Bonded Flexible Pipe

Val M. Northcutt
Manuli Oil & Marine (U.S.A.), Inc. 2755 East Oakland Park Blvd. Ft. Lauderdale, FL 33306

ABSTRACT

This paper presents an overview of bonded flexible pipe improvements primarily driven by environmental safety as applied t o offshore development using mobile production systems. Bonded pipe is a flexible pipe where the steel reinforcement is integrated and bonded to a vulcanized elastomeric material. Textile material is included in the structure to obtain additional structural reinforcement o r to separate elastomeric layers. The applications addressed by this paper a r e sweet service production, including well stream product and stabilized crude export. Production products include gas, water and injection chemicals. The bonded flexible pipe is used as static flowline and dynamic risers and loading and discharge marine hose. A new application for bonded flexible pipe t h a t did not require much in the way of new technological development is offshore mobile production systems. Until 1989 there had been very little new development in bonded flexible pipe but with the introduction of offshore mobile production systems (MOPS) this changed. The mobile offshore production systems considered is the MOPS used on the Gombe Beta Field, Gabon, West Africa and the MOPS used on the Tchatamba Field, also offshore Gabon, West Africa. The MOPS is accepted in the oil industry as a means to collect reservoir data through extended well tests, to provide early cash flow from major fields and to produce marginal fields. I will focus on bonded flexible risers, bonded flexible pipelines and bonded floating export hose t h a t comprise the three critical bonded flexible pipe applications. All three a r e used to convey crude between the production unit, storage tanker and export tanker. Zero pollution is the goal especially in the remote offshore areas where equipment for pollution control response is either limited o r difficult to mobilize. Strict environmental regulations govern the use of bonded flexible pipe in remote offshore areas where mobile production systems operate. Contingency planning for emergencies such as well blow-outs and oil spills r a n k high among operator requirements. Operators carry out baseline environmental studies in cooperation with the local government to make sure all components, including the bonded flexible riser, flowline and floating export hose used on the mobile production system meet o r exceed the environmental requirements. Bonded flexible pipe must provide a safe passage through which the oil can be transferred. It is exposed to continual wave and current motion a n d is always under stress.
I. INTRODUCTION

a pattern is the use of bonded flexible pipe for offshore loading, dynamic riser and flowline applications. Bonded flexible pipe is categorized in two designs
0

bonded flexible flowlines and risers and bonded flexible marine hose.

Bonded flexible marine hose for offshore loading was first used offshore Miri, Sarawak, in 1959. Bonded flexible flowlines and risers were first installed in 1988 in the British sector of the North Sea. This paper will discuss how bonded flexible pipe is used as part of a mobile offshore production system to convey crude oil from the mobile offshore production unit to the FSO (Floating Storage Offshore) or FPSO (Floating Production Storage Offshore) and to the export tanker. The three products discussed will be bonded flexible pipe risers, bonded flexible pipe flowlines, and bonded flexible pipe marine hose.
11.

BONDED FLEXIBLE FLOWLINE & IUSERS ,

The fabrication of bonded flexible pipe requires careful selection of chemical materials, precise control of elastomeric formulations and processing, together with rigid quality control. It is designed and manufactured under a quality system in accordance with I S 0 9001 (Model for Quality Assurance Design, Development, Production, Installation and Servicing). Third party verification; e.g., American Bureau of Shipping (ABS), Det Norske Veritas (DNV) or Rontgen Technische Dienst (RTD), is standard industry practice during the design, manufacture and testing of bonded flexible flowline and risers.
A. Manufacture of Bonded Flexible Pipe

Bonded flexible flowline and risers are rapidly becoming the pipe of choice in remote offshore areas of the oil and gas industry. Composed of helically wound, steel loadbearing wires that are captured in an elastomeric matrix, bonded flexible pipe is lightweight, compliant and durable. Fig. 1 shows the smooth inner tube, 6-ply wire reinforcement and the outer neoprene cover.
1) Liner: The material that makes up the liner or tube of the pipe is fabricated to resist processed crude oil, aromatic blended fuels, and diesel fuels. The liner is also fabricated

There are many instances in industrial technology of old ideas being revisited and exploited to their full potential many years after initial invention. A good example of such

