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User’s Guide
User’s Guide
Coflexip® flexible
pipes for drilling and
service applications
are manufactured by
the Drilling & Refining
Applications Division
of the Technip Group
CONTENTS
Contents
0 GENERAL INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3
3.3 PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.3.1 Rated working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.3.2 OEM test pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4
9 ACIDIZING AND FRACTURING LINE APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
9.1 DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
9.1.1 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
9.1.2 Well service operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
9.1.3 Dynamic operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
9.1.4 Static operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
9.2 SOUR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
9.3 VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
9.4 PERIODICITY OF FIELD TESTING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
9.4.1 Flushing of the lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
9.4.2 Routine external visual inspection (Section 6 - Para. 6.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
9.4.3 After installation pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
9.4.4 Full inspection (Section 6 - Para. 6.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
9.4.5 Manufacturer's inspection - Major survey (Section 6 - Para. 6.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
5
A B B R E V I AT I O N S U S E D
Abbreviations
used
ACD: Acidizing / Fracturing
CEM: Cement
6
0. GENERAL INTRODUCTION
General
introduction
This copy of the “Coflexip® FLEXIBLE STEEL PIPES DRILLING AND SERVICE APPLICATIONS USER'S GUIDE” (hereinafter referred
to as “the Guide”) is revision 4 of the guide originally issued in 1989 revised in September 1990, and 1993.
The main differences from revision 3 are an up-date of the product characteristics and compatibility charts made possible
by the on-going tests performed as part of Technip's policy of continual research into the safe application of flexible pipes.
Coflexip® flexible steel pipe systems are manufactured by the Drilling & Refining Applications (DRAPS) Division of the Technip
Group.
The DRAPS Division 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 infor-
mation contained in this Guide is intended primarily for those clients who are not familiar with the use of Coflexip® products.
For the purpose of this document, “End User” shall mean a person, a company, its and
their co-contractors, co-lessees and joint ventures, its and their respective affiliates, and
its and their respective officers and employees, including agency personnel (but shall not
include any member of the Technip Group), who purchase, transport, handle, package,
use or work with the Coflexip® products as described in this Guide.
The DRAPS Division relies on the feedback of all End 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 guide specifically written for Drilling and Service Applications.
In producing this Guide, we have attempted to cover all aspects of both the design and safe use of our drilling and service
application flexibles in normal, current applications. We are always available to answer questions from End Users. Any ques-
tions should be directed towards your local DRAPS Division office listed on the back cover of this Guide.
This document can be viewed and downloaded from our website at:
http://www.technip.com
7
1. DESCRIPTION
OF A COFLEXIP® FLEXIBLE LINE
1. Description
of a Coflexip® flexible line
This section 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 handling collars
Integral connectors
Optional stiffeners
Identification collars
Connector Connector
Termination Termination
Flexible pipe Stiffener
Identification collars
End fitting Handing collars End fitting
Figure 1
1.3 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.
8
1.3.1 Protection against corrosion
All steel materials used in the manufacture of a Coflexip® end-fitting meet the requirements of NACE MR-01-75.
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 Nikaflex® 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 Nikaflex® coated parts to improve that property. The DRAPS Division has selected
the most effective process which is a long duration, high temperature heat treatment conducted between 600°C
to 650°C (1,112°F to 1,202°F) for 10 hours. This process ensures diffusion of the coating into the steel, thus avoiding
any possible scaling of the protection.
The Nikaflex® coating bears the following properties:
The surface hardness of the coating is about 400 to 450 HV, in the range of most hardened steels, 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 internal flow condi-
tions. If the coating is damaged or cracked, traces of corrosion and rust may be visible and a complementary
inspection should be completed.
The Nikaflex® 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.
1.3.2 Connectors
The end-fittings can be supplied with most types of connectors, the most common being API hubs (formerly "CIW
hubs"), hammer unions and API 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.
