DRILLING AND REFINERY APPLICATIONS (DRAPS)

COFLEXIP DRILLING&SERVICE APPLICATIONS USER'S GUIDE

Revised with minor corrections 9-12-96

0 1 1.1 1.2 1.3 1.4 1.5 2 2.1 2.2 2.3 2.4 3 3.1 3.2 4 5 6 6.1 6.2 6.3 6.4

CONTENTS General introduction Description of a Coflexip flexible line End-Fittings Ancillary equipment Flexible Pipe Structure Mechanical behaviour of the flexible line Failure modes of Coflexip flexible lines General Guidelines Storage Handling Installation - Connection Welding Operating Conditions Fluids to be transported Temperature ratings Lifetime of drilling and service application flexible lines Repair of flexible lines Inspection and testing of lines Introduction Routine visual inspection Full inspection Manufacturer's inspection - Major survey

6.5 6.6 6.7 6.8 6.9 7 7.1 7.2 7.3 7.4 7.5 8 8.1 8.2 8.3 8.4 9 9.1 9.2 9.3 9.4 10 10.1 10.2

Field pressure testing (optional) Full pressure test Recording of inspections and tests Periodicity of inspections and tests Unused lines Choke and kill applications Definition Bend test Sour service Venting Periodicity of field testing and inspection Test line applications DST and PTL lines - definition Sour service Venting Periodicity of field testing and inspection Acidizing and fracturing line applications Definition Sour service Venting Periodicity of field testing and inspection Drag chain applications Definition Periodicity of field testing and inspection

GENERAL INTRODUCTION This copy of the "COFLEXIP DRILLING AND SERVICE APPLICATION USER'S GUIDE" is revision 3 of the guide originally issued in 1989 with last revision in September 1990. The main differences from revision 2 are the inclusion of acid line and drag chain applications, a re-write of the sections on inspection and testing plus an up-date of the product compatibility charts made possible by the on-going tests performed as part of CSOLs policy of continual research into the use of flexible pipes. CSO recognises the fact that the majority of our clients have used Coflexip drilling application products for many years and have therefore built up a great deal of experience in their use. It follows therefore that much of the information contained in this guide is intended primarily for those clients who are not familiar with the use of Coflexip flexibles and may appear somewhat basic to more established clients. CSOL relies on the feedback of all users to ensure the continued reliability of our products and to act as the basis for research into the flexible pipes of the future. We therefore welcome any comments on both the flexible pipes themselves and User's Guides such as this one specifically written for Drilling and Service Applications. In producing the guide, we have attempted to cover all aspects of both the design and safe use of our drilling and service application flexibles in all circumstances, however there may well be omissions or recommendations which end-users may wish to comment on or have clarified to some degree or other. We are always available to assist in

either circumstance and such comments should be directed towards your local CSO office listed in the last chapter of the guide. All information and data contained herein are subject to change without further notice.

DESCRIPTION OF A COFLEXIP FLEXIBLE LINE This paragraph will discuss the construction of a typical Coflexip flexible line and, according to the pipe construction, present the failure modes that might be caused by a possible misuse of the equipment. As shown in Figure 1, a typical Coflexip line is composed of: A length of flexible pipe Two end-fittings complete with lifting/handling collars

1.1

Fig 1 END-FITTINGS The end-fitting itself consists of the following: The termination which ensures the seal and the mechanical attachment of the end-fitting to the flexible pipe The connector to allow the connection of the end-fitting to any other compatible connector.

1.1.1

NACE compatibility All steel materials used In the manufacture of a Coflexip end-fitting meet the requirements of NACE MR-01 -75, latest revision. Coating protection of the end-fitting The whole surface, both inside and outside of a standard end-fitting is protected against corrosion, wear, abrasion and handling by a Ni-Kanigen coating. The adhesion of the coating to the underlying steel is essential for the long term integrity of the protection. Various heat treatments are applicable for Ni-Kanigen coated parts to improve that property. CSO has selected the most effective process which is a long duration, high temperature heat treatment conducted at 600 to 650C (1112 to 1202F) for 10 hours. This process ensures a good diffusion of the coating into the steel, thus avoiding any possible scaling of the protection. The Ni-Kanigen coating bears the following properties: The surface hardness of the coating is about 400 to 450 HV, in the range of most hardened steel, and this improves the end-fitting resistance against corrosion, wear, abrasion and handling. In particular, the end-fitting will resist long term exposure to internal flow of abrasive fluids. The inner coating is 75 thick; a visual inspection of the inner bore of the end-fitting showing that the coating Is still present indicates the satisfactory integrity of those end-fitting parts subjected to the inner effluents. If the coating is damaged or cracked, traces of

1.1.2

corrosion and rust may be visible and a complementary inspection should be completed. The Ni-Kanigen coating is highly resistant against corrosion from marine atmosphere, sea-water and to H2S/C02 gases or other corrosive fluids which might be transported by the line.

1.1.3

Connectors All types of connectors can be supplied with any end-fittings, the most common being API hubs (formerly "CIW hubs"), hammer unions and flanges. Generally the connectors are integral parts of the end-fitting avoiding butt-welding (with some exceptions for non-standard connectors). However, when used, the welding process is always completed BEFORE end-fitting mounting. Terminations The termination will ensure the following functions: Mechanical attachment to the flexible pipe which will resist against internal pressure, traction, torsion, Provides seal against inner effluent, Provides seal against outer environment, Mechanical attachment of the outer stainless steel carcass.