0-7803-655 1-S/OO/$lO.OO 02000 IEEE

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to be resilient to natural gas and most chemicals found in crude oil. Proper compounding of the liner protects it against the long-term effects of aging.
2 ) Wire: Wire reinforcing bias wraps allow the pipe to elongate under tension. As it elongates, it loses diameter at high axial tensions. It also twists about its longitudinal axis similar to a three-strand nylon hawser line or wire rope. These tension characteristics make for a very hardy and forgiving system.
3 ) Cover: The cover compounds must be formulated and processed to have optimum resistance to abrasion, oil, and weathering. Abrasion resistance is provided by reinforcement in those areas where cyclic loading or chaffing may occur.

The length of the wire lays in the conduit is that distance measured parallel to the tube axis, or centerline, in which a reinforcing ply makes a complete spiral or turn about the pipe. Because the pipe is elastic, twist will increase as additional load is applied. The pipe acts as a coreless line until pressure is applied. As the pressure increases, the pipe takes on the appearance of having a core, and its resilience to twist, as well as its overall torsional resistance, increases. The elastomeric pipe stretches under axial loads and like synthetic line, a small portion of the load-induced elongation is permanent and irreversible. This permanent stretch is small and is not progressive with successive loadings, provided the safe working load is not exceeded. Under safe working conditions, the permanent stretch is less than 2 percent of the original length. The pipe is extremely flexible. It also has a high degree of torsional resistance when pressurized with either air or liquid.
TABLE 1 Bonded Flexible Flowline and Riser Specifications

Item
Bore Size
Outside Diameter 152.4 mm 198.2 mm 23.6 k g h 8.0 kg/m 152.4 mm 211.0 mm 28.6 kg/m 7.24 kg/m -8.28 kglm -11.4 kg/m
1220 psi

Weight in Air Empty

Buoyancy in Seawater Emply

Buoyancy in Seawater Full of Oil
(Sp.Gr. 0.85)

-7.5 kglm
-10.7 kglm 1220 psi

Fig. 1. Bonded Flexible Pipe

Buoyancy in Sawaler Full of Seawater

Dwign Pressure (Max)

B. Characteristicsof Bonded Flexible Pipe

Bonded flexible pipe is complex composed of multiple layers designed and manufactured to bear a very definitive relationship to one another. TABLE 1 shows a typical specification for bonded flexible flowline and risers. The spiral wire reinforcement is laid at optimum angles for maximum efficiency of pressure containment and elongation. The four plies of spiral-wire work together to provide component integrity. The construction of the pipe results in it acting very much like nylon three-strand line or hawser. As such, the working and handling procedures are similar and the pipe's reaction to applied loads and handling techniques are similar to that of the synthetic line. As increasing axial tension is applied to the pipe, it will tend to elongate. Then as the wires begin to carry the higher tensile load, the pipe will rotate (twist) about its tube axis. It will also reduce i diameter. The frequency of roll, or twist, is n approximately the same as a lay length at nominal loads.

Burst Pressure Electrical Continuity

3800 psi
No Requirement
50,000 kg 1.Ox1V kg

3800 psi
No Requirement

Axial Load

at Break (Theoretical)

70,030kg

~ x i a i ~ t i f f n e ats Design pressure s

Bend Stiffness
Torsional Stiffness at Dcsign Pressure hfaximuni Fluid Tempemtun: Minimum Environment Tempera" Maximum Flow V l c t eoiy

1.0xlV kg
500 kg m2

50 kg m1
40,oOO kg m2
92 'C

40,030kg m'
92 *c
-29 P C 21 d s

-29'C
21 m/s

111. BONDED FLEXIBLE MARINE HOSE

The initial concept of bonded flexible marine hose used as floating and submarine hose systems as applied to single point mooring (SPM) terminals was pioneered by Uniroyal Scotland in 1959. That same year, Shell installed the first SPM offshore Miri, Malaysia, and became the frst company to use bonded flexible pipe for offshore loading applications.

