User`s Guide

Transcription

User`s Guide

Engineering and technologies
User’s Guide
Coflexip® Flexible Steel Pipes for
Drilling and Service Applications
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.
Engineering and technologies
Coflexip® Flexible Steel Pipes for
Drilling and Service Applications
Coflexip® flexible
pipe for drilling and
service applications is
manufactured by
Technip for Coflexip®
Products Division.
2
Drilling and Service Applications - User’s Guide
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 Sour service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.1.5 Flow rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.2 TEMPERATURE RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.2.1 Standard temperature rated line (-20°C to +100°C / -4°F to +212°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.2.2 High temperature rated Line (-20°C to +130°C / -4°F to +266°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.2.3 High temperature Exposure Test of Choke and Kill Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.2.4 Low temperature use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3
3.3 PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.3.1 Rated working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.3.2 OEM test pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.3.3 Ultra Deepwater End Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 and mud 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 Field pressure testing (Section 6 - Para. 6.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.5.4 Manufacturer's inspection - major survey (Section 6 - Para. 6.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.5.5 Moonpool Choke and Kill lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7.5.6 Subsea 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 COFLEXIP® BLACK PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
11
DRAG CHAIN OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
10.1 DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
10.2.1 After platform installation and hook up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
10.2.2 Routine visual inspection (Section 6 Para. 6.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
10.2.3 Yearly test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
12 SUMMARY OF INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
5
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
MAWHP: Maximum Anticipated Wellhead Pressure
MWP:
Maximum Working Pressure
NACE:
National Association of Corrosion Engineers
OD:
Outer Diameter
OEM:
Original Equipment Manufacturer
OEM TP: Original Equipment Manufacturer Test Pressure
ROV:
Remotely Operated Vehicle
PTL:
Production Test Line
QCDC:
Quick Connect Dis-Connect
QDC:
Quick Dis-Connect
TP:
Test Pressure
UDW:
Ultra Deepwater
WP:
Working Pressure
6
0. 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 6 of the guide originally issued in 1989 revised in 1990, 1993, 2002 and in 2006.
The main purpose of this revision is to modify inspection and operational recommendations, based on field experience and
Technip’s policy of continual research into the safe application of flexible pipes. Additionally, inclusion of land/topside
specific flexibles and ultra deepwater end fittings has been added.
Coflexip® flexible steel pipe products are manufactured by Technip.
Coflexip® recognises the fact that the majority of our clients have used Coflexip® drilling & service 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
Coflexip® products as described in this Guide.
Technip 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, 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 Technip office listed on the back cover of this Guide.
TECHNIP 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 TECHNIP 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/draps
7
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. Mud and cement application flexible pipes are also qualified to meet
API 7K standard. Some of the API 16C requirements do not apply to other applications where Coflexip® 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 the current edition of API 16C.
1.2
NACE COMPATIBILITY
End-fittings: all steel materials used in the manufacture of an end-fitting meet the requirements of
NACE MR-01-75.current edition/ISO 15156….
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/
ISO 15156 current edition.
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. Technip 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 an 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, hammer unions
and API flanges. Generally the connectors are integral parts of the end-fitting avoiding butt-welding (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 Technip 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
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, Technip 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 Technip 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
TECHNIP
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
Technip 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.
The standard handling collars are designed for a maximum safe working load of 3
metric tons.
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.
Lifting collars can be designed to meet specific End User needs when installation
or recovery of the flexible pipes requires a load capacity higher than the standard
collar can bear.
Classical Handling Collar
mounted on the End Fitting
INSTRUCTION: for long lines (acidizing lines for example), typically lines longer than 25m (80'), the End User should
refer to Technip for advice on limitations in the use of the standard handling collars. Special “lifting 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.
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.
(Note that test lines and Coflexip Black™/Coflexip Red™ 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 - Paragraph 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, when bent it will not tend to straighten under pressure. No
significant twist will 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 Technip’s documents, the minimum bending radius is abbreviated as MBR.