1.1.4

1.1.5

Marking The termination bears a permanent marking indicating: Manufacturer (*) Serial number of the line Internal diameter of the line (Inches) Application (*) Working pressure (WP psi) of the line which is always inferior or equal to the maximum design pressure of the line structure Length of the line - face to face from one connection to the other (metres or feet) Date of the factory pressure test If applicable, a stamp of a certifying authority For repaired lines see section 5 (*) This information was optional before second quarter of 1990 Repaired lines If the line has been repaired by the mounting of a new end-fitting, it will bear the same marking as above, but the serial number of the line is changed on that end-fitting. Length and date of the factory pressure test are revised values marked on the new end-fitting. Although optional before the second quarter of 1990, CSO recommends that Application be stamped on above where the information is missing, using the abbreviated classification as follows. In case of doubt, please contact the nearest CSO office. Marking from second quarter of 1990:

From the second quarter of 1990, the end-termination bears a revised marking as follows: Manufacturer Serial number of the line Internal diameter of the line (Inches) Line application abbreviated as follows: > C/K: Choke and Kill > DST/ACD: Dual Service Line > PTL: Production Test Line > ACD: Acidizing/Fracturing > ROT: Rotary > DCL: Decoking > DST: Drill stem test > CEM: Cement > CEM/ACD: Cement/Acid > HYD: Hydraulic line Line length (in metres (M) or feet (FT) Working pressure (WP PSI) Test pressure (TP psi) Temperature range (continuous service: See section 3.2) The stamped test pressure is the OEM.TP (original equipment manufacturer test pressure) Date of the factory pressure test (month/year)

 If applicable, a stamp of a certifying authority when required (For lines repaired by end-fitting replacement, see section 5) Example of marking COFLEXIP............................Manufacturer 7990.01 ................................Serial number W - C/K - 18.3 M...................I.D./Application/Length WP 15000 PSI ......................Working pressure TP 22500 PSI .......................Test pressure TEMP: -20/+100C ...............Temperature range 02/90 ....................................Test date (month/year) Any inquiry regarding the construction of the line and its end-fittings should refer to the serial number through which CSO can trace the relevant information. 1.1.6 Handling collar A groove in the end-termination is fitted with a rotating handling collar with two symmetrical pad-eyes. This collar is designed to allow for safe handling of the flexible pipe. It Is not designed to handle any other equipment which might be attached to the connectors.

1.2 1.2.1

ANCILLARY EQUIPMENT Bend limiter Also called "bend restricter", a typical bend limiter is shown on figure 2. This device can be fitted on an existing line, is made of two half shells, and is designed to limit the local radius curvature of the flexible pipe, near the end-fitting. It is protected against environmental corrosion by a special wear resistant coating.

Figure 2 1.2.2 Bend stiffener The bend stiffener is an additional device mounted on the flexible pipe during its manufacturing (see figure 3 following). It increases the local bending stiffness in the region of the end-fitting, producing a smoother transition from the end-fitting to the flexible pipe structure.

Figure 3 The bend stiffener is optional on most flexible pipes. It will allow the flexible pipe to better resist overbending: flexure damaging strength is increased by a factor of x3 when using this device. Made out of polyurethane, it is intrinsically resistant to corrosion. During the external inspection, check that the bend-stiffener is properly tightened on the end-fitting to avoid any mechanical gap, and is free of damage and cracks. 1.2.3 Fire cover As for the flexible pipe itself, it may occasionally be necessary due to working environment for lines to include a greater degree of fire protection than standard. For such operating conditions, additional fire

protection covers may be installed over the end-fitting assemblies (see also section 1.3 - Para. 1.3.7 concerning fire protection on the flexibles). 1.3 FLEXIBLE PIPE STRUCTURE A typical Coflexip flexible pipe structure, for high pressure applications is shown on Figure 4 following. This construction is known as a "non bonded" structure. From the inside it is composed of the following:

Figure 4 1 3 5 7 Inner plastic liner Flat steel spiral Crosswound tensile armours Optional fire resistant layer 2 4 6 8 Zeta spiral Intermediate plastic sheath External plastic sheath Outerwrap interlocked steel carcass

1.3.1

Thermoplastic inner liner(s) The thermoplastic inner liner makes the pipe leakproof. This layer limits the upper service temperature of the line and the chemical compatibility to the various fluids which may be transported through the line. Various plastic materials are used to manufacture the inner liner, depending upon the service application of the line. Interlocked "zeta" layer This layer takes the hoop stress due to the internal pressure and to external crushing loads. The crushing resistance of a Coflexip line is similar to that of an API rigid pipe designed to withstand the same pressure. However, accidental crushing might damage the outer stainless steel wrap and reduce the lifetime of the line. It is the interlocking of the zeta layer which will limit the bending radius of the line. If this limit is exceeded, irreversible damage to the flexible line will occur leading to perforation of the inner liner when under pressure. Metallic reinforcement of the zeta layer If necessary for extreme high pressure, the zeta layer is reinforced by a flat steel layer which is not interlocked. Intermediate thermoplastic sheath This sheath is a thin anti-friction layer which improves the dynamic behaviour of the line. This layer is not leakproof.

1.3.2

1.3.3

1.3.4

1.3.5

Double crosswound steel armour The double crosswound steel armour wires will resist axial load caused by internal pressure, or external axial loads. It is also this layer which provides the flexible line with its resistance to torsion. Thermoplastic outer sheath This layer is leakproof. It will both: Protect the armour wires against corrosion and Protect the line against hydrostatic external pressure if the line is used subsea, as on LMRP BOP stacks. (note that test lines are vented through this outer layer and may not therefore be used subsea). Fire resistant layer For certain installations, e.g. permanently installed well control lines on fixed production platforms, it may be a requirement for essential service flexibles such as choke and kill lines, to be operable under fire conditions for long periods. The inclusion of a fire resistant layer installed after production of the standard pipe gives a working time at 7000C (1 292F) and full working pressure, well in excess of 30 minutes. This layer is nonstandard and would be the subject of a special order. Refer also to section 1.2 - Para. 1.2.3 for end-fitting fire protection.

1.3.6

1.3.7

1.3.8

Stainless steel outerwrap The stainless steel outerwrap (carcass) protects the thermoplastic outer sheath against mechanical damage caused by using the line in a harsh environment (impacts, wear, handling, etc.). This layer does not contribute directly to the mechanical resistance of the line. However, significant damage to this layer may lead to subsequent damage to the thermoplastic outer sheath causing either: Corrosion of the armour wires, and/or Collapse of the inner tube for subsea lines. MECHANICAL BEHAVIOUR OF FLEXIBLE LINE By design, a Coflexip flexible line is extremely resistant to: Internal pressure Dimensional changes under pressure are very limited; typical values are: > Relative elongation at design pressure 0.1 5 to 0.25 % > Relative outer diameter change at design pressure < 0.25 % The line is extremely stable under pressure. In particular, if bent it will not tend to straighten under pressure. No significant twist would occur. It will not pulsate or whip during high flow rate circulation. Tensile Strength Resistance to pulling forces ranges from about 50,000 daN for 2" ID to more than 100,000 daN for 3" ID (50 to 100 tons or 100,000 to 200,000 lbs).

