Coflexip® Flexible Steel Pipes for Drilling and Service

Transcription

Technip’s Drilling & Refining Applications Division
Coflexip® Flexible Steel Pipes
for Drilling and Service
Applications
User’s Guide
User’s Guide
This User’s Guide allows for a safe application of Coflexip®
flexibles pipes and is the extension to the Flexible Steel Pipe for
Drilling and Services Applications brochure.
Technip’s Drilling & Refining Applications Division
Coflexip® - Flexible Steel Pipe
for Drilling and Service
Applications
Coflexip® flexible
pipes for drilling and
service applications
are manufactured by
the Drilling & Refining
Applications Division
of the Technip Group
CONTENTS
Contents
0
GENERAL INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1
DESCRIPTION OF A COFLEXIP® FLEXIBLE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.1 DESIGN OF FLEXIBLE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.2 NACE COMPATIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.3 END-FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.3.1 Protection against corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.3.2 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.3.3 Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.3.4 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.3.5 Handling collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1
1.4 ANCILLARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1
1.4.1 Bend stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1
1.4.2 Adapters/Cross-Overs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1
1.4.3 Fire cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.5 FLEXIBLE PIPE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.5.1 Thermoplastic inner liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.5.2 Interlocked Zeta layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.5.3 Metallic reinforcement of the Zeta layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.5.4 Intermediate thermoplastic sheath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.5.5 Double cross-wound steel armour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.5.6 Thermoplastic outer sheath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.5.7 Fire resistant layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.5.8 Stainless steel outer-wrap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.6 MECHANICAL BEHAVIOUR OF COFLEXIP® FLEXIBLE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.7 FAILURE MODES OF COFLEXIP® FLEXIBLE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2
GENERAL GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.1 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.2 HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.3 INSTALLATION - CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.4 WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3
OPERATING CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.1 FLUIDS TO BE TRANSPORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.1.1 Chemical compatibility of standard temperature rated lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.1.2 Chemical compatibility of high temperature rated lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.1.3 Exposure of high temperature rated lines to C02 combined with H2S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.1.4 Chemical compatibility of acid (HDPE) lines (former design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.1.5 Sour service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.1.6 Flow rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1
3.2 TEMPERATURE RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1
3.2.1 Standard temperature rated line (-20°C to +100°C / -4°F to +212°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1
3.2.2 High temperature rated Line (-20°C to +130°C / -4°F to +266°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1
3.2.3 High temperature Exposure Test of Choke and Kill Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.2.4 Acidizing/fracturing lines (-20°C to +65°C / -4°F to +149°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3
3.3 PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.3.1 Rated working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.3.2 OEM test pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4
LIFETIME OF DRILLING AND SERVICE APPLICATION FLEXIBLE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5
REPAIR OF FLEXIBLE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6
INSPECTION AND TESTING OF LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.2 ROUTINE VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.2.1 External inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.2.2 Internal inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.3 FULL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.4 MANUFACTURER'S INSPECTION - MAJOR SURVEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.5 FIELD PRESSURE TESTING (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.6 FULL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.7 RECORDING OF INSPECTIONS AND TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.8 PERIODICITY OF INSPECTIONS AND TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.9 UNUSED LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
7
CHOKE AND KILL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
7.1 DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
7.1.1. Choke and kill lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
7.1.2 Cement lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
7.2 SOUR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
7.3 COMPLETION FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.4 VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.5 PERIODICITY OF FIELD TESTING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.5.1 After installation pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.5.2 Routine visual inspection (Section 6 - Para 6.2.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.5.3 Full inspection (Section 6 - Para 6.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.5.4 Manufacturer's inspection - major survey (Section 6 - Para. 6.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.5.5 Field pressure testing (optional) (Section 6 - Para. 6.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.5.6 Subsea (BOP stack) Choke and Kill lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8
TEST LINE APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.1 "DST" AND "PTL" LINES DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.2 SOUR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.3 VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.4 PERIODICITY OF FIELD TESTING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.4.2 Routine external visual inspection (Section 6 - Para 6.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.4.3 Full inspection (Section 6 - Para 6.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.4.4 Manufacturer's inspection - Major survey (Section 6 - Para 6.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4
9
ACIDIZING AND FRACTURING LINE APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
9.1 DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
9.1.1 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
9.1.2 Well service operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
9.1.3 Dynamic operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
9.1.4 Static operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
9.2 SOUR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
9.3 VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
9.4.1 Flushing of the lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
9.4.2 Routine external visual inspection (Section 6 - Para. 6.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
9.4.4 Full inspection (Section 6 - Para. 6.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
9.4.5 Manufacturer's inspection - Major survey (Section 6 - Para. 6.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
10 DRAG CHAIN OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
10.1 DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
10.2.1 After platform installation and hook up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
10.2.2 Routine visual inspection (Section 6 Para. 6.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
10.2.3 Yearly test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
11
SUMMARY OF INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5
A B B R E V I AT I O N S U S E D
Abbreviations
used
ACD:
Acidizing / Fracturing
BOP:
Blowout Preventer
CEM:
Cement
C/K:
Choke and Kill
DST:
Drill Stem Test
FAT:
Factory Acceptance Test
HDPE:
High Density Polyethylene
VH:
Vickers Hardness
ID:
Inner Diameter
LMRP:
Lower Marine Riser Package
MBR:
Minimum Bend Radius
MWP:
Maximum Working Pressure
OD:
Outer Diameter
OEM:
Original Equipment Manufacturer
OEM. TP: Original Equipment Manufacturer Test Pressure
PTL:
Production Test Line
QCDC:
Quick Connect Dis-Connect
QDC:
Quick Dis-Connect
TP:
Test Pressure
WP:
Working Pressure
6
0.
GENERAL INTRODUCTION
General
introduction
This copy of the “Coflexip® FLEXIBLE STEEL PIPES DRILLING AND SERVICE APPLICATIONS USER'S GUIDE” (hereinafter referred
to as “the Guide”) is revision 4 of the guide originally issued in 1989 revised in September 1990, and 1993.
The main differences from revision 3 are an up-date of the product characteristics and compatibility charts made possible
by the on-going tests performed as part of Technip's policy of continual research into the safe application of flexible pipes.
Coflexip® flexible steel pipe systems are manufactured by the Drilling & Refining Applications (DRAPS) Division of the Technip
Group.
The DRAPS Division recognises the fact that the majority of our clients have used Coflexip® drilling application products for
many years and have therefore built up a great deal of experience in their use. It follows therefore that much of the information contained in this Guide is intended primarily for those clients who are not familiar with the use of Coflexip® products.
For the purpose of this document, “End User” shall mean a person, a company, its and
their co-contractors, co-lessees and joint ventures, its and their respective affiliates, and
its and their respective officers and employees, including agency personnel (but shall not
include any member of the Technip Group), who purchase, transport, handle, package,
use or work with the Coflexip® products as described in this Guide.
The DRAPS Division relies on the feedback of all End Users to ensure the continued reliability of our products and to act as
the basis for research into the flexible pipes of the future. We therefore welcome any comments on both the flexible pipes
themselves and User's Guides such as this guide specifically written for Drilling and Service Applications.
In producing this Guide, we have attempted to cover all aspects of both the design and safe use of our drilling and service
application flexibles in normal, current applications. We are always available to answer questions from End Users. Any questions should be directed towards your local DRAPS Division office listed on the back cover of this Guide.
The DRAPS Division MAKES NO REPRESENTATION ON WARRANTY IN CONNECTION
WITH ITS DRILLING APPLICATION PRODUCTS SAVE AS EXPRESSLY AGREED WITH THE
END USER(S) IN A DOCUMENT EXECUTED BY the DRAPS Division AND THE END USER.
All information and data contained herein are subject to change without further notice, and are to be considered as RECOMMENDATIONS in general or INSTRUCTIONS (when stated in the text) by the (Original Equipment Manufacturer) only.
This document can be viewed and downloaded from our website at:
http://www.technip.com
7
1.
DESCRIPTION
OF A COFLEXIP® FLEXIBLE LINE
1. Description
of a Coflexip® flexible line
This section will discuss the construction of a typical Coflexip® flexible line and, according to the pipe construction,
present the failure modes that might be caused by a possible misuse of the equipment.
As shown in Figure 1, a typical Coflexip® line is composed of:
A length of flexible pipe
Two end-fittings complete with handling collars
Integral connectors
Optional stiffeners
Identification collars
Connector
Connector
Termination
Termination
Flexible pipe
End fitting
Identification collars
Handing collars
Stiffener
End fitting
Figure 1
1.1
DESIGN OF FLEXIBLE LINES
All Coflexip® Drilling Applications flexible pipes are designed in accordance with API 16C which is the only specific reference/regulation existing for Choke and Kill lines and/or API 7K for Rotary lines. Some of the API 16C requirements do
not apply to other applications where our lines can be used (Acid/fracturing lines for example) when the resistance
to H2S is not an issue; on the other hand all of our lines supplied for Choke and Kill applications are fully compliant
with API 16C.
1.2
NACE COMPATIBILITY
End-fittings: all steel materials used in the manufacture of a Coflexip® end-fitting meet the requirements of
NACE MR-01-75.
Steel wires: the carbon steel wires used for the Zeta, reinforcement wire and armour layers meet the NACE requirements in force at manufacturing date. The present steel wires have been tested according to TM 0284 and
TM 0177 - 1996.
1.3
END-FITTINGS
The end-fitting itself consists of the following:
The termination which ensures the seal and the mechanical attachment of the end-fitting to the flexible pipe.
The connector to allow the connection of the end-fitting to any other compatible connector.
