Objective
The aim of the project was to qualify a new concept of flexible pipeline in which classic steel armours are replaced by lighter armours made of composite materials, thus to reduce the weight of the pipeline when keeping or improving its performances regarding service or installation obligations. Typical application for such flexible pipelines concerns the developments of offshore oil fields characterized by deepwater beyond 600 meters.
This project was based on preliminary results obtained through a research programme carried out by COFLEXIP assisted by the INSTITUT FRANCAIS DU PETROLE which had proved the flexible pipeline lightening feasibility.
FLEXIBLE PIPE MANUFACTURING
The two lengths of 500 m equipped with new type of end fittings has been subject to hydrostatic tests. The characterization of the armours had been performed allowing use in very severe environment . A 8" light armour sample has been tested, pull tested over 100 tons, bursting tested at 44,2 MPa, allows the use of such flexible pipe for deep sea applications.
ENGINEERING FOR THE LAYING TEST
The engineering for the modification of the actual laying equipment has been performed, manufacturing of modification is under process, and a specific engineering for laying of the 2 lengths of 500 m flexible by 1000 m water depth has been developed.
The project consists in engineering and manufacturing of the 1000 m long 8" flexible pipeline made of light armours. It was splitted in two main phases :
PHASE 1 concerns project engineering and implementation.
It comprises the following :
MATERIAL ENGINEERING
- Detailed specification, selection of materials, detailed manufacturing process of the light armours,
- Study of composite material mechanical behaviour,
- Study of facilities and methods required for industrial production of the composite armours.
PIPELINE STRUCTURE DESIGN
- Specification of flexible pipe (working pressure, fluid carried waterdepth, laying and operating obligations, dynamic constraints life),
- Static and then dynamic analysis of behaviour under wind, swell and current when being laid and during operation,
- Study of new deepwater effects on the pipeline structure,
- Static and dynamic tests performed on light flexible pipe samples - Design of pipeline end-fittings.
LAYING ENGINEERING
- Detailed specifications required for laying an 8" flexible pipe in 1000 meters of water; study of any necessary adaptations of existing equipment
- Procedures applicable for laying, operating and cases of emergency.
PHASE 2 concerns the manufacture of the flexible pipe. It comprises the following :
- Design and assembly of an automated pilot production line to manufacture composite sections,
- Manufacture of composite armours and quality control,
- Adaptation of existing armouring mahines for correct placement of light armours into flexible pipe structure,
- Manufacture of 1000 meters of 8" flexible pipe, control of the process,
- Assembly of end-fittings,
- Hydrostatic test for 24 hours at 1. 5 times working pressure,
- Winding of the pipe on drum,
- Completion of all documents relating to production and quality control of the flexible pipe.
Programme(s)
Topic(s)
Call for proposal
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DEM - Demonstration contractsCoordinator
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