric layers of different geometries, materials and structural functions in order to withstand a series of static and dynamic loads from its adverse operating environment. The local analysis is an important stage in the design of a flexible pipe and consists in determining the stresses and strains distributions along its layers. Multipurpose finite element packages, such as ANSYS and ABAQUS, are commonly used in this task, but present many limitations for their generic nature, varying from the absence of specific tools for model creation to heavy restrictions of the number of degrees-of-freedom to make computational processing feasible. Over the past years, several macro finite elements were formulated by PROVASI & MARTINS specifically for modeling a flexible pipe, allowing a reduction in the total number of degrees-of-freedom. However, until the present moment, there is no parallel processing software that efficiently implements these elements for large model applications. Aiming greater computational performance, the macro elements can be combined with the element-by-element (EBE) method, which is characterized by the global stiffness matrix elimination, is highly parallelizable, scalable and shows a memory consumption that grows linearly with the number of elements in the model. In this context, a parallelized architecture for structural analysis of flexible pipes that explores the EBE method and macro finite elements has been developed, being of great interest for design applications in the industry.

Controlling Factors of Carcass Fatigue in Unbonded Flexible Pipes

2019 ◽  
Author(s):  
Upul S. Fernando ◽  
Andrew P. Roberts ◽  
Michelle Davidson
Keyword(s):  
Fatigue Failure ◽  
Failure Modes ◽  
Dynamic Stress ◽  
External Pressure ◽  
Controlling Factors ◽  
Flexible Pipe ◽  
Flexible Pipes ◽  
Innermost Layer ◽  
Key Features ◽  
Unbonded Flexible Pipes

Abstract Carcass, the innermost layer of a flexible pipe structure is designed to prevent the collapse of the pressure sheath due to external pressure. Weakness, damage or failure of the carcass layer can result in collapse with associated loss of production and potentially serious risk to pipe integrity and hydrocarbon leakage to the environment. Avoiding carcass failure in service is therefore an essential consideration during the design of unbonded flexible pipes. Carcass failure is rare in service. This paper highlights the three possible failure modes and presents further analysis on the fatigue failure mode, relevant to dynamic service. Two key features of carcass manufacture are identified as causes for dynamic stress; locking of the carcass profile due to extended pitch and polymer ingress within the carcass cavity. Guidelines for the design of carcass profiles, setting safe pitch limits and appropriate barrier profile controls to mitigate carcass fatigue failure in dynamic service are presented.

Evaluation of Aluminum-Coated Flexible Pipe Armour Wires Exposed to a Sour Environment

2018 ◽  
Author(s):  
João C. B. Bertoncello ◽  
Mariana R. Tagliari ◽  
Tiago B. Coser ◽  
Felippe S. Kerpen ◽  
Luciano M. Santana ◽  
...  
Keyword(s):  
High Strength Steels ◽  
High Strength ◽  
Good Alternative ◽  
Metallographic Analysis ◽  
Flexible Pipe ◽  
Destructive Testing ◽  
Four Point Bending ◽  
Aluminum Corrosion ◽  
Sulfide Stress ◽  
Thermally Sprayed Aluminum

In general, tensile armour wires of flexible pipes that are designed for sour applications have their strength limited to 850 MPa due to the possibility of embrittlement phenomena to occur. A Thermally Sprayed Aluminum (TSA) coating 250 μm thick was applied to high strength steels with UTS of 1470 MPa and YS of 1280 MPa. Three specimens conditions were evaluated: full coating, no coating and coating with a designed defect. The load was applied using a four point bending fixture, maintaining a constant stress of 90% of material’s yield strength. All tests were performed in accordance with recommendations of NACE TM 0177 method B. The test solution was distilled water with NaCl 5.0% saturated with a gas mixture of 10,000 ppm of H2S in balance with CO2 during 720 hours. It was observed that samples without coating were more susceptible to the effect of the environment presenting higher degradation and failure. The fractures presented typical characteristic of the Sulfide Stress Corrosion Cracking (SSCC). Furthermore, it was detected parallel cracks to the surface of the wires indicating the embrittlement phenomenon of Hydrogen-Induced Cracking (HIC). On the other hand, coated samples with and without defects did not fail during the 720 hours of testing. A posterior non-destructive testing and a metallographic analysis did not identify the presence of cracks. These results were attributed to the physical barrier of the aluminum coating and the cathodic protection generated by the preferential aluminum corrosion. This preliminary study shows that TSA coatings can be a good alternative to increase the corrosion resistance of armour wires in sour environments allowing the application of higher strength steels.

Analysis of Structural Parameters for Unbonded Flexible Pipes

2013 ◽  
Vol 652-654 ◽  
pp. 1514-1519
Author(s):  
Zhi Bo Li ◽  
Hui Xu ◽  
Gui Zhen Zhang
Keyword(s):  
Structural Parameters ◽  
Steel Strip ◽  
Complex Structure ◽  
Flexible Pipe ◽  
Complex Deformation ◽  
Flexible Pipes ◽  
Bending Behavior ◽  
Unbonded Flexible Pipes ◽  
Walled Cylinder ◽  
Nonuniform Material

Due to the complex structure and nonuniform material of unbonded flexible pipes, an elastic thin-walled cylinder model and a helical steel strip model were established respectively to simulate different layers based on the specific structure form and parameters. Quasi-static incremental load was adopted to identify the structural parameters which had significant effects on the axial, radial and bending behavior of the pipes during the complex deformation. Sensitivity of these parameters were also analysed. The conclusion in this paper could provide guaidance for the design of unbonded flexible pipe.

Helical Wire Behavior of Unbonded Flexible Pipes Under Bending

2015 ◽  
Author(s):  
Yutian Lu ◽  
Huibin Yan ◽  
Yong Bai ◽  
Peng Cheng
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Axial Strain ◽  
Bending Moment ◽  
Element Model ◽  
Flexible Pipe ◽  
Slip Mechanism ◽  
Flexible Pipes ◽  
Bending Behavior ◽  
Unbonded Flexible Pipes

The bending behavior of unbonded flexible pipe is governed by the response of the helical wires in the tensile armor to bending. The behavior of the helical wire, especially the axial strain, is influenced by the slip mechanism as a result of an increasing curvature under bending. In the present paper, two limit curves are considered with a certain curvature. A 3-D finite element model using ABAQUS is developed to simulate the practical behavior of the helical wires under bending. By comparing the FEA and theoretical results, a basic conclusion about the real slip path of the helical wire between two limit curves is introduced. A hysteretic bending moment-curvature relationship induced by the slip mechanism is obtained from the finite element model as well.

Finite Element Analysis of Flexible Pipes Under Compression: Influence of the Sample Length

2015 ◽  
Author(s):  
Eduardo Ribeiro Malta ◽  
Clóvis de Arruda Martins
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
High Strength ◽  
Element Model ◽  
Sample Length ◽  
Flexible Pipe ◽  
Element Analysis ◽  
Flexible Pipes ◽  
The Stability

In order to study the compressive behavior of flexible pipes, a nonlinear tridimensional finite element model was developed. This model recreates a five layer flexible pipe with two tensile armor layers, an external polymeric sheath, an orthotropic high strength tape and a rigid inner nucleus. Using this model, several studies are being conducted to verify the influence of key parameters on the wire instability phenomenon. The pipe sample length can be considered one of these parameters and its variation causes significant change at the stability response of the tensile layers. This article includes a detailed description of the finite element model itself and a case study where the length of the pipe is changed. The procedure of this analysis is here described, along with the results.

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