8
1.3.1 Protection against corrosion
All steel materials used in the manufacture of a Coflexip® end-fitting meet the requirements of NACE MR-01-75.
Coating protection of the end-fitting
The whole surface, both inside and outside of a standard end-fitting is protected against corrosion, wear, abrasion
and handling by a Nikaflex® coating.
The adhesion of the coating to the underlying steel is essential for the long term integrity of the protection. Various
heat treatments are applicable for Nikaflex® coated parts to improve that property. The DRAPS Division has selected
the most effective process which is a long duration, high temperature heat treatment conducted between 600°C
to 650°C (1,112°F to 1,202°F) for 10 hours. This process ensures diffusion of the coating into the steel, thus avoiding
any possible scaling of the protection.
The Nikaflex® coating bears the following properties:
The surface hardness of the coating is about 400 to 450 HV, in the range of most hardened steels, and this
improves the end-fitting resistance against corrosion, wear, abrasion and handling. In particular, the end-fitting
will resist long term exposure to internal flow of abrasive fluids.
The inner coating is 75 thick; a visual inspection of the inner bore of the end-fitting showing that the coating
is still present indicates the satisfactory integrity of those end-fitting parts subjected to the internal flow conditions. If the coating is damaged or cracked, traces of corrosion and rust may be visible and a complementary
inspection should be completed.
The Nikaflex® coating is highly resistant against corrosion from marine atmosphere, sea-water and to H2S/C02
gases or other corrosive fluids which might be transported by the line.
1.3.2 Connectors
The end-fittings can be supplied with most types of connectors, the most common being API hubs (formerly "CIW
hubs"), hammer unions and API flanges. Generally the connectors are integral parts of the end-fitting avoiding buttwelding (with some exceptions for non-standard connectors).
However, when used, the welding process is always completed BEFORE end-fitting mounting.
Some restrictions on the type of connector used may apply e.g. API 16C does not allow the use of threaded connectors for choke and kill applications. Similarly it is not a DRAPS Division practice to fit a connector which has a higher
pressure rating than the flexible pipe itself.
1.3.3 Terminations
The termination will ensure the following functions:
Mechanical attachment to the flexible pipe which will resist against internal pressure, traction and torsion
Provides seal against inner effluent
Provides seal against outer environment
Mechanical attachment of the outer stainless steel carcass
1.3.4 Marking
The termination bears a permanent marking indicating:
Manufacturer (*)
Serial number of the line
9
Internal diameter of the line (inches)
Application (*)
Working pressure (WP bar or psi) of the line which is always inferior or equal to the maximum design pressure of
the line structure
Length of the line - face to face from one connector to the other (metres or feet)
Date of the factory pressure test
If applicable, a stamp of a certifying authority
For repaired lines see section 5
(*) This information was optional before second quarter of 1990
Repaired lines
If the line has been repaired by the mounting of a new end-fitting, it will bear the same marking as above, but the
serial number of the line is changed on that end-fitting. Length and date of the factory pressure test are revised values
marked on the new end-fitting.
Although optional before the second quarter of 1990, The DRAPS Division recommends that the type of application
be stamped where the information is missing, using the abbreviated classification as follows. In case of doubt, please
contact the nearest DRAPS Division office.
From the second quarter of 1990, the end-termination bears a revised marking as follows:
Manufacturer
Serial number of the line
Internal diameter of the line (inches)
Line application abbreviated as follows:
C/K: Choke and Kill
CEM: Cement
PTL: Production Test Line
ACD: Acidizing/Fracturing
DST: Drill Stem Test
Line length in metres (m) or feet (ft)
Working pressure (WP bar or psi)
Test pressure (TP bar or psi)
Temperature range (continuous service: see section 3.2)
The stamped test pressure is the OEM.TP (Original Equipment Manufacturer Test Pressure)
Date of the factory pressure test (month/year)
If applicable, a stamp of a certifying authority when required
(For lines repaired by end-fitting replacement, see section 5)
Example of marking
COFLEXIP®
TR 95314.01
3" - C/K - 18.3 m
WP 15000 psi
TP 22500 psi
TEMP: -20/+130°C
02/2002
Manufacturer
Serial number
I.D./Application/Length
Working Pressure
Test Pressure
Temperature range
Test date (month/year)
Any inquiry regarding the construction of the line and its end-fittings should refer to the serial number through which
the DRAPS Division can trace the relevant information.
10
1.3.5 Handling collar
A groove in the end-termination is fitted with a rotating handling collar with two symmetrical pad-eyes.
This collar is designed to allow for safe handling of the flexible pipe. It is not designed to handle any other equipment
which might be attached to the connectors.
This collar is NOT designed for lifting more than the weight of the flexible itself.
INSTRUCTION: for long lines (acidizing lines for example), typically lines longer than 25m (80'), the End User should
refer to the DRAPS Division for advice on limitations in the use of the standard handling collars. Special collars can
be designed for specific needs.
For further details on Acidizing Applications see Section 9.
1.4
ANCILLARY EQUIPMENT
1.4.1 Bend stiffener
Figure 2
The bend stiffener is an additional device mounted on the flexible pipe during its manufacturing (see figure 2 above).
It increases the local bending stiffness in the region of the end-fitting, producing a smoother transition from the endfitting to the flexible pipe structure.
The bend stiffener is optional on most flexible pipes. It will allow the flexible pipe to better resist overbending: flexure
damaging strength is increased by a factor of x3 when using this device.
Made out of polyurethane, it is intrinsically resistant to corrosion.
During the external inspection, check that the bend-stiffener is properly tightened on the end-fitting and is free of
damage and cracks.
1.4.2 Adapters/Cross-Overs
Adapters/Cross-Overs can be supplied if the End User needs to
connect his flexible pipe to different or non standard connectors. These adapters are typically 0.3 metres or one foot long
depending on the I.D. and rating.
Represented is an API Hub / Weco® adapter.
11
1.4.3 Fire cover
As for the flexible pipe itself, it may occasionally be necessary, due to the working environment, for lines to include a
greater degree of fire protection than standard. For such operating conditions, additional fire protection covers may
be installed over the end-fitting assemblies.
1.5
FLEXIBLE PIPE STRUCTURE
A typical Coflexip® flexible pipe structure, for high pressure applications is shown in Figure 3 below.
This construction is known as a “non-bonded” structure.
From the inside out it is composed of the following:
8
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
Thermoplastic inner liner
Aramid tape
Zeta spiral
Flat steel spiral
Thermoplastic intermediate sheath
Cross-wound tensile armours
Thermoplastic external sheath
Outer wrap interlocked steel carcass
Figure 3
1.5.1 Thermoplastic inner liner
The thermoplastic inner liner makes the pipe leak-proof. This layer limits the upper service temperature of the line
and the chemical compatibility to the various fluids which may be transported through the line. Various plastic materials are used to manufacture the inner liner, depending upon the service application of the line. This liner can be reinforced by aramid tapes depending on the application.
1.5.2 Interlocked Zeta layer
This layer takes the hoop stress due to internal pressure and external crushing loads.
The crushing resistance of a Coflexip® line is similar to that of an API rigid pipe designed to withstand the same internal
pressure. However, accidental crushing might damage the outer stainless steel wrap and reduce the lifetime of the
line.
It is the interlocking of the Zeta layer which will limit the bending radius of the line. If this limit is exceeded, irreversible damage to the flexible line will occur leading to perforation of the inner liner when under pressure.
1.5.3 Metallic reinforcement of the Zeta layer
If necessary for extreme high pressure, the Zeta layer is reinforced by a flat steel layer which is not interlocked.
1.5.4 Intermediate thermoplastic sheath
This sheath is a thin anti-friction layer which improves the dynamic behaviour of the line. This layer is not leak-proof.
12
1.5.5 Double cross-wound steel armour
The double cross-wound steel armour wires will resist axial load caused by internal pressure, or external axial loads.
It is also this layer which provides the flexible line with its resistance to torsion.
1.5.6 Thermoplastic outer sheath
This layer is leak-proof.
It will both:
Protect the armour wires against corrosion and
Protect the line against hydrostatic external pressure if the line is used subsea, as on LMRP BOP (Lower Marine Riser
Package Blowout Preventer) stacks.
(Note that test lines are vented through this outer layer and may not therefore be used subsea).
1.5.7 Fire resistant layer
For certain installations, e.g. permanently installed well control lines on fixed production platforms, it may be a requirement for essential service flexibles such as choke and kill lines, to be operable under fire conditions for long periods.
The inclusion of a fire resistant layer installed after production of the standard pipe gives a working time at 700°C
(1,292°F) and full working pressure, well in excess of 30 minutes. This layer is non-standard and would be the subject of
a special order. Refer also to section 1 - Para. 1.4.3 for end-fitting fire protection.
1.5.8 Stainless steel outer wrap
The stainless steel outer wrap (carcass) protects the thermoplastic outer sheath against mechanical damage caused
by using the line in a harsh environment (impacts, wear, handling, etc.).
This layer does not contribute directly to the mechanical resistance of the line.
However, significant damage to this layer may lead to subsequent damage to the thermoplastic outer sheath causing
either:
Corrosion of the armour wires, and/or
Collapse of the inner tube for subsea lines.
1.6
MECHANICAL BEHAVIOUR OF COFLEXIP® FLEXIBLE LINES
By design, a Coflexip® flexible line is extremely resistant to:
Internal pressure
Dimensional changes under pressure are very limited; typical values are:
Relative elongation at design pressure 0.15 to 0.25%
Relative outer diameter change at design pressure < 0.25%
The line is extremely stable under pressure. In particular, if bent it will not tend to straighten under pressure. No significant twist would occur. It will not pulsate or whip during high flow rate circulation.
