Professional Documents
Culture Documents
Abstract: Subsea umbillicals, risers and flowlines (SURF) technologies are an essential element of any deepwater oil and
gas exploration, with countless associated challenges but immense potential. This work intended to explore the available
solutions existent nowadays in terms of riser systems, as well as possible future technological developments in the area.
Combining specific technical analyses with an overview of the whole oil and gas industry was the key to reach this thesis
objectives.
This thesis was based on IRGCs risk analysis framework, which contemplates interviews with experts and extensive
literature review, and a comparative case-study analysis. The dynamic analysis and comparison of two flexible riser
configurations, namely Free Hanging and Lazy Wave, gives an insight on the systems limitations and the path to follow
towards innovation in SURF engineering.
From the results and investigation throughout this work, the most unanimous solution found for the future of riser systems
consists of changing part of the structures material to composites. Moreover, it is believed that the key to SURF
technologies development is the systemic integration of structural modelling with hydrodynamic and heat transfer analysis
within engineering education, since this collaboration is crucial to the systems global analysis. Therefore, this work is a
helpful tool to understand the correlation between engineering, the intricate global market that the oil and gas industry is
inserted in and the influence an improvement in engineering education can have in such a complex industry as this one.
Keywords: Oil and Gas; Deepwater; SURF Engineering; Riser Systems; Risk Governance; Technological Development.
1
2. RESEARCH PROBLEM AND OUTLINE highly iterative procedure and very dependent of
specific data. [2]
In this thesis it is aimed to open the debate about
It has been stated, with extensive proof and
technological questions of the deepwater oil
support, that this technique can be applied to
exploration challenges. SURF (Subsea Umbillicals,
science related subjects if there is enough data to
Risers and Flowlines) engineering is a major topic
overlap and reach actual conclusions. Once the
within the oil and gas exploration industry,
theory is built, one must guarantee that it is
gathering some of the most complex engineering
evaluated, testable and logically coherent. [3]
design processes. Those challenges are
The reason why technology is such an important
exponentially increased when considering
part of the companies strategy is the fact that it is
deepwater exploration, therefore being relevant to
responsible for providing them with competitive
survey the existent solutions and assess the
advantages within the market. It goes without
viability of an alternative to the current option.
saying that the increases of factors like cost,
A review of the available riser technologies is
complexity and rate of technology change and the
presented, characterizing its benefits and
globalization of technology sources, contribute to
drawbacks, properly accompanied and justified
turning these technological outbreaks into critical
with examples and real applications in a case
issues. [4]
study basis with appropriate bibliographic review
and interviews.
3.2. Risk Governance International Risk
The main focus of the work is to evaluate the
Governance Council
feasibility of using a Free Hanging riser in a simple
There is a primal objective in doing a risk
catenary as a substitute of a Lazy Wave
governance analysis that consists in assisting
configuration in a deepwater field, through
experts to design policies, strategies and
structural dynamic analysis and thorough
regulations to maximize the benefits of a
comparisons.
technological improvement and new approaches to
With the knowledge from the first chapters in mind,
the deep-sea offshore oil and gas industry.
one can analyse in what manners can these riser
Recognizing the existence of risks is the first step
technologies be improved, what are the probable
of a process that leads to working on measures to
paths to future developments and relate to the
comprehend, prevent and solve those same risks.
Portuguese industry and the way it can be a part of
This process includes risk analysis of new
those developments. This discussion and the
technologies projects in the oil and gas industry,
suggested future work are addressed in the end.
and also possibly combining other industries
3. METHODOLOGY developments. Clearly, this thesis aims for these
3.1. Case Study Definition analysis, with results on the risks for the
technologies approached in the case studies.
The process of inducting theory from case studies
The International Risk Governance Council, IRGC,
analysis is a validated concept, considered of
provides a risk governance framework that
special importance to new topic areas. This is a
2
consists of an understanding approach to pay help
in the analysis and management of relevant risk
issues for which there is a shortage of structures
and processes in risk governance.