“d” is the minimum
inside distance
between the two
surfaces
MBR
OD
d = (2 MBR minus OD)
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 6 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.
INSTRUCTION: All Subsea lines, in line with rig operating procedures, should be flooded at all times, including during
the deployment of the drilling riser.
15
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
Technip. 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 Technip 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 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.
As a general rule the minimum acceptable bending radius for a
flexible pipe in operations should be 1.5 times the MBR. If impossible to meet, contact Technip for advice.
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.
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
R
MB
Figure 6
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. 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
Technip 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 Technip 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)
Tables I and II 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 Technip 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 11 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%
100%
saturated
saturated
saturated
100%
100%
100%
50%
< 20%
< 20%
Presence
Hydrochloric acid HCl
Hydrofluoric acid HF
Xylene C6 H4 (CH3)2
Methanol CH30H
Glycol
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
S
F
L
S
S
S
S
S
S
L*
L*
75°F
24°C
F
F
F
F
S
S
S
F
L
S
S
S
S
L
S
L*
L*
150°F
66°C
F
F
F
F
S
L
L
F
L
L
S
S
S
NR
S
L*
L*
200°F
93°C
F
F
F
F
S
NR
NR
F
L
L
S
S
S
NR
S
L*
L*
250°F
121°C
F
F
F
F
NR
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 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
Hydrochloric acid HCl
Hydrofluoric acid HF
Xylene C6 H4 (CH3)2
Methanol CH30H
Glycol
Zinc bromide ZnBr2
Calcium Bromide CaBr2
Calcium chloride CaCl2
Methane CH4
Diesel
Crude oil
Sodium hydroxide NaOH
Hydrogen sulphide H2S
S: Satisfactory
NR: Not Recommended
15%
30%
3%
7.5%
100%
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
S
75°F
24°C
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
F: Forbidden
150°F
66°C
S
S
S
S
S
S
S*
S
S
S
S
S
S
L
S
200°F
93°C
S
S
S
S
S
S
L*
S
S
S
S
S
S
NR
S
250°F
121°C
S
S
S
S
S
S
NR*
S
S
S
S
S
S
NR
S
* Line must be vented
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 Sour service
All components of the end-fittings and of the flexible pipe, in contact with the inner fluids, meet
NACE-MR-01-75/ISO 15156 current edition.
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 are tested as per the NACE requirements in force at manufacturing date.
The present steel wires used 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 Technip
office.
3.1.5 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
replace 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 +177°C / +355°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 Technip 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.
20
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 - Paragraph 3.1.3).
Higher temporary service temperature
When an application requires the exposure to a higher temperature than standard, Technip must be contacted on
a case-by-case basis with the expected parameters so that specific recommendations can be given, if possible.
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
Technip 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.
INSTRUCTION: Recommendations must be obtained from Technip BEFORE using a high temperature rated flexible
pipe outside the normal temperature range.
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, 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.
21
3.2.4. Low Temperature Use
Rilsan® flexibles may be stored and used in static and quasi-static applications at temperatures down to -40°C (-40°F). For Rilsan®
flexible use below -20°C (-4°F) please consult your local Technip office.
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
OEM. TP
517 bar/7,500 psi
1035 bar/15,000 psi
1550 bar/22,500 psi
Test duration: factory pressure tests last 24 hours after stabilisation at ambient temperature for standard lines, 6 hours for
Coflexip® Red™ products and 2 hours for Coflexip® Black™ products.
Note: the standard Technip FAT (Factory Acceptance Test) is well
in excess of the minimum requirement of API 16C & API 7K.
3.3.3. Ultra Deepwater End Fittings
Standard Coflexip® flexible steel pipes are designed to operate in depths over 2,000m (6,000 feet) and have proven their effectiveness in the deepest drilling operations to date.
In view of improving the capacity of our products, Technip has developed a new design of end fitting which not only allows deeper
operations, but also allows us to provide a positive seal against hydrostatic pressure ingress to a water depth of 3,000m (11,500 feet).
