Stresses in Tensile Armour Layers of Unbounded Flexible Risers Loaded With External Pressure: Application to Lateral Buckling Mode

2017 ◽  
Author(s):  
Fabien Caleyron ◽  
Jean-Marc Leroy ◽  
Martin Guiton ◽  
Pascal Duchêne ◽  
Pascal Estrier ◽  
...  
Keyword(s):  
Failure Modes ◽  
External Pressure ◽  
Engineering Model ◽  
Flexible Pipe ◽  
Lateral Buckling ◽  
Buckling Mode ◽  
Periodic Model ◽  
Scale Test ◽  
Flexible Risers ◽  
Offshore Field

Life6 software, developed by IFP Energies nouvelles, is the local model used by Technip to determine stresses in tensile armour layers of unbounded flexible risers. These stresses and their variations are then used to predict fatigue limits of the dynamically loaded risers. Life6 is based on periodic conditions to reduce the model length, with the assumption that all the tensile armour wires of a same layer share the same kinematics. This paper firstly presents recent improvements to obtain a better modeling of tensile armour wires kinematics, when the flexible riser loading includes external pressure. New models of the external sheath and the anti-buckling tapes have been developed and implemented in Life6. The results are successfully compared to a Finite Element periodic model. Applications to lateral buckling prediction of tensile armour layers are secondly presented in the paper. Indeed, in the design of flexible pipelines for offshore field developments, lateral buckling is one of the critical failure modes for the tensile armour wires, being associated with external pressure and flexible pipe cyclic bending. The latest developments made on the modeling of the external kernel of the flexible pipe allow to use Life6 as the basis of the enhancement of the lateral buckling engineering model used by Technip. It has been calibrated and validated against an extensive full scale test data base resulting in a physical, reliable and fast engineering model to predict lateral buckling mode. In accordance with standards, Technip methodology for flexible pipe lateral buckling determination ensures a robust and competitive design.

Prediction and Qualification of Radial Birdcage and Lateral Buckling of Flexible Pipes in Deepwater Applications

2015 ◽  
Author(s):  
Linfa Zhu ◽  
Zhimin Tan ◽  
Victor Pinheiro Pupo Nogueira ◽  
Jian Liu ◽  
Judimar Clevelario
Keyword(s):  
Failure Modes ◽  
Local Buckling ◽  
External Pressure ◽  
Design Guidelines ◽  
Prediction Theory ◽  
Flexible Pipe ◽  
Lateral Buckling ◽  
Operation Conditions ◽  
Flexible Pipes ◽  
Compressive Loads

Increasing oil exploitation in deepwater regions is driving the R&D of flexible pipes which are subjected to high external pressure loads from the hydrostatic head during their installation and operation. One of the challenges of flexible pipe design for such applications is to overcome the local buckling failure modes of tensile armor layers due to the combination of high external pressure, compressive loads and pipe curvature. This paper presents the latest progress in local buckling behavior prediction theory and the qualification process of flexible pipes. First, the mechanisms of two types of buckling behaviors, radial birdcage buckling and lateral buckling, are described. For each failure mode, the analytical buckling prediction theory is presented and the driving parameters are discussed. As part of the qualification process, the ability to resist radial birdcage and lateral buckling must be demonstrated. Suitable test protocols are required to represent the installation and operation conditions for the intended applications by deep immersion performance (DIP) tests. Several flexible pipes were designed based on radial birdcage and lateral buckling prediction theory, and pipe samples were manufactured using industrial production facilities for DIP tests. The results clearly show that flexible pipes following current design guidelines are suitable for deepwater applications. An alternative in-air rig was developed to simulate the DIP tests in a controlled laboratory environment to further validate the model prediction as a continuous development.

Lateral Buckling of Armor Wires in Flexible Pipes: Reaching 3000m Water Depth

2011 ◽  
Author(s):  
Philippe Secher ◽  
Fabrice Bectarte ◽  
Antoine Felix-Henry
Keyword(s):  
Deep Water ◽  
Failure Modes ◽  
External Pressure ◽  
Internal Diameter ◽  
Flexible Pipe ◽  
Lateral Buckling ◽  
Flexible Pipes ◽  
Valid Solution ◽  
Sour Service ◽  
Water Depths

