DeepstarRisers 2007&2008 1400 CTRs For Ballot

CTR 840F
Title: Determination of acceptance criteria for weld

defects in high-performance SCRs
CTR No: CTR 840F Champion: Statoil (Steinar Kristoffersen) and Chevron
(Pedro Vargas)
BUSINESS INCENTIVE AND THEME (Why invest?):

Fatigue is the governing design criterion in the majority of SCR-projects related to floating oil or gas recovery
facilities. To verify high-quality welds with enhanced fatigue properties compared to international codes, it
has become standard to include full scale endurance testing in the welding procedure qualification. Based on
statistical evaluation, a project-specific design fatigue endurance curve with typically 97.6% probability of
survival is determined (DNV-RP-C203).
Full-scale specimens representing actual high quality riser girth welds will have the same distribution of
defects as the actual girth welds, which tend to be free from conventional defects but do contain inherent
flaws that are not detectable by conventional automated ultrasonic testing (AUT). To illustrate the implications
of this, typically a 3 mm high surface breaking flaw will with 90% probability of detection (PoD) and 95%
confidence be detected by AUT. However, a slightly smaller undetectable surface breaking planar defect 2.9
mm high and 12 mm long could by standardized crack growth analysis (BS7910) have a fatigue life only 20-
40% of the endurance test (D-curve).
It is well known that fatigue crack growth analysis carried out as part of an engineering critical assessment
(ECA) that is based on the actual initial defect size is conservative when compared to endurance tests, but
guidance for ECA-based design fatigue factor (DFF) is not provided in design codes. One half of the
endurance DFF has been informally adopted by the industry for ECA based assessments. The industry is
pursuing riser girth welds with increased fatigue properties, even beyond the D-curve, proven by endurance
testing. Hence, either the standardized PoD of AUT and conservative crack growth analysis will limit the
fatigue utilization of these high fatigue performance riser girth welds, or the girth weld acceptance criteria will
not be supported by existing scientific methods.
This could be solved by:

1. Mapping of the defects controlling riser girth weld fatigue by analysis of existing full scale fatigue test
data made available for the study or tests performed in the study. Crack growth analysis and
endurance test results could then be compared and a conservative crack initiation/short crack
propagation model could be included in the overall crack growth model for riser girth welds. Weld
geometry, including misalignment and inner surface mis-match (Hi-Lo), will help characterize the
notch effect and SCF. In this context, it is becoming necessary to update the traditional formula used
to compute SCF based on eccentricity. It will also be important to consider features such as weld
geometry and defects in girth welds that did not become initiation sites to help establish statistical
association of these details with respect to fatigue performance.
2. Combination of several complementary inspection methods during and after welding to increase the
PoD for small defects. In addition, a study of current AUT technology to obtain a statistical
description of remaining defects for typical screening criteria would be of value.
3. Statistical analysis of maximum defect heights within one welding bead. Statistical analysis of the
possibility of two overlapping/stacked defects in risers will most likely limit defects within one welding
bead only. The defect height within one welding bead will be controlled by welding process and
parameters, re-melting of subsequent weld beads and individual weld bead height.
4. Consideration of the use of a post-weld improvement technique, such as grinding or peening. Then it
would also be necessary to include their effects in terms of such factors as residual stress and the
effective stress ratio in the crack initiation/short crack growth model.
5. Calibrated DFF for crack growth analysis based on probabilistic methods.
This is viewed as an enhancing technology as the fatigue resistance of riser girth welds in many
circumstances will limit available field development concepts.
RPSEA RFQ Data Sheet Page 3 of 43

CTR 840F

(Pedro Vargas)
OBJECTIVE:
The purpose of the CTR is to develop a less conservative crack growth analysis model which will be valid for
high fatigue performance riser girth welds and would lead to more accurate acceptance criteria related to
defects that are detectable with sufficient PoD. This will allow better utilization of the high fatigue performance
riser girth welds existing and pursued by the industry, and be based on rational theoretically based
acceptance criteria.
DELIVERABLES:
Extensive data from the mapping of the defects and other characteristics of riser girth welds that
control their fatigue performance.
A validated crack initiation/short crack growth model of the fatigue behaviour of high performance
riser girth welds in either the as-welded or improved (e.g. ground or peened) condition.
Recommendations for complementary inspection methods for use during and after welding with
estimated associated PoDs.
Statistical distributions of the types and maximum sizes of defects for welding processes and
process parameters used in riser girth welding.
Risk based calibrated DFF for ECAs based on fatigue crack growth analysis.
Overall report and practical Guidelines.
SCOPE OF WORK (Work plan & schedule):
Project management
Welding, Inspection and Defect Distributions
Review of fatigue controlling defects from representative fatigue tests, 01.08-05.08
Review and analysis of representative NDT records, 01.08-05.08
Evaluation of welding methods and appurtenant defect distributions, 06.08-12.08
Statistical analysis and prediction of defect distribution, 01.09-05.09
Fatigue crack initiation and initial growth from defects
Development of models for crack initiation and initial growth from defects, 01.09-05.10
Fatigue testing, 06.09-05.10
Probabilistic analysis and determination of design fatigue factors (DFF), 01.09-05.09
Development of Design Guidelines and Recommended Practice, 07.10-12.10
Completion Date:
December 2010
VALUE:
Based on cost saving of 5% CAPEX of approximately ten fields the benefit could be expected to be several
100 million USD.
CONTRACTING PLAN:
The management for the work will be by a primary contractor (possible candidates include DNV, TWI, SWRI,
EWI) in close contact with the steering committee. All the sponsors will have a seat in the JIP steering
committee, with representatives from the major contractors as consultants/experts. Some of the different work
packages will be subcontracted to experienced research institutes with the best qualifications (relevant data
basis, previous experience, testing facilities, human resources) to complete the scope of work. The primary
contractor will be responsible for subcontracting, however, the steering committee may be asked to help

CTR 840F

(Pedro Vargas)
evaluate and rank the candidates. Separate subcontracts, to be managed by the main contractor, will be
issued to experienced welding- and AUT contractors.
RELATED PROGRAMS (Linked Projects, JIPs & partners):

TWI is planning a JIP that will follow up a previous project that resulted in tentative guidance on
some aspects of girth welded joint alignment and quality to achieve specific fatigue resistance.
Some cross pollination may be possible in the form of data exchange and or subcontracting.
TWI also hopes to follow up a previous JIP that addresses the fatigue performance of girth welds
under variable amplitude loading, specifically directed at the types of spectra induced by vortex
induced vibration (VIV) of risers. Some cross pollination may be possible in the form of data
exchange and or subcontracting.
A RPSEA proposal for the evaluation of cathodic protection on the fatigue performance of high
strength steels is being considered. It may be possible to coordinate these two efforts.
WHAT NEXT (Potential future work to advance/deploy technology)?
Ready for deployment.

Technology Readiness Level (TRL) for this project technology.
CTR BUDGET Hours / Rate Cost

Project management 350.000
Welding, Inspection and Defect Distributions 400.000
Fatigue Crack Initiation and Initial Growth from Defects 150.000
Fatigue testing 700.000
Probabilistic Analysis and Determination of Design Fatigue 200.000
Factors (DFF) for crack growth (ECA)
Development of Design Guidance and Recommended Practice 250.000
Contingency 350.000
TOTAL PROJECT COST $US 2.400.000
Industry Funds $ US 1.200.000

Statoil (300.000)
Chevron (300.000)
NN (operator) (300.000)
NN (operator) (300.000)
RPSEA Matching Funds $ US 1.200.000

CTR 840G
Title: Determine Remaining Life of Polyester Rope

Moorings
CTR No: 840G Champion: BP (Dave Petruska)

Operators are required to remove and recover polyester rope inserts for testing to prove the structural
integrity of the mooring system. The removal/recovery activities involve the real risk of accidental damage to
the overall mooring system. Tests continually show minimal degradation of integrity, and they dont tell us
anything about remaining life of the mooring segments.
OBJECTIVE:
Use full scale rope tests and subrope tests to develop and validate a method to predict remaining life of
mooring systems, so that we have proof that insert recovery is not necessary. Use risk and reliability
methods to determine the relative risk of insert removal/recovery vs. not recovering inserts. Develop
alternative methods (to insert recovery) to demonstrate that installed mooring systems are safe.
DELIVERABLES:
Deliverables willl be a fully verified polyester rope remaining-life prediction model. Results from a industry-
validated risk and reliability analysis to quantify risks of insert recovery. Valid methods to verify in-situ
mooring rope integrity other than insert recovery and test.