1.4

Crushing The crushing resistance of Coflexip flexible pipes is similar to that of an API rigid pipe of the same design pressure Bending The line is resistant to bending, including frequent or continuous flexure with the imperative condition that the minimum bending radius is not exceeded. In CSO's documents, the minimum bending radius is abbreviated as MBR. The minimum bending radius is an extremely important characteristic of a flexible steel line. As a rule of thumb, the minimum bending radius is roughly equal to: MBR = 12 x ID (ID: inner diameter of the line). Example: If ID = 3" then MBR = 12 x 3 = 36", i.e. 3 ft. For specific DRAG CHAIN applications, the MBR for installed use is 1.1 x the storage MBR, as defined on the relevant data sheet. The accurate value of the MBR is part of the technical specification of the flexible line.

Figure 5

1.5

FAILURE MODES OF COFLEXIP FLEXIBLE LINES Coflexip flexible steel lines are extremely reliable due to: The design of the product; The use of the highest standards applicable; The CSO quality assurance system. However, misuse might damage the line, and it is useful to identify the four main failure modes. Bending - If the minimum bending radius is exceeded, the zeta layer may open; in which case, the inner tube is not properly supported and perforation will occur under pressure.

Overbending generally occurs due to mishandling during installation. Particular attention must be paid at this time to the first few feet of flexible pip immediately behind each termination. An optional bend stiffener is available on request to improve the pipe's resistance to such overbending. Figure 6 shows how overbending may be caused, whether or not the line be under internal pressure.

Figure 6

Ageing of the inner liner - The mechanical properties of the inner liner can be affected by ageing. This phenomenon causes the degradation of the long thermoplastic molecules and may be due to: > Long exposure to high temperature, exceeding the maximum rated temperature; > Use of incompatible chemical products through the line.

The degradation of the material could make it brittle and the tube may break when bent with or without internal pressure, leading to a leakage. Corrosion of the armour wires - If the outer thermoplastic sheath is damaged, corrosion of the steel armour wires will occur. This will progressively reduce the thickness of the wires, causing a progressive decrease of the burst pressure. This failure mode may cause the line to burst. Collapse of the inner liner - If damaged, the outer sheath may not be leakproof. For subsea lines, the external hydrostatic pressure will be applied on to the inner liner which may collapse.

2 2.1

GENERAL GUIDELINES Storage Storage in general does not require specific precautions regarding environment or duration of storage. According to its length, the best ways to store a line are either: > In a straight line (up to 20 ft long); > Coiled to its MBR, attached to a wooden pallet or crate; > Installed in a DRAG CHAIN prior to hook-up and start of operations. Coflexip flexible lines are shipped with protection on the connectors. A similar protection should be reinstalled when the line is disconnected. It may consist of a metallic blind flange that fits the connection - which is preferable or of a good wooden protection. This protection must ensure that: > The inner bore of the line is closed to avoid accidental intrusion of any foreign material; > The connector, especially the seal area, is properly protected against impacts, etc. If stored below minimum rated temperature, ensure that no handling is done before the line is brought back to minimum rated temperature. The inner bore of a Coflexip line should be thoroughly flushed with fresh water prior to long term storage.

2.2

HANDLING The line must never be bent below the minimum bend radius, as this may damage it. > As a rule of thumb, the minimum bend radius is equal to: MBR = 12 x ID The accurate value of the MBR of the line is part of the technical characteristics of the Coflexip structure and can be obtained from the nearest CSO office. The minimum bend radius (MBR) must be respected at all times, whether the line is under pressure or not. User should avoid bending the flexible just behind the end-fitting. As a rule of thumb, a straight length of about 2 to 3 feet should be used as a safety distance. See section 1.5 - FAILURE MODES OF Coflexip FLEXIBLE LINES The use of wire ropes or chains may damage the anti-corrosion treatment of the end-fitting. If so required, use a shackle connected through the eye of the lifting collar. Never use wire ropes or chains directly against the stainless steel outerwrap. If force needs to be applied to the body of the flexible line itself, use nylon slings. Moving flexible line on the ground > Do not attach slings directly to the end-fitting - use the lifting collar instead. Always connect slings to both lifting eyes in order to have the pulling force in a straight line with the main axis of the line.

> >

Prevent abrasion of the flexible line against the ground; use wooden supports or planks. To lift the line, a forklift may be used provided that slings are installed to prevent sharp edge contact (see Coflexip Handling Guide inside cover).

2.3

INSTALLATION - CONNECTION The preferred installation for a Coflexip flexible line is with the pipe positioned in a J configuration and the end-fittings pointing up in a vertical position. See fig. 7 on next page.

Figure 7

If, due to the rig equipment, this configuration is not feasible, special care must be taken when securing a non-vertical connection that overbending is avoided behind the end-fitting. Installation of a flexible line to a connector requires > Supporting the weight of both the end-fitting and the line; > Correct alignment of the end-fitting. The best way to achieve this is to support the weight of the line through the use of the lifting collar, then control the alignment with a non-metallic rope or sling attached about 3 feet behind the end-fitting. See figure 8 following:

Figure 8 Never do the reverse, i.e.: > Do not support the weight immediately behind the end-fitting; > Do not align the line from the end-fitting attachment.

2.4

WELDING A flexible steel line is a mixed construction of steels and thermoplastics. It must be recognised that through heat diffusion which occurs during any Welding process, the thermoplastic layers may suffer irreversible damage leading to an unsafe line. When used, welding processes are only completed during the original manufacturing process of the line at a stage where the operation cannot affect the other components. Consequently, any field welding repair of a flexible line, involving either the end-fitting (including the stainless steel ring groove) or the stainless steel outer carcass, will render the line unsafe and unusable. Such lines must be withdrawn from service and stamped "NOT-REUSABLE". OPERATING CONDITIONS Although similar, the construction of Coflexip lines for different drilling applications such as Choke and Kill lines, Acid lines or Test lines differ significantly. These lines must never be used for any purpose other than the original for which the line was supplied. In case of doubt, contact the nearest CSO office. FLUIDS TO BE TRANSPORTED All kinds of drilling muds and oil production fluids, or chemical additives may be transported through flexible lines depending upon the applications. All components of the end-fittings in contact with the inner fluids are satisfactorily protected against corrosion.

