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 Drilling and Service Applications - User’s Guide 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 8.4.1 After installation pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 Drilling and Service Applications - User’s Guide 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 PERIODICITY OF FIELD TESTING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 9.4.1 Flushing of the lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 9.4.2 Routine external visual inspection (Section 6 - Para. 6.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 9.4.3 After installation pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 PERIODICITY OF FIELD TESTING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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. Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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. Drilling and Service Applications - User’s Guide 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. Drilling and Service Applications - User’s Guide 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. Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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. Drilling and Service Applications - User’s Guide 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. INSTRUCTION: All Subsea lines, in line with rig operating procedures, should be flooded at all times, including during the deployment of the drilling riser. 22 Drilling and Service Applications - User’s Guide 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. Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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. Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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. INSTRUCTION: in case of doubt please contact the nearest Technip office. Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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. INSTRUCTION: in case of doubt please contact the nearest Technip office. 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. Drilling and Service Applications - User’s Guide 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. INSTRUCTION: All Subsea lines, in line with rig operating procedures, should be flooded at all times, including during the deployment of the drilling riser. 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 Drilling and Service Applications - User’s Guide 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 PERIODICITY OF FIELD TESTING AND INSPECTION 8.4.1 After installation pressure test 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. Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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 PERIODICITY OF FIELD TESTING AND INSPECTION 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 9.4.3 After installation pressure test 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. Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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 PERIODICITY OF FIELD TESTING AND INSPECTION 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. Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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 27 - PARA 6.9: in case of doubt please contact the nearest Technip office. 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 29 - PARA 7.3: in case of doubt please contact the nearest Technip office. 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. 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 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. Drilling and Service Applications - User’s Guide 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 ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. ................................................................................................................. 38 Drilling and Service Applications - User’s Guide 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 Drilling and Service Applications - User’s Guide 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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