Phase A (1) Utilize test results with subropes to develop and validate polyester remaining life predictive
model, (3) Determine and validate quantitative relative risk model for insert recovery, (4) Determine
alternative method (to insert recovery) for monitoring mooring system integrity.
Phase B: Perform full rope tests and compare results with results from Phase A (1) above
Completion Date:
15 months
VALUE:
Although various methods of predicting mooring rope remaining life have been advanced and tested, and
although we believe that polyester rope has a longer life than other components of a typical mooring system,
as of yet industry cannot rely on a remaining life prediction methodology. Removing inserts and insert
recovery from synthetic rope mooring systems, if validated, can reduce risks of damage and avoid costly and
unnecessary insert recovery operations.
CONTRACTING PLAN: To be developed.
A. Related Programs: 2006 MMS/OTRC/Industry JIP on Damaged Rope Testing, (2) MMS sponsored
project: Evaluate Accuracy of Polyester Subrope Damage Detection Performed by ROVs Following
Hurricanes just starting. (3) ARELIS program by DNV Norway, SIM testing program managed by
TTI Ltd, UK
B. Potential Funding sources for 20%: DeepStar, Industry JIP, or a combination thereof.
Perform Phase B testing with full-scale rope, and compare with Phase A results. Develop remaining life
models for synthetic fibers other than polyester (like HMPE). Results on polyester should form good basis.

We are expecting a technical breakthrough in being able to fully validate a remaining life model for the first

CTR 840G
Title: Determine Remaining Life of Polyester Rope

Moorings
CTR No: 840G Champion: BP (Dave Petruska)
time .
TOTAL PROJECT COST $US 250,000
Industry Funds (Kind, & source to be identified in $ US 50,000

proposal).
RPSEA Matching Funds $ US 200,000

CTR 840M
Title: Riser & Flowline Crack Detection and Sizing Tool

CTR No: 840M Champion: BP (Adam Ballard)
BUSINESS INCENTIVE AND THEME (Why invest?): Riser Life-Cycle Integrity Management Heavy
walled riser and flowline integrity in deepwater systems are susceptible to fatigue cracks due in part to
metocean conditions, temperature cycling, and corrosion pitting. To properly assure integrity of these systems
during production operations, a means for detecting and sizing fatigue cracks is essential. Current riser and
flowline designs are expected to be conservative. However, the industry is designing for conditions outside of
the design experience (e.g., XHPHT, ultra-deepwater, high currents, etc.) making the need for proper
inspection and integrity assurance. This work would best be described as science leading to an enabling
technology for inspection.
OBJECTIVE: The objective of this work is to develop an ultrasonic technique for detecting and sizing cracks
in risers and flowlines. Current methods, such as Magnetic Flux Leakage, are not capable of this due to the
heavy wall. Conventional Ultrasonic techniques, such as TOFD, for crack detection and sizing have been
found to be inadequate for seeing cracks in both tension and compression. Note that, in order to detect and
size cracks in flowlines, free swimming tools (pigs) would be necessary. Therefore, the technique identified as
suitable for crack detection and sizing would be incorporated into a free swimming inspection tool.
DELIVERABLES: Ultrasonic technique capable of detecting and sizing cracks in risers and flowlines.
Incorporation of this technique into a free swimming tool.
SCOPE OF WORK (Work plan & schedule): A phased approach is proposed for this work:
1. Feasibility and Concept (12 months)
a. Ultrasonic technique for detection and sizing cracks
b. Incorporation of technique in free swimming tool
2. Detailed engineering (12 months) Completion Date:
3. Tool building and operations (12 months) 4Q2010
VALUE: Improved reliability and uncertainty reduction of subsea systems.
CONTRACTING PLAN: It would be expected that all development would be performed and owned by a third
party inspection contractor. Teaming contractors with different expertise in ultrasonics and pigging would be
preferred, but may not be feasible.

Phase 1 : Feasibility and Concept US$ 2,000,000
Phase 2 : Detailed Engineering US$3,000,000
Phase 3 : Tool Building and Operations US$2,000,000
TOTAL PROJECT COST US$7,000,000
Industry Funds (Kind, & source to be identified in $ US 1,400,000

proposal).
RPSEA Matching Funds $ US 5,600,000

CTR 840N
Title: Fatigue Performance of High Strength Riser Materials

CTR No: 840N Champion: BP (Steven Shademan, Himanshu Gupta)

The search for offshore reserves is leading the industry into deeper waters and more hostile, problematic conditions than
those encountered during previous developments. Deepwater, Sour service conditions and increasingly higher pressure
and higher temperature reservoirs require development of lighter, stronger, corrosion and fatigue resistant materials. Use of
higher strength materials will reduce the riser weight in deepwater and high pressure conditions, which produces significant
economic benefits in the overall field development. The access to these reserves requires development of enabling
technologies for riser materials. The reservoir pressures encountered in these developments limit the use of conventional
materials. High strength and newer materials will have to be employed, although sour service conditions expected in these
reservoirs degrades the mechanical properties compared to in-air properties and fatigue performance of materials. As an
example, the chart below shows the feasibility boundary of risers with conventional materials for Spar buoyancy can
application. The limitation of conventional materials can be seen for deeper water depth and higher pressure applications.
Same conclusion is expected to be true for other riser applications.
Understanding the performance of high strength materials would further enable development of such reserves by making
them more economical. The fatigue performance data of high strength materials is non existent. Development of such data
would allow designers to use the high strength materials and thus enabling development of these fields. This proposal is
thus considered to be of an enabling technology theme.
OBJECTIVE:
The objective of this program is to develop fatigue data for High Strength Steels (such as X-80, X-100, C-110, Q-125, C-
125, V-140), Titanium (such as Grade 29 and newer alloys) and carbon fiber wrapped pipe (steel and titanium liner) riser
materials. The test matrix will be designed to reflect various production environments and different types of riser
configurations such as SCRs, dry tree risers, drilling and completion risers. The results from these tests will help qualify
these materials. The test program will also establish data for designers, enabling the use of high strength materials in
offshore environments. The tests will also be conducted on intermediate scale and full scale specimens and under more
realistic variable amplitude loading spectra consistent with service loading conditions. Such data is non-existent and would
establish validity of strip specimen results used in current practice. The sour service tests for intermediate and full scale
specimens will help in establishing the correct scaling parameters for strip specimen results. This will be an evolution from

CTR 840N

current practice of using knock down factors.
DELIVERABLES:
1) Phase 1 results detailing fatigue crack growth rates and SN curves for materials tested.
2) Phase 2 results of SN curves for intermediate scale pipe materials tested.
3) Phase 3 results of SN curves for full scale pipe materials tested.

The test program will be split into three phases. The materials to be tested under the program are High Strength Steels (X-
80, X-100, C-110, Q-125, C-125, V-140), Titanium (Grade 29 and newer alloys) and carbon fiber wrapped pipe (steel and
titanium liner) riser materials.
Phase 1: This phase will address fracture toughness, crack growth and S-N curve tests on strip specimens of materials
listed above (except carbon wrapped pipe). The samples will be tested in air, seawater (with CP charging), sour service
conditions and other production environments to simulate the conditions for drilling and production riser systems. Effect of
corrosion inhibitors would also be included. Both smooth and notched specimens would be used. 18 months
Phase 2: This phase will address SN Curve tests on intermediate scale pipe models for the successful materials and
environments selected from Phase 1 tests. The intermediate scale model tests will be welded as well as threaded
connectors as appropriate for the selected materials. The objective of the tests is to establish the validity of strip specimen
results of SN curves and to study the scaling effects. 18 months
Phase 3: This phase will address SN curve tests on full scale samples for materials selected from Phase 2. Full scale tests
will be conducted on welded (X-80 and X-100) as well as threaded connectors as applicable for selected materials. The
objective of these tests is to develop an appropriate scaling approach and to validate the results of Phase 1 and Phase 2.
18 months
Some of the tests in Phase 2 and Phase 3 will also be conducted using a variable amplitude loading spectrum to reflect the
service loads on risers in offshore environments.
Completion Date:
4.5 years
VALUE:
The prequalification of high strength materials for risers would enable development of several of the deepwater, high
pressure, high temperature and sour/corrosive reservoirs. These fields currently can not be developed with existing
technology and require expensive and long development programs. The results of this program will help all the operators to
develop such reservoirs and reduce the development time. The qualification work will also reduce the risks involved in
developing such reservoirs. Thus the value of this program is considered to be tremendous.
CONTRACTING PLAN:
The program will be bid out to qualified testing labs.

