Magma and Shawcor collaborate to offer insulated m-pipe
m-pipe® with Shawcor ULTRA™ coating improves flow and in-water stability
Portsmouth, UK, 5th March 2019: Magma Global, the leader in carbon-fibre composite pipe, today announces it has added Shawcor’s Thermotite® ULTRA™ insulation to its m-pipe® offering. It will be primarily used to improve flow by maintaining the temperature of production fluids. Additionally, the insulation material can be adjusted to add weight or buoyancy to manage stability of the pipe in the water column. The insulated product is currently in qualification for use in jumpers for a project in the North Sea and in the Ocyan CompRiser design.
Magma sought to further improve the thermal insulation properties of m-pipe in order to maintain flow temperature for a number of current projects. Magma identified Shawcor’s Thermotite® ULTRA™ for the required thermal insulation to achieve this. It is a styrene alloy subsea insulation system designed specifically for flow assurance in subsea environments for use in ultra-deep water. The insulation layer allows the pipe to retain the ability to be transported and deployed on standard reels.
Tony Duncan, Executive VP at Magma, said: “Integrated insulation and ballast are an important part of Magma’s strategic roadmap towards the all-composite riser. We undertook a thorough evaluation of what would be the right solution for our customers’ needs; Shawcor is the market leader and this product has given us excellent results. We look forward to having the ability to extrude insulated m-pipe in Magma’s facility and fully managing production in-house.”
The ability to manage pipe stability through adding buoyancy or weight directly into the insulation material improves the potential simplicity of each design thus reducing engineering and installation time on designing and building buoyancy and ballast modules. This is of particular interest for flowlines, jumpers and pure carbon fibre riser designs.
Kevin Reizer, President of Shawcor Pipeline Performance, said: “I am very pleased with the announcement of this collaboration agreement with Magma. It reflects Shawcor’s contribution of technical, material science and processing expertise to advancing the industry. The Thermotite® ULTRA™ product platform continues to prove its value to industry stakeholders. We look forward to engaging with the offshore TCP market leader on these new opportunities”
The product will first be applied in the evaluation of m-pipe jumpers in Norway. In this case the Shawcor insulation layer is cast moulded at a 45mm thickness providing a U-Value of ≤ 5.0 W/m2K. This retains consistent flow temperature in water temperatures of 2oC which is important to maintain a good flowrate and minimise build-up. Once qualified, the collaboration calls for Shawcor expertise and a cross-head extrusion line to be integrated into the main m-pipe production line at Magma Global’s manufacturing site in Portsmouth, UK.
In 2018 Magma stamped its mark on the all-important Brazilian deepwater market with two complimentary partnerships with Ocyan and Keppel Fels to develop CompRiser and TechnipFMC to develop their hybrid flexible product. These ‘hybrid’ solutions exploit the performance of the PEEK and carbon fibre m-pipe to address the demanding requirements of Petrobras’ Libra fields in an architecture that allow rapid adoption of the TCP.
Magma began the year in the Gulf of Mexico setting another milestone using m-pipe as a deep open water riser as part of Transocean’s innovative RISEX solution. Coupled to Magma’s Integrated Deployment Package Transocean and Magma demonstrated the use of continuous choke and kill lines in a range of operating conditions.
We wrapped up a busy year in the Gulf with orders for 6in HPHT jumpers from both HWCG and MWCC. These companies include BP, Shell, Petrobras and Total in their membership making this a major watershed in adoption of TCP. The team has been equally busy across the Atlantic. Equinor joined the Joint Development Agreement as part of their ongoing strategy to test and adopt new pipeline technologies. Saudi Aramco presented at SPE on their recent successful installation of two high sour hydrocarbon m-pipe jumpers in Abqaiq and Haradh. Finally, Magma started production of two 2,500m 6in deep water flowlines destined for West Africa.
The coming year will see Magma going through another phase of growth and becoming widely recognised, not just for producing the most advanced pipe in the world, but for delivering simplicity.
The start of a new year is always a good time to reflect on the journey so far and what the future holds. For Magma it has been a long journey since we first introduced our PEEK carbon fibre m-pipe to the oil and gas industry. It’s been an amazing decade which has seen significant technology development, the creation of specific DNV standards for our product and the increasing acceptance of this technology as delivering significant cost benefits, enabling and simplifying new architectures.
