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EWSHM2016, Bilbao, SPAIN
New generation of flexible risers equipped with motion capture
Morphopipe System
N. SAGUIN-SPRYNSKI1, M. CARMONA1, L. JOUANET1, O. DELCROIX2
1 CEA, LETI, Univ. Grenoble Alpes, Grenoble, France – 2 Technip, Flexifrance, Le Trait, France
[email protected] ; [email protected] ; [email protected] ; [email protected]
Riser integrity management can be performed at different levels. As a first indicator, the system compare the actual curvature and angle
versus the expected envelop. This validate the expected and safe riser behaviour and alert the operator if required. Data from Morphopipe
combined with other data from monitoring systems or inspections can give refined indication on the status of the riser. Morphopipe will
provide valuable data for accurate re-assessment of the fatigue. The calculated life span of the riser can be updated.
Through FORSYS Subsea, the alliance between FMC Technologies and TECHNIP, Morphopipe data will act as an additional enabler of
pro-active condition-based maintenance so as to increase uptime and accelerate decision time.
CONTEXT, CHALLENGES
MONITORING SOFTWARE
ASSIOCIATED SERVICES
METHODOLOGY AND VALIDATION
Summary Structural dynamic monitoring is a fundamental element for predictive maintenance of flexible risers, subject to harsh constraints. The
collaboration CEA/Technip resulted in a new solution with MEMS accelerometers, called Morphopipe. The flexible riser equipped with
the Morphopipe system allows the estimate of the consumed service life via the curvature knowledge. The context, the technology and the
algorithms will be mentioned, as well as the industrial integration at manufacturing stage and the added values of such a system.
Use of MEMS accelerometers in manufacture challengeStructural monitoring of flexibles
• Flexible risers: multilayers structures to convoy oil/gas offshore
• Harsh constraints over 20 years
• Curvature at the bend stiffener: main parameter to estimate
(detection of extreme events, involved in cumulated fatigue)
• Needed to improve safety and will potentially extend lifetime
• Expertise in shape/motion capture via inertial sensors in CEA
• Need to use highly performant 1-axis MEMS accelerometers
• Instrumentation have to be embedded, in a non-accessible zone
during life time, with a process compatible with each project
[specific requirements: water depth, sea state, pressure,
temperature…]
• Additional instrumented layer, compliant with riser design and industrial
manufacture
• Reliability considerations: reliable sensors, redundancy, architecture and
encapsulation designed for ATEX and IECEx certification
• Calibration process dedicated in order to provide accurate final data
Schematization of the
layout of a riser
instrumented with the
Morphopipe system
The data acquisition unit and supervision software has been specifically developed
based on CyXense® from Cybernetix. It allows:
• The supervision of the electronic cards (power supply, communication) for up to
ten risers at the same time
• Administration and logs (user accounts, health check, historical logs)
• Display of data (maximum, direction, profile, localisation) and alerts
• Possibility for standard communication protocol to other system (Modbus)
Screenshots of the monitoring software (left: view of alerts tab; right: view on direction of
bending plane, location and value of maximum curvature)
INDUSTRIAL INTEGRATION
Left: Experimental dynamic setup at Technip/Flexi-France site – Flexible riser
instrumented by 5 external rings of 2 nodes and reconstructed flexible riser superimposed
(colours for variations of curvature). Right: values of curvature along the instrumented
section, compared to the radius of the davier
Schematization of the Morphopipe
principle and architecture. By
deploying at least two 1-axis
MEMS, the system creates
instrumented rings. The rings act as
inclinometers measuring the tilt of
the tangent at discrete times and at
different points of the central axis
The curvature is the space-
derivative of the tilt function, thus is
computed in filtering in space and
time the tiltsSimplified view of electronic
prototype embedded within riser
The Morphopipe layer assembly is performed
manually, step by step, at the entry point for
the manufacturing machine at Flexi-France.
Then, standard processes are used to cover
and protect it: High strength tapes and
Plastic sheathing