Some restrictions on the type of connector used may apply e.g. API 16C does not allow the use of threaded connec-
tors for choke and kill applications. Similarly it is not a DRAPS Division practice to fit a connector which has a higher
pressure rating than the flexible pipe itself.
1.3.3 Terminations
The termination will ensure the following functions:
Mechanical attachment to the flexible pipe which will resist against internal pressure, traction and torsion
Provides seal against inner effluent
Provides seal against outer environment
Mechanical attachment of the outer stainless steel carcass
1.3.4 Marking
The termination bears a permanent marking indicating:
Manufacturer (*)
Serial number of the line
9
Internal diameter of the line (inches)
Application (*)
Working pressure (WP bar or 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 connector 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, The DRAPS Division recommends that the type of application
be stamped where the information is missing, using the abbreviated classification as follows. In case of doubt, please
contact the nearest DRAPS Division office.
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 CEM: Cement
PTL: Production Test Line ACD: Acidizing/Fracturing
DST: Drill Stem Test
Example of marking
COFLEXIP® Manufacturer
TR 95314.01 Serial number
3" - C/K - 18.3 m I.D./Application/Length
WP 15000 psi Working Pressure
TP 22500 psi Test Pressure
TEMP: -20/+130°C Temperature range
02/2002 Test date (month/year)
Any inquiry regarding the construction of the line and its end-fittings should refer to the serial number through which
the DRAPS Division can trace the relevant information.
10
1.3.5 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.
This collar is NOT designed for lifting more than the weight of the flexible itself.
INSTRUCTION: for long lines (acidizing lines for example), typically lines longer than 25m (80'), the End User should
refer to the DRAPS Division for advice on limitations in the use of the standard handling collars. Special collars can
be designed for specific needs.
For further details on Acidizing Applications see Section 9.
Figure 2
The bend stiffener is an additional device mounted on the flexible pipe during its manufacturing (see figure 2 above).
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.
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 and is free of
damage and cracks.
1.4.2 Adapters/Cross-Overs
Adapters/Cross-Overs can be supplied if the End User needs to
connect his flexible pipe to different or non standard connec-
tors. These adapters are typically 0.3 metres or one foot long
depending on the I.D. and rating.
Represented is an API Hub / Weco® adapter.
11
1.4.3 Fire cover
As for the flexible pipe itself, it may occasionally be necessary, due to the 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.
8
7
6
1 Thermoplastic inner liner
5 2 Aramid tape
4
3 3 Zeta spiral
2 4 Flat steel spiral
1 5 Thermoplastic intermediate sheath
6 Cross-wound tensile armours
7 Thermoplastic external sheath
8 Outer wrap interlocked steel carcass
Figure 3
12
1.5.5 Double cross-wound steel armour
The double cross-wound 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.
WARNING: you must be aware that a Coflexip® flexible can be stronger than some of the pipework to which it is
connected and that it will rarely be the "weak point" of a system.
13
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 the DRAPS Division's documents, the minimum bending radius is abbreviated as MBR.
OD Example:
2.5” Coflon 15 kpsi W.P.
d = (2 MBR minus OD)
MBR = 0.86 m/2.81 ft
OD = 140.2 mm/52 inches
d = 1.58 m/5.18 ft
Figure 4
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 0.076 = 0.92 metre or 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.
14
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 metre or few feet of flexible pipe immediately behind
each termination.
An optional bend stiffener is available on request to improve the pipe's resistance to such overbending.
This failure mode may cause the line to burst.
Figure 5 shows how overbending may be caused, whether or not the line is under internal pressure.
NO YES
Figure 5
Ageing of the inner liner - The mechanical properties of the inner liner can be affected by ageing. This pheno-
menon causes the degradation of the long thermoplastic molecules and may be due to:
Long exposure to high temperature, exceeding the maximum rated temperature
Exposure of the internal surfaces to incompatible chemicals
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.
