Proceedingsof

Proceedings ofthe
theASME
ASME2010
201029th
29thInternational
InternationalConference
Conferenceon
on Ocean,
Ocean, Offshore
Offshore and
and Arctic
Arctic Engineering
Engineering
OMAE2010
OMAE2010
June 6-11,
June 6-11, 2010,
2010, Shanghai,
Shanghai, China
China

OMAE2010-20383
OMAE2010-20383

FLEXIBLE PIPE SYSTEMS CONFIGURATIONS FOR THE PRE-SALT AREA

Judimar Clevelario Fabio Pires Claudio Barros

Wellstream International Limited Wellstream International Limited Wellstream International Limited
Rio de Janeiro, RJ, Brazil Rio de Janeiro, RJ, Brazil Rio de Janeiro, RJ, Brazil

Terry Sheldrake
Wellstream International Limited
Newcastle, United Kingdom

ABSTRACT
Unbonded flexible pipes are being considered as an
actual solution for the following developments for the Brazilian
Pre-Salt area. This technology is already being successfully
used in the first EWT installed in the Brazilian Pre-salt and
being qualified for the first Pre-salt Pilot Project development.
However, unlikely the current project developments in water
depths around 1500m, the free catenary configuration is not
always an applicable option not only due to the 2500m water
depth but also to the presence of contaminants such as CO2 and
H2S in the conveyed fluids which in certain applications make
the use of conventional high strength steels unfeasible, making
the use of sour service armour wires mandatory. This paper
presents the result of the global and local analysis performed for
different applications such as 4” gas lift, 6” water injection, 6”
production and 9.13” Gas export structures designed
specifically for the ultra deep water in Brazilian Pre-Salt area.
The aim of this study was to verify the feasibility of the
free hanging catenary configuration and determine the most
suitable flexible pipe system configuration for different
applications, confirming that the flexible pipes are an adequate
solution for the Pre-Salt even when the service life requirements
exceeds 20 years and associated safety factors.
NOMENCLATURE
EWT Extended Well Test
HIC Hydrogen Induced Cracking
SCC Stress Corrosion Cracking
TDZ Touch Down Zone
WD Water depth
INTRODUCTION
The first phase of the Brazilian Pre-salt cluster
development will be based on the current offshore pipeline
technology, considering the use of conventional flexible risers
systems and the use of FPSO’s [1]. Based on this scenario a
peer evaluation of the flexible pipe system was carried out by
Wellstream in order to identify the main challenges related to
the installation and operation of flexible risers systems in the
Pre-salt cluster.
A comprehensive flexible riser systems risk assessment was
performed in order to identify any potential new failure mode
and possible technical limitations which could be caused by the
loads imposed by the riser systems to the production unit’s
supports and the nature of the conveyed fluids.
Special attention was given to the permeation behavior of
the flexible risers systems once it is already known that a
significant part of the fluids produced in the fields located in the
Pre-salt cluster will have the presence of contaminants such as
CO2 and H2S [2] [3], which have a major impact on the flexible
pipe’s material selection and fatigue service life.
Wellstream has also performed a comparison between the
service loads expected for similar flexible pipe structures which
were supplied and are operating in FPSOs in different water
depths in order to quantify the loads associated to the flexible
pipe operations in 2250m water depth and compare it with
conventional applications. Wellstream has included in this paper
the comparison with the flexible pipe systems which are
operating in the TUPI EWT in a maximum water depth of
2250m since May 2009.