Tensile Forces
Resistance to pulling forces ranges from about 50,000 daN for 2" ID to more than 100,000 daN for 3" ID (50 to
100 tons or 100,000 to 200,000 lbs).
WARNING: you must be aware that a Coflexip® flexible can be stronger than some of the pipework to which it is
connected and that it will rarely be the "weak point" of a system.
13
Crushing
The crushing resistance of Coflexip® flexible pipes is similar to that of an API rigid pipe of the same design pressure
Bending
The line is resistant to bending, including frequent or continuous flexure with the imperative condition that the
minimum bending radius is not exceeded.
In the DRAPS Division's documents, the minimum bending radius is abbreviated as MBR.
MBR
OD
d = (2 MBR minus OD)
“d” is the minimum
inside distance
between the two
surfaces
Example:
2.5” Coflon 15 kpsi W.P.
MBR = 0.86 m/2.81 ft
OD = 140.2 mm/52 inches
d
= 1.58 m/5.18 ft
Figure 4
The minimum bending radius is an extremely important characteristic of a flexible steel line.
As a rule of thumb, the minimum bending radius is roughly equal to:
MBR = 12 x ID (ID: inner diameter of the line).
Example: If ID = 3" then MBR = 12 X 0.076 = 0.92 metre or 12 x 3 = 36", i.e. 3 ft.
For specific DRAG CHAIN applications, the MBR for installed use is 1.1 x the storage MBR, as defined on the relevant
data sheet.
The accurate value of the MBR is part of the technical specification of the flexible line.
1.7
14
FAILURE MODES OF COFLEXIP® FLEXIBLE LINES
Coflexip® flexible steel lines are extremely reliable due to:
The design of the product
The use of the highest standards applicable
The use of the highest quality raw materials
The Technip quality assurance system
However, misuse might damage the line, and you must be aware that four main failure modes can occur:
Corrosion of the armour wires - If the outer thermoplastic sheath is damaged, corrosion of the steel armour wires
will occur. This will progressively reduce the thickness of the wires, causing a progressive decrease of the burst pressure.
This failure mode may cause the line to burst catastrophically.
Bending - If the minimum bending radius is exceeded, the Zeta layer may open; in which case, the inner tube is not
properly supported and perforation will occur under pressure.
Overbending generally occurs due to mishandling during installation.
Particular attention must be paid at this time to the first metre or few feet of flexible pipe immediately behind
each termination.
An optional bend stiffener is available on request to improve the pipe's resistance to such overbending.
This failure mode may cause the line to burst.
Figure 5 shows how overbending may be caused, whether or not the line is under internal pressure.
NO
YES
Figure 5
Ageing of the inner liner - The mechanical properties of the inner liner can be affected by ageing. This phenomenon causes the degradation of the long thermoplastic molecules and may be due to:
Long exposure to high temperature, exceeding the maximum rated temperature
Exposure of the internal surfaces to incompatible chemicals
The degradation of the material could make it brittle and the tube may break when bent with or without internal
pressure, leading to a leakage.
This failure mode can result in a burst, or more often, in a high pressure leak.
Collapse of the inner liner - If damaged, the outer sheath may not be leak-proof. For subsea lines, the external
hydrostatic pressure will be applied on to the inner liner which may collapse. This can lead to the rupture of the
liner and failure of the line.
This failure mode may cause the line to burst.
15
2.
GENERAL GUIDELINES
2. General guidelines
2.1
STORAGE
Storage in general does not require specific precautions regarding the environment or duration of storage.
Depending on length, the best ways to store a line are either:
In a straight line (up to 6 metre or 20 ft long)
Coiled to its MBR, attached to a wooden pallet or crate
Installed in a DRAG CHAIN prior to hook-up and start of operations
Coflexip® flexible lines are shipped with protection on the connectors.
INSTRUCTION: a similar protection should be reinstalled when the line is disconnected. It may consist of a metallic
blind flange that fits the connection, which is preferable, or of a good wooden protection.
This protection must ensure that:
> The inner bore of the line is closed to avoid accidental intrusion of any foreign material;
> The connector, especially the seal area, is properly protected against impacts, etc.
INSTRUCTION: if stored below minimum rated temperature, ensure that no handling is done before the line is brought
back to the minimum rated temperature.
INSTRUCTION: the inner bore of a Coflexip® line should be thoroughly flushed with fresh water prior to long term
storage.
2.2
HANDLING
INSTRUCTION: only qualified and trained personnel should handle flexible lines such as those manufactured by the
DRAPS Division. Whilst we make every effort to assist End Users whenever possible on the methods of handling to
be deployed, the final decision on the best methods for local conditions and capacities rests with End Users or their
appointed agents, either of whom should have their own procedures for such handling operations.
Any rigging should be suitably adapted to the specific flexible line in question, as mishandling can be dangerous to
operations, surrounding personnel, equipment and property.
The line must never be bent below the minimum bend radius (MBR), as this may damage it.
As a rule of thumb, the minimum bend radius is equal to:
MBR = 12 x ID
The accurate value of the MBR of the line is part of the technical characteristics of the Coflexip® structure and
will have been supplied to the original End User: it can be obtained from the nearest DRAPS Division office.
The MBR must be respected at all times, whether the line is under pressure or not.
User should avoid bending the flexible just behind the end-fitting. As a rule of thumb, a straight length of about
0.6 to 0.9 metre (2 to 3 feet) should be used as a safety distance.
See section 1.7 - FAILURE MODES OF COFLEXIP® FLEXIBLE LINES
The use of wire ropes or chains may damage the anti-corrosion treatment of the end-fitting. If so required, use a
shackle connected through the eye of the handling collar. Never use wire ropes or chains directly against the stainless steel outer-wrap. If force needs to be applied to the body of the flexible line itself, use soft slings.
Moving flexible line on the ground
16
Do not attach slings directly to the end-fitting - use the handling collar provided. Always connect slings to both
eyes in order to have the pulling force in a straight line through the main axis of the flexible pipe.
Prevent abrasion of the flexible line against the ground; use wooden supports or planks.
If a forklift has to be used to lift a flexible line, soft slings must be used to prevent damage, and to prevent the
flexible line from falling off the forks (see the DRAPS Division Handling schematics inside the rear of this Guide).
End User assumes all responsibility for essential safety precautions to avoid injury or death in connection with
these operations.
2.3
INSTALLATION - CONNECTION
The preferred installation for a Coflexip® flexible line is with the
pipe positioned in a J or U configuration, with the end-fittings
pointing up in a vertical position. See Figure 6.
If, due to the rig equipment, this configuration is not feasible,
special care must be taken when securing a non-vertical connection that overbending behind the end-fitting is avoided.
Connection of the flexible line to other pipework requires:
Supporting the weight of both the end-fitting and the line
Correct alignment of the end-fitting
INSTRUCTION: The best way to achieve this is to support the
weight of the line through the use of the handling collar, then
control the alignment with a non-metallic rope or sling attached
about 0.9 metre (3 feet) behind the end-fitting. See Figure 7.
R
MB
Figure 6
Never do the reverse, i.e.:
Do not support the weight immediately behind the endfitting;
Do not align the line from the end-fitting itself.
2.4
WELDING
A flexible steel line is a mixed construction of steels and thermoplastics. It must be recognised that because of the heat diffusion that occurs during any welding process, the thermoplastic
layers may suffer irreversible damage leading to an unsafe line.
When used, welding processes are only completed during the
original manufacturing process of the line at a stage where the
operation cannot affect the other components.
Consequently, any field welding repair of a flexible line, involving either the end-fitting (including the stainless steel ring groove)
or the stainless steel outer carcass, will render the line unsafe
and unusable. Such lines will must be withdrawn from service
and stamped "NOT-REUSABLE".
Figure 7
17
3.
O P E R AT I N G C O N D I T I O N S
3. Operating conditions
Although similar in appearance, the construction of Coflexip® lines for different drilling applications such as Choke
and Kill lines, Acid lines or Test lines differ significantly.
INSTRUCTION: these lines must never be used for any purpose other than the original for which the line was supplied
and which is stamped on the end-fitting identification collar (see section 1.3). In case of doubt, contact the nearest
DRAPS Division office for information on guidelines to be respected.
3.1
FLUIDS TO BE TRANSPORTED
Generally, all kinds of drilling muds and oil production fluids, or chemical additives, may be transported through flexible
lines depending upon the applications. The compatibility tables included in this Guide give an indication on the behaviour of the liners with most common chemicals.
Due to the number of chemicals used, often in concentrated forms, and the infinite number of possible combinations, it is virtually impossible to guarantee the behaviour of our products in all circumstances.
INSTRUCTION: in case of doubt please contact the nearest DRAPS Division office.
All components of the end-fittings in contact with the inner fluids are adequately protected against corrosion.
In most cases it is the internal liner made of thermoplastics that will limit the chemical compatibility of the flexible
line. They are different for:
Standard temperature rated line (-20°C to +100°C / -4°F to +212°F)
or
High temperature rated line (-20°C to +130°C / -4°F to 266°F)
or
Acid line (HDPE) (-20°C to +65°C / -4°F to +149°F). (Former designs, no longer in production i.e. typically pre-1998
although some later examples may have been supplied).
Tables I, II and III give a limited list of the different chemicals relevant for drilling and service applications and their
effects on the flexible line. In case of doubt, contact the nearest DRAPS Division office.
3.1.1 Chemical compatibility of standard temperature rated lines
The inner lining of these lines is made of RILSAN®, which is a grade of polyamide II material.
It must be noted that Standard Temperature Rated lines (-20°C to + 100°C / -4°F to +212°F) are not designed to handle
any acidified effluents and/or heavy metallic salts such as zinc or calcium bromides.