This failure mode can result in a burst, or more often, in a high pressure leak.
Collapse of the inner liner - If damaged, the outer sheath may not be leak-proof. For subsea lines, the external
hydrostatic pressure will be applied on to the inner liner which may collapse. This can lead to the rupture of the
liner and failure of the line.
This failure mode may cause the line to burst.
15
2. GENERAL GUIDELINES
2. General guidelines
2.1 STORAGE
Storage in general does not require specific precautions regarding the environment or duration of storage.
Depending on length, the best ways to store a line are either:
In a straight line (up to 6 metre or 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.
INSTRUCTION: 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.
INSTRUCTION: if stored below minimum rated temperature, ensure that no handling is done before the line is brought
back to the minimum rated temperature.
INSTRUCTION: the inner bore of a Coflexip® line should be thoroughly flushed with fresh water prior to long term
storage.
2.2 HANDLING
INSTRUCTION: only qualified and trained personnel should handle flexible lines such as those manufactured by the
DRAPS Division. Whilst we make every effort to assist End Users whenever possible on the methods of handling to
be deployed, the final decision on the best methods for local conditions and capacities rests with End Users or their
appointed agents, either of whom should have their own procedures for such handling operations.
Any rigging should be suitably adapted to the specific flexible line in question, as mishandling can be dangerous to
operations, surrounding personnel, equipment and property.
The line must never be bent below the minimum bend radius (MBR), 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
will have been supplied to the original End User: it can be obtained from the nearest DRAPS Division office.
The 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
0.6 to 0.9 metre (2 to 3 feet) should be used as a safety distance.
See section 1.7 - 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 handling collar. Never use wire ropes or chains directly against the stain-
less steel outer-wrap. If force needs to be applied to the body of the flexible line itself, use soft slings.
Moving flexible line on the ground
16
Do not attach slings directly to the end-fitting - use the handling collar provided. Always connect slings to both
eyes in order to have the pulling force in a straight line through the main axis of the flexible pipe.
Prevent abrasion of the flexible line against the ground; use wooden supports or planks.
If a forklift has to be used to lift a flexible line, soft slings must be used to prevent damage, and to prevent the
flexible line from falling off the forks (see the DRAPS Division Handling schematics inside the rear of this Guide).
End User assumes all responsibility for essential safety precautions to avoid injury or death in connection with
these operations.
2.4 WELDING
A flexible steel line is a mixed construction of steels and ther-
moplastics. It must be recognised that because of the heat diffu-
sion that 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, invol-
ving 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 will must be withdrawn from service Figure 7
and stamped "NOT-REUSABLE".
17
3. O P E R AT I N G C O N D I T I O N S
3. Operating conditions
Although similar in appearance, the construction of Coflexip® lines for different drilling applications such as Choke
and Kill lines, Acid lines or Test lines differ significantly.
INSTRUCTION: these lines must never be used for any purpose other than the original for which the line was supplied
and which is stamped on the end-fitting identification collar (see section 1.3). In case of doubt, contact the nearest
DRAPS Division office for information on guidelines to be respected.
INSTRUCTION: in case of doubt please contact the nearest DRAPS Division office.
All components of the end-fittings in contact with the inner fluids are adequately protected against corrosion.
In most cases it is the internal liner made of thermoplastics that will limit the chemical compatibility of the flexible
line. They are different for:
Tables I, 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 DRAPS Division office.
18
TABLE I
Chemical compatibility of standard temperature rated lines.
Exposure resistance of RILSAN® inner lining at given temperature ranges.
0°F 75°F 150°F 200°F 250°F
Concentration -18°C 24°C 66°C 93°C 121°C
15% F F F F F
Hydrochloric acid HCl
30% F F F F F
3% F F F F F
Hydrofluoric acid HF
7.5% F F F F F
Xylene C6 H4 (CH3)2 100% S S S S NR
Methanol CH30H 100% S S L 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 sulphide H2S (pure gas) < 20% S S S S L
Hydrogen sulphide H2S (condensate) < 20% L* L* L* L* L*
Water Presence L* L* L* L* L*
TABLE II
Chemical compatibility of high temperature rated lines.