This paper presents the latest progress on the armor wires lateral buckling phenomena with the qualification of flexible pipes for water depths up to 3,000m. The design challenges specific to ultra deep water are governed by the effect of the external pressure: Armor wires lateral buckling is one of the failure modes that needs to be addressed when the flexible pipe is empty and subject to dynamic curvature cycling. As a first step, the lateral buckling mechanism is described and driving parameters are discussed. Then, the program objective is presented together with flexible pipe designs: - Subsea dynamic Jumpers applications; - Sweet and Sour Service; - Internal diameters up to 11″. Dedicated flexible pipe components were selected to address the severe loading conditions encountered in water depths up to 3,000m. Hydrostatic collapse resistance was addressed by a thick inner carcass layer and a PSI pressure vault. Armor wires lateral buckling was addressed by the design and industrialization of new tensile armor wires. The pipe samples were manufactured using industrial production process in the factories in France and Brazil. The available testing protocols are then presented discussing their advantages and drawbacks. For this campaign, a combination of Deep Immersion Performances (DIP) tests and tests in hyperbaric chambers was selected. The DIP test campaign was performed End 2009 beginning 2010 in the Gulf of Mexico using one of Technip Installation Vessel. These tests replicated the actual design conditions to which a flexible pipe would be subjected during installation and operation. The results clearly demonstrated the suitability of flexible pipes as a valid solution for ultra deep water applications. In addition, the DIP tests results were compared to the tests in hyperbaric chambers giving consistent results. This campaign provided design limitations of the new designs for both 9″ and 11″ internal diameter flexible pipes, in sweet and sour service in water depths up to 3,000m.

Effect of Installation on Collapse Performance of Flexible Pipes

2017 ◽  
Author(s):  
Fabien Caleyron ◽  
Vincent Le Corre ◽  
Laurent Paumier
Keyword(s):  
Finite Elements ◽  
Failure Modes ◽  
External Pressure ◽  
Residual Effects ◽  
Cyclic Plasticity ◽  
Flexible Pipe ◽  
Collapse Resistance ◽  
Flexible Pipes ◽  
Offshore Field ◽  
Finite Elements Model

This paper investigates the effect of installation on collapse performance of flexible pipes. In the design of flexible pipelines for offshore field developments, one of the critical failure modes being associated with external pressure and bending loadings is the hydrostatic collapse. In accordance with standards, Technip methodology for flexible pipe collapse resistance determination ensures a robust and competitive design. The model has an analytical basis, leading to a fast and straightforward use. It has been validated with more than 200 tests performed on all possible pipe constructions on straight and curved configurations. As the industry is moving to deeper and deeper water, there is a greater need to understand all factors which could affect collapse. This includes residual effects due to the high installation loads from the laying system. As a consequence, Technip has performed several collapse tests on samples previously submitted to a loading representative of installation conditions (tension and crushing). Moreover, Technip and IFP Energies Nouvelles have developed and improved over the past few years a Finite Elements model dedicated to collapse prediction. The model accounts for the detailed geometry of the wires (carcass, pressure vault, spiral), ovalization, cyclic plasticity, contacts and residual stresses due to manufacturing. It allows to evaluate the effect of installation on the ovalization and plasticity of each layer and the collapse performance of the flexible pipe. The purpose of this paper is to present the collapse tests results and the corresponding calculations performed with the Finite Elements Model on several cases representative of Technip flexible pipes portfolio.

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.

Flexible Pipe Curved Collapse Resistance Calculation

2009 ◽  
Author(s):  
Laurent Paumier ◽  
Daniel Averbuch ◽  
Antoine Felix-Henry
Keyword(s):  
Failure Modes ◽  
Analytical Calculation ◽  
External Pressure ◽  
Calculation Model ◽  
Third Party ◽  
Flexible Pipe ◽  
The Past ◽  
Curved Pipes ◽  
Pressure Resistance ◽  
Collapse Failure

In the design of flexible pipelines for offshore field developments, the determination of the pipe resistance while subjected to external pressure and bending is very important in deepwater and is now required by the ISO and API standards. One of the critical failure modes being associated with this type of loads is the hydrostatic collapse. The collapse value of flexible pipe is calculated with a model validated with over 200 tests performed on all possible pipe constructions. This model has an analytical basis, and has been established in the past, leading to a fast and straightforward use. In order to address the bent collapse failure mode, Technip and IFP have therefore developed and improved over the past few years an analytical calculation model, based on the collapse model for straight pipes. The purpose of this paper is to present this design methodology and its validation. The modelling principles of the collapse calculation of straight flexible pipes are firstly presented, along with the main hypotheses. The adaptation to the case of curved pipes is detailed in the sequel of the paper. Many types of flexible pipe samples have been tested up to collapse both in straight and curved configurations. The results of these tests have been used to validate this model. In the paper, several tests results will be presented and compared with the calculations. This model is effective, of straightforward use, and has been certified by a third party. It allows Technip to optimize the flexible pipe design in particular for ultra-deep water applications, where external pressure resistance is very important.