CTR 840N

Phase 1 $US 1,000,000

Phase 2 $US 1,500,000
Phase 3 $US 3,500,000
TOTAL PROJECT COST $US 6,000,000
Industry Funds (Kind, & source to be identified in $ US-------------

proposal).
RPSEA Matching Funds $ US-------------

840O (combined with CTR 840FF)
Title: Composite Riser for Ultra-Deepwater High

Pressure Wells
CTR No: 840O Champion: Shell (Tom Walsh, K. Him Lo), BP (Roy
Shilling)

As industry moves into ultra-deepwater, supporting the weight of a steel riser becomes a major issue. The
problem is further exacerbated when high-pressure reservoirs are encountered and heavy walled risers are
needed. Drilling, completion, and production of ultra-deepwater high-pressure wells can benefit by the use of
lightweight risers with high-pressure capability.
One solution that appears to have significant potential is the use of carbon fiber wrapped steel (hybrid) riser
pipes. This technology is not new and has been used in various military applications, and recently, the
French Petroleum Institute (IFP) completed a qualification program for hybrid choke and kill lines on
conventional low pressure MODU drilling risers. Subsequent engineering studies looking at high pressure
drilling risers for Spars and TLPs indicate an overall riser system weight savings potential of 40-50%. This
technology shows promise in that it can be used with lower strength X-80 steel materials, where weld-on
connectors are either desirable or necessary. As an example, the technology was recently used to size a
single tube 15,000 psi x 19.5 I.D. X-80 drilling riser with weld-on connectors. The steel only riser case
resulted in a wall thickness greater than 3 and was not considered feasible. The steel and carbon fiber
wrapped design required only 1.5 wall thickness, well within current welding technology, and was considered
feasible. In addition to the +/-50% weight savings, the hybrid architecture may also provide some inherent
advantages to VIV fatigue damage due to increased structural damping of the carbon wrap system.
Therefore, in the case of a single HP drilling riser for Spar or TLP based drilling operations, this is considered
an enabling technology, in that it can keep the pipe wall thicknesses and riser pipe materials within the
practical/accepted manufacturing capabilities, without the need for untested higher strength steels and large
bore threaded connectors. For production risers in both dry and wet tree options, wherein T&C connectors or
all welded joints would be required, this is considered an enhancement of technology by allowing the use of
lower yield steel pipe materials which are suitable to welding and sour service.
The business case for pursuing this technology lies in being able to perform dry tree Spar or TLP based
drilling and sidetrack operations, which lead to substantial savings over comparable deepwater MODU
operations with the differential approaching $400-$500K per day, or up to $50MM on a single 100 day well.
Additionally, safe, reliable, and lighter weight production risers for both wet and dry tree solutions help reduce
platform and life cycle costs.
Shell, BP and industry have conducted several composite related laboratory-scale programs which address
the fundamental issues of materials selections and manufacturing processes as related to composite risers.
Most recently, Shell has completed a program to design high pressure hybrid risers (composite over wrapped
steel casing risers) with an ID ranging from 14.5 to 19. A 14.5 ID riser rated for 15000 psia working
pressure and 10,000 ft water depth was selected for manufacturing feasibility study and design verification
test. Both burst and bending fatigue tests were conducted, and verified a design life in excess of 20 years.
It is the intent of this program to work with the industry to move the technology out of the laboratory and
demonstrate viability through one or more field trials.
OBJECTIVE:
The focus of this project is on development and field trial of a light-weight drilling/completion riser (a few riser
joints, not the entire string) with the following attributes:
Inner diameter of 14 to 19 inches
Water depth capability in excess of 10,000 feet
Operating pressure rating in excess of 15,000 psia
Provide a 50% reduction in the in-water weight of a comparable steel riser.


Pressure Wells
Shilling)
The purpose of this project is to determine, through large scale tests, if carbon fiber wrapped steel riser pipe
(steel/composite hybrid) is suitable for long-term use in the harsh environment of deep water offshore. In
specific, it will establish design methodology and end termination issues, cost effective wrapping
method/manufacturing process, and address handling, storage and impact energy absorption capacity, along
with long-term durability and fitness for purpose for drilling and production riser applications.
Industry participants will further define the functional performance requirements (dimension, load, thermal,
etc.) during execution of the first task
DELIVERABLES:
PHASE I
1. Function performance requirements of the drilling/completion riser.
2. Comparative evaluation of various options for lightweight drilling/completion riser.
3. Path to resolve any regulatory issues and concerns.
4. Candidate riser for development and field trial.
5. Design methodology, including load sharing between steel pipe and carbon fiber, end
termination/interface design verified with the results of burst tests.
6. Cost effective wrapping method/manufacturing process, including comparative cost benefit analysis
including auto-frettage pre-stressing process vs. minimal tension required to effectively wrap, plus end
termination manufacturing/fabrication process.
7. Test results of handling, storage, and impact energy.
8. Test results of long term degradation due to environment, and associated design factors to be included in
the design.
9. Proof of concept through design, fabrication and laboratory testing to meet functional performance
requirements.
PHASE II
10. Fabricate full scale hybrid riser joints for field trial
11. Field trial results of candidate riser and comprehensive post deployment materials testing
12. Final report
PHASE I
1. Work with industry participants to define functional performance requirements with respect to potential
field trial candidate(s)
2. Perform comparative evaluation of various options for light-weight riser, including the composite
architecture (hoop wrap only pressure enhancement, or hoop+axial for enabling pressure and tension
capacity)
3. Select riser candidate for development and field trial
4. Resolve regulatory issues and concerns
5. Design and fabricate short length full diameter riser joints for proof of concept testing
PHASE II
6. Confirm field trial candidate(s)
7. Fabrication and acceptance testing of field trial joint(s)
8. Conduct field trial(s)


Pressure Wells
Shilling)
9. Evaluation of field trial test joints (post field trial)
Completion Date:
Tasks 1-5: 18 months
Tasks 6-9: TBD, pending field
VALUE:
Light-weight riser with high pressure capability is both an enhancing and enabling technology for ultra-
deepwater high-pressure fields. It is envisioned that the technology that will be developed for the drilling /
completion riser can be easily translated for other riser applications such as DVA production risers.
Composite risers will allow brownfield structures additional tiebacks with minimal additional loading, thereby
enhancing production rates. Greenfield structures will benefit from reduced loads imparted by the composite
riser, resulting in either decrease of overall structure requirements, or an increase in the topside payload
capacity.
As an example, the differential loaded day rate of a 5th generation MODU and dry tree spar drilling unit is
currently running about $500,000/day. Many of the new developments in the GoM will have well depths of
25,000 or greater resulting in 100 day wells for drilling and 60 days for completion. Being able to use the
less expensive spar drilling rig on a 10 well development program would result in savings of more than
$500MM dollars
CONTRACTING PLAN:
Use competitive bidding process to obtain skilled and capable 3rd party contractor(s) to perform the work and
solicit potential suppliers to bring such a system to market. Industry 20% (TBD) can come from a JIP of
operators and suppliers. Shell has already invested in this system development. The intent is to offer one of
deepwater facilities as a candidate for the field trial.