Exposure resistance of COFLON® inner lining at given temperature ranges.
0°F 75°F 150°F 200°F 250°F
Concentration -18°C 24°C 66°C 93°C 121°C
15% S S S S S
Hydrochloric acid HCl
30% S S S S S
3% S S S S S
Hydrofluoric acid HF
7.5% S S S S S
Xylene 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 sulphide H2S < 20% S S S S S
19
3.1.3 Exposure of high temperature rated lines to CO2 combined with H2S
Under certain conditions, exposure to relatively high concentrations of CO2 combined with H2S, can lead to damage
of the COFLON® liner. For this reason, the following limitations are to be respected:
PRESSURE TEMPERATURE FLUID CONDITIONS
1035 bar/15,000 psi 130°C (+266°F) CO2 + H2S < 10 %
690 bar/10,000 psi 130°C (+266°F) CO2 + H2S < 30 %
690 bar/10,000 psi 110°C (+230°F) CO2 + H2S < 50 %
TABLE III
Chemical compatibility of acid (HDPE) lines.
Exposure resistance of HDPE inner lining at given temperature ranges
0°F 75°F 150°F 200°F 250°F
Concentration -18°C 24°C 66°C 93°C 121°C
15% S S S F F
Hydrochloric acid HCl
30% S S S F F
3% S S L F F
Hydrofluoric acid HF
7.5% S S L F F
Xylene C6 H4 (CH3)2 100% S S L 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% S S L F F
Diesel 100% S S L F F
Crude oil 100% S S L F F
Sodium hydroxide NaOH 50% S S S F F
Hydrogen sulphide H2S < 20% S S S F F
20
3.1.6 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 flow-rates 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, therefore maximum short term flow-rates cannot be quantified for all
flow conditions. Extreme flow rates and abrasive fluids can cause erosion in the end-fittings. It is common practice to
change the end-fittings when these show severe scoring or pitting. Experience has shown that for those types of lines
subjected to severe abrasive conditions (fracturing operations), the end-fittings can be replaced twice before the
flexible pipe itself should be considered not fit for further use.
21
3.2.3 High temperature Exposure Test of Choke and Kill Lines
All Coflexip Choke and Kill lines have been tested in accordance with the latest edition of API 16C and are in full compliance with
the highest standards imposed. These standards include the following destructive testing:
Flexible Line High Temperature Exposure Test
This test is intended to determine the maximum temperature that a flexible Choke and Kill line will withstand for a short duration
when exposed to the rated working pressure. This test represents severe, survival conditions and should not be used to define the
temperature rating of the line. It is imperative that both the line structure and the end terminations be exposed to the tempera-
ture excursions during the tests.
Successful completion of verification testing qualifies the size and pressure rating of the flexible tested, together with smaller sizes
of equal or lower pressure ratings and temperature of equivalent design and construction.
Upon reaching the manufacturer’s rated working pressure and maximum temperature, the temperature is raised at a rate not to
exceed 5°F (2.8°C) per hour to 350°F, +10°F, (177°C +5.5°C) and held for one hour. The temperature should be measured, either at the
fluid inside the line or at the inside wall of the line. At the end of one hour, the temperature is raised at a rate not exceeding 5°F
(2.8°C) per hour until failure. Failure is defined as a visible fluid leak in the end connection, the body of the line or burst of the line.
The total time of exposure to 350°F (177°C) and above should be recorded together with the temperature and the failure mode of
the pipe: leak and its location, or burst and its location. Acceptance criteria will be sustaining the 350°F (177°C) hold period, at rated
working pressure, for one hour with no visible leakage.