The massive strides made in 2018 both in deployment and the broader acceptance of m-pipe have played their part in leading the wider industry acceptance of thermoplastic composite pipe. The stage is now set for widespread adoption in response to the continued drive for simpler, lighter and more cost effective solutions.
As I look forward, we face an exciting year ahead, we have a number of significant deliveries to make in 2019 and a major focus for us is also our key strategic programmes which will see Magma focused on delivering a Hybrid Flexible Pipe (the next generation Flexible) for riser application in Brazil with our partner TechnipFMC and delivering a hybrid riser tower with our partners Ocyan and BrasFells.
Our thanks goes to all our customers and partners who continue to support us on this exciting journey.
The path hasn’t always been easy but Magma remains true to its mission to deliver the worlds most reliable and cost effective pipe for subsea exploration and production and in so doing speed delivery, reduce cost and improve performance for all our customers.
Magma to qualify performance of m-pipe at high pressures and temperatures to augment HWCG’s well containment solution to perform top kill operations or capture hydrocarbons when a subsea well has lost mechanical integrity.
29 January 2019, Houston, Texas and Portsmouth, UK: HWCG, a deepwater oil and gas emergency response consortium for the US Gulf of Mexico, today announces it has commissioned Magma Global, manufacturer of carbon-fibre composite pipe, to qualify m-pipe® for a 350°F, 15ksi rated riser to augment HWCG’s rapid deployment emergency well containment system. The lightweight, flexible m-pipe section will enable a quicker response in shallow waters and for floating production facilities where vertical access may be a challenge.
The flexible riser would remain in a ready-for-deployment mode on the US Gulf Coast for deployment following a subsea well blowout. When installed to capture hydrocarbons it could remain in place for up to 6 months while a relief well is drilled. The design envisions approximately 800-ft (~250-m) of m-pipe connected on one end to a ridged riser and on the other end to the incident well. The m-pipe will form a lazy wave between the two ridged ends thereby decoupling motions and improving operability. Using a temporary flowback solution, hydrocarbons are processed via the riser system and then collected in tankers for transportation.
HWCG requires the flexible section to be lightweight and easy to handle offshore to enable rapid deployment. It must also be resistant to degradation with continuous exposure to hydrocarbons at temperatures up to 350 degrees F (180C), pressures up to 15,000 psi and water depths of up to 10,000-ft (~3,000-m). Magma will qualify a 6-inch nominal ID m-pipe specimen to meet the specified project requirements prior to manufacturing the final pipe order.
HWCG’s Members have identified a range of potential demanding containment scenarios requiring high pressure and high temperature performance. HWCG selected m-pipe for its pressure and temperature performance, is lightweight and flexible properties which enable heave compensation at the base of a steel riser and because it is suitable for a wide range of fluids, provides low frictional resistance and is resident to abrasion.
Craig Castile, Managing Director for HWCG, said: “HWCG is committed to providing a Rapid Response Solution for well containment which minimizes potentially severe environmental and economic impacts to the Gulf of Mexico and its stake holders. Our Members approved the OFR Project to accomplish this mission. We are committed to working with Magma Global to develop and manufacture an m-pipe solution to enhance our Member’s response plans.”
Martin Jones, CEO at Magma Global added: “We created m-pipe to solve the problems that were a challenge to steel and flexibles, such as corrosion, high temperatures, high pressures and speed and ease of deployment. This is one such scenario; where the unknowns of an incident mean that high temperatures and pressures may be encountered in an emergency situation. It is crucial in this area of the oil and gas industry that the very best technology can be put in place at speed and with confidence. We are excited to be working with HWCG to develop such a solution.”
In response to the Deepwater Horizon oil spill, HWCG LLC formed with the commitment to provide a new containment response capability for the Gulf of Mexico, recognising the need to be better prepared for a deep-water well control incident. HWCG is a not-for-profit consortium of deepwater oil and gas companies. HWCG maintains a comprehensive deepwater well containment response model that can be activated immediately in the event of a US Gulf of Mexico subsea blowout. It comprises 16 oil and gas companies operating in the Gulf and who incorporate the consortium’s generic well containment plan. HWCG has a robust mutual aid component whereby HWCG members will respond and support another member’s incident.
Tony Duncan considers smaller, simpler and more cost-effective options for age old industry problems
The oil and gas business has, is, and will probably continue to be, conservative in its approach to engineering. If it develops a product or system that works on one project, its variant will likely be used again on the next project and so on, project after project. Operators tend to repeat what has been done before, because it is tried and tested.
