Ultra-Deepwater Riser Concepts for High Motion

Vessels
10121-4401-02
Brian Royer
Stress Engineering Services, Inc.

Ultra-Deepwater Floating Facilities and Risers & Systems Engineering TAC Meeting
May 29, 2013
Apache Corp HQ, Houston, TX

1 rpsea.org
 Main Objective

o Overall
Bring to maturity safe Riser System(s) that can meet the performance demand
of High Motion Vessels in Ultra-deep water (10,000 ft)

Conventional Semi-submersible

Floating Production Storage Off-loading

2 Vessel (FPSO) -- Internal Turret
 Phase Objectives

o Phase 1
Identify concepts that show potential to meet the overall
objective through literature search, numerical modeling, and
secondary evaluations
o Phase 2
Identify and evaluate technical gaps and risks of down selected
riser concepts
o Phase 3
Fill gaps with Development, Analysis, and Testing

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 Previous Achievements

o Establish Design Basis

o Developed matrix of Riser Configurations and Riser Pipe Materials
o Sized Riser Pipe Wall Thickness
o Created Models of Riser Concepts
o Down selected Concepts to carry forward to Dynamic Analyses

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 Recent Achievements

o First Level Concept Evaluation

Vessel Motion Processing
Evaluate Strength Capacity of Riser Concepts to Design Storms
o Second Level Concept Evaluation
Evaluate Fatigue Performance of Riser Concepts
Riser Concept Cost Estimates
Installation Assessment

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 Project Schedule Update

Task 2012 2013 2014...2015

TaskName
Code Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Nov Dec Jan Feb ... Jun Jul Aug
AdministrativeTasks
1&2 PMPandTechnologyStatusAssessment
3 TechnologyTransfer
4 OtherReportsandSpecialItems
TechnicalTasks
Phase1
5 DesignBasisPreparation
6 RiserConceptDefinitionandSizing
7 DynamicAnalyses
8 SecondLevelRiserConceptEvaluation
Phase2
9 TechnologyGapIdentification
10 DevelopmentofDraftRiserConceptTestingProgram
Phase3
11 DevelopmentandTestingProgram
12 DataAnalysis,Integration,andCoordination

May20,2013

Legend: WorkCompletedperPMPSchedule WorkCompletedLate

WorktobePerformedperPMPSchedule DelayofScheduledWork
WorktobePerformedLate

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 Project Cost Update

$450,000
Phase 1 Phase 2
$400,000

$350,000 Baseline
Actual
$300,000 Cost Share
Cumulative Totals

$250,000

$200,000

$150,000

$100,000

$50,000

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 Highlight Key Design Basis Parameters

o Shut-in Tubing Pressure Design Storm Environments:

20,000 psi (at Wellhead) o 100-year Winter Storm
o Max. Operating Temperature HS = 29 ft, TP = 13 sec., VW = 82 ft/s
350F (at Wellhead) o 100-year Loop Current
o Fluid Service Surface Current Speed = 7.5 ft/s
Sour
o Production Riser # & Size API 2INT-MET
8 8.625 OD o 100-year Hurricane
HS = 52 ft, TP = 15.4 sec. , VW = 150 ft/s
o Externally Insulated
U-value 0.8 o 1000-year Hurricane
( Technology Gap exists for external insulation
at well product temperature of 350F ) HS = 66 ft, TP = 17.4 sec. , VW = 187 ft/s

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 Vessel Motion Processing

o WAMIT model of Vessel

Program used for computing wave loads on floating bodies
o Force Coefficients for Wind and Current
o Perform Coupled Analysis of Floater and Mooring Lines
Two sets of analyses: Semi-submersible and FPSO with Internal Turret
Output are wave frequency and low frequency floater responses (surge, sway,
heave, roll, pitch, and yaw) to environments
Output of Coupled Analysis used to drive risers
For the Turret Moored FPSO, solution includes orientation of the vessel relative
to environment
NOT Assumed
Wind, Waves, and Current are not necessarily colinear

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 Down Selection of Riser Concepts

o Primary factor is Vessels Riser Payload Capacity

Semi-submersible
None, limited only by size of vessel
FPSO
Disconnectable Turret
o When disconnected the turret
becomes a buoy supporting
the mooring and risers
o For this study, riser payload
capacity set to 3000 kips
Captive Turret
o For this study, riser payload cap
set to 9000 kips (3 disconnectable)
Disconnectable Turret FPSO
10 with Internal Turret
 Down Selection of Riser Concepts (1/5)

Simple Catenary Riser

Semi & Captive Turret FPSO
o Steel Base Case
Disconnectable Turret FPSO
o Titanium

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 Down Selection of Riser Concepts (2/5)

Lazy Wave Riser

Semi & Captive Turret FPSO
o Steel
Disconnectable Turret FPSO
o Composite Reinforce Pipe

Distributed Buoyancy

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 Down Selection of Riser Concepts (3/5)

Steep Wave Riser

Disconnectable Turret FPSO
o Steel with Lightweight Coating
o Composite Reinforce Pipe

