Roadmap to the all-composite riser - MCEDD
Transcript of Roadmap to the all-composite riser - MCEDD
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April 2019
Roadmap to the all-composite riser
Simplicity
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© Magma Global Ltd Confidential 2
All engineering follows a progressive adoption path
© Magma Global Ltd Confidential 2
PREDICTABLE PROGRESSION
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F-111 A310 A330/340 A320 series F-35 Boeing 787
Composite % of aircraft massStructurally almost all
composites
Source: Technovation, Sept 2015
First composites
used
RudderSpoilers
Airbrakes
Wing skinsFixed skins
Engine nacelles
Access covers
FlapsDry HTP box
LG doorsEngine cowlings
Rear bulkheadKeel beam
J-nose
Hybrid risers
All-composite risers
JumpersFlowlines
Heidrun riser joint
Grids gratings
floors
Frac balls Plugs
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WHY PEEK CARBON FIBRE RISERS?
© Magma Global Ltd Confidential 3© Magma Global Ltd Confidential
Flexibility Corrosion resistanceStrength : weight ratio
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RELEVANT MILESTONES
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✓ Sour service capability
✓ Deepwater deployment
• Insulated and weighted m-pipe
• High pressure high temperature
• 8” composite riser pipe for Hybrid Riser Tower
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© Magma Global Ltd Confidential 5© Magma Global Ltd Confidential 5
SOUR SERVICE SUBSEA DEPLOYMENT
• High sour service gas injection
• 25 year design life, 1000m water depth, 5ksi
• 2.5” 40m jumpers for gas injection
• Light weight simplification
• Rapid installation
• Lowest pipe and installation cost
• Pipe, end fittings and FAT in 8 weeks
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DEEPWATER DRILLING RISER
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• m-pipe deployed independently of drilling riser
• 4 ¾" boost lines
• 840m per hour (70% speed) to 1200m depth
• ROV stabbed & latched in 2 minutes
• Tensioned to remain 10m aft of riser in 0.5kt current
• m-pipe is “stout, tolerant of compression and clashing”
• Deployed from 8.2m reel
© Magma Global Ltd Confidential 6
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© Magma Global Ltd Confidential 7© Magma Global Ltd Confidential 7
NORTH SEA QUALIFICATION PROJECT
• Current project
• 6inch insulated and weighted m-pipe
• Insulation improves flow by maintaining temperature of production fluids
• Material composition can be adjusted to add weight for stability of the pipe in the water column
• Chemical compatibility, strength and flexibility to be evaluated
• Flowlines with the most severe geometrical route selected for the project
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HIGH PRESSURE HIGH TEMPERATURE QUALIFICATION
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• Current project
• Next generation emergency well containment riser
• Rapid response solution for 6 month lifespan
• 250m m-pipe connects a rigid riser to the incident well
• Decoupled solution improves operability and reduces risk
• Qualification of 180°C, 15ksi 6inch m-pipe
© Magma Global Ltd Confidential 8
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HYBRID RISER TOWER ALLIANCE
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CompRiser® benefits versus rigid steel riser tower
• Reduces build from 250 to 50 days
• Reduces production & installation vessel payload
• Reduces project cost and risk
• Avoids corrosion challenge
CompRiser® Qualification Programme DNV and Petrobras
• 6” and 8” qualification for pre-salt conditions to commence soon
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© Magma Global Ltd Confidential 10© Magma Global Ltd Confidential 10
PREFERRED ALL-COMPOSITE DESIGN: SLOR
• Carbon fibre SLOR design
• Lightweight and fatigue resistant
• m-pipe spans seabed to just below surface
• Small buoyancy module provides stability
• Connects to FPSO via dynamic m-pipe jumper
• Cost-effective solution
• Suited to any deepwater basin
• Decouples subsea architecture from the FPSO to reduce risk
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TENSILE STRENGTH VERSUS FLEXIBILITY
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• Composite laminate is built up in layers of fibre/PEEK tape
• Fibres run in one direction along the length of the tape
• Strength and stiffness corresponds with the fibre direction
– Tape lay angle dictates flexibility versus axial tension
• Biaxial gives the highest flexibility
– Suitable for jumpers
• Triaxial gives high tension and axial strength
– Suitable for risers
Biaxial high flex
Triaxial high tension
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REMAINING CHALLENGES
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High tension carbon fibre pipe can still be spooled
• Large MBR, bigger reels
Logistics and installation implications
• Bigger, lighter, reels on customised vessels
• Or tow out as seen in CompRiser® design
The O&G industry is still very steel focused
• Now becoming more accepting of composites
Boeing 787 structure is almost entirely compositeDubbed 7E7 with E for Efficient
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CONCLUSIONS
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Hybrid riser designs are the next generation of riser systems
• HFP is the optimal design for free-hanging risers
• CompRiser® is the hybrid riser tower option
Composite history suggests further exploitation will come as surrounding infrastructure develops
© Magma Global Ltd Confidential
Looking forward:• Investigate Magma’s all-composite riser designs• Consider vessel design to accommodate• Consider alternative deployment methods