3.1

It is the internal liner made of thermoplastics which will limit the chemical compatibility of the flexible line. They are different for: Standard temperature rated line (-20C to +100C / -4 to +212F) or High temperature rated line (-20C to +130C / -4 to 266F) or Acid line (H.D.P.E.) (-20C to ++65C / -4 to +149F). Tables 1, II and III give a limited list of the different chemicals relevant for drilling and service applications and their effects on the flexible line. In case of doubt, contact the nearest CSO office. It must be noted that Standard Temperature Rated line s (-20C to + 1OOC / -4F to +212F) are not designed to handle any acidified effluents and/or heavy metallic salts such as zinc bromide. 3.1.1 Chemical compatibility of standard temperature rated lines The inner lining of these lines is made of RILSAN which is a grade of polyamide II material. See Table I following. Chemical compatibility of high temperature rated lines The inner lining of these flexible lines is made of COFLON, a fluorinated thermoplastic: Polyvinylidene fluoride (PVDF) material. See Table II following.

3.1.2

3.1.3

Exposure of high temperature rated lines to C02 Under certain conditions, exposure to relatively high concentrations of C02 can lead to damage of the coflon liner. For this reason, the following limitations are to be respected:
PRESSURE ......................TEMPERATURE...............FLUID CONDITIONS 15,000 PSI .........................130C (+266F).................. C02 + H2S < 10 % 10,000 PSI .........................130C (+266F).................. C02 + H2S < 30 % 10,000 PSI .........................110C (+230F).................. C02 + H2S < 50 %

3.1.4

Chemical compatibility of acid (HDPE) lines The inner lining of these flexibles is made of high or medium density polyethylene (HDPE) which is a polyolefinic material. See Table Ill following.

TABLE I Product compatibility of standard temperature rated lines. Corrosion resistance of rilsan inner lining. TEMPERATURE
Concentration or 0F 75 F 150 F 200 F 250 F Exposure Time -18C 24 C 66 C 93 C 121 C Hydrochloric acid HCl ..................15% ...............F ............ F.............F ............ F.............F .....................................................30% ...............F ............ F.............F ............ F.............F Hydrofluoric acid HF .....................3% ................F ............ F.............F ............ F.............F ....................................................7,5%...............F ............ F.............F ............ F.............F Xylene C6 H4 (CH3)2.................100% ..............S ............ S.............S ............ S........... NR Methanol CH30H ........................100% ..............S ............ S........... NR..........NR ......... NR Zinc bromide ZnBr2 .................saturated ...........F ............ F.............F ............ F.............F Calcium Bromide CaBr2 ..........saturated ...........L ............ L.............L ............ L.............L Calcium chloride CaCl2 ...........saturated ...........S ............ S.............L ............ L.............L Methane CH4 .............................100% ..............S ............ S.............S ............ S.............L Diesel..........................................100% ..............S ............ S.............S ............ S.............L Crude oil .....................................100% ..............S ............ S.............S ............ S.............L Sodium hydroxide NaOH.............50% ...............S ............ L........... NR..........NR ......... NR Hydrogen sulfide H2S................< 20%..............S ............ S.............S ............ S.............L S: Satisfactory L: Limited use NR: Not Recommended F: Forbidden

TABLE II Product compatibility of high temperature rated lines. Corrosion resistance of coflon inner lining.
TEMPERATURE Concentration or 0 F 75 F 150 F 200 F 250 F Exposure Time -18C 24 C 66 C 93 C 121 C Hydrochloric acid HCI..................15% ...............S ............ S.............S ............ S.............S .....................................................30% ...............S ............ S.............S ............ S.............S Hydrofluoric acid HF .....................3% ................S ............ S.............S ............ S.............S ....................................................7,5%...............S ............ S.............S ............ S............SXylene C6 H4 (CH3)2.................100% ..............S ............ S.............S ............ S.............S Methanol CH30H ........................100% ..............S ............ S.............S ............ S.............S Zinc bromide ZnBr2 .................saturated ...........S ............ S.............S ............ S.............S Calcium Bromide CaBr2 ..........saturated ...........S ............ S.............S ............ S.............S Calcium chloride CaCl2 ...........saturated ...........S ............ S.............S ............ S.............S Methane CH4 .............................100% ..............S ............ S.............S ............ S.............S Diesel..........................................100% ..............S ............ S.............S ............ S.............S Crude oil .....................................100% ..............S ............ S.............S ............ S.............S Sodium hydroxide NaOH.............50% ...............S ............ S.............L ........... NR ......... NR Hydrogen sulfide H2S................< 20%..............S ............ S.............S ............ S.............S

S : Satisfactory

L : Limited use

NR : Not Recommended

F : Forbidden

TABLE III Product compatibility of acid (HDPE) lines. Corrosion resistance of HDPE inner lining. TEMPERATURE
Concentration or 0 F 75 F 150 F 200 F 250 F Exposure Time -18C 24 C 66 C 93 C 121 C Hydrochloric acid HCI..................15% ...............S ............ S.............S ............ F.............F .....................................................30% ...............S ............ S.............S ............ F.............F Hydrofluoric acid HF .....................3% ................S ............ S.............L ............ F.............F ....................................................7,5%...............S ............ S.............L ............ F.............F Xylene C6H4(CH3)2 ...................100% ............ NR..........NR ...........F ............ F.............F Methanol CH30H ........................100% ..............S ............ S.............S ............ F.............F Zinc bromide ZnBr2 .................saturated ...........S ............ S.............S ............ F.............F Calcium Bromide CaBr2 ..........saturated ...........S ............ S.............S ............ F.............F Calcium chloride CaCl2 ...........saturated ...........S ............ S.............S ............ F.............F Methane CH4 .............................100% ............ NR..........NR ......... NR........... F.............F Diesel..........................................100% ..............S ............ S.............S ............ F.............F Crude oil .....................................100% ............ NR..........NR ......... NR........... F.............F Sodium hydroxide NaOH.............50% ...............S ............ S.............S ............ F.............F Hydrogen sulfide H2S................< 20%..............S ............ S.............S ............ F.............F

S : Satisfactory

NR : Not Recommended

L : Limited use

F : Forbidden

3.1.5

Sour service All components of the end-fittings and of the flexible pipe, in contact with the inner fluids, meet NACE-MR-01 -75. However, due to gas diffusion, some other internal components may be in contact with low concentrations of sour gas. Depending upon the application, Coflexip pipes are classified either: Permanent sour service, or Temporary sour service See sections 7 to 1 0 for the different applications of Coflexip pipes. In case of doubt, contact the nearest CSO office. Flow Rates The maximum continuous flowrate for all smooth bore i.e. thermoplastic inner sheathed lines, Is 15 metres per second. Many lines, particularly those for acidizing / fracturing applications, have been subjected to flowrates well in excess of this figure for relatively short periods of time without any damage being sustained. This is entirely dependent on the abrasive properties of the flow medium and maximum short term flowrates cannot therefore be quantified for all flow conditions. Temperature Ratings Standard temperature rated line(-20C to + 100C/-40F to + 212F) Continuous service Standard Coflexip Choke and Kill lines are designed for -20C to 100 C / -4F to +212F) continuous service, with no time limit (within the lifetime of the whole line).