The pressurization fluid can be water, or heat transfer oil. The fluid may be static or flowing. Because the objective of the testing
is to simulate, as closely as possible, service conditions, line heating should be from the inside.
In connection with flexible pipes, a "burst" is defined as the catastrophic failure of the pipe assembly, either by loss of a complete
end fitting, or by rupture of the complete assembly such that no flow is possible between the opposing end connectors. A “leak”
is defined as a loss of pressure integrity in the flexible pipe assembly, but which allows a significant quantity of flow between the
opposing end connectors enough to allow a continued temporary limited use in its intended service.
The Coflexip® line survived the above destructive testing procedure for a total period in excess of 20 hours, and to a final tempe-
rature of 232°C(450°F). Failure mode was a “leak” as defined above, no bursting occurred.
3.3 PRESSURE
WP OEM. TP Test duration: all factory pressure tests last a minimum of 24 hours
345 bar/5,000 psi 690 bar/10,000 psi after stabilisation at ambient temperature.
690 bar/10,000 psi 1035 bar/15,000 psi Note: the standard DRAPS Division FAT (Factory Acceptance Test)
1035 bar/15,000 psi 1550 bar/22,500 psi is well in excess of the minimum requirement of API 16C.
22
4. LIFETIME OF DRILLING AND SERVICE
A P P L I C AT I O N F L E X I B L E L I N E S
4. 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 their rated tempera-
ture range, fluid compatibility and allowable bending radius.
However, because of the many disparate factors affecting the service life 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, handling, manipulations, repairs when necessary and other
requirements and precautions recommended by the DRAPS Division in the User's Guide.
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 the DRAPS Division as expressly agreed in writing with the End User, 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". The DRAPS Division MAKES NO REPRESENTATION
OR WARRANTY SAVE AS EXPRESSLY AGREED IN WRITING WITH END USER.
INSTRUCTION: flexible lines removed from service upon expiration of the service life should be stamped "NOT
REUSABLE" or preferably cut into pieces.
Any line which reaches 20 years since its OEM pressure test, and which continues to function correctly, should be
returned to the DRAPS Division for investigation and recommendation on its continued use.
During this 20 year period, it is probable that a considerable number of design changes will have been made, and regu-
lations or recommendations on the use of any particular application are likely to have changed: a combination of
these factors may make it impossible to recommend any further use of a particular line.
23
5. R E PA I R O F F L E X I B L E S L I N E S
5. Repair of
flexibles 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 DRAPS Division facility, depending upon the
degree of the damage:
Serviceable parts of end-fitting, including handling collar and the rear locking nut attachment of the external carcass
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 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
reusable and that, because 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.
The DRAPS Division reserves the right of declining to carry out a repair on a line which is found in a condition rende-
ring it unsafe for use.
Except in exceptional circumstances, the DRAPS Division will not proceed with any repair on lines which do not meet
current industry standards or Technip's internal standards. (For unused lines, see Section 6.9).
24
6. INSPECTION AND TESTING OF LINES
6. Inspection and
testing of lines
6.1 INTRODUCTION
This section details the actual inspections and tests recommended by the DRAPS Division 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 the DRAPS Division 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 the DRAPS Division recommends End Users, whenever possible, to have this inspection and testing
work carried out by the manufacturer. Under such circumstances, Technip's DRAPS Division will issue a certificate detai-
ling the inspection and/or testing work performed on each line.
Circumstances may make this impractical and, in such instances, the DRAPS Division 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.
INSTRUCTION: 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.
25
6.3 FULL INSPECTION
A full inspection includes at least:
Entire external inspection;
Entire internal inspection
Full pressure test at OEM test pressure for a period of 24 hours
Technip's DRAPS Division recommends that this inspection should be done by the DRAPS Division at a convenient
DRAPS Division facility.
However, it must be recognised that this may be impractical according to the drilling programme schedule or loca-
tion. If so, this full inspection should be carried out by a competent person who is qualified by the End User's QA/QC
system (See also Para. 6.5).