Various programs and JIPs have been conducted on composite risers and related components; some recent
programs are highlighted below.
1. NIST-ATP Composite Production Riser JIP (circa 1995 2000). JIP conducted design and testing of
composite production riser for 6000ft water depth. No field trial was conducted.
2. CompRiser JIP (circa 1997 2001) field trial on Heidrun TLP. Statoil has carried out successfully field
tests with one composite marine drilling riser joint on the Heidrun TLP platform (1300ft water depth and
4000psia). The field trial confirmed the ability of composite materials to withstand functional performance
requirements demanded from a medium-pressure marine drilling riser.
3. Composite Choke & Kill lines, various initiatives from 1987 through present. Limited field trials to date.
4. US-DoE Magnolia Production Riser JIP (circa 2002-2005). JIP conducted design and testing of composite
production riser for 4700ft water depth and 10,000psia. No field trial to date.
5. Composite Riser for High Pressure and Deep Water Applications (2005) joint effort between Shell,
General Dynamics, and Lincoln Composites to design, fabricate and proof of concept testing of a
drilling/completion riser suitable for 10,000ft water depth and 10,000 20,000 psi pressure capability.


Pressure Wells
Shilling)
6. Hoop wound pipes for risers and choke and kill line IFP concept.
Prior programs have addressed the fundamental issues of materials selection (reinforcing fiber type and
matrix material), fiber architecture (hoop, axial, and bias ratios), manufacturability, autofrettage, metal-
composite interface, and delivered requisite performance milestones (static, fatigue, thermal, and shock).
These programs have all culminated in qualification of the design and manufacturing methodology, through
both short and long-term laboratory testing verification.
However, most of the aforementioned programs did not progress beyond proof of concept testing in the
laboratory. Only one program has conducted field trials - a specific and unique titanium/composite
application of a low/medium pressure marine drilling riser rated for 1300ft water depth.
Through this RPSEA program, success of the planned field trials / demonstrations using a few riser joints will
facilitate the acceptance and deployment of composite riser joints throughout the entire riser string.
The logical next step will be to seek industry co-operation to deploy an entire riser string of composite joints,
for ultra deepwater drilling and completion.
Current technology readiness level for composite riser is estimated to be 3.
CTR BUDGET (against deliverables) Duration Cost

PHASE I
1. Define functional performance 2 mo $50 k
2. Comparative evaluation of options 3 mo $150 k
3. Regulatory issues and concerns 12 mo $200 k
4. Select riser candidate for development and field trial 1 mo $50 k
5. Design, fabricate, and POC testing 12 mo $1,650 k
18 months $US 2.1 Million
PHASE II
6. Field trial TBD $2,700 k
7. Final Report 6 mo $200 k
TBD $US 2.9 Million
TOTAL PROJECT COST $ US 5.0 Million
Industry Funds (Kind, & source to be identified in $ US 1.0 Million

proposal).
RPSEA Matching Funds $ US 4.0 Million

CTR 840W
Title: Ultra-deepwater Dry Tree System for Drilling and

Production in GOM, Phase 1
CTR No: 840W, Rev 2 Champion: CVX, Shell, Statoil

The GOM is increasingly looking to ultra-deepwater and challenged reservoirs, i.e. subsalt, adding drilling,
completion, artificial lift and workover complexity pointing toward dry tree options as the most economical
solution. In many cases, the depth of the reservoir requires large drilling rig and drilling variable payload
resulting in very large topsides challenging the limits of spar technology.
GOM dry tree solutions have been dominated by Spars and TLPs in water depths below 5,000 ft. For water
depths beyond about 6,000 ft, the TLP becomes cost prohibitive. For large payload systems, especially
those requiring large drilling payload, the spar size, transportation and installation become a challenge. The
semisubmersible or similar offers advantages over spar such as larger deck space and possibility of quayside
topsides installation and integration. It is expected that the dry tree semi will be cost competitive with the spar
in most cases and overcome the size limitations on the spar in other cases.
For moderate payload systems in ultra-deep water, the spar is the only dry-tree option. Having a dry tree
semi solution increases contracting options.
OBJECTIVE:
To define the potential and gaps for developing a dry tree semi or similar to a feasible and competitive floater
solution for GOM in 8,000 ft water depth and moderate to large payloads. This study will explore use of
conventional technologies to the extent possible, such as hull form, riser hull interface, tensioning options,
riser configurations and riser materials. The study will explore tradeoffs such as:
Semi draft for possibility of quayside integration
Deep draft semi that allows use of standard tensioning technology (motions comparable to spar)
Topsides installation options such as quayside versus near-shore floatover versus offshore lift
The study will identify gaps and challenges associated with each option including equipment limitations,
fabrication, transportation, installation, well-bay layout and HSE considerations. The study is expected to
move the technology to TRL 3.
DELIVERABLES:
1. Design basis
2. Work shops and meetings with intermediate results presentation
3. Final report and presentation to DeepStar/RPSEA

Phase 1
1. Define a basis of design
2. Outline study options (e.g., hull draft, tensioner, riser configuration, topsides installation, etc),
pros and cons, expected technology gaps, cost tradeoffs (high level) and shortlist options
through workshop of contractor and DeepStar/RPSEA representatives. Options will be short
listed to two.
3. Engineer and develop cost estimate for the two hull options and two payload options.
a. Perform cost-benefit analysis of the systems.
b. Identify technically challenged areas and promising new technologies requiring qualification
before being field ready.
c. Recommend one option to carry through to phase 2.
4. Develop scope of work and cost estimate for phase 2 and preliminary qualification plans for new
technologies.
5. Model test for one concept

CTR 840W

Phase 2
1. Front end engineering for single concept
2. +/-15% cost estimate
3. Finalize qualification plans for new or extended technologies.
Phase 3 (as required)

Qualification of new or extended technologies
Completion Date:
15 months
VALUE:
This CTR will provide a cost-effective, and potentially lower cost dry-tree solution for ultra-deepwater
moderate to large payload systems. The market is currently limited to a single concept. A competitive
alternative will spur improvement and cost reduction in current dry tree hosts for ultra deep water. This
solution is expected to improve field development economics on the order of $100MM or more.
CONTRACTING PLAN:
Work will be awarded to a primary contractor with EPCI experience. Subcontracts for specific portions, e.g.,
model tests, will be handled by the prime contractor.

Will build off learnings from prior DeepStar work: CTR 6405 10,000 ft Spar, CTR 7404 10,000 ft Semi,
CTR 7405 TLP with Composite Tendons and Risers, and CTR 8401 Dual Casing TTR Weight
Management, and from other industry work such as Demo2000 deep draft semi study.

Qualification for new tensioner designs or hull optimizations may be required.

While many of the components for a dry-tree semi in the GOM are proven in other applications, i.e. standard
draft semi hull and riser tensioners, this proposed application represents a significant step-out from current
application ranges and is expected to require qualification of new designs. TRL is expected to be in the
range of 0-2.

1. Basis of design $20,000
2. Outline study options and workshop. $30,000
3. Engineer and develop cost estimate for the three options. $650000
4. Develop scope of work and cost estimate for phase 2. $10,000
5. Model test $350,000
6. Study management $110,000
NOTE: Estimate for phase 1 only.
TOTAL PROJECT COST $US1,170,000
Industry Funds (Kind, & source to be identified in $ US234,000

CTR 840W

proposal).
RPSEA Matching Funds $ US936,000

CTR 840X
Title: XHPHT Drilling Riser Design (Rev 1)

CTR No: 840 X Champion: BP (Roy Shilling)

Provide better design methodology and guidelines for operators use high pressure dry tree drilling risers on
for upcoming XHPHT developments (it is becoming a trend), especially in GOM.
Perform testing to provide data to support the new methodologies and work with the MMS and API to
enhance GoM regulations and recommended practices (MMS, API)
Aid and provide early/real-time influence on advanced technology development, e.g. high strength steel,
titanium, XHPHT boost line, etc.
OBJECTIVE:
Key XHPHT (extremely high pressure and high temperature) technology development in deepwater has
become increasingly demanding. For the high pressure drilling riser typically used with a surface BOP,
pressures are up to 22.5 ksi. Riser design methodology and fabrication capabilities for pipe structures,
connectors, flexible jumpers, plus global environmental load criteria have to be carefully re-thought. The CTR
intends to enhance the relevant technologies and develop a feasible, economical, and reliable system for the
XHPHT drilling riser. The following tasks have been identified:
Reduce wall thickness requirements for extremely high internal pressure;