As the sector keeps changing and adapting to the
constant new challenges that emerge everyday,
the analysis to the risks is essential to the
development of state of the art technology. The
IRGCs methodology is important to collect vital Figure 1 - Example of a typical subsea layout with underwater
information to overcome, analyse, govern and equipment, a support vessel and riser systems [8]
manage all the possible phenomena, generating The kind of platform or vessel being used in the
knowledge around uncertainty. exploration activity is also responsible for the
different shapes and formats that the riser systems
4. EMERGING FORMS OF SURF
can assume. In terms of deepwater riser concepts,
ENGINEERING some have been successfully deployed to FPSO
application, such as classic steel catenary risers
Subsea technologies play a vital role in the
(SCR), flexible risers and hybrid risers. Also,
hydrocarbon exploration process, where each
options like Tension Leg Riser (TLR), Hybrid
pump, sensor or cable has its specific function and
Catenary Riser (HCR) and few more, have also
must not fail. Within these range of equipment and
been having positive feedback when applied in
parts, there is one that is widely recognized as the
deepwater. [20]
most critical one, carrying enormous implications
along with its possible failure: the riser. 4.1. Riser systems technology
In a very simplistic way, a riser is basically a pipe
connecting the platform or vessel on the surface The variables that define the operating conditions
and the wellhead at the seabed, with fluid can take numerous ways and, given that, selecting
transportation as its main function. Obviously, this the type of system adequate to each case is a
is a very reductionist definition, as the level of challenge by itself. Even though the number of
complexity involved in this particular component is options when choosing the adequate riser system
as high as modern technology can go. to an application is quite high, following some
Different kinds of riser systems concepts and simple criteria can make the primary selection
technologies are idealized for dissimilar conditions; much simpler. Emphasis here on the word
water depth and environmental issues are the key primary, since the final choice depends on more
factors responsible for this need of different than this technical issues. Some of the most
approaches. Following the trend of every other influencing technical factors in the selection are:
3
Application (static or dynamic); The most common rigid riser is the SCR, steel
Working conditions; catenary riser, which can be used in applications
Number of lines; with larger diameters, higher pressures and
Crowding of seabed; temperatures and, overall, is cheaper than flexible
Platform displacements and admissible lines. The increased diameter allows for a higher
loads; production flow rate, consequently making a more
Ease and speed of installation, performed All things considered, the main challenge in the
by a lightweight and economical vessel; riser systems is to find a compromise between the
cost, including development and installation costs,
High reliability due to its complete
and every factor linked to costs afterwards, like
manufacture onshore;
maintenance, operability, and risk of damage.
Functions separation (leakproofness and
There is no denying of the fact that the major factor
mechanical resistance) which increases its
is the economical one.
reliability;
Ability to adapt to all sorts of seabeds 4.2. Flexible riser configurations
without buckling problems;
High corrosion resistance. The flexible riser solutions, which are the focus
here, can have different configurations. The most
Brazilian exploration is the best example of flexible
common solution is designated Free Hanging,
riser usage, given the fact this concept is widely
consisting of a pipe that runs in a catenary shape
spread over their deepwater fields, commonly used
from the upper connection point (on the floating
in applications with FPSOs.
4
unit) to the seabed. The fact that all the weight is Wave and Steep S, the Free Standing Riser or
suspended and supported by the sole connection the recent Double Camel Wave type.
with the vessel makes it difficult to bear when Accounting for all the flexible solutions presented,
higher depths are attained. Also, the dynamic it is safe to say that the starting point of any
motions caused by the hydrodynamic loads on the flexible riser analysis should be the Free Hanging
riser and vessel constitute a major problem in configuration, considering the fact that it is the
terms of fatigue in the top connection. most economical (both in hardware requirements
The Lazy Wave configuration shows a sort of and installability terms). Its dynamic limitations,
loop formed between the upper connection and however, put it aside very soon in many situations.