See Table I
18
TABLE I
Chemical compatibility of standard temperature rated lines.
Exposure resistance of RILSAN® inner lining at given temperature ranges.
Concentration
15%
30%
3%
7.5%
100%
100%
saturated
saturated
saturated
100%
100%
100%
50%
< 20%
< 20%
Presence
Hydrochloric acid HCl
Hydrofluoric acid HF
Xylene C6 H4 (CH3)2
Methanol CH30H
Zinc bromide ZnBr2
Calcium Bromide CaBr2
Calcium chloride CaCl2
Methane CH4
Diesel
Crude oil
Sodium hydroxide NaOH
Hydrogen sulphide H2S (pure gas)
Hydrogen sulphide H2S (condensate)
Water
0°F
-18°C
F
F
F
F
S
S
F
L
S
S
S
S
S
S
L*
L*
75°F
24°C
F
F
F
F
S
S
F
L
S
S
S
S
L
S
L*
L*
150°F
66°C
F
F
F
F
S
L
F
L
L
S
S
S
NR
S
L*
L*
200°F
93°C
F
F
F
F
S
NR
F
L
L
S
S
S
NR
S
L*
L*
250°F
121°C
F
F
F
F
NR
NR
F
L
L
L
L
L
NR
L
L*
L*
S: Satisfactory
NR: Not Recommended
L: Limited use** F: Forbidden
* The PH value of the fluid may greatly influence the behaviour of Rilsan® inner lining
** Technip’s DRAPS Division to be consulted for exact exposure time
3.1.2 Chemical compatibility of high temperature rated lines
The inner lining of these flexible lines is made of COFLON®, a fluorinated thermoplastic: Polyvinylidene fluoride (PVDF)
material.
See Table II
TABLE II
Chemical compatibility of high temperature rated lines.
Exposure resistance of COFLON® inner lining at given temperature ranges.
Concentration
Xylene C6 H4 (CH3)2
Methanol CH30H
Zinc bromide ZnBr2
Methane CH4
Diesel
Crude oil
Hydrogen sulphide H2S
S: Satisfactory
NR: Not Recommended
15%
30%
3%
7.5%
100%
100%
saturated
saturated
saturated
100%
100%
100%
50%
< 20%
L: Limited use
0°F
-18°C
S
S
S
S
S
S
S
S
S
S
S
S
S
S
75°F
24°C
S
S
S
S
S
S
S
S
S
S
S
S
S
S
150°F
66°C
S
S
S
S
S
S
S
S
S
S
S
S
L
S
200°F
93°C
S
S
S
S
S
S
S
S
S
S
S
S
NR
S
250°F
121°C
S
S
S
S
S
S
S
S
S
S
S
S
NR
S
F: Forbidden
19
3.1.3 Exposure of high temperature rated lines to CO2 combined with H2S
Under certain conditions, exposure to relatively high concentrations of CO2 combined with H2S, can lead to damage
of the COFLON® liner. For this reason, the following limitations are to be respected:
PRESSURE
TEMPERATURE
FLUID CONDITIONS
1035 bar/15,000 psi
130°C (+266°F)
CO2 + H2S < 10 %
690 bar/10,000 psi
130°C (+266°F)
CO2 + H2S < 30 %
690 bar/10,000 psi
110°C (+230°F)
CO2 + H2S < 50 %
3.1.4 Chemical compatibility of acid (HDPE) lines (former design)
The inner lining of these flexibles is made of high or medium density polyethylene (HDPE) which is a polyolefinic material (no longer used as an inner lining in standard production flexibles).
See Table III
TABLE III
Chemical compatibility of acid (HDPE) lines.
Exposure resistance of HDPE inner lining at given temperature ranges
Concentration
Xylene C6 H4 (CH3)2
Methanol CH30H
Zinc bromide ZnBr2
Methane CH4
Diesel
Crude oil
Hydrogen sulphide H2S
S: Satisfactory
L: Limited use
15%
30%
3%
7.5%
100%
100%
saturated
saturated
saturated
100%
100%
100%
50%
< 20%
0°F
-18°C
S
S
S
S
S
S
S
S
S
S
S
S
S
S
75°F
24°C
S
S
S
S
S
S
S
S
S
S
S
S
S
S
150°F
66°C
S
S
L
L
L
S
S
S
S
L
L
L
S
S
200°F
93°C
F
F
F
F
F
F
F
F
F
F
F
F
F
F
250°F
121°C
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F: Forbidden
3.1.5 Sour service
All components of the end-fittings and of the flexible pipe, in contact with the inner fluids, meet NACE-MR-01-75 edition 2001.
As well as those internal surfaces which come into direct contact with the inner flow, due to gas diffusion, some other
flexible pipe components may be in contact with low concentrations of sour gas. The carbon steel wires used for the
Zeta, reinforcement wire and armour layers meet the NACE requirements in force at manufacturing date. The wires
used at present have been tested according to TM 0284 and TM 0177 - 1996
Depending upon the application, Coflexip® pipes are classified either:
Permanent sour service, or
Temporary sour service
See Sections 7 to 10 for the different applications of Coflexip® pipes. In case of doubt, contact the nearest DRAPS
Division office.
20
3.1.6 Flow Rates
The maximum continuous flowrate for all smooth bore i.e. thermoplastic inner sheathed lines, is 15 metres per second.
Many lines, particularly those for acidizing / fracturing applications, have been subjected to flow-rates well in excess
of this figure for relatively short periods of time without any damage being sustained. This is entirely dependent on
the abrasive properties of the flow medium, therefore maximum short term flow-rates cannot be quantified for all
flow conditions. Extreme flow rates and abrasive fluids can cause erosion in the end-fittings. It is common practice to
change the end-fittings when these show severe scoring or pitting. Experience has shown that for those types of lines
subjected to severe abrasive conditions (fracturing operations), the end-fittings can be replaced twice before the
flexible pipe itself should be considered not fit for further use.
3.2
TEMPERATURE RATINGS
3.2.1 Standard temperature rated line (-20°C to + 100°C / -4°F to + 212°F)
Continuous service
Standard Coflexip® Choke and Kill lines are designed for -20°C to +100° C / -4°F to +212°F continuous service, with
no time limit (within the lifetime of the whole line).
Higher temporary service temperature
Standard Coflexip® flexible pipes may be used up to +130°C / +266°F, maximum temperature of the transported
fluids for a maximum of one month, continuous or cumulative service.
Lines exposed to temperatures higher than +100°C / +212°F but no more than +130°C / +266°F for continuous or
cumulative service of 1 month must be removed from service and stamped not reusable following this exposure.
Survival conditions
All Coflexip® flexible lines (C/K, DST, PTL) are designed to resist to +160°C / +320°F maximum inner temperature of
the contained fluids for a duration in excess of one hour.
A copy of the qualification test report is available upon request from all DRAPS Division sales offices.
Standard temperature rated Coflexip® flexible lines are deemed not reusable for further service after sustaining a
temperature above the temporary rating of +130°C / +266°F. Lines exposed to temperature higher than +130°C /
+266°F must be removed from service, properly stamped not reusable, and replaced by a new line.
3.2.2 High temperature rated Line (-20°C to +130°C / -4°F to +266°F)
Continuous service
High temperature rated flexible pipes are designed for -20°C to +130°C (-4°F to +266°F) continuous service, with no
time limit (within the lifetime of the whole line).
Note:
under certain fluid conditions, there may be limitations on pressure and/or temperature ratings
(Refer to Section 3 - Para. 3.1.3).
Higher temporary service temperature
High temperature rated flexible pipes are not designed for a higher temperature than the maximum continuous
temperature rating.
Survival conditions
All Coflexip® flexible lines are designed to resist to +160°C (+320°F) maximum inner temperature of the contained
fluid for a duration in excess of one hour. A copy of the qualification test report is available upon request from all
DRAPS Division sales offices.
High temperature rated Coflexip® flexible lines are deemed not reusable for further service after sustaining a temperature above the continuous rating of +130°C (+266°F). Lines exposed to temperatures higher than +130°C (+266°F)
must be removed from service, properly stamped not reusable, and replaced by a new line.
21
3.2.3 High temperature Exposure Test of Choke and Kill Lines
All Coflexip Choke and Kill lines have been tested in accordance with the latest edition of API 16C and are in full compliance with
the highest standards imposed. These standards include the following destructive testing:
Flexible Line High Temperature Exposure Test
This test is intended to determine the maximum temperature that a flexible Choke and Kill line will withstand for a short duration
when exposed to the rated working pressure. This test represents severe, survival conditions and should not be used to define the
temperature rating of the line. It is imperative that both the line structure and the end terminations be exposed to the temperature excursions during the tests.
Successful completion of verification testing qualifies the size and pressure rating of the flexible tested, together with smaller sizes
of equal or lower pressure ratings and temperature of equivalent design and construction.
Upon reaching the manufacturer’s rated working pressure and maximum temperature, the temperature is raised at a rate not to
exceed 5°F (2.8°C) per hour to 350°F, +10°F, (177°C +5.5°C) and held for one hour. The temperature should be measured, either at the
fluid inside the line or at the inside wall of the line. At the end of one hour, the temperature is raised at a rate not exceeding 5°F
(2.8°C) per hour until failure. Failure is defined as a visible fluid leak in the end connection, the body of the line or burst of the line.
The total time of exposure to 350°F (177°C) and above should be recorded together with the temperature and the failure mode of
the pipe: leak and its location, or burst and its location. Acceptance criteria will be sustaining the 350°F (177°C) hold period, at rated
working pressure, for one hour with no visible leakage.
The pressurization fluid can be water, or heat transfer oil. The fluid may be static or flowing. Because the objective of the testing
is to simulate, as closely as possible, service conditions, line heating should be from the inside.