Investigate high strength steel Threaded and Coupled (T&C) connector and Titanium
configurations
Evaluate boost line configuration options
Develop overall system configuration and tensioner requirements
Perform testing to provide data to support the new methodologies and system design
DELIVERABLES:
- Final report, including new design methodology, code change recommendation, and case study;
- Design recommendation for high strength steel and titanium XHPHT riser;
- System design configuration for XHPHT drilling riser;
- Prototypes and test data
1). Reduced Wall thickness for extremely high internal pressure

Design code reconciliation and pressure rationalization will be attempted to reduce unnecessary
conservativeness on wall thickness requirements. This has become critical in terms of riser weight and
thus top support and connector welding and fabrication feasibility. 100% wall inspection/mapping
technology has been implemented in multiple mills and the data can be used to provide advanced
performance properties for XHPHT riser systems.
2). High strength steel and titanium structures

The task is to determine the technical advantages of using high strength steel with T&C connectors and
titanium to withstand the extremely high pressures while reducing hook load requirements during riser
running. Design parameters will be optimized.
3). Evaluation of mud boost line configurations

The efforts include case studies to assess various mud boost line configurations for dry tree high
pressure drilling riser configurations. Being able to jet the large diameter drilling riser while drilling long
smaller hole sections could substantially improve dry tree drilling efficiency.
4). System Configuration and Test

Develop the overall system configuration for both material options, including boost line, buoyancy etc.
Develop estimated system costs and a detailed road map for additional technology qualification

CTR 840X
Title: XHPHT Drilling Riser Design (Rev 1)

CTR No: 840 X Champion: BP (Roy Shilling)
requirements. Also, perform testing to provide data to support the new methodologies and work with the
MMS and API to enhance GoM regulations and recommended practices (MMS, API).
Completion Date:
12/31/2008
VALUE:
The XHPHT drilling riser design will enable drilling for those XHPHT wells which are not feasible with current
X-80 steel risers.
CONTRACTING PLAN:
Use RPSEA's standard contracting procedures

None

Trial and applications in real field development projects.

TRL 1 (after this study)
Man hours 6000 / $110/hr $ 660,000
Tests and prototype models $ 500,000
Travel expenses $ 10,000
Industry Funds (Kind, & source to be identified in $ US-------------

proposal).
RPSEA Matching Funds $ US-------------

CTR 840DD
Title: Drag-Reducing VIV Mitigators for Drilling Risers

CTR No: 840DD Champion: BP (Mike Tognarelli)
BUSINESS INCENTIVE AND THEME (Why invest?): With drilling vessel day rates in the range $500k -
$800k, large down-time costs are incurred in high current areas as contractors and operators wait on weather
to run, retrieve or simply to proceed with connected drilling operations. Platform drilling operations incur
similar costs in high-current regions. In such cases, it is not sufficient to simply mitigate VIV with helical
strakes, which carry a drag penalty with them. Devices must be available that not only mitigate VIV, but also
reduce drag. Examples of such devices are (but are not limited to) fairings, tailfins and splitters. Some such
devices are already available, but little is publicly known about their hydrodynamic performance. In addition,
even if it can be shown that a VIV/drag reduction device performs well hydrodynamically, such a device may
be difficult and time-consuming to handle, store, run and retrieve and this can offset the savings offered by an
increased operability window. Further, any such devices must be structurally robust enough to handle the
forces of being run through the splash zone. Thus, significant cost savings could be gained by the industry
by developing a VIV/drag reduction device that not only acceptably meets key hydrodynamic performance
criteria, but is also structurally sound, compact as possible and quickly installable.
This CTR falls under the themes of Improved Design and Analysis Methods Riser VIV and Optimized Field
Development Concepts for Improved Economics Installation and could be considered enabling in situations
where high current would have otherwise prohibited drilling operations.
OBJECTIVE: Design a VIV mitigation device that also reduces drag that: (a) performs hydrodynamically; (b)
is structurally robust; (c) is lightweight and compact; (d) is easy to handle, store and install; (e) is resistant to
(or its performance is insensitive to) marine fouling.
DELIVERABLES: (a) A proven prototype design that is ready for mass production and implementation in the
field. (b) Installation, handling and storage procedures suitable for operations.

Phase I: Selection of designs (based on hydrodynamic performance and compactness) via CFD, testing or
verification of CFD/test data provided by candidate manufacturers. (0.5yr - 1yr, $500k - $1MM)
Phase II: Rigorous mechanical / structural / material design of one or a small set of preferred candidates from
Phase I with emphasis on items (c) (e) in the objective statement above (0.5yr, $250k)
Phase IIa: Development of associated handling, installation and storage procedures (0.25 yr, $75k)
Phase III: Building and testing of a prototype from Phase II (1yr, $1MM)
Completion Date:
2.25 2.75 yrs
VALUE:
Significant cost savings could be realized in terms of days waiting on weather. Savings could also be
realized in reduction of wear-and-tear to riser components, reduction of frequency of inspections and
reduction of number of joint change-outs. Costs associated with rig/platform modifications to accommodate
and handle fairing.
CONTRACTING PLAN: Scope of work would be submitted for competitive bidding and would ideally include
a multi-disciplinary team consisting of expertise from among drilling contractors, hydrodynamicists, VIV
mitigation manufacturers, structural/mechanical designers, material scientists.

Ideally, technology will be ready to deploy.

CTR 840DD
Title: Drag-Reducing VIV Mitigators for Drilling Risers

CTR No: 840DD Champion: BP (Mike Tognarelli)

Phase I: $500k - $1MM
Phase II/IIa: $325k
Phase III: $1MM
Industry Funds (Kind, & source to be identified in $ US 465,000

proposal).
RPSEA Matching Funds $ US 1,860,000

CTR 840EE
Title: Offshore Riser VIV Measurement Program

CTR No: 840EE Champion: Chevron (Owen Oakley)

VIV has cost the industry considerably in deepwater operations and in the design of deepwater floating
drilling and production systems. The deepwater GOM is affected by Loop Currents, i.e. large, persistent
current systems which can cause high velocity currents that impact an area for days to weeks. These high
currents result in VIV of production & drilling risers. Deepwater designs are impacted by the costs to mitigate
the fatigue failures of risers. Mitigation practices (fairings, strakes, high strength pipes, fatigue resistant
welds) tend to be conservative (and costly) because the cost of failures can be high. The need for
conservatism because of uncertainties concerning VIV and its mitigation (e.g., accurate prediction, long term
impact on fatigue failures, effectiveness of suppression devices) further increases the costs as extra margins
are used to combat the uncertainties. One can readily understand how the deepwater industry spends many
millions per year in conservative designs and repairs due to VIV. A better prediction of fatigue life and the
effectiveness of mitigation measures can lead to more cost effective designs and project savings in first costs
(capital) and/or risk (operating) costs. A program to measure VIV on near-prototype scale risers is needed to
validate existing and/or new design tools used to predict riser fatigue damage and life, and to select and
distribute VIV suppression devices along the riser. Understanding and demonstrating how risers operate in
actual prototype conditions is a priority issue.
OBJECTIVE:
The object of this project is to develop and execute a field project to measure VIV on a near-prototype scale
riser in uniform and sheared flows in the Gulf of Mexico. The project is proposed in two phases. The
objective of Phase 1 is to develop a detailed technical and execution plan and a budget for executing the field
measurement project. The objective of Phase 2 will be to execute the project. There will be a milestone and
decision point at the end of Phase 1 to continue with the execution of the project.
DELIVERABLES:
Phase 1: A detailed design, execution plan, schedule, and costs suitable for executing Phase 2 of the project.
Phase 2: A dataset suitable for validating and/or calibrating existing design tools at near full scale conditions,
and complete enough to help improve existing tools or develop new tools.
The project planning for Phase 1 will include the following:
1. The riser would be sized based on expected VIV responses, data needs and instrumentation,
installation and retrieval capabilities. A target starting point would a riser with L/D ~ 4000. Riser
design would include estimating riser fatigue damage during the experiment.
2. Plans to construct and instrument the riser. Various riser construction options will be considered.
The final choice would be based on considerations including (1) the fatigue of the model riser during
the planned deployment, and (2) cost of constructing, deploying, and retrieving the riser.
3. Logistical planning to store the prepared riser component and instrumentation and transport the riser
components and instrumentation to the offshore vessel for deployment.
4. The riser would be deployed from an offshore construction or drilling vessel and towed in still water
and/or in a loop current. Deployment schemes consistent with offshore construction vessels or
drillships that could be expected to be available in 2008 -2009 would be developed and evaluated.
Several (3-4) options would be investigated.
5. An experimental plan would be developed to obtain the maximum amount of data in the minimum
amount of offshore deployment time. The experimental plan would include the following:
bare riser
riser with distribution(s) of VIV suppression devices (fairing and/or strakes)
riser exposure of each configuration to uniform and sheared currents
6. Instrumentation planning would consider data needs and measurement options that can fulfill those
needs. Sensor selection would focus on existing, proven, and reliable sensors, installation, power
requirements, data transmission & recording.
7. Preliminary configuration & designs for surface fixtures and other hardware needed to install,
support, and retrieve the riser.
8. Data acquisition and QA/QC plan

