Comprehensive Approach to In Integrity Assessment of f Critical Structural Components with ASPIRE™ Payam Jamshidi, TWI Ltd Sebastian Hartmann, Innospection Ltd
OVERVIEW - Well conductor integrity challenges - What is ASPIRE TM ? - Advanced well conductor inspection - Assessment procedure - Case study - Conclusion The ASPIRE TM - Project is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 Slide 2
Well ll Conductors • Offshore well bores consist of several concentric tubes • The outermost well casing, the conductor, protects the inside casings from aggressive corrosion. • The conductor should not leak, nor buckle or collapse under both axial load and bending moment The ASPIRE TM - Project is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 Slide 3
Past Conductor Failures The ASPIRE TM - Project 760460 is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 4
Well Conductor In Integrity Management Challenges • Ageing assets • Missing documentation of the asset • No or insufficient inspection data available • Lack of advanced technology available for effective cleaning and inspection of vulnerable areas (i.e. splash zone) • Lack of advanced technology available for processing of the inspection date to provide a risk based condition assessment of the asset • Lack of assessment application that can be used on site while the inspection is ongoing allowing for immediate decision making • No means for easy planning of mitigation options (i.e. repair) The ASPIRE TM - Project 760460 is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 5
TM ? IRE TM What is is ASPIR ASPIRE TM stands for “ Assess Strategy for Upstream Plant Inspection and Re pair” and is a software package to integrate the collection, management and analysis of inspection data for the purpose of providing RBI and repair decision making for upstream assets. What ASPIRE TM does : • Incorporates a customisable probabilistic based algorithm to use advanced reliability methods to assess failure scenarios for several types of non-standard geometries, loading, environment and operations. • Links the assessment to input from advanced NDT to analyse the results seamlessly. • Provides information about operational risk and remaining service life as an output. The ASPIRE TM - Project 760460 is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 6
Advanced In Inspection (M (MEC-MPS200+) System Set Up arrangement & Power Supply Deck Cable Umbilical 20m ~150m Scanner IN E-Magnet max DC 40V 36A Camera/Light MEC Computer Power : DC 12-19V DC Power Supply & IN: 110V AC , Rated 130W 2.5 Amp full density Sensor Multiplexer OUT: ET Board Output DC 12V IN: 110V AC & DC 5V OUT: max DC 40V – 36A Monitor & DVD Recorder Camera IN: 110V AC , ~ 150W The ASPIRE TM - Project 760460 is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 7
MEC-MPS200+ In Inspection Equipment - Operations - Little pipe preparation needed (no couplant) - Remote controlled deployment - Includes a spray bar for marine growth cleaning based on high pressure jetting - NDE key points - up to 1.3” Wall Thickness, sensitive for isolated pit detection, sizing accuracy ≤ +/ - 10% - inspection through coatings (Neoprene etc.) & CRA layers (Monel, Inconel, TSA ) with the MEC technology - also includes an array of UT probes for a simultaneous mapping of the remaining wall thickness (in addition to MEC) EC - inspection speed (net average run speed 0.25m – 0.5 m/sec) field - separate C-Scan corrosion mapping of near side & far side or merged - Direct online data assessment & integrity assessing data set up - Delivers wall thickness matrix data in a neutral format (i.e. csv files) Magnetic Field Lines The ASPIRE TM - Project 760460 is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 8
MEC-MPS200+ Spla lash Zone In Inspection - Riser / Caissons / Conductors - Combined cleaning & inspection - MEC & UT Technology combination - Inspecting through coatings - No operational interruptions - RAT Deployment / remotely operated Splash Zone The ASPIRE TM - Project 760460 is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 9
WT Matrix Data used as In Input to Assessment WT matrix data to be used as input for an advanced integrity assessment Provided in open data format (i.e. as csv file) The ASPIRE TM - Project 760460 is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 10
Well Conductors • Purpose • To demonstrate / document viability & integrity of each of conductors • For next “x” years – Endorsement period – Time/Risk Based Inspection period • Avoiding any major repairs • Process • Review of available data • Design analyses and engineering assessments • Inspection scopes & results • Operational history including incidents The ASPIRE TM - Project 760460 is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 11
Assessment Procedure • Design check of well conductors is a stability check based on international best practices: • Petroleum and Natural Gas Industries, “Fixed Offshore Platform”, ISO -19902, 2007 • Institute of Petroleum, “Guideline for the Analysis of Jackup and Fixed Platform Well Conductor System”, 2001 • Design of Concentric Tubular Members, G. R. Imm, B. Stahl, Offshore Technology Conference, 1988. • Design Methodology for Offshore Platform Conductors, B. Stahl, M. P. Baur, Offshore Technology Conference, 1980. • Minimum Required Thickness (MRT) is the thickness below which the required cross sectional area is not achieved and failure may occur • Grouting in annulus of conductor and other internal casing/tubing will influence the MRT calculation. It will be in-conservative not to consider the effect of grouting. The ASPIRE TM - Project 760460 is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 12
Assessment Procedure In summary, design evaluation of conductors include: • Determine the equivalent section of the conductor by the supports configuration. • Determine the stiffness of the conductor based on effective length • Calculation of the axial loads and bending moment • Calculation of stress ratio MRT calculation which is the critical thickness at which the stress ratio is equal to 1.0 . Conductor Subjected to Axial, Internal and Bending Strength Stability Check Check Stress Buckling Design of Concentric Tubular Members, G. R. Imm, B. Stahl, Offshore Technology Conference, 1988. The ASPIRE TM - Project 760460 is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 13
Lo Loading Mi & M e Axial Compression P i & P e P i : - Axial load due to weight of conductor, internal casings etc. P e : - Axial load at each elevation due to weight on top of the conductor Global Bending M e : - Bending moment due to environmental condition such as “100 year storm – Wave and current” calculated by SACS software M i : - Bending moment due to eccentricity of casings The ASPIRE TM - Project 760460 is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 14
Remaining Lif ife Assessment MEC Inspection Results Internal Indication External Indication (Marine corrosion zone) 1 Segment 1 The retirement thickness required to meet the loading Averaged Minimum 2 condition at each measured thickness segment of the from the SLOFEC results conductor (Splash zone) t MRT Segment 2 3 mm ( i ) Distribution of RL RL (per segment) CR --- The remaining time to 4 exceed the Probability of Distribution of corrosion rate Failure (PoF) target will per segments based on be considered as the risk thickness data or corrosion (Sea Water zone) models based remaining life. Segment 3 5 Cumulative Distribution nom t Trd Function (CDF) CR age The ASPIRE TM - Project 760460 is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 15
Corrosion Rates Current Study Literature According to HSE Research Zones of corrosion for Steel Piling in Report 016 - Guideline for use Seawater of statistics analysis of sample Marine Zone inspection of corrosion Splash Zone Estimated CR will be the 95% confidence limit Source: F. L. LaQue, Marine Corrosion cause and Precention, P. 116, john Wiley & Sons, 1975. Reproduced by permission of The Electrochemical Society. The ASPIRE TM - Project 760460 is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 16
Ris isk and Ris isk Based Remaining Lif ife • Predictive target risk date (RLI) • Inspection frequency determined The ASPIRE TM - Project 760460 is funded by the EU under the Horizon 2020 Framework Programme 22/01/2019 17
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