For example, the development of floating production storage and offloading (FPSO) vessels found their original use in the UK North Sea. Since then, they have been adopted and adapted globally and the system designers have incrementally modified the designs, because of increases in top tension, water depth, environmental conditions and so on. However, these developments have driven the technology towards a trend of making everything larger, more complicated and more expensive. The flexible pipes used have become more complex, the vessels utilised to install the FPSOs have become larger, the buoy systems used to support the riser system have been made bigger, and the result is a FPSO that has a large turret or porch system that can, in some cases, break project economics or introduce a too high a level of project risk.
Engineers in oil companies, design houses and engineering, procurement, construction and installation (EPCI) contractors, use past project experience when they look to a new project or tender. Take, for example, a mid-water arch, commonly used for supporting risers. When engineers start a new project, what is the first thing they look to? Past examples of mid-water arch design or design bases are a natural starting point. Then, they add in the new conditions such as water depths, environmental load, sour service and CO2 requirements, temperature, etc. Factoring in these new conditions often adds in more complexity, more weight and more risk, all without challenging why a mid-water arch is being used in the first place. Some of the early mid-water arches used in the UK sector weighed about 150 t. Offshore Brazil, projects such as Guará-Lula use a form of the mid-water arch that weighs in excess of 2000 t. The spiral is in train: larger projects mean more and larger installation vessels, and more commercial and technical risk.
The full article is available to download here: Simpler_Options_For_Oil_Industry_Problems
This article appeared in the December 2018 issue of Oilfield Technology.
Ocyan and Magma Global announce new CompRiser® partner
BrasFELS shipyard arrives to strengthen the project
Ocyan and Magma Global today signed a new MOU (Memorandun of Understanding) that guarantees the participation of BrasFELS in the CompRiser® solution, a riser tower system that utilises carbon fibre composite pipes. BrasFELS, located in Angra dos Reis, is the Brazilian shipyard of Keppel Offshore & Marine, the global leader in offshore rig design, construction and repair, ship repair and conversion, and specialised shipbuilding.
“The BrasFELS participation in the CompRiser® development is another achievement of this initiative. The shipyard location, its installed manufacturing capacity and reputation in the Brazilian market further reduces the project risk assessment. It’s certainly a partner that aggregates a lot of value”, explains Marcelo Nunes, Ocyan Director – Subsea Services.
Tony Duncan, Executive Vice President at Magma Global, said: “The CompRiser is an effective solution for deepwater and pre-salt environments. It’s a clever design that uses m-pipe in a static application thus streamlining the qualification needs versus dynamic riser designs. Confirming BraFELS as the manufacturing location means we can bring this design project to fruition in the very near future.”
Mr Marlin Khiew, CEO and President, Keppel FELS Brasil, said, “BrasFELS is the most established shipyard in the Latin American region, with a strong track record in the construction, integration, upgrading and repair of a wide range of products. We are proud to collaborate with Ocyan and Magma Global in the development of the innovative CompRiser® solution, which will strengthen the position of BrasFELS as a one-stop provider of solutions for deepwater production platforms.”
CompRiser® is a hybrid riser system created in partnership with Magma Global for use in the deepwater and ultradeep water oil exploration industry. The Thermoplastic Composite Pipe (TCP) used in the CompRiser® will be m-pipe®, manufactured by Magma. TCP provides high corrosion resistance (e.g. CO2 and H2S), of great value to the subsea systems at the pre-salt area, significant weight reduction and the possibility of withstanding high temperature and pressure. Its mechanical flexibility allows the design of a new concept for the lower termination (patent pending) that allows the riser to be connected directly to the flowline – both rigid and flexible.
Its compact and modular manufacturing method allows high local content. Additionally, m-pipe is delivered in reels and does not require welding, simplifying the bundle assembly which can be completed in less than 30 days. The offshore installation takes another 20 days, without the need for special vessels and with minimal exposure to bad weather conditions.
As a decoupled solution, the product uses less than 20% of the load applied by other solutions in the production units. The result of this difference can exceed 9,000 tons per FPSO, conditioned to quantity of project risers. The reduction of weight and load in the FPSOs (floating production storage and offloading) operations is a constant demand of the operators.