CTR 840EE

9. Data analysis plan to process, analyze, document, and archive the data for storage and distribution.
Regular meetings will be held with DeepStar or JIP representatives for review & feedback. Consultations will
be held with VIV specialists and subcontractors providing specialty work to support the project. Phase 1
would seek to develop as complete a plan & budget as possible and make all major technical decisions
regarding the execution of the project in Phase 2.
Completion Date:
6 - 9 month from
initiation for Phase 1
VALUE:
Value of this project is predicated on the overall value of have a high quality data set that will allow calibration
and validation of accurate design tools for VIV design. DS/RPSEA sponsored a VIV Forum (2/07) to help
update the riser/VIV program. A high Re and high L/D test program was identified as a critical step in the
validation of VIV design methods and to guide project designers.
CONTRACTING PLAN:
Issue an RFP for this test program with Phase 1 industry funds provided by DS for the experimental design
and planning, with a milestone before going on to Phase2. The CTR has been formulated around a tow test,
ensuring access to controlled current profiles and a short test duration. However, alternative approaches will
be considered in response to the RFP. This could include a long term monitoring of a riser (SCR?) from a
fixed installation, or other scheme to achieve the same goal of better understanding the behavior of prototype
risers in an offshore environment. Due to the tailor nature of the design and likely transient availability of the
offshore equipment, Phase 2 would proceed as soon as DS/RPSEA approved the plan from Phase 1 and the
industrial funds are available for RPSEA 4:1 matching.

This project will build upon DeepStars VIV projects to date in terms of learnings regarding VIV responses of
long risers and experiences from field projects to gathering VIV data.

Execute Phase 2 of the project. The completed Phase 1 would allow rapid contracting and project initiation of
Phase 2.

1:4 due to the fundamental nature of the research program.

Phase 1 $ 200,000
Phase 2 $8,000,000 (upper level estimate)
Total $8,200,000
Phase 1 $40,000 from DeepStar or a JIP
$160,000 from RPSEA
Phase 2 $1,600,000 from DeepStar or a JIP
$6,400,000 from RPSEA
TOTAL PROJECT COST Ph1 $200,000

Ph2 $8,000,000
Ph1 $40k (DS);
Industry Funds (Kind, & source to be identified in
proposal). Ph2 $1,600k
(TBD)

CTR 840EE

Ph1 $160k
RPSEA Matching Funds
Ph2 $6,400k

CTR 840II
Title: Validation and Improvement of Design Tools and

Platform Integrity Management
CTR No: 840II Champion: Chevron

Instrumentation system installed on a deepwater platform will yield valuable full-scale global response results
- even without a hurricane hitting - that can be used to validate the floating system global analysis methods as
well as validate model test results that were used to support the system design, thus to accomplish the
RPSEA themes of (1) Improving Design and Analysis Methods by validation with model and full scale test
data, and (2) providing results and conclusions from the validation that could lead to more Optimized Field
Development Concepts for Improved Economics.
OBJECTIVE:
Validate floating system global analysis techniques and model testing verification for ultra-deep
water depths.
Improve design, predictive, and life-management tools for the hull global analysis, and analysis of
moorings and risers using full-scale measured data.
Develop hybrid systems using real-time, full-scale measurements combined with analytic tools to
monitor and predict remaining life of components.
DELIVERABLES:
Final Report including results, conclusions and recommendations from the validation and calibration of design
analysis methods/tools, and recommendations for establishing hybrid systems (real time full scale
measurements combined with analytic tools to monitor responses and predict remaining life, and results of
the comparisons between selected platforms.

(1) Assemble and refine full scale and model data from selected hurricane events, (2) perform global
analyses of the events to compare with results of (1), validate the global analyses, (3) improve analysis
methods, and (4) propose methods for response monitoring and making remaining life predictions.
Schedule: Two years to complete the work. Completion Date:
VALUE:
Hurricanes Katrina and Rita caused storm loads on deepwater floating systems that were in excess of then
existent design conditions.
The Shell Mars deepwater production system, the largest producing system in the Gulf of Mexico, delivering
160,000 boe/d, was shut in for 9.5 months to repair damage from Hurricane Katrina. During that downtime,
crews of some 500 people per day participated in repair operations to bring Mars back on line.
Improvement of global analysis tools can result in improved operational reliability, reduced downtime, and the
associated deferred production.
CONTRACTING PLAN:
Use competitive bidding to select the best contractor.

This kind of work was performed for the Marlin TLP. Similar work was also performed for another TLP: Marco
Polo Field Measurement JIP.

CTR 840II
Title: Validation and Improvement of Design Tools and

Platform Integrity Management
CTR No: 840II Champion: Chevron

Implementation of design tool improvement if found necessary.

Competent Analysis tools are available, but validations with full scale data are scarce, particularly for
platforms in deepwater other than TLP; validations with model test data are limited by the inability to
adequately model test ultra-deepwater conditions.
TOTAL PROJECT COST $US1,750,000
Industry Funds (Kind, & source to be identified in $ US350,000

proposal).
RPSEA Matching Funds $ US1,400,000

CT840KK
Title: Composite Carbon Thermoplastic Tube Fabrication

and Testing for Deepwater Applications
CTR No: 840KK Champion: TOTAL
BUSINESS INCENTIVE AND THEME: Enabling & Enhancing technology

As production of oil and gas move into deep and ultra-deep waters up to 3000m, the weight of steel risers
become a major concern for both surface support structures like FPSOs & SPARs as well as for drilling and
installation vessels.
Composite materials offer the attractive properties of light weight for high strength and stiffness, good
corrosion and excellent fatigue resistance that make them ideal candidates for use in deepwater. This
technology will benefit the offshore industry in terms of reducing topside riser payloads as well as installation
and handling loads that makes it both an enhancing and enabling technology for future deepwater
applications.
Composite carbon fiber tubes with a thermoplastic matrix are currently being developed within the frame of
the 3C-Partnership with Soficar, Freyssinet and Doris Engineering. Soficar has developed a special machine
to fabricate the composite thermoplastic tube as a continuous process, Freyssinet is responsible for the
design and fabrication of the end connectors that are fitted to the composite tube and DORIS Engineering is
responsible for the design of the tube itself. A 6" high performance composite tube has already been
designed and manufactured for pressures corresponding to a water depth of 3000 m, and the promising
results of the tests will be presented at OTC 2007.
To extend the range of tubes for future applications and further develop this technology, it is proposed to
fabricate and test a 3 tube with its connectors in a first phase, followed by a 10 tube for a specific
deepwater application in the second phase.
OBJECTIVE:
The main objective of this project is to bring composite thermoplastic tubes from the development phase to a
stage where a full size prototype section could be tested in the field for a real application. To reach this
objective, the program has been broken into two phases as follows:
PHASE I: Design, fabrication and testing of a 3" tube with connectors

- Design of a 3" composite tube and validation of the fabrication process
- Tube and connector fabrication
- Tube and connector testing:- material tests, collapse, tensile and burst tests with end terminations,
PHASE II: Design, fabrication and testing of a 10 tube with connectors

- Design of a 10 composite tube with its end connectors for a specific deep water application
- Tube and connector fabrication
- Tube and connector testing:- collapse, tensile and burst tests with end terminations
DELIVERABLES:
PHASE I & II: Reports including:
- Technical design report
- Fabrication procedures for tube and end connectors
- Test results and analyses
PHASE I
Design and fabrication procedures for tube and connectors
- Design of 3" composite tube
- Verification of limiting fiber laying angles less than 25 and greater than 67
- Fabrication procedure, detailed engineering for tube and end terminations