The new design of fittings is presently qualified to a depth beyond 3,000m (10,000 feet). The limits of this design are still being
tested but external pressure testing performed at 350 bar (equivalent to about 11,500 feet of water) provided satisfactory results.
22
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 Technip 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 Technip 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". Technip 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 Technip 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. 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 Technip or authorized Coflexip® line repair 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 the damaged
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 in accordance with section 3.3.2.
after completion.
Technip 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, Technip 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).
A list of all current Technip and Coflexip® Authorized Inspection, Maintenance & Repair (IMR) facilities can be found
at http://www.technip.com/draps
24
6. Inspection and testing of lines
6.1
INTRODUCTION
This section details the actual inspections and tests recommended by Technip 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 Technip 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 Technip recommends End Users, whenever possible, to have this inspection and testing work
carried out by the manufacturer or a Coflexip® line authorized testing facility. Under such circumstances, Technip will
issue a certificate detailing the inspection and/or testing work performed on each line.
Circumstances may make this impractical and, in such instances, Technip 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.
Note: Current Technip and Coflexip® authorized testing facilities list can be found at: http://www.technip.com/draps/
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 and liner is to be carried out after cleaning, to check that
it is free of cracks and liner deformation that the end-fitting corrosion resistant coating is undamaged. In case of cracks
or severe abrasion, the line shall be removed from service and a more detailed inspection shall be performed by the
manufacturer or authorized Coflexip® line testing facility.
For Choke and Kill or Test Lines, inspection should show that the internal lining is free from any collapse:
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 determined in paragraph 3.2.2.
Technip recommends that this inspection should be done by Technip or at an authorized Coflexip® line testing 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 Paragraph 6.5).
6.4
MANUFACTURER'S INSPECTION - MAJOR SURVEY
In accordance with the certifying authorities' specifications or Technip’s recommendations, or in the event of any doubt
on a line's integrity, the line may be inspected by Technip or at a convenient Coflexip® line testing facility.
This inspection will include, as a minimum:
Entire external inspection and stainless steel outer carcass repair, as necessary
Entire internal inspection
Pressure test at OEM test pressure for a period determined in paragraph 3.3.2 depending on the product type
Inspection, refurbishment or replacement of handling collars
Inspection and replacement of rear flange bolts, if necessary
6.5
FIELD PRESSURE TESTING (OPTIONAL)
Performed on High Pressure Drilling Application Lines only (Section 7 – Paragraph 7.5.3).
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 and one of the following alternatives may be substituted for no
greater than four consecutive years.
Option 1 - A field pressure test 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.
Option 2 - Pressure test frequency shall be in compliance with API 53 but with intervals no greater than one month
at MAWHP or MWP of the flexible, whichever is lower. A one hour test at MWP (after stabilization) of the flexible
shall be performed whenever the BOP is returned to the surface and prior to each deployment or annually, whichever
is greater.
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 - Paragraph 7.5.3. of the guidance on High Pressure Drilling Application 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) for a period
defined in section 3.3.2.
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
Flexible pipes must not be bent or coiled to less than 1.5 times MBR during pressure testing. Otherwise, no particular configuration requirements are necessary.
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 - Paragraph 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 Technip either on site, at a Technip or at an authorized Coflexip® line testing 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: Pressure Drilling Application 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 Guide. Nevertheless, it is the End User’s responsibility to check whether the line still meets the current Industry
standards.
27
7. High pressure drilling application 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 Paragraph 1.1) and to resist a continuous dynamic use.
7.1.2 Cement and mud lines
A flexible pipe used to convey high pressure drilling mud (or cement slurry in the case of cement lines) located anywhere in the high pressure mud piping system. The pipe may be used to accommodate relative movement, vibration,
misalignment and/or thermal expansion. All Coflexip® flexible mud and cement lines are designed to meet the API 7K
specification.
Note: All Standard Coflexip® lines are designed in line with API 16C. Lines manufactured for mud & cement applications may also be used for well control operations as long as the external marking instructions on the end
fitting are followed.