1 Copyright © 2010 by ASME

PRE-SALT CLUSTER CHALLENGES
The Brazilian Pre-salt cluster is located approximately 300
km offshore in a region which can reach up to 2500 m WD,
bringing both logistic and technological challenges to the
cluster development [4].
The first Pre-salt commercial project development was
started in 2008, focusing the development of subsea equipment,
flexible risers systems and top side equipment for the TUPI
EWT project. Wellstream has awarded the scope of flexible
pipe for the TUPI EWT and started the development of a new
generation of flexible pipes for 2250m WD.
During the flexible pipe design process several flexible
pipe related technological challenges were identified as the
increase of the bucking forces on the TDZ due to the increased
water depth and the increased loads associated to both
installation and operation of the flexible pipes in such water
depth.
The presence of contaminants in the conveyed fluids would
also make the use of sour service pressure and tensile armour
wires mandatory, based on the permeation analyses results for
each specific application.
Each one of the challenges mentioned above were
addressed and solved during the flexible pipe design phase
which is discussed in this paper.
CONVEYED FLUID EFFECTS ON THE MATERIAL
SELECTION
As it is already well known by the industry, flexible pipes
structures are susceptible to the gas permeation from the pipe
bore through the polymeric layers, therefore creating corrosive
environments in the pipe annulus, between the pressure barrier
and the pipe’s outer sheath, region where both tensile and
pressure armour wires are located.
Based on this fact, it becomes apparent that the flexible
pipe armour wires material selection shall be based on the
predicted permeated annulus environment in order to take into
account the actual CO2 and H2S partial pressures expected for
the annulus environment in a given flexible pipe application.
As a standard design rule, Wellstream performs permeation
analyses as part of the regular design process in order to
technically support the material selection of both tensile and
armour wires for flexible pipes. The permeation analyses
performed by Wellstream are carried out using its proprietary
diffusion and permeation model DIFLEX.
Wellstream has performed the permeation analyses to
different applications expected for the Brazilian Pre-salt cluster
2 Copyright © 2010 by ASME
in order to identify and quantify the presence of contaminants in
the flexible pipes annulus, mainly the H2S which can lead to
HIC and SCC failures.
Figure 1 presents the H2S permeation analyses results,
where it is observed that in four of the foreseen applications, the
H2S partial pressures will be below the sweet service wires H2S
tolerance limit (A, B, F and G) indicating that this material
grade may be used for the structure manufacturing. For the
applications C, D and E, the H2S partial pressures will be higher
then the sweet service wires H2S tolerance limit making the use
of sour service armour wires mandatory to avoid HIC and SCC
failures during operation.
16
14
H2S partial pressure
12
10
8
6
4
2
0
"A" "B" "C" "D" "E" "F" "G" Sweet Sour
wire wire
limit limit
Figure 1. H2S partial pressures predicted for the annulus
environment of different applications for the Brazilian Pre-
salt
The selection of both pressure and tensile armour wire
material, based on the expected annulus environment will have
a major influence on the riser system configuration due to the
lower resistance inherent to the sour service armour wires when
compared to the high strength steels used in sweet service
designs.
As can be seen in Fig. 1, the proper prediction of the
flexible pipe annulus shall be the first step for a flexible riser
system design once it will provide the basis for an appropriate
material selection and therefore dictate the actual loading limits
of the flexible riser structures designed for ultra deep waters
and define the corrosion-fatigue SN curve to be used in the
service life assessment.
GLOBAL ANALYSES
This summary provides the design basis and references for
the results of the global analysis performed to the risers
designed to operate in the TUPI field at Santos Basin, Offshore
Brazil. Wellstream has also performed a comparison with
flexible riser systems loads which are already operating in both
1000m and 1500m water depths. All the global analyses results
presented herein were based on FPSOs.
 All the analyses presented herein were performed using
finite element, time domain, non-linear commercial software
which was used to simulate the system configuration and
determine the load cases for the global analyses.

This section presents the extreme and fatigue analyses

results for different flexible risers applications designed for the
Brazilian Pre-salt cluster and a comparison between the weights
per meter of flexible risers designed for different water depths.

