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Marine Riser Systems
ChevronTexaco ChevronTexaco –– BP BP Training Training Alliance Alliance Floating Floating Drilling Drilling
Integrating … Wellhead, BOP and Riser Design
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The design of casing and wellhead systems should be performed with the complete wellhead system – including the riser.
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Guideline Type Drilling System
Guidelineless Drilling Systems Connector to Housing Interface
Guidebase/GRA Interface
Housing Interface
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Mudmat Interface
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MS-700 Family of Wellhead Systems
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H-4 Family of Wellhead Connectors
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BOP and Lower Marine Package
Courtesy of Hydril Company
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Lower BOP w/ Frame
Courtesy of Hydril Company
Lower BOP
LMRP Mandrel
w/o Frame
Annular
Choke Line
Blind -Shear Rams Kill Line
Super Shear Rams
Upper Pipe Rams Accumulators (x4) Middle Pipe Rams (Varible) Lower Pipe Rams
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(Varible Bore)
Wellhead Connector Courtesy of Hydril Company
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Lower Marine Riser Package (LMRP)
Courtesy of Hydril Company
Lower Marine Riser Package (LMRP) Riser Adapter
Mud Boost Line Control Pod (1 of 2) Single Flexjoint
Annular
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Choke Line Stab
LMRP Connector (H4) Courtesy of Hydril Company
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Funnel Down (Optional)
Hydrate Protection Hydrates must be prevented from entering the bottom of the connector. Ice formed from hydrates will prevent the connector from releasing
Fiber Reinforcement PN H12025-2 (16-3/4" Wellhead) PN H12025-3 (Super Wellhead) Rubber
Groove
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Groove
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Hydrate Protection (Methane Gas)
Hydrate Protection Plum H4 To Inject Freezing Inhibitor
Glycol Inhibitor
Outlet Thru Wash Ports ROV Hot Stab Inlet Thru Wash Ports
SHD H-4 Wellhead Connector
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Cavity Capacity 32 Gallon
Type of Well
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Exploratory Wells
Disposal
Non-Disposal
Developmental
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Wellhead Re–Entry Systems
DP
Moored
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Subsea Wellhead Angle
Riser Deployment and Retrieval
Environmental conditions Location Season Vessel
Deployment / Retrieval Riser fatigue life
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Currents
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Riser Handling and Lifting Gear Capacity
Substructure
Derrick
Drawworks
Hook block
Handling gear
Riser Running Tool
Riser Gimble Shock Absorber
API Riser Coupling Class
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API RP 2R establishes riser coupling classes based on the tensile capacity of the coupling. These are; API Riser Coupling Class
Tensile Capacity in millions of pounds
A
.5
B
1.0
C
1.25
D
1.5
E
2.0
F
2.5
G
3.0
H
3.5
J (Proposed)
4.0
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MR-6E Riser Coupling
Easy stabbing, fast makeup, and positive alignment
Suitable for operating in water depths up to 7,500 ft depending on environmental and well control conditions; MR-10 designs can operate in depths to 10,000 ft.
Preloaded connection significantly reduces the range of alternating stresses induced by cyclic loading to improve fatigue life
Primary load path for tensile and bending loads through the dogs and into the body, does not impact actuating screws
MR Riser Running Tool 4-1/2” IF API Connection
18o Tapered Drill pipe Connection
Lift / Handling Eye
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Choke, Kill & Auxillary Test Caps
MR Box Connection Profile
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HMF Riser Coupling
Ideal for deep water applications where high load operating conditions exist
Stepped diameter design of pin and box simplifies engagement, even with severe vessel movement
No loose parts preventing bolt loss and potential thread damage
Field removable and replaceable nose piece
Locking bolts preloaded in excess of rated coupling loads to extend fatigue load of riser system
HMF Riser Running Tools
Casing Elevator Lift Shoulder
Handling Lift Eye
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HMF Male Connection Profile
Mechanical Running Tool
Hydraulic Running Tool
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Riser Handling Tool
Spider
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MR-style riser handling spider supports the riser string on manual or hydraulically operated sliding dogs.
Hydraulic-gate riser spider is used when running or retrieving HMF riser joints through the rotary table.
Gimbal
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Gimbal shock absorber supports up to 2,000,000 lb and gimbals when the riser is positioned in the spider.
Reduces impact loads when running and landing marine riser joints.