INSTRUCTION: one should always check the temperature and pressure ratings before using mud and/or 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 - Paragraph 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/ISO 15156 current
edition.
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 industry
accepted recommendations such as API 53.
7.5.2 Routine visual inspection (Section 6 - Paragraph 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. Field pressure testing (Section 6 - Paragraph 6.5)
It is recognised by Technip that due to a rig's location, lack of pressure testing and/or inspection facilities, it is either
inconvenient to return a line to Technip or impossible to perform a full inspection on board the rig. Under these
circumstances, a FIELD PRESSURE TEST (Section 6 - Paragraph 6.5) may be performed as a minimum test requirement.
It can only be carried out on a maximum of four consecutive occasions i.e. a maximum of 5 years between major
surveys.
7.5.4 Manufacturer's inspection - major survey (Section 6 - Paragraph 6.4)
Technip recommends that a first major survey be performed five (5) years after the date of initial OEM Pressure Test.
Following a major survey, and dependent on the results of such survey, Technip will at that time make recommendations to periodicity of further major inspections.
7.5.5. Moonpool lines
By virtue of their location, moon pool lines differ from subsea lines in the following ways:
They are much longer and are subjected to high dynamic motions. Damage to these lines by external causes occurs
from time to time, often by mishandling. For example, leaving the K&C lines hanging in the moon pool during transit
of the rig can cause problems, depending on the position of the lines. It is recommended that during transit the lines
are recovered and that a thorough external inspection is carried out.
Day to day inspection is possible for these lines as they are situated in the moon pool, but only very major damage
can be monitored from a distance. Therefore it isn’t possible to ascertain precisely the real state of the lines at a given
moment.
In conjunction with the recommendations of the API 53, Technip requires that a full external visual inspection is carried
out on a yearly basis as a minimum.
29
7.5.6 Subsea lines
By virtue of their location, subsea 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 - 45 metres (55 - 150 feet) overall length).
INSTRUCTION: Subsea lines cannot be re-used on another LMRP without a detailed study confirming the lines are
compatible with the new installation. In case of doubt please contact the nearest Technip office.
Recovering subsea lines 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 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, testing work, and recording of such. Normally such work should be
performed on a opportune basis when other work necessitates the recovery of the BOP stack for disassembly, testing
and/or refurbishment.
Furthermore, regular visual (ROV) inspections should be documented and recorded.
INSTRUCTION: Without exception there shall be no greater than 5 years between major surveys by OEM .
30
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/ISO 15156 current edition..
DST and PTL lines are designed for permanent exposure to sour service.
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 Paragraph 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 (API 53).
8.4.2 Routine external visual inspection (Section 6 - Paragraph 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 - Paragraph 6.3)
A full inspection, including the internal inspection and an OEM pressure test must be performed on a yearly basis.
Technip recommends that this inspection is done by Technip at a convenient Technip or authorized Coflexip® line
test facility, when and where practicable.
8.4.4 Manufacturer's inspection - Major survey (Section 6 - Paragraph 6.4)
Technip recommends that at least one major survey is performed by Technip or at a convenient Coflexip® authorized
test facility no more than 5 years from date of initial OEM pressure test. Following a major survey, and dependent on
the results of such survey, Technip will at that time make recommendations to periodicity of further major inspections.
31
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 shall be carried out by qualified and trained personnel
using adapted lifting/handling equipment.
The deployment of the flexible lines shall be carried out following the End User's operating procedures in which all
safety aspects shall 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 shall be completely 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.
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
Coflexip® acidizing/fracturing lines are Coflon® line, capable of handling acids, produced well fluids and heavy metallic
salts such as calcium or zinc bromide (See Section 3 - Paragraph 3.1). Temperature ranges for these operations are given
in Section 3 - Paragraph 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 required for "dual-purpose" i.e. DST or PTL applications in addition to acidizing/fracturing are vented -refer to OEM pressure test certificate or line data book for
precise application, alternatively contact nearest Technip 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 Paragraph 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 - Paragraph 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 - Paragraph 6.3)
A full inspection must be performed on a yearly basis. Technip recommends that this inspection is done by Technip
or at a convenient Coflexip® line authorized testing facility, when and where this is practicable.
