Design Challenges & Solutions for Large Diameter Export Risers
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2 Design Challenges & Solutions for Large Diameter Export Risers Elizabeth Tellier, Hugh Howells & Mark Cerkovnik 2H Offshore Engineering AOG 2011
3 Agenda WA export riser design challenges Development options & design parameters Current industry examples Export riser types and design limitations Alternative large diameter export riser arrangements More gas developments Learn more Higher at gas volume Large diameter export systems
4 WA Export Riser Design Challenges Severe environments Cyclones Swells Floaters in shallow water Long service lives (40+ years) Design for larger return periods Sour service Minimal processing on vessel
5 Development Options Export Risers Flexible Steel Catenary Riser (SCR) Top Tension Riser (TTR) Freestanding Hybrid Riser (FSHR) Vessel Semi Submersible TLP FPSO Spar
6 Design Parameters Gas developments Water depths 300m to 1,300m Flexible riser ID 16 + Steel riser OD 18 + Operating Pressure 135 to 550 bar
7 Large Diameter Risers Current Industry Examples Riser Type Field Name Water Depth (m) Max OD/ID (in) Vessel Type Location Flexible Bonga FPSO Nigeria Statfjord B FPSO NS Nor Prince TLP GoM SCR TTR FSHR Ind. Hub 2, Semi GoM Thunder Horse 2, Semi GoM Snorre TLP NS Nor Heidrun TLP NS Nor Kizomba 1, FPSO Angola Learn P52 more at 1, FPU Brazil
8 Flexible Pipe Technology Limits Large Diameter Risers Water Depth (m)/design Pressure (bar) Design Pressure (bar) Water Depth (m) Internal Diameter (in) Qualified Learn more 19, at 500m WD, 1500psi (103 Bar)
9 Steel Catenary Risers (SCR) Large Diameter Limits GoM Projects Large Diameter SCR by Function and Vessel Type Outer Diameter (inch) TLP/Spar Semi ,000 1,500 2,000 2,500 3,000 Water Depth (m) TLP Oil Export SCR Spar Oil Export Semi Oil Export SCR TLP Gas Export SCR Spar Gas Export Semi Gas Export SCR
10 Why might WA export risers be different? Many riser system variations evaluated in the past Gulf of Mexico Deep and Ultra deep water (1,000m to 2,500m+) Predominately Oil service Harsh environment West Africa Deep water (1,300m to 2,700m) Predominately Oil service Mild environment Norwegian Sea/West of Shetland Shallow and marginally deep water (350m to 1000m) Gas and oil Harsh environment Australia s NWS does not fully fit into any of these categories Water depth (300m to 1300m) Gas Harsh environment Modifications may be needed for robust riser solutions Alternative arrangements based on extensive work done previously for Learn WoS and more Norwegian at Sea
11 Steel Catenary Risers (SCR) and Alternatives
12 SCR Challenges Buckling
13 SCR Alternatives Weight Optimization Weighting Weighting near touchdown improves performance OMAE 29049, 2007
14 SCR Alternatives Weight Optimization STATIC RESULTANT CURVATURE No Environmental Loading Curvature (1000/m) Distance From Vessel (m) Bare SCR Heavy Coating Clump Weight SCR curvature in TD zone is reduced by 20% with additional weight OMAE 29049, 2007
15 Lazy Wave Catenaries 800m Plan length x water depth
16 Lazy Wave Catenary Response Large Diameter/Deep Water 28in, 2300m water depth
17 Lazy Wave Catenary Response Effect of Internal Fluid 30 OD Gas filled Water filled
18 SCR Vessel Interface Design Flex-joints Historic failures Pressure cycles High Temperature Larger diameter increased stiffness Gas service high and low temp 24, 90C, 3700psi (255 bar) Stress Joints Large loads from vessel offset Multiple forgings for large diameters Titanium alternative
19 SCR Alternatives Bottom Weighted Riser Vertical Section Pile Foundation Tether (3 Off) Flex Joint/Elbow and Weight Assembly Horizontal Section
20 SCR Alternatives Bottom Weighted Riser
21 SCR Alternative Tethered Riser Buoy Petrobras Pre Salt Development
22 Top Tensioned Risers Wellbay interface Large valve stacks Flexible jumper Congestion/routing of topside piping Stroke sensitive Connector design
23 Export TTR Alternatives Jumper Arrangements 30 OD TTR Single 24 rigid jumper with flex joints Multiple 12 rigid jumper with flex joints Multiple 12 titanium jumpers
24 Export TTR Base Arrangement
25 Freestanding Hybrid Riser Clearance issues Large spatial requirement Size of flexible jumper ID Pigging Solutions Dual Jumpers Bundle with multiple jumpers/modified manifold Use of intervention vessel for pigging
26 FSHR Alternative Dual Flexible Jumpers OTC 17521, 2005
27 FSHR Alternative Bundle
28 Bundle Riser Base with 30in Core
29 Summary Current and future production systems for offshore Western Australia require the use of large diameter risers for export of gas Riser design limits may impact the selection of production facility Export riser choice dependant on water depth, diameter, vessel and environment Flexible riser greater than 16 ID - limited by water depth and pressure ratings SCR, TTR and FSHR are optimal solutions for large diameter export riser solutions in WD>500m Use of Norway NS and WOS concepts and current GoM deep water riser technology will enable feasible riser solutions for NWS
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