4 Inch Gas Lift Risers

Figure 2 presents a comparison of the weight of different 4

inch gas lift pipes designed for different water depths but within
similar operating conditions, such as operating pressure and
temperature. Fig. 2 indicates that an increase in the pipe weight
is directly related to the increase in the design water depth. This
increase in the structure weight is mainly related to the tensile
armour wire reinforcement to provide the required axial load
resistance to the pipe structure to operate in such water depth in
a free catenary configuration.
160%
140%
120%
weight (kg / m)
Figure 3. Comparison of 4 inch gas lift pipes extreme load
cases
By the completion of the global analyses for 2250m water
depth, Wellstream has verified the suitability of the assessed
loads to the riser’s supports available in the current FPSO
operating in Brazil, confirming that the load envelope for
2250m WD is within the majority of the supports loads
capacity.
The fatigue service life of the 4 inch riser system in a free
hanging configuration was also evaluated. Even considering the
corrosive environment for the pipe annulus with the adoption of

100%
a SN curve assessed in an environment containing CO2 and H2S
80%
the 4 inch gas lift pipes designed to 2250m water depth
133%

presented a service life greater then 200 years

117%

60%
100%

40% Based on both, extreme and fatigue load cases it can be

20% noticed that the free hanging riser system configuration is a
suitable option for the 4 inch gas lift pipes to be installed in the
0% Pre-salt cluster
1000 Design WD 1500 Design WD 2250 Design WD

Figure 2. Comparison of 4 inch gas lift flexible risers
weight per meter
Figure 3 presents the top tension X top angle envelope for
the extreme load cases of the same 4 inch gas lift pipes
presented in Fig. 2 for FPSOs.
As shown, an increase in the tension X angle envelope can
be noticed due to both the increase of the pipe weight per meter
and the increase in the water depth. In addition to the clear
increase in the lop loads, a slight reduction in the angle
envelope may also be noticed.
6 Inch Production Risers
Figure 4 presents a comparison of the weight of different 6
inch production pipes designed for different water depths but
within similar operating conditions, such as operating pressure
and temperature. As shown, an increase in the pipe weight can
be noticed. The increase in the pipe weight is given by the
increase of the tensile wire layers to improve both the tensile
load resistance of the structure and its resistance to the buckling
loads, generated by the massive water depth, which will axially
compress the pipe in the TDZ, therefore increasing the risk of
tensile armor wire buckling.

3 Copyright © 2010 by ASME

 160%
140%
120%
weight (kg / m)
100%
80%
142%
127%
60%
100%
40%
20%
0%
1000 Design WD 1500 Design WD 2250 Design WD
Figure 4. Comparison of 6 inch production flexible riser’s
weight per meter
Figure 5 presents the top tension X top angle envelope for
the extreme load cases of the same 6 inch production pipes
presented in Fig. 4 . As shown, an increase in the tension X
angle envelope can be noticed due to both the increase of the
pipe weight and the increase in the water depth.
By the completion of the global analyses for 2250m water
depth of the 6 inch production risers, Wellstream has also
verified the suitability of the assessed loads to the riser’s
supports available in the current FPSO operating in Brazil,
confirming that the load envelope for 2250m WD is within the
majority of the supports loads capacity.
Figure 5. Comparison of 6 inch production pipes extreme
load cases
Although the current risers supports are capable to
withstand the tension and load envelope generated by the free
hanging system, such system configuration may not be suitable
in all the cases, depending on the materials used in the pipe
manufacturing which should be defined based on the
permeation analyses for each specific application.
4 Copyright © 2010 by ASME
As discussed previously in this paper, the presence of
contaminants in the conveyed fluids may require the use of sour
service armour wires instead of conventional high strength
steels. In this specific case, the pipe maximum tension load
capacity may be reduced what would imply in higher utilization
factors which could not be in accordance with the product
international standards. When such situation is faced, the free
hanging system configuration needs to be changed into a lazy
wave system in order to reduce the top tension and improve the
fatigue service life of the riser system
The fatigue service life of the 6 inch production riser
system in both free hanging and lazy wave configuration were
evaluated. When the use of high strength wires was possible,
based on the permeation analyses, the free hanging system
configuration presented a service life greater then 200 years.
When the use of sour service material was found to be
mandatory due to the presence of H2S in the pipe annulus, a
specific analysis for the lazy wave system configuration was
also performed and a service life greater then 200 years was
also found.
Based on the exposed, it becomes evident that the system
configuration of 6 inch production pipes will be driven by the
permeation analyses which will dictate the armour wire material
selection and consequently the riser system configuration to be
adopted.
6 Inch Water Injection Risers
Figure 6 presents a comparison of the weight of different 6
inch water injection pipes designed for different water depths
but within similar operating conditions. As shown, an increase
in the pipe weight can be noticed. The increase in the pipe
weight is given by the increase of the tensile wire layers to
improve both the tensile load resistance of the structure and its
resistance to the buckling loads, generated by the massive water
depth, which will axially compress the pipe in the TDZ.
300%
270%
240%
210%
weight (kg / m)
180%
150%
269%
120%
191%
90%
100%
60%
30%
0%
1000 Design WD 1500 Design WD 2250 Design WD
Figure 6. Comparison of 6 inch water injection flexible
riser’s weight per meter
 Figure 7 presents the top tension X top angle envelope for
the extreme load cases of the same 6 inch water injection pipes
presented in Fig 6. As shown, an increase in the tension X angle
envelope can be noticed due to both the increase of the pipe
weight and the increase in the water depth associated to a slight
reduction of the angle envelope.
This different behavior is inherent to large diameter
flexible risers which naturally presents high tension load
resistance due to its constructive characteristics. The buckling
resistance of the tensile armour wires for the 9.13 inch pipe was
increased both the tensile armour wire lay angle and the
disposition of the high strength tape bandage.
300%