3.1.6

3.2 3.2.1

Higher temporary service temperature Standard Coflexip flexible pipes may be used up to + 130/+266F, maximum temperature of the transported fluids for a maximum of one month, continuous or cumulative service. Lines exposed to temperatures higher than +130C / +212F but no more than +130C / +260F for continuous or cumulative service of 1 month must be removed from service and stamped not reusable following this exposure. Survival conditions All Coflexip flexible lines (C/K, DST, PTL) are designed to resist to +160C / +320F maximum inner temperature of the contained fluids for a duration in excess of one hour. A copy of the qualification test report is available upon request from all CSO's sales offices. Standard temperature rated Coflexip flexible lines are deemed not reusable for further service after sustaining a temperature above the temporary rating of +130C (+260F). Lines exposed to temperature higher than +130C (+260F) must be removed from service, properly stamped not reusable, and replaced by a new line. High temperature rated Line (-20C to +130C / -40F to +266F) Continuous service High temperature rated flexible pipes are designed for -20C to +130C (-4F to +266F) continuous service, with no time limit (within the lifetime of the whole line). NOTE Under certain fluid

3.2.2

conditions, there may be limitations on pressure and/or temperature ratings. (Refer to section 3, Para. 3.1.3). Higher temporary service temperature High temperature rated flexible pipes are not designed for a higher temperature than the maximum continuous temperature rating. Survival conditions All Coflexip flexible lines are designed to resist to +160C (+320F) maximum inner temperature of the contained fluid for a duration in excess of one hour. A copy of the qualification test report is available upon request from all CSO's sales offices. High temperature rated Coflexip flexible lines are deemed not reusable for further service after sustaining a temperature above the continuous rating of +130C (+266F). Lines exposed to temperatures higher than +130C (+266F) must be removed from service, properly stamped not reusable, and replaced by a new line. 3.2.3 Acidizing/fracturing lines (- 20C to + 65C / - 4F to + 149F) Coflexip acidizing/fracturing lines are designed for -20 to +65C (-4F to +149F) continuous service, without limit on time (within the lifetime of the whole line). As acidizing/fracturing lines are normally only used to pump into well formations, it is unlikely that there will be the requirement to operate lines at temperatures higher than ambient and for this reason there are no other temperature ranges, temporary or survival. These lines are not designed for flowing produced well fluids.

3.3 3.3.1

PRESSURE Rated working pressure The working pressure stamped on the end-fitting must be understood as the maximum design pressure to which the line may be permanently subjected. It Is not the manufacturer's responsibility to define allowances for eventual surges that may occur through the lines. We recommend users to be aware of guidelines or specifications to be issued by Certifying Authorities or regulatory bodies. OEM test pressure All Coflexip flexible lines are pressure tested at the factory when completed. Test pressures are as follows: WP OEM. TP 5,000 PSI 1 0,000 PSI 10,000 PSI 15,000 PSI 15,000 PSI 22,500 PSI Test duration: all factory pressure tests last a minimum of 24 hours at ambient temperature. LIFETIME OF DRILLING AND SERVICE APPLICATION FLEXIBLE LINES Coflexip flexible lines utilised for drilling and service applications are designed for twenty (20) years life in dynamic service conditions. This design life is based on lines operating for their intended service, within

3.3.2

their rated temperature range, fluid compatibility and allowable bending radius. However, because of the many disparate factors affecting the lives of individual flexible lines, including extreme weather conditions, mishandling and abuse, incorrect installation and storage, frequency of exposure to extremes of temperature and pressure, improper care and maintenance, use of incompatible fluids, etc. it is not possible to predict accurately the service life of any individual flexible line. The designation of a "design life" should not be relied upon as a prediction or warranty of the life of a particular flexible line. Nor should purchasers and users of Coflexip flexible lines rely upon this design life in lieu of proper installation, care, maintenance, storage, recommended inspections, repairs when necessary and other requirements and precautions recommended by CSO in the User's Manual. The design life is not intended to, and will not extend, modify or alter in any manner the expressed warranty or other conditions of sale given by CSO, nor shall the design life convey any expressed or implied warranties of merchantability, fitness for a particular purpose or any warranties except those expressly made in the "general conditions of sale". Flexible lines removed from service upon expiration of the service life should be stamped "NOT REUSABLE" or preferably cut into pieces. 5 REPAIR OF FLEXIBLE LINES As a result of periodic inspections, or "in field" observations, damage may be noticed and require repair.

The following parts of a flexible line may be repaired at a convenient CSO facility, depending upon the degree of the damage: Serviceable parts of end-fitting, including handling collar, back nut attachment of carcass and/or bend-stiffener; Stainless steel outer carcass; Outer plastic sheath underneath the carcass. For significant damage, such as overbent lines, the repair may consist of mounting a new end-fitting(s) to a used line. This would involve cutting off one complete end-fitting and installing a new one, thus reducing slightly the overall line length. The new fitting would be marked with the repair project number and line test date plus the new overall length: the original fitting which remains with the line will be stamped "repaired". It should be noted that old fittings are not in general reusable and that, as a variety of re-marking procedures have been employed since the first repairs were carried out, it is always worth checking line details on both end-fittings. Whatever the nature of the repair, the lines are pressure tested at OEM test pressure for 24 hours after completion. CSO reserves the right of declining any repair on a line which is found in a condition rendering it unsafe for use. Except in exceptional circumstances, CSO will not proceed with any repair on lines which do not meet current industry standards or CSO's internal standards. (For unused lines, see section 6.9).