Magma wins Energy Institute Award for Innovation
Portsmouth, UK, 27th November 2018: Magma Global, manufacturer of carbon-fibre composite pipe, today announces it has won the Energy Institute’s 2018 Award For Innovation. Magma was up against a variety of renewable energy innovations, including SSE’s Wind Turbine Nitrogen Accumulators and Imperial College’s Next-Generation High-Efficiency Affordable Hybrid Solar Systems, but m-pipe was selected due to its positive impact on the oil and gas industry.
Martin Jones, MD at Magma Global, said: “m-pipe is being seen as a game changer as it delivers cost effective and ecologically improved development of deepwater reserves. It significantly simplifies engineering and in doing so reduces cost and time to first oil. Most importantly it doesn’t corrode or degrade in the oil field and can be lifted and reused at the end of a field’s life.
“We’d like to thank our early supporters who helped pave the way for qualification and market adoption, and our team of engineers who strive to simplify a complicated world. m-pipe is being embraced by a justifiably risk averse industry and we are delighted to be recognised with this award.”
Energy Institute President Malcolm Brinded CBE FREng FEI said: “Beating climate change – whilst extending the tremendous benefits of energy to all populations – calls for innovation and a lot of hard work, by many smart people, all around the world.
“Too often these efforts are behind the scenes and complicated, and so they go unnoticed. That’s what the Energy Institute Awards are for – an opportunity to sing the praises of the very best within our industry – from India to the Highlands, from oil and gas to the most advanced smart tech, from the seabed to our classrooms.
“In so doing we also acknowledge the collective endeavour of all energy professionals around the world whose day-to-day is building the energy system of the future.”
The EI Awards is a competition run by the Energy Institute for those shaping the world’s energy future. The awards celebrate the achievements of the energy industry across the globe, giving recognition to individuals and organisations who take an innovative and responsible approach to solving the industry’s challenges of providing society with clean, sustainable, low cost and dependable energy.
Understanding corrosion of flexible pipes at subsea oil and gas wells
“Flexible pipes installed at two offshore natural gas wells in Brazil’s pre-salt fields recently ruptured after only a few years of operation. These pipes were expected to last more than 20 years, so Petrobras, the company developing the fields, investigated the cause of the failure. They discovered damage to the pipes’ outer cover and found corroded steel armor wires in the pipes. Executives were surprised to learn that high concentrations of carbon dioxide contributed to the corrosion and eventual ruptured pipes. Failures, while infrequent relative to the thousands of flexible pipes in operation, have also occurred in at least four flexible risers connecting floating production vessels to subsea wells off the coasts of Norway and Africa.
When flexible pipes were first introduced 30 years ago, it was thought that the interior of the pipes remained dry and noncorrosive. However, engineers now know that the unique environment that traps water vapor and carbon dioxide between layers of steel inside the pipe contributes to corrosion—even when its external cover is undamaged. Producers are beginning to use corrosion-resistant composite flexible pipes for subsea flow lines at deep wells. Companies are also testing and developing hybrid systems that combine steel and composite pipes to maximize the benefits of both systems.
With oil and gas reserves in shallow waters running dry, producers are turning to fields in deep and ultra-deep waters off the coasts of Brazil, Norway, Angola, and the United States. Bringing fluids through 3000 meters of water to the surface poses new challenges for well operators: production fluids with increased temperatures and pressures that challenge welds; increased carbon dioxide—and sometimes hydrogen sulfide—that scour and weaken steel; deep ocean water pushing on pipes with increased pressures; and currents trying to drag pipes through the water.
However, there is a way to eliminate stress-induced corrosion cracking: Eliminate the steel from flexible pipes. Companies such as Magma produce flexible pipes for the oil and gas industry by winding layers of composite reinforced with glass or carbon fibers around a polymer liner. Each layer of the thermoplastic composite is fused to the one below it. Composite pipes are much lighter than steel flexible pipes, so operators can use simpler, less expensive equipment to install them.”
The full article is available to download here: Understanding_Corrosion_Of_Flexible_Pipes_At_Subsea_Oil_And_Gas_Wells.