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Bonded flexible marine hose is basically a tube which is reinforced in such a way that it can survive in its working environment. The tube, or inner lining, is very important to the successful working life of the hose. The rubber compound of the tube is constantly exposed to crude oil therefore it must be completely leak free to insure proper adhesion between the tube and the adjacent components. Fig. 2 shows a typical fully floated bonded flexible marine hose. Bonded flexible marine hose marked as complying with the OCIMF guidelines must be designed and manufactured under a quality system in accordance with IS0 9001, TABLE 2 shows the specification for a 20" x 10m floating marine hose. Although it has a complex geometry and loading defies accurate calculations of design margins, it has proven to be highly reliable in service due to the use of conservative, empirical design methods and experimental validations. Bonded flexible pipe is economically competitive in applications where there are significant repetitive motions, hostile and remote offshore environments and where simple and reliable installation is required.

pressure, with zero twist and zero permanent elongation is achieved. The resistance to abrasion on the outer cover often plays

a major role in the working life of the hose. For instance

the tail hose is in constant contact with the side of the tanker and must be protected from abrasion by applying a PU (polyurethane) coating to the outer cover to give maximum resistance to abrasion.
TABLE 2 Bonded Flexible Marine Hose Specification for 20" x 10m Floating Marine Hose

I Hose Size and Type

I 20" x 10m Fully Floated I

Mainline Marine Hose

1V. FIELD DEVELOPMENT USING BONDED FLEXIBLE PIPE

Bonded flexible pipe has a long history of successful use in the marine environment. Its primary use is for dynamic flexible risers, static flow lines and for conveying petroleum products from sub-sea pipelines to ships or temporary floating storage facilities.
Fig. 2. Bonded Flexible Marine Hose (Fully Floated)

A seamless tube is applied to a carefully prepared mandrel by means of a continuous extrusion of hot uncured rubber compound. The extrusion is applied as a spiral at constant pitch and tension overlapping to give a solid lining tightly fitted around the mandrel. The standard tube compound is capable of handling aromatic content up to 60%. The tube lining and carcass of the hose is protected from its working environment with reinforcing layers of textile cord, rubber compound, a high tension steel wire helix embedded in the rubber, and an external cover to make it weather, seawater, oil and abrasion resistant. The carcass of the hose contains the pressure and controls the movement of the hose under stress. It is reinforced with layers of steel tire cord applied at the optimum angle to give maximum efficiency on pressurp retention and stability. Due to the accuracy on the lay of the steel cord, temporary elongation of up to 1% at test

'

Users are increasingly concerned with the ruggedness and cost effectiveness of hoses designed to meet the challenges of future applications. As offshore production technology has developed, smaller, less viable fields are favoring the use of smaller pipeline systems to interconnect the production facilities. Bonded flexible pipe is the pipe of choice to connect these facilities. Safety and the time-cost of money dictate the selection and use of high reliability, low risk equipment. The cost penalties associated with spills having environmental impact have also escalated. There are four factors that are of prime importance in deciding whether to use less expensive technology to develop a field.

1. Size of field and field life - Offshore loading is particularly feasible and cost effective for smaller fields which have a limited production life. The capital costs for this type of development are relatively low and much of the equipment can be reused upon abandonment.

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Existing export systems - In mature areas, existing platforms and pipeline networks provide convenient routes for export. In new provinces or areas where fields occur only occasionally, the availability of existing facilities may be limited. The cost of reaching those that do exist may therefore be prohibitive.

response to the combined action of wind, current and waves. The crude oil is transferred from the FSO or FPSO to the export tanker via a floating bonded marine hose string. The MOPS is made-up of the following components: production rig, 0 a bonded flexible pipeline and riser to connect the production rig to the FSO or FPSO via a submarine pipeline, 0 FSO or FPSO for storage of the oil and for export to a shuttle tanker, and a 0 bonded flexible floating marine hose string to offload the oil to the export shuttle tanker.
All of the above listed mobile offshore production system components play an integral part in the overall development of the field.

Water depth - Water depth influences many of the components; e.g., type of drilling and production rig to be used, mooring systems for FSO or FPSO, flowline and riser systems.
Pipeline Options - In certain areas pipeline options may not be an option. Economics and political instability play a major part in determining what type of production facilities are to be installed. In many cases out of sight means out of harms way.
V. MOBILE OFFSHORE PRODUCTION SYSTEMS (MOPS)

A. MOPS Gombe Beta Field The Gombe Beta Field is located in 55 feet of water fifteen miles offshore Gabon, West Africa. It was a marginal production field that at startup had a production of 12,00Obbls/day and experienced a significant drop in production two months later to 2,000bblsfday of crude oil. In 1991, the operator determined the only economically sound way to produce this field was to use a MOPS.