In connection with flexible pipes, a "burst" is defined as the catastrophic failure of the pipe assembly, either by loss of a complete
end fitting, or by rupture of the complete assembly such that no flow is possible between the opposing end connectors. A “leak”
is defined as a loss of pressure integrity in the flexible pipe assembly, but which allows a significant quantity of flow between the
opposing end connectors enough to allow a continued temporary limited use in its intended service.
The Coflexip® line survived the above destructive testing procedure for a total period in excess of 20 hours, and to a final temperature of 232°C(450°F). Failure mode was a “leak” as defined above, no bursting occurred.
3.2.4 Acidizing/fracturing lines (-20°C to +65°C / -4°F to +149°F)
Coflexip® HDPE acidizing/fracturing lines are designed for -20°C to +65°C (-4°F to +149°F) continuous service, without time limit
(within the lifetime of the whole line). As acidizing/fracturing lines are normally only used to pump into well formations, it is unlikely that there will be the requirement to operate lines at temperatures higher than ambient and for this reason there are no other
temperature ranges, temporary or survival. These lines are not designed for flowing produced well fluids.
Coflexip® Coflon® acidizing lines have the same temperature limitations as the high temperature rated lines (see section 3.2.2).
3.3
PRESSURE
3.3.1 Rated working pressure
The working pressure stamped on the end-fitting must be understood as the maximum operating pressure to which the line may
be permanently subjected. It is not the manufacturer's responsibility to define allowances for eventual surges that may occur through
the lines. We insist that Users acquaint themselves with guidelines, specifications, or limitations issued by Certifying Authorities or
regulatory bodies.
3.3.2 OEM test pressure
All new Coflexip® flexible lines are pressure tested at the factory prior to supply. Test pressures are as follows:
WP
345 bar/5,000 psi
690 bar/10,000 psi
1035 bar/15,000 psi
22
OEM. TP
690 bar/10,000 psi
1035 bar/15,000 psi
1550 bar/22,500 psi
Test duration: all factory pressure tests last a minimum of 24 hours
after stabilisation at ambient temperature.
Note: the standard DRAPS Division FAT (Factory Acceptance Test)
is well in excess of the minimum requirement of API 16C.
4.
LIFETIME OF DRILLING AND SERVICE
A P P L I C AT I O N F L E X I B L E L I N E S
4. Lifetime of drilling
and service application flexible lines
Coflexip® flexible lines utilised for drilling and service applications are designed for twenty (20) years life in dynamic
service conditions. This design life is based on lines operating for their intended service, within their rated temperature range, fluid compatibility and allowable bending radius.
However, because of the many disparate factors affecting the service life of individual flexible lines, including extreme
weather conditions, mishandling and abuse, incorrect installation and storage, frequency of exposure to extremes of
temperature and pressure, improper care and maintenance, use of incompatible fluids, etc. it is not possible to predict
accurately the service life of any individual flexible line.
The designation of a "design life" should not be relied upon as a prediction or warranty of the life of a particular flexible
line, nor should purchasers and Users of Coflexip® flexible lines rely upon this design life in lieu of proper installation,
care, maintenance, storage, recommended inspections, handling, manipulations, repairs when necessary and other
requirements and precautions recommended by the DRAPS Division in the User's Guide.
The design life is not intended to, and will not extend, modify or alter in any manner the expressed warranty or other
conditions of sale given by the DRAPS Division as expressly agreed in writing with the End User, nor shall the design
life convey any expressed or implied warranties of "merchantability", fitness for a particular purpose or any warranties
except those expressly made in the "General Conditions of Sale". The DRAPS Division MAKES NO REPRESENTATION
OR WARRANTY SAVE AS EXPRESSLY AGREED IN WRITING WITH END USER.
INSTRUCTION: flexible lines removed from service upon expiration of the service life should be stamped "NOT
REUSABLE" or preferably cut into pieces.
Any line which reaches 20 years since its OEM pressure test, and which continues to function correctly, should be
returned to the DRAPS Division for investigation and recommendation on its continued use.
During this 20 year period, it is probable that a considerable number of design changes will have been made, and regulations or recommendations on the use of any particular application are likely to have changed: a combination of
these factors may make it impossible to recommend any further use of a particular line.
23
5.
R E PA I R O F F L E X I B L E S L I N E S
5. Repair of
flexibles lines
As a result of periodic inspections, or "in field" observations, damage may be noticed and require repair.
The following parts of a flexible line may be repaired at a convenient DRAPS Division facility, depending upon the
degree of the damage:
Serviceable parts of end-fitting, including handling collar and the rear locking nut attachment of the external carcass
Stainless steel outer carcass
Outer plastic sheath underneath the carcass
For significant damage, such as overbent lines, the repair may consist of mounting a new end-fitting(s) to a used line.
This would involve cutting off one complete end-fitting and installing a new one, thus reducing the overall line length.
The new fitting would be marked with the repair project number and line test date plus the new overall length: the
original fitting which remains with the line will be stamped "repaired". It should be noted that old fittings are not
reusable and that, because a variety of re-marking procedures have been employed since the first repairs were carried
out, it is always worth checking line details on both end-fittings.
Whatever the nature of the repair, the lines are pressure tested at OEM test pressure for 24 hours after completion.
The DRAPS Division reserves the right of declining to carry out a repair on a line which is found in a condition rendering it unsafe for use.
Except in exceptional circumstances, the DRAPS Division will not proceed with any repair on lines which do not meet
current industry standards or Technip's internal standards. (For unused lines, see Section 6.9).
24
6.
INSPECTION AND TESTING OF LINES
6. Inspection and
testing of lines
6.1
INTRODUCTION
This section details the actual inspections and tests recommended by the DRAPS Division to ensure the continued
safe use of our drilling and service application flexible lines.
It defines precisely what is meant by the terminology used by the DRAPS Division for each type of inspection and/or
test and therefore allows End Users to know the extent or limitation of each procedure.
The very nature of a flexible pipe's construction and that of its end-fittings does not allow a detailed examination of
all of the internal components, and therefore we rely heavily on external examination and regular pressure testing.
It will be noted that the DRAPS Division recommends End Users, whenever possible, to have this inspection and testing
work carried out by the manufacturer. Under such circumstances, Technip's DRAPS Division will issue a certificate detailing the inspection and/or testing work performed on each line.
Circumstances may make this impractical and, in such instances, the DRAPS Division relies on the End User's QA/QC
system, together with their experience of using these lines, to ensure that they remain fully functional.
The recommended periodicity of each inspection or test varies depending on the application, and the relevant section
(7 to 10) should be referred to for each type of line whilst reading this section to know the circumstances applicable
to each inspection or test procedure.
INSTRUCTION: although common practice for most Users of such flexibles, it is strongly recommended that a record
of all service work should be maintained for each line.
6.2
ROUTINE VISUAL INSPECTION
6.2.1 EXTERNAL INSPECTION
A visual inspection throughout the entire length of the line should include:
Stainless steel outer wrap: the outer wrap must always ensure its primary function which is to protect the polymeric sheath underneath from being torn or punctured.
Check that the carcass is properly attached at both end-fittings
Check that the entire surface of the polymeric sheath is protected
Check, if any damage is noticed on the stainless steel outer-wrap, that it would not be detrimental to the underlying external polymeric sheath (deep notches or cuts for example)
Termination: record any damage to the coating on the end-fitting, and follow its progression, if any.
Connector: same as above, with particular attention to the seal area.
6.2.2 INTERNAL INSPECTION
A visual inspection of the inner surface of the end-fitting is to be carried out after cleaning, to check that it is free of
cracks and that the corrosion resistant coating is undamaged. In case of cracks or severe abrasion, the line should be
removed from service and a more detailed inspection should be performed by the manufacturer.
For Choke and Kill or Test Lines, inspection should show that they are free from any collapse of the internal lining,
this may be verified by either visual inspection or internal pigging or gauging.
25
6.3
FULL INSPECTION
A full inspection includes at least:
Entire external inspection;
Entire internal inspection
Full pressure test at OEM test pressure for a period of 24 hours
Technip's DRAPS Division recommends that this inspection should be done by the DRAPS Division at a convenient
DRAPS Division facility.
However, it must be recognised that this may be impractical according to the drilling programme schedule or location. If so, this full inspection should be carried out by a competent person who is qualified by the End User's QA/QC
system (See also Para. 6.5).
6.4
MANUFACTURER'S INSPECTION - MAJOR SURVEY
In accordance with the certifying authorities' specifications or the DRAPS Division's recommendations, or in the event
of any doubt on a line's integrity, the line may be inspected by the DRAPS Division at a suitable DRAPS Division facility.
This inspection will include, as a minimum:
Entire external inspection
Entire internal inspection
Bending at the minimum bending radius
Pressure test at OEM test pressure for a period of 24 hours
6.5
FIELD PRESSURE TESTING (OPTIONAL)
Performed on Choke and Kill lines at least on an annual basis and only in those circumstances where the full inspection proves impractical to perform (see Section 7 - Para. 7.5.3). It should include:
A routine visual inspection as detailed in 6.2.1.
A field pressure test (Section 7 - Para. 7.5.5) should be performed at 1.5 times working pressure and recorded for a
period of six (6) hours. The purpose of the pressure test is to ensure that no damage has occurred to any part of
the line’s structure, or excess load applied, which could result in an insufficient pressure containing capability both
at the time of the test and for the next year that the line is in service.
