Jason Sun

Extra High-Pressure High-Temperature (XHPHT) Flowlines: Design Considerations and Challenges

Development of deep water oil reservoirs in the Gulf of Mexico may encounter conditions where the flowline product temperatures approach 177°C (350°F), water depths range to 3000 m (10,000 ft), and tie-back distances up to 40 miles are presently being considered. These high flowline temperatures, water depths and distances, present real challenges to the design of flowlines. The objective of this paper is to present the design considerations and challenges of designing for extra high pressure high temperature (XHPHT) conditions. For such conditions, a pipe-in-pipe (PIP) flowline system with thermal expansion management, and a limit state-based design are viable solutions. This paper is split into three main parts and covers (i) design challenges and how they are overcome, (ii) finite element analysis design methods, and (iii) qualification testing of PIP components. The first section presents the main design issues, and challenges, of designing flowlines for deepwater and high-temperature conditions. The paper discusses aspects of controlling the large axial loads, such as thermal expansion management using buckle initiators and end constraints for flowlines, and presents current methods. The second section describes the use of advanced finite element analysis (FEA) tools for the design and simulation of PIP systems, and presents local and global FEA models, using ABAQUS, to investigate the limit state design of XHPHT flowlines. A 3-D helical response of the inner pipe subjected to high temperature, and the sequential reeling and lateral buckling of flowlines is also discussed. The final section of the paper describes the qualification testing to be undertaken on PIP components to ensure structural integrity and long-term thermal and structural performance. Qualification testing for PIP components for 177°C (350°F) service is discussed, and includes the testing of centralizers, waterstop seals, thermal insulation and loadshares. This paper is based on both theoretical and practical research work.Copyright

Upheaval Buckling Analysis of Partially Buried Pipeline Subjected to High Pressure and High Temperature

Offshore industry is now pushing into the deepwater and starting to face the much higher energy reservoir with high pressure and high temperature. Besides the significant impacts on the material, strength, and reliability of the wellhead, tree, and manifold valve; high Pressure (HP) also leads to thicker pipe wall that increases manufacturing and installation cost. High Temperature (HT) can have much wider impact on operation since the whole subsea system has to be operated over a greater temperature range between the non-producing situations such as installation, and long term shut down, and the maximum production flow. It is more concerned for fact that thicker wall pipe results in much greater thermal load so to make the pipeline strength and tie-in designs more challenging. Burying sections of a HPHT pipeline can provide the advantages of thermal insulation by using the soil cover to retain the cool-down time. Burial can also help to achieve high confidence anchoring and additional resistance to the pipeline axial expansion and walking. Upheaval buckling is a major concern for the buried pipelines because it can generate a high level of strain when happens. Excessive yielding can cause the pipeline to fail prematurely. Partial burial can have less concern although it may complicate the pipeline global buckling behavior and impose challenges on the design and analysis. This paper presents the studies on the upheaval buckling of partially buried pipelines, typical example of an annulus flooded pipe-in-pipe (PIP) configuration. The full-scale FE models were created to simulate the pipeline thermal expansion / upheaval / lateral buckling responses. The pipe-soil interaction (PSI) elements were utilized to model the relationship between the soil resistance (force) and the pipe displacement for the buried sections. The effects of soil cover height, vertical prop size, and soil resistance on the upheaval and lateral buckling response of a partially buried pipeline were investigated. This paper presents the latest techniques, allows an understanding in the global buckling, upheaval or lateral, of partially buried pipeline under the HPHT, and assists the industry to pursue safer but cost effective design.Copyright

Comprehensive FEA of Thermal Mitigation Buoyancy Module (TMBM)–Soil Interaction Using the Coupled Eulerian–Lagrangian (CEL) Method