Field development using the MOPS has become an accepted practice in the offshore oil industry. It offers a means to collect reservoir data through extended well tests, provides early cash flow from the field and is used to produce marginal fields. The bonded flexible riser and flowline system is designed to provide an efficient means to transfer processed crude oil from the mobile offshore production system to the FSO or FPSO for storage. The sub-sea riser and flowline system is simplistic in design, basically consisting of two export risers supported in hang-off clamp assemblies, one on the MOPS and one on the FSO or FPSO, and a flexible flowline in between. Fig. 3 shows a typical mobile offshore production system field layout.

- .2L A -. . L / / V . /TL
i l X l l O h % PJlT

____A'

MX
-FIl. w l Ir ? L . 3 .

L...L.U7

Fig. 4 Gombe-Beta Field Wellhead Platform

Fig. 3. Mobile Offshore Production System (MOPS)

The MOPS delivers processed crude oil to the moored FSO or FPSO by way of a subsea bonded flexible riser and flowline system. The FSO or FPSO stores the transferred crude oil for the purpose of offloading to a candidate export tanker. The export tanker is moored to the FSO or FPSO from its bow to a single point allowing it to swing freely about the FSO or FPSO stern without fouling, and in

1) Riser and Flowline: The operator chose a field-proven riser and flowline system to support equipment to permit crude oil to be transported approximately 820 feet from the wellhead platform, Fig. 4, through two 6" I.D. combination bonded flexible flowline and risers connected the production riser to the FPSO, Fig. 5.

2 ) Export System: A string of bonded floating marine hose 16" I.D. and approximately 1,000 feet long connected the FPSO to the export tanker.

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6-ply wire float-sink bonded flexible pipe, however, it is not reinforced. The flowline joins the two risers together.
3 ) FSO Riser: The FSO riser is identical to the production rig riser in size, length and construction. It is also fitted with a Grayloc weld-neck hub and special riser bearing and clamp assembly on one end. The other end is equipped with a low profile male sub-sea coupling.
4) Floating Hose System: The floating hose system, Fig. 7, makes up the interface between the FSO and the export tanker. The system is a single floating hose string (16-inch diameter x 760 feet long) comprised of 20 sections of various styles of bonded floating marine hose.

Fig. 5. Gombe-Beta Field Production Risers and FPSO

B. MOPS TchatambaField
The Tchatamba Field, is located in 154 feet of water twenty miles offshore Gabon and consists of a mobile offshore production rig, a FSO, a bonded flexible riser and flowline system to transfer processed crude from the production rig to the FSO, a bonded marine hose floating hose string to transfer product from the FSO to the export tanker.

Fig. 7 TchatambaField Bonded Flexible Marine Hose Export System

VI. CONCLUSION

Fig. 6 . Tchatamba Field Production Rig and Export Riser

Mobile offshore production systems have been used effectively to exploit resources that would otherwise be considered uneconomical. MOPS success using bonded flexible pipe for offshore loading, dynamic riser and flowline applications has demonstrated that industrial technology of old ideas can be revisited and exploited to their full potential many years after their initial invention.
ACKNOWLEDGMENTS

1) The Riser: The production rig riser, Fig. 6, is 5 18 feet long and connects the discharge piping on the production rig to the flowline. It is constructed of 6-inch intemal diameter x 6-ply wire float-sink bonded flexible pipe. The riser is reinforced on one end (approximately 295 feet) to add weight, provide chaffing protection and provide bend restriction as required. The riser is fitted with a Grayloc weld-neck hub and special riser bearing and clamp assembly on one end, and a low profile female subsea coupling on the other end. 2) Flowline: The bonded flexible flowline consists of one 1,014 foot long section with low profile sub+.ea couplings fitted on each end (one end male, the other end female). It is also constructed of 6-inch intemal diameter

My appreciation to R.L. Furness for his support during the preparation of this paper and my thanks to Don Johnson for his opinions and comments.
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