Magma Global SUT April 2012

8/10/2019 Magma Global SUT April 2012

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Carbon Fiber Pipe for RisersSUT Conference, London, 18/19 April 2012

Technology for the Coming Decade


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Strictly confidential. Property of Magma Global Ltd.

Presentation

Background and Scene Setting

Carbon Fiber Technology

Riser Applications

Installation

Summary


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Background

Only 15 years ago there was general concern that riser

technology was insufficient to meet the demands of discoveries

beyond 1000m

To accelerate technology Operators were proactive in

supporting JIPs and also actively shared riser experience

Some deep water projects were sanctioned using riser

technology that had very limited track record but achievedselection through criteria such as local content


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Current Industry Riser Capability

In 2012 we feel confident about riser technology with

successful applications in depths up to 2000m

A range of riser technologies are considered proven withdocumented track records spanning 10 years + of production

Flexible risers

SCR - Steel Catenary Risers and PIP SCRs

SLORs Single Line Offset Risers

Hybrid Bundles

Companies capable of riser design, hardware supply and

installation services are established and EPIC contracting istypical

The riser industry feels mature and ready for the next step

using proven technology


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Validity of Confidence ?

Every project has a different set of issues that makes them

individual and always challenging

Risers are typically the repository for design changes which

further compounds the problem technically and commercially

At the end of a project the feeling is often of:

Relief and pride by the project team

Surprise at how much it has all finally cost $10-20m per SCR

$30-70m per SLOR


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Whats the Real Status

Whilst we have good riser experience we are not turning the

handle and in fact this will never be the case high EPIC risk

Actual riser costs are much higher than estimated at FEED or

tendered during Execute (Underestimate challenge + Design

changes)

Many risers require rework during the early stages of life and

some require replacement

20 years riser performance is still to be proven feasible and

practical under some conditions


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Future Industry Trends

Depths are increasing (3000m +)

Pressures are increasing (10ksi to 17ksi)

Larger diameters needed to meet project rates - (10-12in)

Process flow issues are more demanding - (Depth and fluids)

Ship shaped FPSOs are preferred with external turrets

Corrosive production fluids - (CO2 and H2S)

Higher temperatures associated with deeper reservoirs


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Conclusion on Industry Status

Were actually struggling with current riser requirements and

future riser requirements are a significant step out

Existing technologies have little head room for further

specification extension

We should not simply assume existing technology has the legs to

meet future requirements

We need to keep pressure on development of riser technology.

Composites are finally an option that could resolve many issues


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Composite Technology is Maturing

80% composite by volume

50% composite by weight

32Te carbon fiber in each aircraft


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Dreamliner Construction - Thermoset


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Polymer Technology

Thermoset

A polymer that irreversibly cures typically through heat or

chemical reaction (epoxy)

Thermoplastic

A polymer that solidifies when cooled. It can then be

reheated and remelted (PP, PE, PA/Nylon)

Thermoplastics can be joined by welding

Offers improvements in manufacturing processes

Offers improvements in material properties/performance


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m-pipe - a high end, high

strength carbon/ thermoplasticpolymer pipe with a monolithic

structure from bore to surface

Differentiated by different:

Material

Manufacturing process

End Fittings


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Material Selection

Victrex PEEK

Extensively used in offshore and subsea applications

Extensively qualified across key performance areas

Exclusive development contract for subsea oil & gas

pipe

T700 Carbon Fibre Toray International

Extensive qualification of T700 to aerospace standards

Worlds largest carbon manufacturer

Supply agreement in place


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mpipe Riser Advantages

Lightweight 10% of the weight in water as steel or flexible

High strain to failure up to 2.5%

Corrosion resistant to seawater and CO2 High fatigue capability unaffected by H2S

High temperature operation

High resistance to permeation High resistance to rapid gas decompression

Low thermal conductivity

Better erosion and wear resistance compared to steel Smooth bore reduced pressure drop 20% compared to steel

Victrex

.an ideal riser material


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Why PEEK?

Polymer Comparative Properties - Victrex PEEK

5 = Good

0 = Poor

TemperatureResistance

ChemicalResistance

AbrasionResistance

MechanicalStrength

VictrexPEEK

5 4 5 5

PTFE 5 5 2 1

PFA 5 5 3 2

PVDF 3 4 3 3

PPS 4 4 42 (unreinforced)4 (reinforced)

PA11 2 3 5 3/4


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Typical PEEK Applications

Application Examples

Electronic sensors Wireline and data

logging Communication and

power cables Plugs and packers

Thrust washers

Electrical connectors Umbilicals and industrial

hoses Tubulars and pipes Seals and back-up rings

Bearings and brushings(as above: 200C, watercooled, high load)

Motor and pumpcomponents

Adhesive tapes


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Testing Four Point Bending & Axial

Compression


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Testing Compression Ring


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Testing - Collapse


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Testing Inter Laminar Shear


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Testing High Strain Bending


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Testing Impact and Tensile


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Test Over 1000 Test Specimens


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Ultrasonic C-Scan NDT

Bonding Porosity De-lamination

Cracking Foreign bodies Impact damage


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End Fitting

Collar

LockingNut

m-pipe


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End Fitting Resonant Rig


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4in ID 10ksi Spool Piece

E d Fi i D i F


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End Fitting Design Features

Flush bore seal with proven AX gasket

Load capacity greater than pipe strength

Smooth structural transition to standard pipe

Compact and low profile

Standard plain end steel pipe interface

Fully preloaded for good fatigue performance

External seal pressure test facility

A li ti W i ht d C t


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Applications Weighted Catenary

A li ti Ch i W i ht d SCR


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Applications Chain Weighted SCR

A li ti SLOR B dl


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Applications SLOR or Bundle

Applications TTRs (Spar and TLP)


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Applications TTRs (Spar and TLP)

Applications Offloading line


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Applications Offloading line

Applications Floating Hose


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Applications Floating Hose

Applications Other Applications


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Applications Other Applications

SCR TDP high fatigue zones

Taper Joints to replace Flex Joints

Marine Drilling riser Kill and Choke lines

CWOR joints (tapered and cased wear)

Flowline Upheaval Buckling

Rigid Jumper Spool

Installation


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Installation

Reel, J lay or Tow out

Lower specification vessels

Shorter installation durations

Reduced overall risk

Lower maximum lift weights Higher permissible deflections at lower loads Shorter installation durations Increased operational windows

Reduced coating damage Offshore re-spooling Increased tow feasibility

Unique Manufacturing Process


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Unique Manufacturing Process

Fully automated robotic manufacturing Single repetitive process High degree of process control and documentation Diameter capability 2-24

Wall thickness unlimited by process or materials pressures >20ksi Wall thickness variation along pipe and riser length Discrete (80ft) and continuous length (km) production

Summary


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Summary

A step change in riser technology to

Enable future subsea discoveries

Thermoplastic technology providesmanufacturing, quality andperformance benefits

High end polymers and fibers ensurespipes with appropriate performance

Underpinning engineering and design

validation is largely completed

Volume manufacturing is beingestablished ready for end 2013

Documents

Magma Global SUT April 2012