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Single Flex Joint with Mud Boost Line
Flex Joints
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Single Flex Joint & Intermediate Flex Joint
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Riser Extension
Key Riser Components and Inspection
Drilling Riser
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Prepped for Buoyancy
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Installation of Syntactic Foam Buoyancy Modules on a Riser Joint
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90’ (27.4m) Riser Joint (w/ Spreader Bar)
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Telescopic Joint
Telescopic Joint
Available for both multiple riser systems Compensates for heave and offset of the vessel Maximum rated riser tensile load capacity in
locked position Hydraulic latch release for inner and outer barrels
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Dual split/solid packer elements Fixed or rotating integral/non-integral tensioner
rings SDL, SLS, KT and SDC tensioning rings
Primary Components of Telescopic Joint The outer barrel sub assembly has several functions:
Providing a means to apply tension to the Marine Riser / BOP
Fluid assist bearing to allow rig rotation
Tension ring to eliminate the tensioner wire removal
Dual packer assembly
Kill, choke and Auxiliary line supply assembly
The inner barrel sub assembly functions:
Providing communication between the vessel and the BOP during drilling
Contains an Auto latch system to lock inner/outer
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barrel
Split lock nut for easy servicing
Cross-over flange to riser connection and diverter
Fully extended can support 1.5m lbs
Crossover to Riser Connector
Split Lock Nut
Hydraulic Latch
Dual Packer Inner Barrel Latch
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Inner Barrel
Slipjoint / Telescopic Joint
Slipjoint / Telescopic Joint
Options Options
SDL Tension Ring
Fluid Assist Bearing
Kill & Choke & Hydraulic Supply Terminations
SLS Tension Ring
Options
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KT Tension Ring
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Type SDL Riser Support Ring
Saves rig time by eliminating tensioner wire removal
Stored below diverter and allows the rest of the riser to be pulled through
Contains two sets of hydraulic dogs One to latch to diverter for storage The other to latch to outer barrel while drilling
Diverter System
In Floater Operations
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The primary function of a diverter is to divert shallow gas through overboard piping before the installation of the BOP stack. This vents the well and protects the formation before it is capable of handling closed-in pressure from the installed BOP. After the BOP is installed it is used to vent gas in the riser, above the BOP.
There are two primary models of Vetco Gray diverters used on floaters: KFDS – using an expandable rubber packer KFDS- CSO – using a collapsible rubber element
There is one primary model of diverter used on Jack-ups and Platform rigs : KFDJ – using an expandable rubber packer
Diverters are available in 39-1/2”, 49-1/2” and 60” nominal sizes
Pressure ratings range from 500 to 1000 psi
Hang-off capacities range 500 kips – 2000 kips
KFDS Diverter System
Pressure Rating (Wellbore): 500 PSI
Diverter Operating Pressure:
Rotary Table
Control Lines/Block
Normal 750 psi ( 52 bar) Maximum 1500 psi (103 bar)
Insert Packer
Diverter Assembly
DiverterLocking Dogs
Diverter Housing Flowline
Flowline Seals (x2)
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Flex Joint
Crossover to Riser Connector
KFDS Diverter System
Pressure Rating (Well bore): 500 PSI
Diverter Operating Pressure: Normal 750 psi ( 52 bar)
Control Lines/Block
Maximum 1500 psi (103 bar)
Insert Packer
Diverter Assembly DiverterLocking Dogs
Diverter Housing
Flowline Seals (x2)
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Flowline
Diverter Assembly Packer Element
CSO Diverter Divert Line Flow Line
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Diverter Flex Joint
C
B D
Current induced loads can cause the Riser to bind as it is run through the Rotary Table and Diverter Housing.
A D
DIVERTER HOUSING REGION
W.L.
D
A
D
CURRENTS
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A STRUCTURE/RISER CONTACT B
BINDING CONTACT, RESULTING IN RISER DAMAGE AND FOAM MODULE DAMAGE.
C MAKE-UP DIFFICULTIES DUE TO ANGLE. D RISER OVERSTRESS.
Lifting Equipment Rig lifting equipment must be able to deploy the Riser with the LMRP/BOP Package without exceeding design capacity.
WAVE HEAVE W.L.
HOOK LOAD INDICATOR
RATED LIFTING GEAR CAPACITY
DYNAMIC LOAD ON LIFTING GEAR
HOOK LOAD NET WEIGHT OF RISER ON LIFTING GEAR
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TIME
AMPLIFIED RISER RESPONSE
MUDLINE
Storm Hang-off of Riser HARD HANGOFF, RISER HEAVES WITH VESSEL
SOFT HANGOFF, RISER HEAVE IS MINIMIZED BY TENSIONER STROKE
Stay attached during storm conditions
Disconnect the riser and pull out of the hole
Hang-off – Hard or Soft
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W.L.
LMRP
Riser Fatigue Considerations
Wave Loads Environmental Conditions Riser Pipe
Current-induced Vortices
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⇒ Steady ⇒ Current ⇒ ⇒
VIV Excitation Due to Currents Vortex shedding due to steady current acting on a pipe results in pipe dynamic motions and fatigue.
Drift-Off/Drive-Off D E G R A D IN G S T A T U S G REE N
P REP FO R E DS
E D S T IM E ( A P P R O X . 60 SEC ON D S)
YE LL O W A LE RT
R E D ALER T
D IS C O N N E C T C I R C L E
V ESSEL O FFSE T FR OM W ELL C EN TE R
G R E E N - N O R M A L O P E R A T IO N S Y ELL O W A LER T - P RE PA RE FO R E DS R E D A L E R T - E D S IN IT IA T E D
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D IS C O N N E C T C IR C L E - E D S C O M P L E T E D , R IS E R D IS C O N N E C T E D
• Disconnect Speed • Control System
• Riser Tension Recoil • Control of Disconnect
Limits for Connected Riser Operations
VESSEL MOTIONS ANGLE
WAVE ACTION
CURRENTS
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ANGLE
MUDLINE
W.L.