270%

240%

210%

weight (kg / m)
180%

150%

267%
262%
120%

90%

100%
60%

30%

0%
1000 Design WD 1500 Design WD 2250 Design WD

Figure 8. Comparison of 9.13 inch gas export flexible

Figure 7. Comparison of 6 inch water injection pipes
extreme load cases
By the completion of the global analyses for 2250m water
depth of the 6 inch water injection risers, Wellstream has also
confirmed the suitability of the assessed loads to the riser’s
supports available in the current FPSO operating in Brazil.
riser’s weight per meter
Figure 9 presents the tension load X top angle envelope for
the extreme load cases of the same 9.13 inch gas export pipes
presented in Fig. 8. As shown, an increase in the tension X
angle envelope can be noticed due to the increase in the water
depth.

The fatigue service life of the 6 inch water injection riser

system in a free hanging configuration was also evaluated. Even
considering a the corrosive environment for the pipe annulus
with the adoption of a SN curve assessed in a deaerated
seawater environment, the 6 inch water injection pipes designed
to 2250m water depth presented a service life greater than 200
years demonstrating that the free hanging riser system
configuration is an adequate solution for the Brazilian Pre-salt
cluster.

9.13 Inch Gas Export Risers

As mentioned in the previous sections, the produced fluid
exportation to the shore will be a massive logistic challenge to
the development of the Brazilian Pre-salt cluster. Based on this,
Wellstream has performed also the analysis of a 9.13 inch riser
system specifically designed to the TUPI field.
Figure 8 presents a comparison of the weight of different
9.13 inch gas export pipes designed for different water depths
but within similar operating conditions, such as operating
pressure and temperature.
Unlikely the other applications presented previously, no
significant weight increase may be seen in the riser weight when
both 1000m and 1500m WD designs are compared.
5 Copyright © 2010 by ASME
Figure 9. Comparison of 9.13 inch gas export pipes extreme
load cases
In specific situations where the permeation analysis
indicates the presence of high levels of H2S in the pipe annulus
or in situations where the FPSO’s riser support load limit is
exceeded, the adoption of the lazy wave system configuration
was found to be an adequate solution to reduce the extreme and
fatigue loads to the same levels of 1500 m water depth
applications.
 Figure 10 presents the comparison of both free hanging and
lazy wave riser system configurations considering the same
2250 m water depth pipe design in the same FPSO.
Figure 10. Comparison of 9.13 inch gas export pipes
extreme load cases – Free catenary and Lazy wave
configurations.
As can be seen in Fig. 10, the adoption of a proper
distributed buoyancy modules system can drastically reduce the
top load envelope, making the use of large diameter flexible
risers feasible, where the use of sour service armor wires is
found to be mandatory or where the load capacity of the risers
support is limited.
TENSILE ARMOUR BUCKLING
The top loads associated to the pipe operation in 2250 m
WD is not the only challenge related to the installation and
operation of large diameter flexible pipes at the Brazilian Pre-
salt cluster. The massive water depth has a direct impact on the
compressive loads which will act on the flexible pipes when