Extract from MRS Bulletin, 43(9), 654-655. Understanding corrosion of flexible pipes at subsea oil and gas wells. Author Fellet, M., & Nyborg, R. (2018). doi:10.1557/mrs.2018.214
£10.5m funding secured to qualify an insulated all carbon fibre subsea pipe
Equinor joins Magma in UK government backed qualification programme
ONS, Norway and Portsmouth, UK, 29th August 2018: Magma Global, manufacturer of carbon-fibre composite pipe, today announces a joint initiative with Equinor, previously Statoil, to qualify an all-Magma solution for jumpers, initially envisaged for use in Norway. This secures the £10.5m project being supported by Innovate UK and will be a step towards fulfilling Magma’s vision of owning the fluid transfer infrastructure from seabed to surface.
Charles Tavner, COO at Magma Global, said: “There is no doubt in our minds that the future subsea infrastructure will be dominated by carbon-fibre composites. We have seen acceptance of this from large contractors, each developing their own solution using m-pipe, which is a natural adoption path. This initiative will fast forward the delivery of an all-Magma solution, thanks to funding support from Innovate UK and Equinor’s vision and understanding of how they can best use available technologies.”
Derek Allen, Innovation Lead at Innovate UK, said: “We are delighted to have supported this innovative project that will ultimately lead to improved efficiency and cost reduction in the UK energy sector”
Ocyan and Magma Global complete Composite Multi-Bore Hybrid Riser (CMHR) design
Commercial commitment signed in readiness to bid for Brazil’s deep-water fields
OTC, Houston, Texas. 2 May 2018: Ocyan and Magma Global, manufacturer of the world’s most advanced thermoplastic composite pipe (TCP), today announce the completion of a Composite Multi-Bore Hybrid Riser design for ultra-deep fields. The companies have signed a long term commercial agreement and will jointly bid the CMHR for deep water developments in Brazil. The design has been validated by a third-party engineering company and is in discussion and analysis with potential clients.
The CMHR offers multiple benefits which address barriers for operators. Today’s FPSOs are on a constant demand for reduced weight and loads. As a decoupled solution, the CMHR applies less than 20% of the loads applied by other solutions resulting in a weight difference of up to 9.000 tons per FPSO.
The use of TCP brings high resistance to corrosion (for example CO2 and H2S), light weight and the ability to withstand high temperature and pressure. Its flexibility enables the design of a novel lower riser termination assembly concept (patent already in place and under final analysis) which allows for the direct connection between the risers and the flowlines – either flexible or steel – with no design change to the CMHR.
The pipe used in the CMHR will be Magma’s m-pipe which is reeled onto reels and needs no welding which makes fabrication compact, simple and standardised, therefore enabling higher local content. Once all CMHR components are at the selected yard, the CMHR assembly takes just 20 days. To complete installation requires only 20 more days offshore, with no need for a specialized vessel and minimum risk from exposure to weather conditions.
Charles Tavner, COO at Magma Global said: “The design phase of this project with Ocyan has been really exciting as it fully exploits and builds on the capabilities of m-pipe. No other pipe can meet the requirements, as they are either not flexible enough or not able to withstand the requirements for strength and heat resistance. We look forward to seeing this excellent TCP riser solution used in large scale oil production in the very near future.”
Marcelo Nunes, Subsea Director at Ocyan said: “We have worked closely with Magma to design this incredibly simple yet robust riser system. It is a perfect match on the technical side as the CMHR provides a discrete support so that the riser works very much like a spool, in a quasi-static application. Furthermore, the concept takes advantage of the mechanical properties of m-pipe. The final result of the project has superseded our expectations and the complexity of the project has dropped dramatically.”
Magma at MCE Deepwater Development, Milan, 9-11th April
Join as for a drink at the icebreaker reception at 18:30 in the main exhibition hall then come and hear our Chief Operating Officer, Charles Tavner, present a paper at 14:45 on Tueday 10th April in Le Baron A.
Charles will present a case study detailing the cost, delivery, deployment and performance benefits of two 2.5in m-pipe® gas lift jumpers, linked to an ENI floating production system in a water depth of 850m in the Mediterranean.
He will cover m-pipe® materials, the manufacturing process and production automation systems and the transport and delivery methods. He will examine the commercial and product performance reasons ENI selected m-pipe® over flexible and hose alternatives, and the main factors behind a rapid and low risk deployment via a standard offshore supply vessel.
Charles will also include a cost analysis of m-pipe® versus comparative flexible hose which shows that, for a given specification, m-pipe® has the lowest fully deployed pipe and end fitting cost in the current market.
Download the MCEDD 2018 brochure here.