Distributed Buoyancy

Riser Base

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 Down Selection of Riser Concepts (4/5)

Compliant Vertical Access Riser

Disconnectable Turret FPSO
o Steel with Lightweight Coating
o High Strength Steel
o Steel with Subsea HIPPS

Distributed Buoyancy

Riser Base

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 Down Selection of Riser Concepts (5/5)

Buoyancy Can
Jumper

Discrete Buoy Options

Disconnectable Turret FPSO
o Hybrid Riser Tower
o Tension Leg Riser (not shown)
Steel Jumper
Titanium Jumper

Riser Base

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 Evaluate Strength Capacity to Design Storms (1/3)

Semi-submersible Captive Turret FPSO

Environment FD Steel Steel Steel Steel
Catenary Lazy Wave Catenary Lazy Wave
100-year Winter Storm 0.8 PASS PASS PASS PASS
100-year Loop Current 0.8 PASS PASS PASS PASS

100-year Hurricane 0.8 FAIL PASS FAIL PASS

1000-year Hurricane 1.0 DNA PASS DNA PASS

2
M Teff P
Design Criterion: FD
2

My Ty b
P

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 Evaluate Strength Capacity to Design Storms (2/3)

Disconnectable Turret FPSO

Environment FD Titanium Composite Composite Steel(1) Steel(1)(2) HSS HRT/TLR
Catenary Lazy Wave Steep Wave Steep Wave CVAR CVAR Steel Jumper
100-year Winter Storm 0.8 PASS PASS PASS PASS PASS PASS PASS
100-year Loop Current 0.8 PASS PASS PASS PASS PASS PASS PASS

100-year Hurricane 0.8 FAIL, (N/A) PASS, (N/A) PASS, (N/A) PASS, (N/A) FAIL, (N/A) FAIL, (N/A) PASS, (N/A)
1000-year Hurricane 1.0 N/A N/A N/A N/A N/A N/A N/A
Notes:
(1) Lightweight Coating in Upper Riser Robustness Check
(2) with Subsea HIPPS

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 Evaluate Strength Capacity to Design Storms (3/3)

Stress Joint (Titanium)

Highest Utilization of Strength Capacity at Top of Riser

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 Fatigue Performance Evaluation (1/2)

Semi-submersible Captive Turret FPSO

Pipe Material S-N Curve Steel Steel Steel Steel
Catenary Lazy Wave Catenary Lazy Wave
Carbon Steel BS7608-E/20 FAIL ALMOST(1) FAIL FAIL(2)
ID-Clad Carbon Steel BS7608-C PASS PASS FAIL PASS
Duplex Stainless Steel BS7608-E FAIL PASS FAIL PASS
Titanium Stress Joint RTIES(3) PASS PASS FAIL FAIL
Notes:
(1) Fall short of target fatigue life only at Touchdown Point; insert couple hundred feet of
"specialty pipe" to improve fatigue life locally.
(2) Upper 4000 feet of riser falls short of target fatigue life, remainder of riser, including
touchdown point, passes.

(3) See OTC-18624 "Experience and Guidance in the use of Titanium Components in Steel
Catenary Riser Systems"

PASS = Unfactored Fatigue Life greater than 250 years

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 Fatigue Performance Evaluation (2/2)

Reduced Set of Fatigue Sea States that Excludes HS > 10m

Disconnectable Turret FPSO

Pipe Material S-N Curve Titanium Composite Composite Steel(1) Steel(1)(2) HSS HRT/TLR
Catenary Lazy Wave Steep Wave Steep Wave CVAR CVAR Steel Jumper
Carbon Steel BS7608-E/20 N/A PASS PASS FAIL FAIL N/A PASS
ID-Clad Carbon Steel BS7608-C N/A PASS PASS PASS FAIL N/A PASS
Duplex Stainless Steel BS7608-E N/A PASS PASS PASS FAIL N/A PASS
High Strength Steel
BS7608-B N/A N/A N/A N/A N/A FAIL(4) N/A
(ID-Clad )
Titanium Pipe RTIES(3) PASS N/A N/A N/A N/A N/A N/A
Titanium Stress Joint RTIES(3) PASS PASS PASS N/A N/A N/A PASS
Notes:
(1) Lightweight Coating in Upper Riser
(2) with Subsea HIPPS
(3) See OTC-18624 "Experience and Guidance in the use of Titanium Components in Steel Catenary Riser Systems"
(4) Maximum Allowable SAF for T/C connector too low.

PASS = Unfactored Fatigue Life greater than 250 years

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 Cost Evaluation

o Under Review
o Consists mainly of material and installation costs
o Intention is to Normalize Cost of Alternative Riser Concepts
Steel Catenary Riser = 1.0

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 Contacts

PI: Brian S. Royer RPSEA PM: Bill Head

Stress Engineering Services, Inc. bhead@rpsea.org
brian.royer@stress.com 281-690-5519
281-955-2900

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