accommodated on the seabed or subjected to curvature
variation in the TDZ.
This compressive end cap force may cause the tensile
armour wire buckling if the pipe is not designed in order to
withstand such compressive loads. Figure 11 presents the
graphical output from Wellstream’s analytical model used to
predict the radial buckling behavior of flexible pipes.
Figure 11. Graphical output from Wellstream’s analytical
model to predict tensile armour wire radial buckling
6 Copyright © 2010 by ASME
Wellstream’s analytical model used to evaluate both radial
and lateral buckling failure modes takes into account all the
relevant aspects required to properly evaluate the pipe’s
buckling behavior, such as the flexible pipe constructive
characteristics, tensile armour wire geometry, lay angle, high
strength tape thickness and material employed in pipe
manufacturing among others.
Two external features are related to the occurrence of
tensile armour wire buckling in the TDZ, being the compressive
loads associated to the water depth and the curvature of the pipe
in the TDZ. Based on this, Wellstream has performed a
comparison of the ratio between the flexible pipe minimum
bending radius and the minimum radius experienced by the
structure during operation in the TDZ.
Figures from 12 to 15 present the ratio between the pipe
MBR and the radius calculated for the TDZ in the global
analyses. As can be seen the ration of both radius indicates that
for the 4 inch gas lift pipes, this ratio, for the 2250m water
depth design, is similar to the ones found in applications at
1000m and 1500m WD.
0,9
0,8
(MBR / TDZ Calculated Radius)
0,7
0,6
0,5
0,927
0,867
0,828
0,4
0,3
0,2
0,1
0,0
1000 m WD design 1500 m WD design 2250 m WD design
Figure 12. 4 inch gas lift pipes - MBR/TDZ Calculated
bending radius ratio for different water depths
Figures 13 and 14 present the ratio between the MBR and
the radius calculated for the TDZ in the global analyses for both
6 inch production pipes and 6 inch water injection pipes. From
these figures, it can be noticed that the ratio were considerably
reduced from the 1500m WD application and the 2250 m WD
design, indicating that the minimum bending radius experienced
during operation will be significantly larger than the critical
MBR.
 1,0 1.0

0,9 0.9

(MBR / TDZ Calculated Radius)

0.8
(MBR / TDZ Calculated Radius)

0,8
0.7
0,7
0.6
0,6

0.929
0.5

0,972
0,5

0.737
0.4
0,833

0,4

0,725
0.3
0,3 0.2

0.043
0.237
0,2 0.1

0,1 0.0
1000 m WD 1500 m WD 2250 m WD 2250 m WD
0,0 design design design (Free design (Lazy
1000 m WD design 1500 m WD design 2250 m WD design Hanging) Wave)

Figure 13. 6 inch production pipes - MBR/TDZ Calculated Figure 15. 9.13 inch gas export pipes - MBR/TDZ
bending radius ratio for different water depths Calculated bending radius ratio for different water depths
0,9
Based on this, provided that the pipe structure is properly
0,8
designed to avoid tensile armour wire buckling, the flexible
(MBR / TDZ Calculated Radius)

0,7 pipes are capable to withstand the compressive loads and

curvatures expected for the TDZ
0,6

0,5 Wellstream’s analytical model was successfully used to

design the flexible pipes which are operating in the TUPI EWT
0,794

0,783

0,4
project in an actual water depth of 2140m. Wellstream has
0,3
already manufactured 2 DIP test samples which will be tested at
0,504