9.4.5 Manufacturer's inspection - Major survey (Section 6 - Paragraph 6.4)
Technip recommends that at least one major survey is done by Technip at a convenient Coflexip® line authorized
testing facility no later than 5 years after the OEM original pressure test.
Following a major survey, and dependent on the results of such survey, Technip will at that time make recommendations to periodicity of further major inspections.
33
10. Coflexip® Black Products
10.1. DEFINITION
Coflexip® Black™ products are a more economical solution for land based and topside applications. These products
retain all of the strengths of a traditional Coflexip® pipe but removes the rear sealing of the end fitting making them
unsuitable for subsea applications or installation in a splash zone. The rear weatherproof seal is sufficient to provide
years of weatherproofing, while the front connection is as mechanically strong as the original.
Derivatives of Coflexip® Black™ products may be used for Choke/Kill, Well Testing & API 7K applications. The flexible
is designed and qualified in accordance with API 16C and may be monogrammed API 16C for Choke/Kill applications.
The flexible has also been designed and qualified in accordance with API 7K and may be monogrammed API 7K for
rotary, cement and mud applications.
All Coflexip® Black ™ Products have an integral Coflon® liner.
The OEM pressure test duration for Coflexip® Black™ Products is 6 hours after stabilization.
34
11. Drag chain operations
11.1
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.
11.2
11.2.1 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.
11.2.2 Routine visual inspection (Section 6 - Paragraph 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.
11.2.3 Yearly test
On a yearly basis, from date of initial platform hook-up, Technip 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.
35
12. 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 Technip 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 15: - PARA 1.7 INSTRUCTION: All Subsea lines, in line with rig operating procedures, should be flooded at all times,
including during the deployment of the drilling riser
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. 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 Technip 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 Coflexip® line 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.
36
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
Technip office for information on guidelines to be respected.
Page 18 - PARA 3.1: in case of doubt please contact the nearest Technip 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 Technip 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 mud and/or 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 Technip office.
Page 31 - 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.
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.
37
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 MAKES NO REPRESENTATION OR WARRANTY SAVE AS EXPRESSLY AGREED IN WRITING WITH END USER.
NOTES
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38
For handling, storage and maintenance,
see Section 2
WRONG
RIGHT
Minimum
bend
radius
Minimum
bend
radius
The soft slings on the crate are either for topling the crate or for the lid’s handling.
NEVER USE them to lift the crate
Do not weld parts
on to pipe or
endfittings
Unpacking guide
(is in the crate / pallet)
For Handling, Storage, and Maintenance Instructions, see reserve
39
HEADQUARTERS
Technip
89 avenue de la Grande Armée
75773 Paris Cedex 16
France
Phone: +33 (0)1 47 78 24 00
CONTACTS
Drilling & Refining Applications
Division - Worldwide presence
Technip
Innovation & Technology Center
43-45 Boulevard Franklin Roosevelt
92500 Rueil Malmaison
Phone: +33 (0)1 4901 8400
Technip Brazil
Rua da Gloria 178 - Glória 20241-180
Rio de Janeiro-Rj-Brazil
Phone: +55 21 2139 7441
Fax: +55 21 2139 7006
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,
25 Loyang Crescent
Box 5161Blk 103 TOPS
Ave. 1 #02-07/08 Singapore, 508988
Phone: +65 6546 9100
Fax: +65 6546 9122
Technip Abu Dhabi
Al Muroor Rd.P.O. Box 7657
Abu Dhabi, UAE
Phone: +971 2 6116 548
Fax: +971 2 6266 580
www.technip.com/DRAPS
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 - Group Communications - August 2013 - Photo credits: Technip.

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