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.
26
6.6 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 345 bar / 5,000 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 conse-
quences 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
INSTRUCTION: these tests are carried out at the End User's risk. It must be stressed that a catastrophic burst can be
the result of these tests (although extremely unlikely on well maintained flexibles), and that all precautions MUST be
taken to avoid damage and/or injury (see Section I - Para. 1.7 FAILURE MODES OF COFLEXIP® FLEXIBLE LINES).
INSTRUCTION: in case of doubt please contact the nearest DRAPS Division office.
27
7. CHOKE AND KILL LINES
7.1 DEFINITION
INSTRUCTION: one should always check the temperature and pressure ratings before using cement lines in well
control operations.
INSTRUCTION: the use of a Choke and Kill line as a Test line is unsafe and must be prohibited.
28
7.3 COMPLETION FLUIDS
It may be a requirement for a variety of completion fluids to be pumped through the flexible lines. Many of these
fluids contain acids, zinc bromide, etc. These products may not be compatible with the thermoplastic liner of the
Coflexip® Choke and Kill lines. Please refer to the fluids compatibility charts in Section 3.
INSTRUCTION: in case of doubt please contact the nearest DRAPS Division office.
7.4 VENTING
Coflexip® Choke and Kill lines are not vented.
29
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 3.5 - 6 metres (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 17 - 27 metres (55 - 90 feet) overall length).
INSTRUCTION: BOP stack lines cannot be re-used on another stack without a detailed study confirming the lines are
compatible with the new installation. In case of doubt please contact the nearest DRAPS Division office.
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 mecha-
nical damage.
Technip's DRAPS division would, as a result of these factors expect that End Users, their QHSE systems and their certi-
fying authorities to be diligent in conducting regular inspection and testing work. Normally such work should be
performed on a opportune basis when other works necessitate the recovery of the BOP stack for disassembly, testing
and/or refurbishment.
30
8. T E ST L I N E A P P L I C AT I O N S
INSTRUCTION: each individual Drill Stem Test should not exceed 72 hours.
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 lines cannot be used for long production test applications in excess of 72 hours.
8.3 VENTING
Both DST and PTL flexible lines are vented.
Venting: Coflexip® Test Lines include an independent and automatic method to de-pressurise the flexible pipe body
in the event of pressure build up caused by permeated gas; this process is called venting.
INSTRUCTION: under no circumstances should vented lines be used under water nor should either of their extre-
mities be immersed. This could lead to long term corrosion of the armour wires and risk of failure. (See Section 1 -
Para. 1.7 FAILURE MODES OF COFLEXIP® FLEXIBLE LINES)
31
9. ACIDIZING AND FRACTURING LINE
A P P L I C AT I O N S
9. Acidizing and
fracturing line applications
9.1 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.
9.1.1 Handling
INSTRUCTION: the handling of the Coflexip® flexible lines should be carried out by qualified and trained personnel
using adapted lifting/handling equipment.
The deployment of the flexible lines should be carried out following the End User's operating procedures in which all
safety aspects should be covered.
When connecting acidizing lines from independent vessels to platforms, the lines should be connected to the plat-
form pipe work through an external connection point capable of bearing the loads applied by the flexible pipe.
It must be noted that the flexible pipe must never be considered as the weak point of a system, its breaking
load being several hundred tons.
When the flexible pipe is deployed from a winch, the whole length of pipe MUST be paid out so that the QCDC
(Quick Connect Dis-Connect) or QDC (Quick Dis-Connect) assembly is allowed to operate in a fast and reliable manner.
Relying on the freewheeling of the winch can at best cause some loss of time in circumstances where time is critical.
A guide system should be fitted as part of the winch installation which ensures that the flexible pipes approach angle
with the winch drum is kept within reasonable limits, thus ensuring correct operation of the emergency disconnect
system when required.