0,2 2250m water depth within 2010 in order to generate calibration

data points for the model.
0,1

0,0 Wellstream is also manufacturing 4 DIP test samples, as

1000 m WD design 1500 m WD design
Figure 14. 6 inch water injection pipes - MBR/TDZ
Calculated bending radius ratio for different water depths
Figure 15 presents the same analyses for the 9.13 risers and
additionally presents the bending radius ratio for the lazy wave
system configuration, In a similar way to the one found for the 6
inch designs studied in this paper the pipe bending radius
expected for the TDZ will be significantly higher when
compared to similar pipes in 1500m WD.
When the lazy wave system configuration is considered the
bending radius of the risers at the TDZ will be even higher than
the critical minimum bending radius reducing even more the
possibility of tensile armour wire buckling
Considering the bending radius analyses performed for the
different applications studied in this paper, it become noticed
that the curvatures in the TDZ will be similar or even less
severe for the 2250m WD design then the ones assessed for the
projects which are already installed in 1000 m and 1500m WD.
2250 m WD design
part of the TUPI Pilot project qualification program, which will
be tested in water depths up to 2500m.
CONCLUSIONS
Based on the analysis results presented herein it is
concluded that the permeation analysis plays an outstanding
role on the definition of the flexible riser systems to be installed
in the Brazilian Pre-salt cluster once it will drive the material
selection of the tensile armour wires which will dictate the riser
system configuration.
The extreme and fatigue loads assessed for the free hanging
riser system configuration were increased, as expected, when
compared to the ones expected for systems installed in 1000m
and 1500m WD. However, this load increase is within the
utilization envelope of the riser’s supports of the FPSOs
currently operating in Brazil. This is confirmed by the pipes
which are installed in the TUPI EWT project which are using a
free hanging system configuration.
For riser structures which will require the utilization of
sour service armour wires, it is concluded that the use of the
free hanging system configuration will be limited due to the
7 Copyright © 2010 by ASME
inherent reduced strength of the sour service materials required
to avoid HIC an SSC failures

Large diameter flexible pipes, like the 9.13 inch gas export
considered in this work, were shown to be suitable for operation
in a free hanging system configuration when the top tension
loads are within the FPSO’s supports load capacity. The lazy
wave system configuration for large diameter flexible pipes
demonstrated an adequate behavior for the analyzed 2250m
water depth scenario, bringing the top tension loads to the same
levels of the 1500 m water depth riser systems which are
already operating in Brazil.

The tensile armour wire buckling behavior of the flexible

risers was also addressed and the bending radius of the risers in
the TDZ were found to be within the same range or were found
to be even higher then the ones calculated for the 1500m water
depth designs, indicating that a proper flexible pipe design is
capable to withstand the compressive loads associated to the
2250m water depth.

Based on the exposed above, it is found that the flexible

pipes are an adequate alternative to the offshore pipelines to be
installed in the Brazilian Pre-salt cluster.

ACKNOWLEDGMENTS
The authors wish to thank Wellstream International Ltd
Technology Management for their continued support in this
development project.

REFERENCES

[1] José Miranda Formigli Filho, Antônio Carlos Capeleiro

Pinto, Alberto Sampaio de Almeida, 2009 “Santos Basin’s
Pre-Salt Reservoirs Development—The Way Ahead” OTC,
Houston, TX, paper number 19953.

[2] R. L. C. Beltrão, C. L. Sombra, A. C. V. M. Lage, J. R.

Fagundes Netto and C. C. D. Henriques. 2009 “Challenges
and New Technologies for the Development of the Pre-Salt
Cluster, Santos Basin, Brazil”OTC, Houston, TX, paper
number 19880

[3] Celia M. F. Nakano, Antonio C. C. Pinto, SPE, Jose L.

Marcusso, and Kazuioshi Minami, 2009, “Pre-Salt Santos
Basin — Extended Well Test and Production Pilot in the
Tupi Area —The Planning Phase” OTC, Houston, TX,
paper number 19886

[4] Eberaldo A. Neto, Paulo S.R. Alonso, SPE, Ilton J.

Rossetto Filho, and Flavia G. Serpa, 2009 “Pre-Salt Cluster
Long Term Supply Strategy” OTC, Houston, TX, paper
number 20100

8 Copyright © 2010 by ASME