In those circumstances where a full inspection is impractical due to the above limitations and where regular pressure
testing is performed as part of the End User's QA/QC approved testing procedure, the safety factor and recorded
test period may be reduced accordingly i.e. as an alternative to a 6 hour recorded test at 1.5 x maximum working pressure every year, a one hour recorded test at 1.1 x maximum working pressure every month may be used, thus reducing
the safety factor from 1.5 to 1.1 and the equivalent period in between recorded tests from one year to one month. The
decision to adopt one or other of these testing procedures as an alternative to the full inspection rests entirely with
the End User and their own QA/QC system, and they must be performed in accordance with all applicable safety
procedures.
Note The above testing (6.5) is an alternative to the full inspection, strictly due to the rig limitations detailed in
Section 7 - Para. 7.5.5. of the guidance on Choke and Kill lines only. Wherever possible, the recommendations
on the annual full inspection should be adhered to.
26
6.6
FULL PRESSURE TEST
A full pressure test is performed at the OEM test pressure (1.5 times the maximum working pressure (MWP) of the line
or 2 times MWP for 345 bar / 5,000 psi WP lines) for a minimum of 24 hours.
Permissible test media are drilling muds, oil or water.
The following precautions should always be respected when performing a pressure test.
All personnel involved in the preparation and execution of the test must be trained and aware of the possible consequences of a test failure
Gas is not allowed as a test media; all entrapped gas MUST be bled off during the pressurisation of the line
Test area must be cordoned off, and access restricted throughout the duration of any test
Nobody, including personnel involved in the completion of the test, must stand near the line under pressure
INSTRUCTION: these tests are carried out at the End User's risk. It must be stressed that a catastrophic burst can be
the result of these tests (although extremely unlikely on well maintained flexibles), and that all precautions MUST be
taken to avoid damage and/or injury (see Section I - Para. 1.7 FAILURE MODES OF COFLEXIP® FLEXIBLE LINES).
6.7
RECORDING OF INSPECTIONS AND TESTS
All routine inspections must be properly recorded as per the End User's QA/QC procedures, detailing identification
of the line, inspection, findings and test results.
All full inspections must be properly documented including the details of findings, repairs done and pressure test certificates.
All inspections are to be recorded by the End User's QA/QC system.
Where any or all of the tests and/or inspections are performed by the DRAPS Division either on site or at a DRAPS
Division facility, an inspection report and findings, together with details of repair/refurbishment work performed and
pressure test recordings will be supplied to the End User. Third party verification of such work/testing is normally
provided as standard.
6.8
PERIODICITY OF INSPECTIONS AND TESTS
Refer to the line application.
Section 7:
Choke and Kill lines
Section 8:
Test lines
Section 9:
Acidizing/fracturing lines
Section 10:
Drag chain lines
6.9
UNUSED LINES
It is sometimes the case that, for a variety of reasons, a line may remain unused for a considerable period of time after
delivery. In such instances, no inspection or testing is required during this storage period as long as normal protective
precautions are observed. (See Section 2.1 - General guidelines: Storage). The term "unused" is taken to mean a line
which remains in its original delivery condition and has never been installed or used for any purpose except, for example,
assembled within a DRAG CHAIN system and not installed on the platform since OEM pressure test. After first use, it
is assumed that an inspection and test record would be established in accordance with the recommendations made
in this User's Guide. Nevertheless, it is the End User’s responsibility to check whether the line still meets the current
Industry standards.
27
7.
CHOKE AND KILL LINES
7. Choke and kill lines
7.1
DEFINITION
7.1.1
Choke and kill lines
Choke and Kill lines are an integral part of the blow-out prevention equipment required for drilling well control.
The Kill line provides a means of pumping fluid into the well bore when normal circulation through the drill string
cannot be employed.
The high pressure choke line, which is connected between the well and the choke manifold, provides a means for
applying back pressure into the formation while circulating out the formation fluids, consisting mainly of water, gas
and/or oil, that entered the wellbore following a “kick”. Such an inflow occurs if the drilling fluid's hydrostatic pressure, at the face of the well bore, is less than the pressure of the formation fluid. Hence, further inflow is prevented
by imposing the additional back pressure from the choke into the formation. Failure to control a “kick” would result
in a “blow-out” i.e. the uncontrolled release of formation fluids.
Depending upon the type of rig where they are installed, the flexible Choke and Kill lines are either “static” or “dynamic”.
A “dynamic” use is required to accommodate continuous relative motions of the connections on floating rigs while
“static” lines are used onshore and on fixed platforms and jack-ups to interconnect equipment and piping that may
experience positioning/dimensional variations
On semi-submersible drilling rigs or drill-ships, there are two primary locations for Choke and Kill lines, “moonpool”
lines used above surface to accommodate rig motion in all three planes, and BOP stack lines used on the LMRP (Lower
Marine Riser Package) to allow for movement of the Choke and Kill lines around the ball-joint or flex-joint.
The majority of Coflexip® flexible Choke and Kill lines are designed to meet the API 16C specification (See Section 1 Para 1.1) and to resist a continuous dynamic use.
7.1.2 Cement lines
Cementing operations are regularly carried out using flexible Choke and Kill lines. In addition, specific flexible lines are
often used, particularly in the derrick, to pump cement into the well casing. For this reason, the DRAPS Division considers that cement lines require to be interchangeable with Choke and Kill lines.
All cement lines supplied for a specific working pressure may be used to the same pressure in Choke and Kill operations, and vice versa.
It should be noted that earlier cement lines were sometimes also used for acidizing/fracturing operations and as such
would have had a different thermoplastic liner.
INSTRUCTION: one should always check the temperature and pressure ratings before using cement lines in well
control operations.
7.2
SOUR SERVICE
Generally, all kinds of drilling muds and oil production fluids may be transported through Choke and Kill lines (See
Section 3 - Para 3.1). As the lines may be used in areas where sour service is required, all Coflexip® Choke and Kill lines
are classified Sour Service.
All steel components of the flexible lines directly exposed to the Internal fluid meet NACE MR-01-75, 2001 edition.
However, the behaviour of a flexible line involving the use of steel and thermoplastics is complex and Users must be
aware that Coflexip® lines manufactured earlier are not necessarily designed for a permanent exposure to sour
fluids.
INSTRUCTION: the use of a Choke and Kill line as a Test line is unsafe and must be prohibited.
28
7.3
COMPLETION FLUIDS
It may be a requirement for a variety of completion fluids to be pumped through the flexible lines. Many of these
fluids contain acids, zinc bromide, etc. These products may not be compatible with the thermoplastic liner of the
Coflexip® Choke and Kill lines. Please refer to the fluids compatibility charts in Section 3.
7.4
VENTING
Coflexip® Choke and Kill lines are not vented.
7.5
PERIODICITY OF FIELD TESTING AND INSPECTION
7.5.1 After installation pressure test
After installation, the Choke and Kill lines (both surface and subsea) should be tested according to the relevant API
recommendations such as API RP53.
7.5.2 Routine visual inspection (Section 6 - Para 6.2.1)
An external visual inspection of the Choke and Kill lines should be performed:
At the end of a drilling campaign or,
At a one (1) month interval or,
At the first opportune moment after a kick has occurred, but no more than one (1) month after. This inspection is
to be recorded by the End User's QA/QC system.
Refer also to Section 7.5.6 for subsea lines.
7.5.3 Full inspection (Section 6 - Para 6.3)
A full inspection must be performed on a yearly basis. Technip's DRAPS Division recommends that this inspection is
done by the DRAPS Division at a convenient facility, when and where practicable (for alternative testing where the
full pressure test proves impractical, see field pressure testing below - 7.5.5).
7.5.4 Manufacturer's inspection - major survey (Section 6 - Para. 6.4)
Technip's DRAPS Division recommends that a first major survey be performed five (5) years after the date of initial
OEM Pressure Test. A second major survey should be performed three (3) years later, i.e. eight (8) years after the initial
OEM Pressure Test. Following this second major survey, and dependent on the results of such survey, the DRAPS
Division will at that time make recommendations to periodicity of further major inspections.
7.5.5 Field pressure testing (optional) (Section 6 - Para. 6.5)
It is recognised by the DRAPS Division that due to a rig's location, lack of pressure testing and/or inspection facilities,
it is either inconvenient to return a line to the DRAPS Division or impossible to perform a full inspection on board the
rig. Under these circumstances, a FIELD PRESSURE TEST (Section 6 - Para. 6.5) may be performed as a minimum test
requirement and as an alternative to the recommended full inspection, it can only be carried out on a maximum of
two consecutive annual occasions i.e. a maximum of three (3) years between full inspection.
29
7.5.6 Subsea (BOP stack) Choke and Kill lines
By virtue of their location, BOP stack lines differ from moonpool lines in the following ways:
They are much shorter (typically 3.5 - 6 metres (12 - 20 feet) overall length) and are not subjected to the same degree
of dynamic motion as moonpool lines.
Being custom-built to fit each stack and being relatively short, their length tolerances are more critical than those of
moonpool lines (typically 17 - 27 metres (55 - 90 feet) overall length).
INSTRUCTION: BOP stack lines cannot be re-used on another stack without a detailed study confirming the lines are
compatible with the new installation. In case of doubt please contact the nearest DRAPS Division office.
Installation subsea means that these lines are difficult, if not impossible, to visually inspect. Furthermore, recovery to
the surface in order to carry out inspection work and testing is both time consuming and expensive. Experience has
shown that, assuming the configuration design is strictly adhered to, a combination of less dynamic movement plus
a reduced risk of damage by mishandling or misuse, means that they are a lot less prone to failure as a result of mechanical damage.
Technip's DRAPS division would, as a result of these factors expect that End Users, their QHSE systems and their certifying authorities to be diligent in conducting regular inspection and testing work. Normally such work should be
performed on a opportune basis when other works necessitate the recovery of the BOP stack for disassembly, testing
and/or refurbishment.
30
8.