32
9.2 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).
9.3 VENTING
Acidizing/fracturing flexible lines are not vented. Coflon® flexible lines when sold as acid lines only are not vented,
but when required for "dual-purpose" i.e. DST or PTL applications in addition to acidizing/fracturing, venting is included
- refer to OEM pressure test certificate or line data book for precise application, alternatively contact nearest DRAPS
Division office with line serial number for further details.
INSTRUCTION: under no circumstances should vented lines be used under water nor should either of their extre-
mities be immersed. This could lead to long term corrosion of the armour wires and risk of failure. (See Section 1 -
Para. 1.7 FAILURE MODES OF COFLEXIP® FLEXIBLE LINES)
INSTRUCTION: after completion of any of the above operations, the lines should be thoroughly flushed with water.
33
10. D R AG C H A I N O P E R AT I O N S
34
11. S U M M A RY O F I N ST R U C T I O N S
11. Summary of
instructions
Page 11 - PARA 1.3.5: for long lines (acidizing lines for example) typically lines longer than 25m (80'), the End User should refer
to the DRAPS Division for advice on limitations in the use of the standard handling collars. Special collars can be designed
for specific needs.
For further details on Acidizing Applications see Section 9.
Page 13 - PARA 1.6: WARNING: you must be aware that a Coflexip® flexible can be stronger than some of the pipe-
work to which it is connected and that it will rarely be the "weak point" of a system.
Page 16 - PARA 2.1: a similar protection should be reinstalled when the line is disconnected. It may consist in 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.
Page 16 - PARA 2.1: if stored below minimum rated temperature, ensure that no handling is done before the line is brought
back to the minimum rated temperature.
Page 16 - PARA 2.1: the inner bore of a Coflexip® line should be thoroughly flushed with fresh water prior to long term
storage.
Page 16 - PARA 2.2: only qualified and trained personnel should handle flexible lines such as those manufactured by
the DRAPS Division. Whilst we make every effort to assist End Users whenever possible on the methods of handling
to be deployed, the final decision on the best methods for local conditions and capacities rests with End Users or
their appointed agents, either of whom should have their own procedures for such handling operations.
Any rigging should be suitably adapted to the specific flexible line in question, as mishandling can be dangerous to
operations, surrounding personnel, equipment and property.
The line must never be bent below the minimum bend radius (MBR), 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
will have been supplied to the original End User: it can be obtained from the nearest DRAPS Division office.
The 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
0.6 to 0.9 metre (2 to 3 feet) should be used as a safety distance.
See section 1.7 - 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 handling collar. Never use wire ropes or chains directly against the stain-
less steel outer-wrap. If force needs to be applied to the body of the flexible line itself, use soft slings.
Moving flexible line on the ground
Do not attach slings directly to the end-fitting - use the handling collar provided. Always connect slings to both
eyes in order to have the pulling force in a straight line through the main axis of the flexible pipe.
Prevent abrasion of the flexible line against the ground; use wooden supports or planks.
If a forklift has to be used to lift a flexible line, soft slings must be used to prevent damage, and to prevent the
flexible line from falling off the forks (see the DRAPS Division Handling on the schematics inside the rear of this
Guide). End User assumes all responsibility for essential safety precautions to avoid injury or death in connec-
tion with these operations.
Page 17 - PARA 2.3: the best way to achieve this is to support the weight of the line through the use of the handling collar,
then control the alignment with a non-metallic rope or sling attached about 0.9 metres (3 feet) behind the end-fitting.
Page 18 - PARA 3: these lines must never be used for any purpose other than the original for which the line was supplied
and which is stamped on the end-fitting fitting identification collar (see Section 1.3). In case of doubt, contact the nearest
DRAPS Division office for information on guidelines to be respected.
35
Page 18 - PARA 3.1: in case of doubt please contact the nearest DRAPS Division office.