the seabed caused by the attachment of buoyancy If the first option fails, the next most economical
modules along a given section of the riser. The comes with the wave configurations: typically with
major difference to the Free Hanging solution is the Lazy Wave, which is the simplest of the bunch,
the distributed buoyancy section that allows for but also Steep Wave and Pliant Wave. All require
greater vessel motion: these motions are partially more hardware than the Free Hanging
dissipated by the buoyed sections flexibility and configuration and have sluggish installation
only the rest affects the riser. This constitutes a processes, yet not more complex. The constraints
great advantage, although not the biggest, since in the number of risers appear as a major
that is considered to be the ease of installation. drawback and force these configurations to be
The Lazy S configuration displays a riser in a abandoned in some cases. The S configurations,
double catenary with the help of a subsurface buoy namely Lazy S and Steep S, have more complex
and a mid-water arch. Both the mid-water arch and installation procedures due to the large (and
the buoy are tensioned through a sling (that somewhat cumbersome) equipment needed.
consists of a wire rope loop commonly used for Despite this, they constitute very good solutions,
heavy equipment lifting) and dead weight. Usually, with great technical robustness and permitting
the risers are clamped at the top of the buoy and multiline systems with a large number of risers.
guided over gutters to avoid overbending issues. The Pliant S system should only be considered for
shallow water applications, where it has been
demonstrated that vessel excursion cannot be
accommodated by a Lazy S configuration. It is very
costly to implement this solution, both time
consuming and in terms of complexity, requiring
many additional hardware.
Figure 2 - Flexible pipe riser systems configurations: a) Free All in all, Free Hanging and Lazy Wave are both
Hanging; b) Lazy Wave; c) Lazy S [8] the most common and cost-effective solutions
Other solutions can be found, as the patented within the ones presented, being logical to deepen
Pliant Wave and Pliant S, the classical Steep its study in the context of a practical real life case.
5
5. DYNAMIC ANALYSIS OF A DEEPWATER Figure 3 shows the typical configuration of a
flexible risers layered structure. Within that
FLEXIBLE PIPE RISER SYSTEM
structure one can include the following layers:
The case study here presented is part of a real
Inner interlocked carcass a crushing
project, currently in the design phase; therefore
resistant layer that is optional on the structure,
some of the information is sensible and will be
depending on the need for external radial forces
carefully dealt with. The project is included in the
resistance;
exploration of pre-salt oil field, in the Santos basin,
Thermal screen a thermal barrier with
about 300 kilometres off the coasts of Rio de
the purpose of decreasing the pressure sheaths
Janeiro and Sao Paulo states. The vessel/platform
temperature beneath its maximum allowable
to be used is an FPSO, as usual in the Brazilian
temperature;
fields, spread moored type, and will operate at a
Pressure plastic sheath included to
water depth of 2150 meters. The purposes of the
guarantee internal leakproofness;
project cover many areas like producing, storing
Zeta spiral used to complement the
and offloading oil, also producing, re-injecting and
carcasss function of resisting collapse and radial
exporting gas, injecting water and re-injecting CO2.
mechanical compression and also add the
5.1. Flexible Pipe Design resistance to internal pressure;
Psi spiral similar to the previous;
Whatever the option taken in terms of configuration
Flat steel spiral a pressure backup
is, some basic considerations are common and will
layer used to reinforce the radial resistance;
always be respected: the structure consists of
Anti-collapse plastic sheath a layer
several layers, which are limited in types, although
that it is not necessarily always used but whose
in each case one can detail specific parameters
function is to transmit the external hydrostatic
according to the requirements; the kind of physical
pressure to the pressure armours, preventing
tests that must be performed, some of them in the
collapse;
factory and others on-site.
Anti-wear plastic layer a layer used to
suppress the wear between metallic layers;
Tensile armours intended to resist axial
forces;
Intermediate plastic sheath optional,
above the pressure sheath, or the anti-collapse
sheath, and under the external sheath;
Figure 3 - Typical structure layers of a riser systems flexible External plastic sheath designed to
pipe [8] keep the armours in position, protect them against
environmental corrosion and protect the insulation
layers against water ingress;
6
Outerwrap interlocked steel carcass When designing flexible pipes for riser applications
optional, helps preventing the transfer of crushing there are a number of major failure modes to
loads to the tensile armours. account for, here considered throughout the
analysis. Some of those issues are addressed
Based on the conditions verified and the properties
through the structure design itself, meaning the
of the layers constituting materials, one can define
layers and their properties, whereas others require
the appropriate structure for each application.