C
A
VESSEL OFFSET ANGLE
W.L.
B
POSSIBLE WEAKPOINTS C ANGLE D
E
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MUDLINE F
Riser, Wellhead and Conductor Strength
A
TENSIONERS/TELESCOPIC JOINT
B
RISER
C
FLEX JOINT
D
LMRP/BOP
E
WELLHEAD & CONNECTORS
F
CONDUCTOR PIPE
To prevent failure of Riser/Well System Components, Emergency Disconnect must be completed before vessel offset causes the Riser/Well System to exceed allowable limits.
θ
System Considerations F
System Objective Provide a system level solution for drilling in ultra deepwater drilling:
BOP Flange Wellhead Connector
~6.6 MM ft-lbs
~7 MM ft-lbs
~7.7 MM ft-lbs ~8.4 MM ft-lbs
15,000 psi to 20,000 psi rated pressure
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Wellhead System Conductor/ Casing Connectors
BOP Flange Wellhead Connector Subsea Wellhead System Conductor Sizing (Analysis) Conductor/Casing Connectors
~14 MM ft-lbs (40' Below Mudline)
7,000,000 ft.-lbs. Bending @ 15,000 psi
MUST MAINTAIN CLEARANCE IN TELESCOPIC JOINT
Riser Recoil Response
NO SLACK IN WIRE ROPES
W.L.
LMRP LMRP MUST MAINTAIN CLEARANCE ABOVE BOP STACK
BOP
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LMRP
BOP MUDLINE
After riser disconnect, the LMRP must be lifted to prevent contact with the BOP stack during vessel down heave.
Riser Burst Pressure
Minimal pressure device
Contingency plan for bubble in riser
W.L.
MUD PRESSURE
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SEAWATER PRESSURE BOP MUDLINE
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Gas in Riser vs Choke/Kill Line
Riser Collapse/Riser Fill-Up Valve Placement
W.L.
During an emergency disconnect, external pressure from seawater can collapse the Riser if the mud column drops too fast.
EMPTY RISER
LMRP
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MUD RELEASE FROM RISER SEAWATER PRESSURE BOP MUDLINE
Torque Loads due to Heading Change
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As vessel heading is changed, excessive torque can be applied to the connected drilling riser.
Wellhead with a rigid lockdown mechanism to enhance fatigue life.
Control Panel Release Piston Indicator Power Piston Indicator
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Latch to 36”
Riser Monitoring Systems and Inspection Methods Daily: Mud weight Environmental conditions change Riser tension and rig location
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Long Term: Corrosion Cracks Wear and Damage Choke and Kill lines
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Benefits from Composites
General Increased fatigue life Elimination of corrosion problems
Composite Choke and Kill Lines Provides a 60% weight savings over equivalent steel lines Can save about 25-30% of the total riser string weight, thus extending an existing rig’s drilling depth accordingly
Composite Drilling Riser System Provides a 65% weight savings over steel riser systems Can increase the drilling depth of an existing rig or platform Significantly reduces the variable deck weight
Composite Production Riser Provides a 60-80% weight savings over equivalent steel risers Can eliminate the need for tensioners on TLPs and SPARs Can increase the number of wells for a given vessel smaller space requirements less deck weight Can increase the water depth for a given production system.
VGI Composite Products
X X
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X
Choke & Kill Lines Drilling Risers Production Risers
Harnessing incredibly strong carbon fiber and durable epoxy matrix to produce light-weight oilfield products
Composite products are providing solutions to today’s challenges
Composites enable use of existing rig fleets and production platform designs to go deeper -safer and less expensively.
5,000’ Rig Upgrade to 10,000’
Baseline 5,000’ Water Depth Capable Rig X All Steel Riser System (C&K, booster, hydraulic) X Nominal 2,000 Kip Tension with 15 ppg Mud X 46” Diameter Buoyancy X Deck Weight of 2.3 M lbs X Day Rate of $30k
Steel System
Composite System
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10,000’ Composite Riser Upgrade X System Deck Weight X 5,000’ of Steel Riser Body X 10,000’ of ALL Aux. Lines X Added 3,000’ of Buoyancy X Total
$8.4 Million Savings
3.55 M lbs $2.0 M $11.7 M $1.5 M $15.2 M
OR
10,000’ Steel Riser Upgrade X System Deck Weight X 5,000’ of Full Riser X 7,200’ of 56” Buoyancy X Total
5.8 M lbs $5.3 M $6.1 M $11.4 M
+
Savings in Upgrades on Rig X 12 Months of Docked (50%) X 60” Rotary Table Upgrade X Rig Buoyancy Upgrade ($2.36/lb) X Total
$5.5 M $1.5 M $5.2 M $12.2 M