Qualification of m-pipe® TCP and correlation with FEA models
Managing the qualification of Magma m-pipe® thermoplastic carbon fibre and glass fibre composite pipe for use in high performance oil and gas applications is a unique challenge. To demonstrate m-pipe® reliability to both customers and regulators, Magma is following the guiding principles in the recent DNVGL RP-F119 ‘Thermoplastic Composite Pipe’.
This paper discusses the Magma approach to identifying design and qualification standards and tests to evaluate material behaviour at the coupon level in challenging oilfield environments. It includes developing FEA models to predict structural performance of pipes based on material properties tested on coupons.
It also covers implementation of a non-linear model following the methodology developed by Puck and correlates simulations to structural testing of m-pipe®.
Qualification of m-pipe® Thermoplastic Composite Pipe
Managing the qualification of new technology is a significant challenge. Magma must demonstrate the reliability of m-pipe® to its customers, to third-party assessors, and to the regulators.
Since thermoplastic composite pipe is a new area of technology, Magma has combined the guidance from newly published DNV GL RP F-119 recommended practice with a risk based approach to qualification management.
This paper gives a summary of the approach used by Magma to qualify m-pipe®.
DNV GL Launches Thermoplastic Composite Pipe Recommended Practice
DNV GL has launched a recommended practice (RP) that supports operators in their choice of thermoplastic composite pipes instead of steel or traditional flexibles for pipelines or risers.
The RP provides recommendations and information, technical provisions and recommended acceptance criteria pertaining to TCPs in offshore use.
DNVGL-RP-F119 Thermoplastic Composite Pipes (TCP) was developed through a DNV GL-led joint industry project involving 18 companies covering the whole supply chain; from polymer producers, via TCP manufacturers, to oil companies as the end users.
Integrated downline deployment package for efficient well intervention
65% of subsea wells will be over 5 years old by 2019 and hydraulic Light Well Intervention (LWI) can significantly increase well productivity.
LWI costs are 1/10th of the production cost from new fields, offering higher oil production for minimum CAPEX.
The offshore industry doesn’t yet have an active sector focused on delivering efficient LWI – a challenge given over 95% of active Gulf of Mexico production is from depths over 1,000ft.
Magma has therefore developed an m-pipe and m-IDP system as a compact, lightweight, back-deck package to manage all aspects of pipe transportation, deployment and retrieval for depths down to 10,000ft (3,000m).
Composite material benefits for deepwater riser applications
In the past composite materials have been used offshore in a range of applications.
A number of companies are now scaling up efforts to produce composite pipe for offshore use.
Composite materials offer a range of benefits which could be utilised in the offshore riser application to improve riser technology.
Composites are light with a high specific strength that can be formed into complex shapes and have very good fatigue resistance.
They have the benefit of high corrosion resistance, low maintenance and comparatively low axial and bending stiffness compared to steel and potential ease of installation as reeled pipe.
Materials selection for thermoplastic fibre reinforced risers
As the offshore oil and gas industry has moved into ultra-deep water to develop increasingly challenging hydrocarbon reservoirs, selection of suitable materials for dynamic risers has become increasingly difficult.
Higher pressures, temperatures and increasing levels of H2S have all left materials used in conventional riser designs, whether based on carbon steel or unbonded flexible pipe technology, struggling to meet the industry’s requirements.
To address these challenges, alternate pipe technologies based on fibre reinforced thermoplastic materials are being developed, however appropriate materials selection is still essential for these pipe technologies to be successful as dynamic risers.
This paper reviews the different combinations of thermoplastic and fibre that can be selected for dynamic riser applications. It assesses each combination against key material performance criteria that are essential for riser performance. These include strength, fatigue, high temperature resistance and chemical compatibility. Relevant test data is presented and the relative merits of different material combinations are discussed in relation to different riser applications.
Development and qualification of end fittings for composite riser pipe
< Download the technical paper presented at Offshore Technology Conference (OTC) 2013
Whilst much interest is often focussed on the composite pipe body it is often forgotten that a reliable end fitting is a prerequisite of a successful composite pipe application and further that the design challenge of the end fitting is more challenging than the pipe itself.
Industry focus is often on the pipe rather than the end fitting. However the latter often presents a more difficult design challenge. Without a reliable design solution and methodology composite pipe application cannot be considered.
The development work presented in the current paper therefore presents an important step towards application of composite technology on demanding riser applications.
The purpose of this paper is to present the end fitting arrangement for a composite pipe manufactured from carbon fibre and PEEK polymer. It describes the design approach and testing/qualification program employed for the end fitting to demonstrate reliable application in a critical and structurally demanding application such as for a deep water dynamic riser.
The paper summarises historical design approaches and design alternatives and explains the reason for selecting the proposed arrangement. It presents the design process used to develop the design and to predict its structural response. It discusses manufacturing issues and describes the test program conducted to prove the end fitting performance.
An integrated approach to the design of high performance carbon fibre reinforced risers
< Download the technical paper presented at Deep Offshore Technology (DOT) 2013
The increasing demand for ultra-deep water oil and gas extraction has led to the consideration of high performance materials, such as carbon fibre reinforced composites, in the manufacturing of risers. Whilst the unique properties of composites offer great capability in the design, the lack of field experience and of relevant design codes and standards raise concerns regarding appropriate design methodologies within the oil and gas community.
In this study, an integrated design approach is proposed, whereby information from the micro-scale (i.e. at the fibre and matrix level) is used for the prediction of the structural response at the macro-scale i.e. of the whole pipe.