6 6.1

INSPECTION AND TESTING OF LINES INTRODUCTION This section details the actual inspections and tests recommended by CSO to ensure the continued safe use of our drilling and service application flexible lines. It defines precisely what is meant by the terminology used by CSO for each type of inspection and/or test and therefore allows end-users to know the extent or limitation of each procedure. The very nature of a flexible pipe's construction and that of its end-fittings does not allow a detailed examination of all of the internal components, and therefore we rely heavily on external examination and regular pressure testing. It will be noted that CSO recommends end-users whenever possible, to have this inspection and testing work carried out by the manufacturer. Under such circumstances, CSO will issue a certificate detailing the inspection and/or testing work performed on each line. Circumstances may make this impractical, and in such instances, CSO relies on the end-user's QA/QC system, together with their experience of using these lines, to ensure that they remain fully functional. The recommended periodicity of each inspection or test varies depending on the application, and the relevant section (7 to 10) should be referred to for each type of line whilst reading this section to know the circumstances applicable to each inspection or test procedure. Although common practice for most users of such flexibles, it is strongly recommended that a record of all service work should be maintained for each line.

6.2 6.2.1

ROUTINE VISUAL INSPECTION External inspection A visual inspection throughout the entire length of the line should include: 1. Stainless steel outerwrap: the outerwrap must always ensure its primary function which is to protect the polymeric sheath underneath from being torn or punctured. > Check that the carcass is properly attached at both end fittings; > Check that the entire surface of the polymeric sheath is protected; > Check, if any damage is noticed on the stainless steel outerwrap, that it would not be detrimental to the polymeric sheath. 2. Termination: record any damage to the coating on the end-fitting, to follow its progression, if any. 3. Connector: same as above, with particular attention to the seal area. Internal inspection A visual inspection of the inner surface of the end-fitting is to be done after cleaning, to check that it is free of cracks and that the corrosion resistant coating is undamaged. In case of cracks or severe abrasion, the line should be removed from service and a more detailed inspection should be performed by the manufacturer. For Choke and Kill or Test Lines, inspection should show that they are free from any collapse of the internal lining, this may be verified by either visual inspection or internal pigging or gauging.

6.2.2

6.3

FULL INSPECTION A full inspection includes at least: Entire external inspection; Entire internal inspection Full pressure test at OEM test pressure. CSO recommends that this inspection should be done by CSO at a convenient CSO facility. However, it must be recognised that this may be impractical according to the drilling programme schedule or location. If so, this full inspection should be carried out by a competent person who is qualified by the enduser's QA/QC system (See also Para. 6.5). MANUFACTURER'S INSPECTION - MAJOR SURVEY In accordance with the certifying authorities' specifications or CSO's recommendations, or in the event of any doubt on a line's integrity, the line may be inspected by CSO at a suitable CSO facility. This inspection will include, as a minimum: Entire external inspection; Entire internal inspection; Bending at the minimum bending radius; Pressure test at OEM test pressure.

6.4

6.5

FIELD PRESSURE TESTING (OPTIONAL) Performed on Choke and Kill lines at least on an annual basis and only in those circumstances where the full inspection proves impractical to perform (see section 7 - Para. 7.5.3). It should include: A routine visual inspection as detailed in 6.2.1. A field pressure test (section 7 - Para. 7.5.5) should be performed at 1.5 times working pressure and recorded for a period of six (6) hours. The purpose of the pressure test is to ensure that no damage has occurred to the protective outer sheath, or excess loads applied to the line which could result in an insufficient pressure containing capability both at the time of the test and for the next year that the line is in service. In those circumstances where a full inspection is impractical due to the above limitations and where regular pressure testing is performed as part of the end-user's QA/QC approved testing procedure, the safety factor and recorded test period may be reduced accordingly i.e. as an alternative to a 6 hour recorded test at 1.5 x maximum working pressure every year, a one hour recorded test at 1.1 x maximum working pressure every month may be used, thus reducing the safety factor from 50 % to 1 0 % and the equivalent period in between recorded tests from one year to one month. The decision to adopt one or other of these testing procedures as an alternative to the full inspection rests entirely with the end user and their own QA/QC system and they must be performed in accordance with all applicable safety procedures. The aforementioned options are not interchangeable.

6.6

Important Note. The above testing (6.5) is an alternative to the full inspection, strictly due to the rig limitations detailed in section 7 - para. 7.5.5. of the guidance on Choke and Kill lines only. Wherever possible, the recommendations on the annual full inspection should be adhered to. FULL PRESSURE TEST A full pressure test is performed at the OEM test pressure (1.5 times the maximum working pressure (MWP) of the line or 2 times MWP for 5000 PSI WP lines) for a minimum of 24 hours. Permissible test media are drilling muds, oil or water. The following precautions should always be respected when performing a pressure test. All personnel involved in the preparation and execution of the test must be trained and aware of the possible consequences of a test failure Gas is not allowed as a test media; all entrapped gas MUST be bled off during the pressurisation of the line. Test area must be cordoned off, and access restricted throughout the duration of any test. Nobody, including personnel involved in the completion of the test, must stand near the line under pressure. RECORDING OF INSPECTIONS AND TESTS All routine inspections must be properly recorded in the toolpusher's log, detailing Identification of the line, inspection, findings and test results.

6.7

All full inspections must be properly documented including the details of findings, repairs done and pressure test certificates. All these inspections are to be recorded by the end-user's QA/QC system. Where any or all of the tests and/or inspections are performed by CSO either on site or at a CSO facility, an inspection report and findings, together with details of repair/refurbishment work performed and pressure test recordings will be supplied to the end-user. Third, party verification of such work/testing is normally provided as standard. 6.8 PERIODICITY OF INSPECTIONS AND TESTS Refer to the line application. Section 7: Choke and Kill lines Section 8: Test lines Section 9: Acidizing/fracturing lines Section 1 0: Drag chain lines UNUSED LINES It is sometimes the case that, for a variety of reasons, a line may remain unused for a considerable period of time after delivery. In such instances, no inspection or testing is required during this storage period as long as normal protective precautions are observed. (See section 2.1 - General guidelines: Storage). The term "unused" is taken to mean a line which remains in its original delivery condition and has never been installed or used for any purpose except assembled within a DRAG CHAIN system and not installed on the platform since OEM pressure test. After first use,