an exhausting and iterative approach posterior to
7
Another possible source of problems is related to (which comes from safety factors and is highly
the vessels supports of each riser; each line, influenced by the service life) one needs to
according to its function and location on the consider a vast list of currents coming from all
balcony, has a specific support associated and a directions, combined with waves that come in
correspondent support limit. The critical situation different periods and heights, as well as the draft
is during the installation process, when all the coming from the vessels load, resulting in
lines weight is being supported there, and the thousands of cases to analyse.
worst case happens if the installation is performed
5.3. Configuration Comparison and Results
with the line full of water. The limits are usually
pretty high, but the supports design has a lazy Table 1 shows the chosen structure for the
wave configuration in mind, where the buoyancy practical case studied in this thesis. Defining this
modules relieve the top connection from much of structure in the adequate software, one could
the weight, and not a free hanging one. Then, this assure that all the criteria associated with the
calculation is particularly necessary in the Free bursting pressure, damaging pull, end-cap effect,
Hanging case, disregarding it in the Lazy Wave. lateral buckling and collapse failure modes were
Although all these problems are relevant, the met. The top connection also endured the total
biggest issues are related to fatigue, as the cyclic weight of the riser, even in the event of installation,
loadings cause much more damage than simple where it is full of water.
one-time loadings. Clearly, when talking about Layer number Type of layer
underwater applications there are always cyclic
1 Interlocked carcass
loadings, given the fact that currents and waves
2 Pressure sheath
act on the structures causing them to move in
3 Teta clip
different directions. In this particular case of a
4 Spiral
flexible riser, the critical sections are located on
5, 7, 10, 12 Anti-wear tape
the top connection and on the TDP, both for the
6, 11 First armour
Lazy Wave and Free Hanging. The fatigue
8, 13 Second armour
problems are prone to be less in the Lazy Wave
9 Fabric tape
configuration, as that is one of the reasons that
14 High strength tape
lead to the configuration choice in the first place.
15 Leakproofness sheath
The buoyed segment helps to isolate some of the
16 Fabric tape
movement and releases some tension from the
17 External sheath
critical fatigue points. As far as the Free Hanging
Table 1 Structure used
configuration is concerned, the worst point is on
the top connection, right next to the bend stiffener, Deeplines was the tool used to model the whole
having all the structures length influencing the system and perform the dynamic global analysis.
dynamic loading. So, in order to assess if the total The result of several configuration studies, which
damage is within the acceptable value range had to ensure conditions like the top angle
requirement (9 in this case), is presented in
8
Figure 5, where the two configurations can be 6. DISCUSSION AND CONCLUSIONS
compared.
6.1. Future of the Oil and Gas industry and
SURF technologies
9
of the structures material to composites, instead of sufficient degree of complexity to justify an
keeping the metallic alloys. The composites analysis of this specificity. Finally, from a not so
industry is fast-growing and spreading to technical perspective, it would be interesting to
diversified areas of application, including some of expand the investigation on the impact of
the most challenging; the aerospace industry must engineers education in the industry and the
be quoted as a reference. Adapting the knowledge opposite. The repercussion of possible future
gained through years of development of aerospace changes in the system should be evaluated.
equipment to the demanding world of deep and
7. ACKNOWLEDGMENTS
ultra-deepwater oil and gas exploration is a
challenge. But starting from zero is an even bigger I would like to thank specially to Professor Manuel
challenge, so it is believed that experience based Valsassina Heitor for his guidance and availability
breakthroughs are the correct path to follow. all through this work, for opening my in mind to
Industrial policies are crucial to major paradigm such different areas of interest and for the
shifts in terms of technological development. In opportunity to work with him.
this case, it is believed that the relations between To my parents and my brother, eternal
industry and universities should be promoted, not gratefulness for their unconditional support.
only with respect to the actual students during their To all the interviewed experts I want to thank for
formation, but also considering the scientific their availability and valuable contributes.
investigations. For one, the level of qualification
and experience of the investigators is very high, 8. REFERENCES
10