T E ST L I N E A P P L I C AT I O N S
8. Test line applications
8.1
"DST" AND "PTL" LINES DEFINITION
The conventional methods of performing a test on a formation before installing the final completion equipment is
the Drill Stem Test which may be carried out through flexible steel lines, thus providing a single length, two connection only section of piping which is both safe and easy to install. Usually a Drill Stem Test is a short test which lasts
less than 72 hours. The flexible line designed for such an application is the "DST" flexible line.
Production tests done on a well any time after the completion are very similar, but they may last longer. The Coflexip®
flexible line designed for that application is the "PTL" line.
8.2
SOUR SERVICE
All steel components of DST and PTL Coflexip® flexible lines, terminations and connectors directly exposed to the
internal fluids meet NACE MR-01 -75.
DST lines are designed for temporary and not permanent exposure to sour service.
INSTRUCTION: each individual Drill Stem Test should not exceed 72 hours.
PTL lines are designed for a permanent exposure to sour service. For this reason, PTL lines can be used for Drill Stem
Test applications whilst DST lines cannot be used for long production test applications in excess of 72 hours.
8.3
VENTING
Both DST and PTL flexible lines are vented.
Venting: Coflexip® Test Lines include an independent and automatic method to de-pressurise the flexible pipe body
in the event of pressure build up caused by permeated gas; this process is called venting.
INSTRUCTION: under no circumstances should vented lines be used under water nor should either of their extremities be immersed. This could lead to long term corrosion of the armour wires and risk of failure. (See Section 1 Para. 1.7 FAILURE MODES OF COFLEXIP® FLEXIBLE LINES)
8.4
After installation in the test system hook-up, the flexible test line should be tested in accordance with API recommendations on blow-out prevention system operation tests (AP1 - RP53).
8.4.2 Routine external visual inspection (Section 6 - Para 6.2)
The external visual inspection of the DST and PTL flexible line should be performed after completion of each test
programme or at a one (1) month maximum interval.
8.4.3 Full inspection (Section 6 - Para 6.3)
A full inspection, including the internal inspection and an OEM pressure test must be performed on a yearly basis.
Technip's DRAPS Division recommends that this inspection is done by the DRAPS Division at a convenient DRAPS
Division facility, when and where practicable.
8.4.4 Manufacturer's inspection - Major survey (Section 6 - Para 6.4)
Technip's DRAPS Division recommends that at least one major survey is done by the DRAPS Division at a convenient
DRAPS Division facility during the first 10 years, preferably in the range of 3 to 6 years after the OEM pressure test.
31
9.
ACIDIZING AND FRACTURING LINE
A P P L I C AT I O N S
9. Acidizing and
fracturing line applications
9.1
DEFINITION
Oil and gas wells require regular maintenance and servicing throughout the life of the well. This can involve pumping
fluids, foam or gas containing treatment materials into the well. These operations start during the drilling phase of the
well with operations such as cementing. During the production phase, they include acid and proppant stimulation,
water and sand control, as well as fluid support for workover operations. At the end of a well's economic or practical
life, the services cover killing and abandonment operations. Well service operations therefore involve using piping to
pump into a well as opposed to extracting from it.
9.1.1 Handling
INSTRUCTION: the handling of the Coflexip® flexible lines should be carried out by qualified and trained personnel
using adapted lifting/handling equipment.
The deployment of the flexible lines should be carried out following the End User's operating procedures in which all
safety aspects should be covered.
When connecting acidizing lines from independent vessels to platforms, the lines should be connected to the platform pipe work through an external connection point capable of bearing the loads applied by the flexible pipe.
It must be noted that the flexible pipe must never be considered as the weak point of a system, its breaking
load being several hundred tons.
When the flexible pipe is deployed from a winch, the whole length of pipe MUST be paid out so that the QCDC
(Quick Connect Dis-Connect) or QDC (Quick Dis-Connect) assembly is allowed to operate in a fast and reliable manner.
Relying on the freewheeling of the winch can at best cause some loss of time in circumstances where time is critical.
A guide system should be fitted as part of the winch installation which ensures that the flexible pipes approach angle
with the winch drum is kept within reasonable limits, thus ensuring correct operation of the emergency disconnect
system when required.
9.1.2 Well service operations
These operations, normally involve pumping treatment materials for short periods of time, usually less than 24 hours.
Flexible lines may be any of the three liner types i.e. HDPE, Rilsan® or Coflon® depending on service type. Acidizing/
fracturing lines are either HDPE or Coflon®, the latter being a "dual-purpose" designation, capable of handling acids,
produced well fluids and heavy metallic salts such as calcium or zinc bromide (See Section 3 - Para. 3.1). Temperature
ranges for these operations are given in Section 3 - Para. 3.2.
9.1.3 Dynamic operations
Such operations involve the use of the flexible lines to compensate for relative motion between the two connection
points. An example is the servicing of wells from a floating service vessel to a fixed production platform: such an application can be highly dynamic and applies a tremendous strain on the pipe's mechanical properties.
9.1.4 Static operations
These normally involve small or negligible amounts of relative movement during hook-up, the lines being used to
accommodate dimensional variations between fixed points in hard piping or for equipment connection.
32
9.2
SOUR SERVICE
All steel components of acidizing/fracturing and well service Coflexip® flexible line terminations and connectors
directly exposed to the internal fluids, meet the requirements of NACE MR-01 -75.
Lines designated "ACD" i.e. acidizing/fracturing are unsuitable for any service where produced well fluids or gases are
present. For this reason, the steels used for the fabrication of these lines do not necessarily meet the requirements
of NACE MR-01 -75. Other lines with Coflon® or Rilsan® liners can be used for temporary or permanent sour service
(see Section 8 - Test line applications).
9.3
VENTING
Acidizing/fracturing flexible lines are not vented. Coflon® flexible lines when sold as acid lines only are not vented,
but when required for "dual-purpose" i.e. DST or PTL applications in addition to acidizing/fracturing, venting is included
- refer to OEM pressure test certificate or line data book for precise application, alternatively contact nearest DRAPS
Division office with line serial number for further details.
INSTRUCTION: under no circumstances should vented lines be used under water nor should either of their extremities be immersed. This could lead to long term corrosion of the armour wires and risk of failure. (See Section 1 Para. 1.7 FAILURE MODES OF COFLEXIP® FLEXIBLE LINES)
9.4
9.4.1 Flushing of the lines
INSTRUCTION: after completion of any of the above operations, the lines should be thoroughly flushed with water.
9.4.2 Routine external visual inspection (Section 6 - Para. 6.2)
The external visual inspection of the acidizing/fracturing line should be performed:
Short lengths (static operations): prior to each hook-up and at one (1) month intervals after hook-up
Long lengths (dynamic operations: vessel or winch-mounted acid lines). During deployment from winch to rig
connection and during re-spooling on to winch
All acidizing/fracturing lines whether short or long length, should be pressure tested after installation and prior to
operating under pressure, at 1.1 x the maximum expected working pressure.
9.4.4 Full inspection (Section 6 - Para. 6.3)
A full inspection must be performed on a yearly basis. Technip's DRAPS Division recommends that this inspection is
done by the DRAPS Division at a convenient DRAPS Division facility, when and where this is practicable.
9.4.5 Manufacturer's inspection - Major survey (Section 6 - Para. 6.4)
Technip's DRAPS Division recommends that at least one major survey is done by the DRAPS Division at a convenient
DRAPS Division facility during the first 10 years, preferably in the range of 3 to 6 years after the OEM original pressure
test.
33
10.
D R AG C H A I N O P E R AT I O N S
10. Drag chain
operations
10.1
DEFINITION
Drag chain applications are specific to any flexibles which are installed within a drag chain system.
These can be lines used for choke, kill, mud, cement, test and well completion fluid or other services, and as such are
governed by Sections 1 to 6 inclusive of this User's Guide.
The drag chain itself also provides a supplementary mechanical protection outside the stainless steel outer wrap, thus
the risk of external mechanical damage is significantly reduced.
Furthermore, each flexible length is specifically engineered to fit between the 2 rigid connection points; it is the low
diametric and longitudinal expansion factors which make flexible steel pipes particularly suitable for these locations.
The flexibles, once installed in the drag chain and hooked-up at each end, are in a controlled, protected environment
and therefore the inspection and test requirements are different to other installations.
10.2 PERIODICITY OF FIELD TESTING AND INSPECTION
10.2.1 After platform installation and hook up
The high pressure flexibles, once fitted into the drag chains are installed as a package on to the platform and hooked
up to the rigid piping at each end via the adapters.
All lines should then be tested in accordance with the relevant API recommendations such as API RP 53. Alternatively,
it is recommended that these lines are tested at a minimum of 110 % of the maximum expected working pressure.
10.2.2 Routine visual inspection (Section 6 - Para. 6.2)
The external visual inspection of the drag chain lines should be performed:
At platform installation upon completion of hook-up
At subsequent 6 monthly periods, or after each skidding operation whichever comes first
After any intervention or maintenance on the drag chain itself
For Choke and Kill lines, at the first opportune moment after a kick has occurred, but no more than 1 month after.
This inspection is to be recorded by the End Users QA/QC system.
10.2.3 Yearly test
On a yearly basis, from date of initial platform hook-up, Technip's DRAPS Division recommends that all Coflexip® lines
are pressure tested at 110 % of the maximum expected working pressure, in order to verify the integrity of the lines.
34
11.
S U M M A RY O F I N ST R U C T I O N S
11. Summary of
instructions
Page 11 - PARA 1.3.5: for long lines (acidizing lines for example) typically lines longer than 25m (80'), the End User should refer
to the DRAPS Division for advice on limitations in the use of the standard handling collars. Special collars can be designed
for specific needs.