Thermal expansion and global buckling is a critical design aspect for subsea flowline systems subjected to high pressure and high temperature (HPHT). In the Gulf of Mexico, HPHT oil/gas production is becoming exceedingly common as drilling and production depths extend deeper. Advanced finite element analysis becomes essential for flowline expansion and buckling design which is highly dependent on pipe-soil interaction behavior. For decades, pipe-soil interaction has been the focus of many research studies and joint industry projects. For HPHT flowline systems, thermal mitigation is decisive for safe design. Thermal mitigation acts to control global buckling at designate locations and avoid buckling in unknown locations. Thermal mitigation results in significant cost savings by lowering the welding class besides the buckling locations and increases safety in terms of local buckling, fracture, and fatigue. One widely used thermal mitigation method involves attaching a buoyancy module around a segment of the flowline. In this paper the Coupled Eulerian Langrangian (CEL) finite element (FE) formulation is utilized to simulate the interaction between soil and the thermal mitigation buoyancy module (TMBM). The paper demonstrates the capability of the CEL FE method to simulate large soil deformation without the numerical difficulties that are commonly associated with other numerical formulations e.g. ALE (Arbitrary Lagrangian Eulerian) or more conventional Lagrangian. Initially, a three dimensional (3D), continuum, FE model is used to establish the variation of initial embedment along the length of the buoyancy and adjoining pipe. The study then establishes the lateral displacement/resistance relationships under different levels of contact pressure and soil embedment for a series of buoyancy-soil interaction segments, also using the CEL FE method. Current practice for global pipeline thermal expansion FEA is to utilize the same friction model for both buoyancy-soil interaction and pipe-soil interaction. The obtained buoyancy-soil interaction model from the current study is to be used as input to the global FE model to more precisely simulate flowline lateral buckling behavior. This paper presents a practical application of the current state of the art in modeling large soil deformations in providing an improved approach for modeling buoyancy-soil interactions in the global FEA of pipeline thermal expansion and lateral buckling.Copyright

Offshore Pipeline Embedment in Cohesive Soil: A Comparison Between Existing and CEL Solutions

A common issue confronted by engineers in analyzing high pressure high temperature (HPHT) pipelines for installation and operating conditions is pipe-soil interaction. For installation, a key concern is whether the soil can generate sufficient resistance to allow the pipeline to be laid on the curve. For operation, a concern is whether the pipeline structural stress can be controlled and mitigated, for the given soil condition, under conditions of thermal expansion and potential global buckling. In both scenarios, pipeline embedment is a critical parameter as it is directly related to soil resistances to the pipeline stability. Previous studies have used experimental, analytical and numerical methods to provide estimates to the pipe embedment during the laying operation. The recently developed Coupled Eulerian-Lagrange (CEL) finite element analysis (FEA) method provides a promising numerical technique in analyzing large-deformation geotechnical problems, such as pipeline embedment analysis. This paper uses this approach, together with currently available embedment solutions, to cross-validate these methods for cohesive soils.Copyright

From Installation to Operation: A Full-Scale Finite Element Modeling of Deep-Water Pipe-in-Pipe System

Developments of deep water oil reservoirs are presently being considered in the Gulf of Mexico (GoM). Pipe-in-Pipe (PIP) systems are widely used and planned as the tie-back flowline for high pressure and high temperature production (HPHT) due to their exceptional thermal insulation capabilities. The installation of PIP flowline in deep water, disregarding the laying method, can present real challenges because of the PIP string weight. The effect of the lowering displacement as well as the lock-in compressive load acting on the inner pipe for the commonly used un-bonded PIP is also a major concern. Such effects will enhance the total flowline compression when the high temperature and high pressure are applied after start-up; they greatly increase the severity of the global buckling and result in local plastic collapse at a larger bending curvature section or strain localization area. An even greater concern is that industry fails to realize the seriousness of such failure potential, and the PIP is generally treated as a composite single pipe which does not evaluate the PIP load response correctly, especially the inner pipe lock-in compression omitted. It could result in an unsafe design for HPHT production. This paper endeavors to provide a trustworthy solution for the HPHT PIP systems from installation to operation by using the advanced analysis tool — “Simulator”, an ABAQUS based in-house Finite Element Analysis (FEA) engine. “Simulator” allows the PIP pipes being modeled individually with realistic interaction between the pipes. A systematic process was introduced by using a generic deep-water PIP flowline as a working example of J-Lay installation and HPHT production. The load and stress responses of the PIP at all installation stages were calculated with a high level of accuracy, they were then included in the global buckling analysis for the HPHT operation. The study demonstrated the effectiveness of Loadshare, an industry-leading solution; which reduces or eliminates the inner pipe lock-in compression and improves the PIP compressive load capacity for the high temperature operation.Copyright