6.9

it is assumed that an inspection and test record would be established in accordance with the recommendations made in this User's Guide. 7.1 DEFINITION Choke and Kill lines are an integral part of the blow-out prevention equipment required for drilling well control. The Kill line provides a means of pumping fluid into the well bore when normal circulation through the drill string cannot be employed. The Choke line connected to the choke manifold provides a means of applying back pressure on the formation while circulating out formation fluids influx into the wellbore following a "kick", the latter being an entry of water, gas, oil or other formation fluid into the wellbore and resulting from insufficient pressure from the drilling fluid column to overcome the pressure exerted by the well formation. Failure to control a "kick" would result in a "blow-out or uncontrolled release of formation fluids or gases. Depending upon the type of rig where they are installed, the flexible Choke and Kill lines are either "static" or "dynamic". A "dynamic" use is required to accommodate continuous relative motions of the connections on floating rigs while "static" use is required for dimensional variations on sequential hook-ups. On semi-submersible drilling rigs or drillships, there are two primary locations for Choke and Kill lines, "moonpool" lines used above surface to accommodate rig motion in all three planes, and BOP stack lines used on the LMRP (lower marine riser package) to allow for movement of the Choke and Kill lines around the balljoint or flex-joint.

In any case, all Coflexip flexible C/K lines are designed to resist a continuous dynamic use. 7.2 BEND TEST Bending the lines to the minimum bending radius (MBR) is required to check for possible degradation of the mechanical properties of the flexible pipe inner lining. The acceptance criteria is that the line passes the pressure test after bending has been performed (the pressure test is not carried out whilst the line Is at the MBR). Due to the nature and purpose of this test, the actual section of the line which is tested is not critical. however the bending radius itself is a precise figure and for this reason a special calibrated BEND TEST RIG must be used. (see photo below).

7.3

7.4 7.5 7.5.1

SOUR SERVICE All kinds of drilling muds and oil production fluids may be transported through Choke and Kill lines. As the lines may be used in areas where sour service is required, all Coflexip Choke and Kill lines are classified Sour service. All steel components of the flexible lines directly exposed to the Internal fluid meet NACE MR-01-75. However, the behaviour of a flexible line involving the use of steel and thermoplastic is complex and users must be aware that these lines are not necessarily designed for a permanent exposure to sour fluids. In particular, the use of a Choke and Kill line as a Test line Is unsafe and must be prohibited. VENTING Coflexip Choke and Kill lines are not vented. PERIODICITY OF FIELD TESTING AND INSPECTION After installation pressure test After installation the Choke and Kill lines (both surface and subsea) should be tested according to API recommendations (API RP53 - Periodic field testing, Para 7.A.6). Routine visual inspection (Section 6 - Para 6.2.1) The external visual inspection of the Choke and Kill lines should be performed: At the end of a drilling campaign or, At a one (1) month interval or,

7.5.2

At the first opportune moment, after a kick has occurred but no more than one (1) month after. This inspection to be recorded by the enduser's QA/QC system. Refer also to section 7.5.6 for subsea lines. Full inspection (Section 6 - Para 6.3) A full inspection must be performed on a yearly basis. CSO recommends that this inspection is done by CSO at a convenient facility, when and where practicable (For alternative testing where the full pressure test proves impractical, see field pressure testing below - 7.5.5). Manufacturer's inspection - major survey (Section 6 - Para. 6.4) CSO recommends that a first major survey be performed five (5) years after the date of initial OEM Pressure Test. A second major survey should be performed three (3) years later, i.e. eight (8) years after the initial OEM Pressure Test. Following this second major survey, CSO will at that time make recommendations to periodicity of further major inspections. Field pressure testing (optional) (Section 6 - Para. 6.5) It is recognised by CSO that due to a rig's location, lack of pressure testing and/or inspection facilities, it is either inconvenient to return a line to CSO or impossible to perform a full inspection on board the rig. Under these circumstances, a FIELD PRESSURE TEST (section 6 - Para. 6.5) may be performed as a minimum test requirement and as an alternative to the recommended full inspection, it can only be carried out on a

7.5.3

7.5.4

7.5.5

maximum of two consecutive annual occasions i.e. a maximum of three (3) years between full inspection. 7.5.6 Subsea (BOP stack) Choke and Kill lines: By virtue of their location, BOP stack lines differ from moonpool lines in the following ways: They are much shorter (typically 12-20 feet overall length) and are not subjected to the same degree of dynamic motion as moonpool lines. Being custom-built to fit each stack and being relatively short, their length tolerances are more critical than those of moonpool lines (typically 55-90 feet overall length). Installation subsea means that these lines are difficult if not impossible to visually inspect. Furthermore, recovery to the surface in order to carry out inspection work and testing is both time consuming and expensive. Experience has shown that, assuming the configuration design is strictly adhered to, a combination of less dynamic movement plus a reduced risk of damage by mishandling or misuse, means that they are a lot less prone to failure as a result of mechanical damage. CSO would, as a result of these factors, expect that end-users, their QA/QC system and their certifying authorities would be more flexible in carrying out regular inspection and testing work. This does not remove the requirement to perform such work but that it would be more likely to be performed on an opportunity basis when other such work necessitates recovery of the BOP stack for disassembly, testing and/or overhaul. TEST LINE APPLICATIONS

8.1

"DST" and "PTL" Lines Definition The conventional methods of performing a test on a formation before installing the final completion equipment is the DRILL STEM TEST which may be carried out through flexible steel lines, thus providing a single length, two connection only section of piping which is both safe and easy to install. Usually a Drill Stem Test is a short test which lasts less than 72 hours. The flexible line designed for such an application is the "DST" flexible line. Production tests done on a well any time after the completion are very similar, but they may last longer. The Coflexip flexible line designed for that application is the "PTL" line. Sour Service All steel components of DST and PTL Coflexip flexible lines, terminations and connectors directly exposed to the internal fluids meet NACE MR-01 75. DST LINES: Temporary sour service DST are designed for temporary and not permanent exposure to sour service. Each individual Drill Stem Test should not exceed 72 hours. PTL LINES: Permanent sour service PTL lines are designed for a permanent exposure to sour service. For this reason, PTL lines can be used for Drill Stem Test applications whilst DST cannot be used for long test applications in excess of 72 hours.