For further details on Acidizing Applications see Section 9.
Page 13 - PARA 1.6:
WARNING: you must be aware that a Coflexip® flexible can be stronger than some of the pipework to which it is connected and that it will rarely be the "weak point" of a system.
Page 16 - PARA 2.1: a similar protection should be reinstalled when the line is disconnected. It may consist in a metallic blind
flange that fits the connection - which is preferable, or of a good wooden protection.
This protection must ensure that:
> The inner bore of the line is closed to avoid accidental intrusion of any foreign material
> The connector, especially the seal area, is properly protected against impacts, etc.
Page 16 - PARA 2.1: if stored below minimum rated temperature, ensure that no handling is done before the line is brought
back to the minimum rated temperature.
Page 16 - PARA 2.1: the inner bore of a Coflexip® line should be thoroughly flushed with fresh water prior to long term
storage.
Page 16 - PARA 2.2: only qualified and trained personnel should handle flexible lines such as those manufactured by
the DRAPS Division. Whilst we make every effort to assist End Users whenever possible on the methods of handling
to be deployed, the final decision on the best methods for local conditions and capacities rests with End Users or
their appointed agents, either of whom should have their own procedures for such handling operations.
Any rigging should be suitably adapted to the specific flexible line in question, as mishandling can be dangerous to
operations, surrounding personnel, equipment and property.
The line must never be bent below the minimum bend radius (MBR), as this may damage it.
As a rule of thumb, the minimum bend radius is equal to:
MBR = 12 x ID
The accurate value of the MBR of the line is part of the technical characteristics of the Coflexip® structure and
will have been supplied to the original End User: it can be obtained from the nearest DRAPS Division office.
The MBR must be respected at all times, whether the line is under pressure or not.
User should avoid bending the flexible just behind the end-fitting. As a rule of thumb, a straight length of about
0.6 to 0.9 metre (2 to 3 feet) should be used as a safety distance.
See section 1.7 - FAILURE MODES OF COFLEXIP® FLEXIBLE LINES
The use of wire ropes or chains may damage the anti-corrosion treatment of the end-fitting. If so required, use a
shackle connected through the eye of the handling collar. Never use wire ropes or chains directly against the stainless steel outer-wrap. If force needs to be applied to the body of the flexible line itself, use soft slings.
Moving flexible line on the ground
Do not attach slings directly to the end-fitting - use the handling collar provided. Always connect slings to both
eyes in order to have the pulling force in a straight line through the main axis of the flexible pipe.
Prevent abrasion of the flexible line against the ground; use wooden supports or planks.
If a forklift has to be used to lift a flexible line, soft slings must be used to prevent damage, and to prevent the
flexible line from falling off the forks (see the DRAPS Division Handling on the schematics inside the rear of this
Guide). End User assumes all responsibility for essential safety precautions to avoid injury or death in connection with these operations.
Page 17 - PARA 2.3: the best way to achieve this is to support the weight of the line through the use of the handling collar,
then control the alignment with a non-metallic rope or sling attached about 0.9 metres (3 feet) behind the end-fitting.
Page 18 - PARA 3: these lines must never be used for any purpose other than the original for which the line was supplied
and which is stamped on the end-fitting fitting identification collar (see Section 1.3). In case of doubt, contact the nearest
DRAPS Division office for information on guidelines to be respected.
35
Page 18 - PARA 3.1: in case of doubt please contact the nearest DRAPS Division office.
Page 23 - PARA 4: flexible lines removed from service upon expiration of the service life should be stamped "NOT
REUSABLE" or preferably cut into pieces.
Any line which reaches 20 years since its OEM pressure test, and which continues to function correctly, should be
returned to the DRAPS Division for investigation and recommendation on its continued use.
During this 20 year period, it is probable that a considerable number of design changes will have been made, and regulations or recommendations on the use of any particular application are likely to have changed: a combination of
these factors may make it impossible to recommend any further use of a particular line.
Page 25 - PARA 6.1: although common practice for most Users of such flexibles, it is strongly recommended that a
record of all service work should be maintained for each line.
Page 27 - PARA 6.6: these tests are carried out at the End User's risk. It must be stressed that a catastrophic burst can
be the result of these tests (although extremely unlikely on well maintained flexibles), and that all precautions MUST
be taken to avoid damage and/or injury (see Section I - Para. 1.7 FAILURE MODES OF COFLEXIP® FLEXIBLE LINES).
Page 28 - PARA 7.1.2: one should always check the temperature and pressure ratings before using cement lines in well
control operations.
Page 28 - PARA 7.2: the use of a Choke and Kill line as a Test line is unsafe and must be prohibited.
Page 30 - PARA 7.5.6: BOP stack lines cannot be re-used on another stack without a detailed study confirming the
lines are compatible with the new installation. In case of doubt please contact the nearest DRAPS Division office.
Page 31 - PARA 8.2: each individual Drill Stem Test should not exceed 72 hours.
Page 34 - PARA 8.3: under no circumstances should vented lines be used under water nor should either of their extremities be immersed. This could lead to long-term corrosion of the armour wires and risk of failure (See Section 1 Para. 1.7 FAILURE MODES OF COFLEXIP® FLEXIBLE LINES).
Page 32 - PARA 9.1.1: the handling of the Coflexip® flexible lines should be carried out by qualified and trained personnel
using adapted lifting/handling equipment.
The deployment of the flexible lines should be carried out following the End User's operating procedures in which all
safety aspects should be covered.
When connecting acidizing lines from independent vessels to platforms, the lines should be connected to the platform pipe work through an external connection point capable of bearing the loads applied by the flexible pipe.
It must be noted that the flexible pipe must never be considered as the weak point of a system, its breaking
load being several hundred tonnes.
When the flexible pipe is deployed from a winch, the whole length of pipe MUST be paid out so that the QCDC
(Quick Connect Dis-Connect) or QDC (Quick Dis-Connect) assembly is allowed to operated in a fast and reliable
manner.
Relying on the freewheeling of the winch can at best cause some loss of time in circumstances where time is critical.
A guide system should be fitted as part of the winch installation, which ensures that the flexible pipes approach angle
with the winch drum is kept within reasonable limits, thus ensuring correct operation of the emergency disconnect
system when required.
36
Page 33 - PARA 9.3: under no circumstances should vented lines be used under water nor should either of their extremities be immersed. This could lead to long term corrosion of the armour wires and risks of failure. (See Section 1 Para. 1.7 FAILURE MODES OF COFLEXIP® FLEXIBLE LINES).
Page 33 - PARA 9.4.1: after completion of any fracturing and/or acidizing operations, the lines should be thoroughly
flushed with water.
REMINDER:
Technip's DRAPS Division MAKES NO REPRESENTATION OR WARRANTY SAVE AS EXPRESSLY AGREED IN WRITING
WITH END USER.
NOTES
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38
HANDLING, STORAGE
AND MAINTENANCE
For handling, storage
and maintenance, see Section 2
WRONG
RIGHT
1
Minimum
bend
radius
Minimum
bend
radius
2
3
4
Short lengths 20 ft, or less
Medium lengths
5
Long lengths
Minimum
bending
radius
3 x O.D.
of pipe
Drilling & Refining Applications Division - Worldwide presence
Flexi France
Rue Jean Huré - 76580 Le Trait
France
Phone: +33 (0)2 35 05 50 85
Fax: +33 (0)2 35 05 50 17
Technip Offshore UK Ltd
Enterprise Drive,
Westhill Industrial Estate,
Westhill, Aberdeen AB32 6TQ
United Kindom
Phone: +44 1224 271 374
Fax: +44 1224 407 671
Duco Inc.
16661 Jacintoport Blvd.
Houston, TX 77015
United States
Phone: +1 281 249 2900
Fax: +1 281 452 6100
Coflexip Singapore Pte Ltd.
Loyang Offshore Supply Base
Box 5161 Singapore
Singapore
Phone: +65 6546 9100
Fax: +65 6546 9122
With a workforce of over 21,000 people, Technip ranks among the top five corporations in the field of oil, gas
and petrochemical engineering, construction and services. Headquartered in Paris, the Group is listed in New
York and Paris. The Group's main operations and engineering centers and business units are located in France,
Italy, Germany, the UK, Norway, Finland, the Netherlands, the USA, Brazil, Abu-Dhabi, China, India, Malaysia
and Australia. In support of its activities, the Group manufactures flexible pipes and umbilicals, and builds
offshore platforms in its manufacturing plants and fabrication yards in France, Brazil, the UK, the USA, Finland
and Angola, and has a fleet of specialized vessels for pipeline installation and subsea construction.
Technip Abu Dhabi
NBAD Tower
Khalifa Street, 19th Floor
PO Box 7657
Abu Dhabi
United Arab Emirates
Phone: +971 2 611 6000
Fax: +971 2 611 6111
SEAMEC
(a member of the Technip Group)
401-404, 4th Floor,
The Eagle's Flight, Suren Road
Off. Andheri-Kurla Road,
Andheri (East)
Mumbai 400 093
India
Phone: +91 22 6694 1800
Fax: +91 22 6694 1818
This document is the property of Technip and is
not intended to be a binding contractual
document.
Any information contained herein shall not result
in any binding obligation on the part of Technip,
or any of its affiliates, and is provided for
information purposes only.
Technip - Public Relations Department - September 2006 - Photo credits: Technip
Headquarters
Technip
Tour Technip
6-8 allée de l’Arche
92973 Paris La Défense Cedex
France
Phone: +33 (0)1 47 78 21 21
Fax: +33 (0)1 47 78 33 40
www.technip.com

Coflexip® Flexible Steel Pipes for Drilling and Service

Transcription

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