CT840KK

Fabrication of 3" composite tube (Total 40m length)

Fabrication of end connectors to fit to the tube (Total 6 No. terminations)
Tests:
- Material tests to assess the laying procedure (X ray inspection)
- Collapse, tensile & burst tests with end connectors (Total 3 tests)
- Bending test (3 points flexure, slinging test)
-
PHASE II
Design and fabrication procedures for 10 composite tube:
- Design of 10 tube using previous conclusions for a specific application
- Fabrication procedure & detailed engineering for tube and end terminations
Fabrication of 10 composite tube (Total of 3No. 12 m sections)
Fabrication of end connections to fit to the tube (Total 6 No. terminations)
Tests: - Material test (Tomography, metrology)
- collapse tests with end caps
- tensile tests with connectors
- burst tests with connectors
Completion Date:
Phase I: Dec. 2008
Phase II: Dec. 2010
VALUE:
This project is aimed at bringing composite carbon thermoplastic tube technology into the offshore industry
for deepwater and ulta-deepwater applications. It represents an attractive alternative to existing steel tube
solutions because steel is heavy and sensitive to corrosion and fatigue. The fabrication process developed by
Soficar allows composite tubes to be manufactured in continuous lengths of 100m or more, reducing the
number of connections required and hence the overall cost and weight of a system.
The range of sizes proposed includes 3", 6" & 10" ID tubes and the possibility to design the tubes for a
range of different pressures and mechanical requirements will allow many different applications to be
considered in future deepwater and ultra deepwater developments, including lighter riser systems for floating
production platforms, drilling and well intervention units as well as hybrid riser tower solutions.
The value of lighter riser systems for floating UDW support structures is estimated to be several $100MM on
a single development
CONTRACTING PLAN:
This project follows a 6 year R&D program supported by the 3C-Partners, with the help of Total. For the
design and fabrication of the tubes and end connections this CTR is intended to be sole sourced. The testing
and analysis for a future application could be performed under RPSEA's standard contracting procedures.
This CTR is not related to any previous DeepStar project. This project will benefit from the 3C-Partnership
between SOFICAR, FREYSSINET and DORIS Engineering who have developed this technology over the
past 6 years with the support of the French CEP&M and TOTAL.
Upon completion of Phase I of this project, it is anticipated that the information provided will be sufficient to
confirm the technology could be used for an industrial application offshore. The 3" prototype created in
Phase I will also be used as basic knowledge for other applications.
At the end of Phase II it is anticipated that a full size prototype system could be installed in the field as a pilot
test.
Technology Readiness Level (TRL) for this project technology. TBD

CT840KK

CTR BUDGET Time Cost

PHASE I - 3" tube with connectors
01 Project Management and follow up $ 257,000
02 Design and fabrication procedures for tube and connectors $ 560,000
03 Fabrication $ 448,000
04 Test and Analyses $ 105,000
05 Progress Report $ 15,000
18 months $US 1,385,000
PHASE II - 10" tube with connectors
01 Project Management and follow up $ 257,000
02 Design of tube for a specific deepwater application $ 535,000
03 Fabrication $ 592,000
04 Test and Analyses $ 154,000
05 Final report and conclusion $ 132,000
24 months $US 1,670,000
Industry Funds (Kind, & source to be identified in Ph I: $US 277,000

proposal). Ph II: $US (TBD)
(Phase I:- Total & Other Oil Companies, Phase II:- To be

determined)
RPSEA Matching Funds Ph I: $US 1,108,000

Ph II: $US (TBD)

Email Subject: DS-RPSEA CTR 840OO Memo
Colleagues,
We would like to thank everyone for your interest in CTR 840OO VIV Analysis and
Modeling Program. In this brief note we would like to clarify some possible
misconceptions concerning the scope and emphasis of the CTR and encourage you to
support this DS/RPSEA program with a favorable vote. The two points that are probably
worth address are (a) the scope and (b) the funding strategy.
Work Scope
The CTR addresses the important analysis phase of DeepStars VIV experimental
program under CTR 8402. The high L/D experiments conducted off of Miami were
highly successful and revealed many new aspects associated with VIV and VIV
suppression. In order to reap the benefits of this effort, the data needs to be interpreted,
models upgraded or created and the resulting capabilities made available for use. We
have explicitly merged ideas from some other proposals. The following attempts to
clarify our primary Task objectives:
VIV Physics: where possible, additional high quality datasets from the 2006
Miami tests will be included to help expand the database and be made available to
the community of investigators pursuing VIV modeling approaches (see second
bullet). In addition, at least one operator would commit to making available full-
scale riser response data with current profiles to investigators for the purpose of
making substantial inroads toward quantifying the distinctions between model-
scale, single-tube test pipes and prototype-scale risers with ancillary equipment
and auxiliary lines. More operators would certainly be welcome to contribute
their full-scale data to the database.
VIV Modeling: numerous VIV models exist and/or are under development, both
empirical and CFD. Our aim is to be able to evaluate and possibly assist with their
optimization, e.g. parameter selection through system identification, stochastic
models for loading in suppressed regions, etc. This effort needs to be selective,
but is not linked to a single model or procedure. It is rather open to, and proposals
would be invited from, the community of VIV investigators who would like to
utilize the data to benchmark their analysis approach. We recognize that multiple
approaches to the analysis and prediction of VIV type behavior are needed.
Model Validation: the emphasis will be on encouraging modelers to achieve a

high level of quality, not focus on a single tool.
One of the benefits of the leverage permitted by the RPSEA program is that we should be
able to take a broader look at models appropriate for the various stages of design and
analysis, thereby permitting a better understanding of the industrys capabilities and
assisting with upgrades.
FN: DS-RPSEA CTR 840OO memo.doc

Funding Strategy
There are two competing timing issues: the need to aggressively improve our VIV and
suppression modeling capabilities, given our new understanding from the Miami tests,
and the recognition that some new modeling approaches may need some longer term
support. Our recommendation is to take immediate advantage of the RPSEA leverage
using the DeepStar funds for the industrial component. If the DeepStar work was split
off, it would be relatively small and hard to address effectively all of the desired scope. A
separate RPSEA CTR would require the equivalent of a JIP to come up with the industry
funds. The latter adds a huge extra administrative burden and degree of risk, and is likely
to slow the whole program down. New RPSEA funding models might help to alleviate
this problem, but are still in the development stage. We strongly recommend that if
further work is warranted, we can add to the program.
In conclusion, we have adjusted the wording of the CTR to clarify the scope covering the
issue discussed above. We recommend support of the proposed DeepStar-RPSEA
program (CTR 840OO) and the active involvement in the CTR steering committee of
those interested in important topic.
If you have any suggestions or concerns, please feel free to contact us.
Owen Oakley (CTR Champion)

Chevron, ohoakley@chevron.com
Michael Tognarelli
BP, Michael.Tognarelli@bp.com.
FN: DS-RPSEA CTR 840OO memo.doc

CTR 840OO
Title: VIV Analysis and Modeling: New Perspectives

CTR No: 840OO - l8402 part 2 Champion: Owen Oakley, Yiannis Constantinides
(Chevron), Mike Tognarelli (BP)

Vortex induced vibration (VIV) is a critical operational issue for deepwater operations. DeepStar has invested
heavily to conduct offshore testing on high length/diameter (L/D) pipe, with and without VIV suppression
devices. The recent 8402 test program (part 1) yielded exceptionally valuable data, exposing higher than
expected harmonic content and revealing convincing evidence on the efficiency of partial strake and fairing
coverage. To be of value, this data needs to be interpreted. Furthermore, along with operator-contributed full-
scale data sets, it must be made available to the community of investigators developing analytical techniques
for VIV that combine (i) the state-of-the-art understanding of VIV physics from the various data sets; and (ii)
the most capable, advanced numerical methods. Ultimately, the incentive is the improvement of VIV analysis
methodologies and design and integrity management guidelines. Current VIV fatigue analysis tools contain
acknowledged limitations that can lead to over-conservatism and general inaccuracy in predictions. More
appropriate levels of conservatism and higher confidence in prediction methods would lead to significant
savings in costs associated with suppression, suppression installation, waiting on weather and riser
inspections.
OBJECTIVE:
Using the high L/D data from the 7402/8402 offshore tests and operator-contributed full-scale measurements
as the primary datasets, the project will (a) develop a high quality case matrix suitable for software verification
and distribution, (b) characterize the responses to fully understand the VIV behaviors, (c) develop advanced
analysis techniques and models specific to VIV and customize tools for riser analysis, (d) develop guidelines
and user guidance.
DELIVERABLES:
Provide (a) benchmark datasets suitable for distribution to the community of investigators of VIV analysis
methods, (b) a detailed analysis report on high L/D VIV behavior based on the recent Deepstar tests, (c)
suitable progress reports and tutorial presentations ,(d) benchmark reports on existing and novel VIV
prediction tools, (e) next-generation VIV prediction tools