FEA of a Laminate Internal Buckle Arrestor for Deep Water Pipe-in-Pipe Flowlines

Development of deepwater oil reservoirs has been undertaken in the Gulf of Mexico (GoM) where flowlines are installed in water depths in the vicinity of 2,740m (9,000ft). Preventing the propagation of local collapse/buckle failures is one of the key engineering design limit states that is defined in the industry codes to ensure the pipeline integrity. Deep-water buckle propagation is almost unavoidable as the wall thickness selection cannot be directly driven by the buckle propagation limit state. Field data indicates that once a buckle happens, the flowline could collapse for many kilometers instantly. Buckle propagation could cause substantial economic impact if left uncontrolled. For Pipe-in-Pipe (PIP) flowline, due to lack of pressure differential, the jacket pipe is a fragile component in terms of buckle propagation. It is crucial to prevent any possible local buckling during the flowline installation and during the entire operational lifetime. One way to stop buckle propagation is to utilize buckle arrestors of various types. Successfully designed buckle arrestors can contain such disasters to a limited pipeline section. Internal buckle arrestors are a relatively new solution for PIP systems being investigated by the industry. As it is installed in the annulus of PIP, it becomes a preferred choice since it fits all types of installation methods. The objective of this paper is to present the design and finite element analysis (FEA) of a laminate type internal buckle arrestor, and to investigate the effectiveness of this innovative buckle arrestor design for deepwater flowline. Sensitivities of key design parameters are explored with the purpose of guiding detailed mechanical design.Copyright

Finite Element Analysis of Clamp-On Buckle Arrestor for Pipe-in-Pipe Flowlines by Reel-Lay Installation

Development of deep water oil reservoirs are undertaken in the Gulf of Mexico (GoM) where the flowlines are installed in the water depths in excess of 3,050m (10,000ft). Deepwater external pressure becomes so significant that it makes local buckling or accidental collapse propagate along the pipeline. Such propagation will not stop until it reaches a region where the external pressure falls below the propagating pressure or where the pipe wall is strengthened. Field data indicates that once a buckle happens, the flowline could collapse many kilometers instantly. It concludes that buckle propagation could cause substantial economical impact if left uncontrolled. For pipe-in-pipe (PIP) flowline, due to lack of pressure differential, the outer pipe becomes a fragile component in terms of buckle propagation. One way to prevent the propagation of local buckling or collapse is to utilize the buckle arrestors of various types. Clamp-on buckle arrestor is so far the best choice for the flowlines to be installed by the Reel-Lay method. The objective of this paper is to present the results of a finite element (FE) study, to reveal the phenomena of collapsing/propagating of the pipe-in-pipe flowline, and to investigate the effectiveness of Clamp-on buckle arrestor for deep water flowlines. Sensitivities of key design parameters are explored with the purpose of guiding detail mechanical design of the clamp-on buckle arrestor.Copyright

Design of Suction Piles for Deepwater HPHT Subsea Pipelines

Thermal expansion management of high pressure and high temperature (HPHT) pipelines using buckle initiators and anchors has proven to be a viable approach for projects in the deepwater Gulf of Mexico. In this study, using suction piles as pipeline anchors is discussed, as suction piles represent the most commonly used anchoring technology in deepwater. Considerations and issues particular to the pipeline anchoring application are discussed and possible solutions are presented. In this study, the traditional suction pile analysis and design procedures (based on simple calculations and/or the finite element method) are discussed, and modifications and simplifications are proposed to suit the new application. In particular, applying the anchor loads at the mudline level, long-term loading and the absence of significant axial loading are examples of issues and particulars that are common to pipeline anchoring that would either simplify analysis or put restrictions on the validity of current suction pile design procedures. Different types of connections to pipelines and subsea structures are also proposed and addressed. This study extends the applicability of suction piles from mooring applications to thermal buckle and walking management for HPHT pipeline applications. It presents solutions to connection and design issues particular to suction piles as anchoring means for HPHT pipeline thermal management.Copyright