8.2

8.3 84 8.4.1

VENTING Both DST and PTL flexible lines are vented. PERIODICITY OF FIELD TESTING AND INSPECTION After installation pressure test After installation in the test system hook-up, the flexible test line should be tested in accordance with API recommendations on blow-out prevention system operation tests (AP1 RP53 - Para. 7 A 6). Routine external visual inspection (Section 6 - Para 6.2) The external visual inspection of the DST and PTL flexible line should be performed after completion of each test programme or at a one (1) month maximum interval. Full inspection (Section 6 - Para 6.3) A full inspection, including the internal inspection and a OEM pressure test must be performed on a yearly basis. CSO recommends that this inspection is done by CSO at a convenient CSO facility, when and where practicable. Manufacturer's inspection - Major survey (Section 6 - Para 6.4) CSO recommends that at least one major survey is done by CSO at a convenient CSO facility during the first 1 0 years, preferably in the range of 3 to 6 years after the OEM pressure test.

8.4.2

8.4.3

8.4.4

9 9.1

ACIDIZING AND FRACTURING LINE APPLICATIONS Definition Oil and gas wells require regular maintenance and servicing throughout the life of the well. This can 'Involve pumping fluids, foam or gas containing treatment materials into the well. These operations start during the drilling phase of the well with operations such as cementing. During the production phase, they include acid and proppant stimulation, water and sand control, as well as fluid support for workover operations. At the end of a well's economic or practical life, the services cover killing and abandonment operations. Well service operations therefore involve using piping to pump into a well as opposed to extracting from it. Well service operations These operations, normally involve pumping treatment materials for short periods of time, usually less than 24 hours. Flexible lines may be any of the three liner types i.e. HDPE, rilsan or coflon depending on service type. Acidizing /fracturing lines are either HDPE or coflon, the latter being a "dual-purpose" designation, capable of handling acids, produced well fluids and heavy metallic salts such as calcium or zinc bromide. Temperature ranges for these operations are given in section 3 - para. 3.2. Dynamic operations Such operations involve the use of the flexible lines to compensate for relative motion between the two connection points. An example is the servicing of wells from a floating service vessel to a fixed production

9.1.1

9.1.2

platform: such an application can be highly dynamic and applies a tremendous strain on the pipe's construction properties. 9.1.3 Static operations These normally involve small or negligible amounts of relative movement during hook-up, the lines being used to accommodate dimensional variations in fixed piping for equipment connection. Sour Service All steel components of acidizing/fracturing and well service Coflexip flexible line terminations and connectors directly exposed to the internal fluids, meet the requirements of NACE MR-01 -75. Lines designated "ACD" i.e. acidizing/fracturing are unsuitable for any service where produced well fluids or gases are present. For this reason, the steels used for the fabrication of these lines do not necessarily meet the requirements of NACE MR-01 -75. Other lines with Coflon or Rilsan liners can be used for temporary or permanent sour service (see section 8 - Test line applications). VENTING Acidizing/fracturing flexible lines are not vented. Coflon flexible lines when sold as acid lines only are not vented, but when required for "dualpurpose" i.e. DST or PTL applications in addition to acidizing/fracturing, vents are included - refer to OEM pressure test certificate or line data book for precise application, alternatively contact nearest CSO office with line serial number for further details.

9.2

9.3

9.4 9.4.1

PERIODICITY OF FIELD TESTING AND INSPECTION Routine external visual inspection (Section 6 - Para. 6.2) The External Visual Inspection of the acidizing/fracturing line should be performed: Short lengths (static operations): prior to each hook-up and at one (1) month intervals after hook-up. Long lengths (dynamic operations: vessel or winch-mounted acid lines). During deployment from winch to rig connection and during re-spooling on to winch. After installation pressure test All acidizing/fracturing lines whether short or long length, should be pressure tested after installation and prior to operating under pressure at 110 % of the maximum expected working pressure. Full inspection (section 6 - para. 6.3) A full inspection must be performed on a yearly basis. CSO recommends that this inspection is done by CSO at a convenient CSO facility, when and where this is practicable. Manufacturer's inspection - Major survey (section 6 - Para. 6.4) CSO recommends that at least one major survey is done by CSO at a convenient CSO facility during the first 1 0 years, preferably in the range of 3 to 6 years after the OEM original pressure test.

9.4.2

9.4.3

9.4.4

10 10.1

DRAG CHAIN OPERATIONS Definition Drag chain applications are specific to any flexibles which are installed within a drag chain system. These can be lines used for choke, kill, mud, cement, test and well completion fluid or other services, and as such are governed by sections 1 to 6 inclusive of this User's Guide.

Fig 9a

Fig 9b As can be seen in figures 9a and b, the flexibles are effectively contained within an articulated metal box. This is constructed to respect the MBR (storage) x 1.1 (see section 1.4) of the largest internal diameter high pressure line and thus ensures that the required MBR will always be respected. Consequently, the MBR of small diameter lines will be in excess of their minimum values. The drag chain itself also provides a supplementary mechanical protection outside the stainless steel outer wrap, thus the risk of external mechanical damage is significantly reduced.

10.2 10.2.1

10.2.2

Furthermore, each flexible length is specifically engineered to fit between the 2 rigid connection points. The flexibles, once installed in the drag chain and hooked-up at each end, are in a controlled, protected environment and therefore the inspection and test requirements are different to other installations. PERIODICITY OF FIELD TESTING AND INSPECTION After platform installation and hook up The high pressure flexibles, once fitted into the drag chains are installed as a package on to the platform and hooked-up to the rigid piping at each end via the adapters (see general arrangement drawing - Figure 1 0). All lines should then be tested in accordance with API recommendations (API RP 53 Periodic field testing, para. 7.A.6). Alternatively, it is recommended that these lines are tested at a minimum of 110 % of the maximum expected working pressure. Routine visual inspection (section 6 Para. 6.2) The external visual inspection of the drag chain lines should be performed: V At platform installation upon completion of hook-up. At subsequent 6-monthly periods, or after each skidding operation whichever comes first. After any intervention or maintenance on the drag chain itself. For Choke and Kill lines, at the first opportune moment after a kick has occurred, but no more than 1 month after. This inspection to be recorded by the end-users QA/QC system.

10.2.3

Yearly test On a yearly basis, from date of initial platform hook-up, CSO recommends that all Coflexip lines are pressure tested at 110 % of the maximum expected working pressure, in order to verify the integrity of the lines.