Predictions of Armour Wire Buckling for a Flexible Pipe Under Compression, Bending and External Pressure Loading

2012 ◽  
Author(s):  
Otávio Sertã ◽  
Rafael Fumis ◽  
Adrian Connaire ◽  
John Smyth ◽  
Rafael Tanaka ◽  
...  
Keyword(s):  
External Pressure ◽  
Pressure Loading ◽  
Flexible Pipe ◽  
Buckling Mode ◽  
Instability Modes ◽  
External Pressures ◽  
Sample Test ◽  
Flexible Designs ◽  
Homogeneous Representation ◽  
Limiting Condition

During installation and operation a flexible pipe may be subjected to high compressive forces, high cyclic curvatures and external pressures leading to high reverse end-cap loads. Under such loading conditions, which occur particularly in the touchdown region for deep water applications, the limiting condition for the flexible pipe can be the compressive stability of the tensile armour wires. Two potential instability modes are possible: radial mode (birdcaging) and lateral mode (lateral wire disorganization). Previous work on the subject has established the key factors which influence the onset of each buckling mode [1],[2],[3] and [4]. In order to ensure the feasibility of flexible designs for applications with increasing water depth, it is important to improve the knowledge of the mechanisms which can lead to instability of armour wires and enhance the ability to predict with greater assurance, the particular conditions which increase the risk of wire instability. The focus of this work is the comparison of finite element prediction of radial buckling (birdcaging) with physical testing results under loading states that lead a pipe to birdcaging failure. The numerical model incorporates all tensile armor wires and their interactions with each other and adjacent layers. The outer sheath and reinforcing tape layers are explicitly represented, while the inner layers of the pipe (pressure armour and carcass sheath) are idealized using a homogeneous representation. The model also incorporates the effects of manufacturing pre-tension and hoop strength in the anti-birdcaging tape layers which are critical determinants for the onset of buckling. A key aspect of the method presented is the means by which the loading is applied. Specifically, the modeling handles the simultaneous and controlled application of end rotations, axial compression and radial resistance of the tapes through to the point of tape failure, pipe ovalisation and subsequent radial displacement and buckling of individual wires. In summary, in this paper a solid modeling approach is presented, which is compared with full a scale sample test data, that enables the simulation of a flexible pipe undergoing large combined compression, curvatures and pressure loading.

Flexible and Rigid Pipe Solutions in the Development of Ultra-Deepwater Fields

2003 ◽  
Author(s):  
Adriano Novitsky ◽  
Fin Gray
Keyword(s):  
Oil Industry ◽  
Technical Cooperation ◽  
Flexible Pipe ◽  
Lateral Buckling ◽  
Collapse Resistance ◽  
Flexible Pipes ◽  
Campos Basin ◽  
Flexible Risers ◽  
Girth Welds ◽  
Full Scale Tests

The development of the offshore segment during the last three years was remarkably important for the oil industry due to some major achievements observed in the technical area, more specifically on the development of pipe solutions for ultra deepwater (UDW) applications. Brazil and Gulf of Mexico (GoM) have lately been the two main regions for application of proven pipe solutions in UDW. In Brazil, flexible pipes have been widely used in the development of UDW fields by Petrobras, while in the GoM, rigid pipelines and SCRs have been used for the majority of deepwater field developments. The main advances in flexible pipe technology are linked to the development of two major Petrobras fields located in the Campos Basin named Roncador and Marlim South. Technip-Coflexip has, through Technical Cooperation Agreements with Petrobras, designed, tested and installed flexible pipes, proving the fitness of this kind of product to UDW applications. The qualification of flexible risers for 1500m WD and flexible flowlines for 2000m WD are highlighted as being the main achievements. Extensive testing programs including, collapse, fatigue and offshore full scale tests have been put in place in order to simulate the design conditions to be seen by the pipes during installation and operation phases. The main design aspects in UDW like collapse, radial and lateral buckling of tensile armours, fatigue and thermal insulation will be covered in this paper and the current available technologies to tackle these issues will be presented. Similar design and qualification issues exist for rigid pipelines and risers (SCRs). The following three areas are specifically covered in this paper: collapse resistance of steel pipe; fatigue strength of plastically strained girth welds: and qualification of pipe-in-pipe thermal performance. These are some of the key areas of reeled pipe in deepwater applications that require successful project qualification. Technip-Coflexip has performed internal R&D programs on these areas as well as project specific qualifications. Both will be addressed by the paper.