Page 23 - PARA 4: flexible lines removed from service upon expiration of the service life should be stamped "NOT
REUSABLE" or preferably cut into pieces.
Any line which reaches 20 years since its OEM pressure test, and which continues to function correctly, should be
returned to the DRAPS Division for investigation and recommendation on its continued use.
During this 20 year period, it is probable that a considerable number of design changes will have been made, and regu-
lations or recommendations on the use of any particular application are likely to have changed: a combination of
these factors may make it impossible to recommend any further use of a particular line.
Page 25 - PARA 6.1: 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.
Page 27 - PARA 6.6: these tests are carried out at the End User's risk. It must be stressed that a catastrophic burst can
be the result of these tests (although extremely unlikely on well maintained flexibles), and that all precautions MUST
be taken to avoid damage and/or injury (see Section I - Para. 1.7 FAILURE MODES OF COFLEXIP® FLEXIBLE LINES).
Page 27 - PARA 6.9: in case of doubt please contact the nearest DRAPS Division office.
Page 28 - PARA 7.1.2: one should always check the temperature and pressure ratings before using cement lines in well
control operations.
Page 28 - PARA 7.2: the use of a Choke and Kill line as a Test line is unsafe and must be prohibited.
Page 29 - PARA 7.3: in case of doubt please contact the nearest DRAPS Division office.
Page 30 - PARA 7.5.6: BOP stack lines cannot be re-used on another stack without a detailed study confirming the
lines are compatible with the new installation. In case of doubt please contact the nearest DRAPS Division office.
Page 31 - PARA 8.2: each individual Drill Stem Test should not exceed 72 hours.
Page 34 - PARA 8.3: under no circumstances should vented lines be used under water nor should either of their extre-
mities be immersed. This could lead to long-term corrosion of the armour wires and risk of failure (See Section 1 -
Para. 1.7 FAILURE MODES OF COFLEXIP® FLEXIBLE LINES).
Page 32 - PARA 9.1.1: the handling of the Coflexip® flexible lines should be carried out by qualified and trained personnel
using adapted lifting/handling equipment.
The deployment of the flexible lines should be carried out following the End User's operating procedures in which all
safety aspects should be covered.
When connecting acidizing lines from independent vessels to platforms, the lines should be connected to the plat-
form pipe work through an external connection point capable of bearing the loads applied by the flexible pipe.
It must be noted that the flexible pipe must never be considered as the weak point of a system, its breaking
load being several hundred tonnes.
When the flexible pipe is deployed from a winch, the whole length of pipe MUST be paid out so that the QCDC
(Quick Connect Dis-Connect) or QDC (Quick Dis-Connect) assembly is allowed to operated in a fast and reliable
manner.
Relying on the freewheeling of the winch can at best cause some loss of time in circumstances where time is critical.
A guide system should be fitted as part of the winch installation, which ensures that the flexible pipes approach angle
with the winch drum is kept within reasonable limits, thus ensuring correct operation of the emergency disconnect
system when required.
36
Page 33 - PARA 9.3: under no circumstances should vented lines be used under water nor should either of their extre-
mities be immersed. This could lead to long term corrosion of the armour wires and risks of failure. (See Section 1 -
Para. 1.7 FAILURE MODES OF COFLEXIP® FLEXIBLE LINES).
Page 33 - PARA 9.4.1: after completion of any fracturing and/or acidizing operations, the lines should be thoroughly
flushed with water.
REMINDER:
Technip's DRAPS Division MAKES NO REPRESENTATION OR WARRANTY SAVE AS EXPRESSLY AGREED IN WRITING
WITH END USER.
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38
HANDLING, STORAGE
AND MAINTENANCE
Minimum
Minimum bend
bend radius
radius 2
Medium lengths
Long lengths
3 x O.D.
Minimum of pipe
bending
radius
Headquarters Drilling & Refining Applications Division - Worldwide presence