Effect of Tension on Collapse Performance of Flexible Pipes

2018 ◽  
Author(s):  
Marcelo Miyazaki ◽  
Laurent Paumier ◽  
Fabien Caleyron
Keyword(s):  
Finite Elements ◽  
Failure Modes ◽  
Cost Model ◽  
Negative Influence ◽  
External Pressure ◽  
Flexible Pipe ◽  
Test Protocol ◽  
Specific Test ◽  
Flexible Pipes ◽  
Finite Elements Model

This paper investigates the effect of tension on collapse performance of flexible pipes. In the design of flexible pipelines for offshore field developments, one of the failure modes being associated with external pressure and bending loadings is the hydrostatic collapse. In accordance with standards, TechnipFMC methodology for flexible pipe collapse resistance determination ensures a robust design. The model has an analytical basis, leading to a fast and straightforward use. It has been validated with more than 200 tests performed on all possible pipe constructions on straight and curved configurations. TechnipFMC and IFP Energies nouvelles have also developed and improved over the past few years a Finite Elements Model dedicated to flexible riser studies. It takes full advantage of the structure periodicities such that a whole riser can be studied with a short length and low CPU cost model associated to specific periodicity conditions. The model is able to represent bent risers in various configurations (bending cycles, internal and external pressure, axial tension, torsion) and has been used for collapse prediction of flexible risers under tension. Additionally, a specific test protocol has been developed to be able to carry out a collapse test associated to tension. The purpose of this paper is to present the collapse test result, the specific development of the model for collapse and tension and the corresponding calculations performed with the Finite Elements Model on several structures, demonstrating that there is no negative influence of tension on collapse mode. It also gives a better understanding on the interaction between tension in the armor layers and collapse phenomenon.

Flexible Pipe Sensitivity to Birdcaging and Armor Wire Lateral Buckling

2004 ◽  
Author(s):  
Mauro Pastor Braga ◽  
Peter Kaleff
Keyword(s):  
Failure Modes ◽  
Failure Process ◽  
Performance Criteria ◽  
Pipe Failure ◽  
Flexible Pipe ◽  
Lateral Buckling ◽  
Cyclic Bending ◽  
Testing Procedures ◽  
Flexible Pipes ◽  
Dip Test

Petrobras has been successfully dealing with deep water floating production systems using flexible pipes since 1977. During the completion of Marlim South 3 well in 1977, Petrobras was surprised by the occurrence of two birdcage type failures. At that time, Marlim South 3, in a water depth of 1709 m was the deepest offshore production well in operation. Since then, Petrobras has been testing flexible pipes using a field test known as DIP test. In a DIP test, an empty end capped sample of a flexible pipe, about 150m long, is partially supported by the sea bottom and connected to a lay vessel by a pipe follower or a wire rope. The flexible pipe has to withstand a 4 hour period of cyclic bending due to the motions of the lay vessel. The DIP test has provided Petrobras with information on a new failure mode: lateral buckling in the armor wire. Although a birdcage failure is equally undesirable, lateral buckling of the armor wires implies more danger because it can go unnoticed. In 2001, a research project was set up by the Research and Development Center of Petrobras that was aimed at reproducing the flexible pipe failure modes under laboratory conditions. The purpose was to obtain a better understanding of the failure process, as well as to develop testing alternatives to avoid the significant costs related to DIP tests. In order to assess the effect of cyclic bending as a major factor in degrading the longitudinal compressive strength of flexible pipes 15 destructive tests were performed on 4 inch diameter flexible pipe samples. Two test rigs that accommodated three types of test and a number of test procedures were developed in the project. The number of bending cycles to failure for each sample was determined when subjected to compressive action corresponding to its operational depth. Tests to evaluate the effect of pre-existing damage were also conducted. Special attention was devoted to the effect of layer arrangement on compressive failure. The test results clearly identified the basic failure modes under investigation (i. e. birdcaging and lateral buckling of the armor wires). Suggestions regarding simplified testing procedures and corresponding performance criteria are also presented.

Critical Assessment of PVDF Multilayer Barriers in Unbonded Flexible Risers: Applications and Benefits

2013 ◽  
Author(s):  
Upul S. Fernando ◽  
Michelle Davidson ◽  
Terry Sheldrake
Keyword(s):  
Failure Modes ◽  
Single Layer ◽  
Design Strategies ◽  
Pipe Failure ◽  
Flexible Pipe ◽  
Essential Requirement ◽  
Flexible Risers ◽  
Service Application ◽  
Test Requirements ◽  
Hydrocarbon Media

The polymer barrier is the key component in a flexible pipe structure that is specifically designed to contain hydrocarbon media within the pipe. Maintaining the integrity of the barrier for the total service life of the pipe is therefore an essential requirement to prevent any leaking or spilling of the hydrocarbon into the external environment. For high temperature (> 100°C) service PVDF is commonly used as a barrier material, and the barrier designs are based on either single layer or multilayer (two or three layers) structures depending on design strategy, manufacturing constraints and service application. This paper presents a critical review of the barrier design strategies, considering both single and multilayer structures. The main parameters in deciding a reliable barrier structure are discussed and the advantages/disadvantages of multilayers over single layers are highlighted. The different pipe failure modes/mechanisms that may be related to different barrier structures, the analyses and test requirements to evaluate and overcome these failures are discussed.

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