This is an extension and expansion of the previous work done by DeepStar on VIV and it is envisioned to
prove the understanding and prediction capability of VIV. The scope of work will be divided into three tasks
and will be guided and championed by a panel of industry experts. This is a multiyear activity with estimated
spending of ($200k DeepStar and $800k RPSEA) for the first phase and expected to increase for later
phases. Matching funds from bidders will also be pursued. Specific CTRs will be developed by the committee
based on the following:
Task1 VIV Physics:

z Analyze DS & other datasets; prepare & distribute benchmark data; scoping of
further small scale lab testing or full-scale monitoring as required.
Task 2 VIV Modeling:
z Improve & optimize modeling approaches that are more appropriate to our
growing understanding of VIV physics.
Task 3 Validation
z Blind tests & validation of tools; attempt to deliver on predictive tools for the
industry.
z Update DS VIV design guidelines
Completion Date:
~2 yrs for phase 1.
Multiyear program.
VALUE:
Data is of little value to deepwater operators unless the data is effectively vetted, extracted, compiled and

CTR 840OO
Title: VIV Analysis and Modeling: New Perspectives

CTR No: 840OO - l8402 part 2 Champion: Owen Oakley, Yiannis Constantinides
(Chevron), Mike Tognarelli (BP)
made available to the VIV community. The value of the high quality data obtained by DeepStar and others will
not be realized unless the data is analyzed in depth, repackaged and distributed to industry, software
developers and academics for easy and rapid use. As a key part of the vetting process, to the greatest extent
possible, model-scale data must be compared to full-scale measurements to gauge its reflection of reality.
This analysis phase (part 2) is therefore essential.
CONTRACTING PLAN:
This critical program should have the industry portion of the funds provided by DeepStar. Bidders should
include an option to subcontract with MIT to assist with data transfer and experiment interpretation, as
required. The primary datasets will be the DeepStar tests from Phase VII and VIII and full-scale data
contributed by BP. It may be possible to include additional, high quality datasets in the analysis. This could
significantly enhance the work and will be recognized in the bid evaluation.

The work should include the possibility of distributing the data to software developers and conducting VIV
software verifications.

This involves fundamental research and characterization of the phenomena, so should be eligible for a 1:4
leverage.
Task1 VIV Physics: (Funding for first phase ~$80k-
DS/$320k-RPSEA)
Task 2 VIV Modeling: (Funding for first phase ~$80k-
DS/$320k-RPSEA. Subsequent industry funding will be
provided by bidders.)
Task 3 Validation: (Funding for first phase (~$40k-
DS/$160k-RPSEA)
Industry Funds (Kind, & source to be identified in proposal). $ US 200,000
RPSEA Matching Funds $ US 800,000

CTR 840UU
Title: The Determination of out of Plane bending Stress

Fatigue in Chains
CTR No: 840UU Champion: CVX, BP, ExxonMobil, Total

In May 2002 mooring leg failures occurred in the Girassol deepwater CALM offloading system offshore West
Africa. The failure of multiple legs occurred in the hawse of the chain attachment system to the buoy. This
failure happened less than a year after the CALM had been installed. The failure of this system, which had
been designed and classed to existing rules revealed a previously unconsidered chain fatigue mechanism of
Out of Plane Bending (OPB).
OPB occurs when two interconnected links are forced to rotate with respect to one another. As alternating
chain links are orthogonal to one another, during this rotation one link will be in the plane of bending and the
other out of the plane of bending. The out of plane link having a low inertia against bending will be seeing
bending stresses leading to OPB fatigue.
SBM who supplied the Girassol buoy has been actively carrying out testing to better identify the OPB
phenomenon with a view to putting in place design procedures to safeguard chain mooring systems against
this type of failure. It is clear the phenomenon becomes more pronounced when mean tensions are increased
making deepwater systems the most vulnerable to these failures. Results of short-term tests performed in the
SBM laboratory have clearly demonstrated the fatigue mechanism. Some of this testing has been published
at several conferences and we attach the 2005 OTC paper on this subject.
The short-term testing and Finite Element Analyses (FEA) have been used to formulate a basic procedure,
which can be used to prevent OPB fatigue failures. These procedures are thought to give overly conservative
fatigue predictions. To improve this fatigue prediction long-term fatigue testing and further FEA is presently
ongoing at the SBM laboratory and offices to yield better procedures.
The OPB chain fatigue can place existing and future deepwater moorings at risk of failure. To identify existing
systems and prevent future systems from OPB risk, SBM proposes to carry out sufficient long-term test work
and FEA to put in place approved design practices for OPB.
Currently a group of sponsors have formed a JIP consisting of 6 oil companies, 6 contractors and 6
classification societies. Current funding totaling $775,000.
OBJECTIVE:
The main objectives of this work will be:
- To improve our knowledge regarding OPB of chain-links and validate, by further testing and
analysis, the OPB chain-link stress relationship implemented by SBM after the Girassol chain
failures.
- Generate S-N curves for chain links subjected to OPB.
DELIVERABLES:
The deliverable will be:
- Reports containing stress measurements and fatigue performance of 4 different chain sizes.
- Chain OPB stress relationships.
- S-N curves to be used for OPB fatigue calculation.

- OPB stress measurements based on chain tests in Stress Engineering Services laboratory in Houston,
Texas. (4 different chain size for 4 different levels of tension).
- Use FEA, in line with the work done by Chevron to calibrate the interlink stiffness and sliding threshold
model by benchmarking tests results.

CTR 840UU
Title: The Determination of out of Plane bending Stress

Fatigue in Chains
CTR No: 840UU Champion: CVX, BP, ExxonMobil, Total
- Develop a specific test rig for fatigue test of large (up to 124 mm diameter) chain-links in OPB.
- S-N curve determination.
- Write API RP for OPB.
Completion Date:
36 months
VALUE:
The main value of this work will be to improve the safety of the deepwater mooring systems as a failure can
have major consequences regarding safety, environment and costs.
CONTRACTING PLAN:
Sole source CTR to SBM for project management, subcontractors SES for the testing and PRINCIPIA for the
FEA work.

Previous SBM and Chevron testing and analytical work. See attached OTC paper.

Identify OPB resistance designs for chains

Current TRL =2, to be raised to 6 upon completion of project.
- Design / Fabrication of the test rig 300000 $

- Chain purchasing (4 different sizes) 30000 $
- Static Tests (4 sizes at 4 tension levels) 300000 $
- Establish OPB Stress Relationships 100000
- FEA vs. test results, develop FEA tools 145000
- Fatigue Tests (around 20 samples), S-N curve 300000
determination 200000
- Design Methodology for OPB static & fatigue determination 175000
- Project Management
Industry Funds (Kind, & source to be identified in $ US775000

proposal) - From JIP that is underway
RPSEA Matching Funds $ US775000

DeepstarRisers 2007&2008 1400 CTRs For Ballot

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CTR 840F

Title: Determination of acceptance criteria for weld

BUSINESS INCENTIVE AND THEME (Why invest?):

This could be solved by:

RPSEA RFQ Data Sheet Page 3 of 43

Title: Determination of acceptance criteria for weld

RPSEA RFQ Data Sheet Page 4 of 43

Title: Determination of acceptance criteria for weld

RELATED PROGRAMS (Linked Projects, JIPs & partners):

WHAT NEXT (Potential future work to advance/deploy technology)?

Ready for deployment.

CTR BUDGET Hours / Rate Cost

TOTAL PROJECT COST $US 2.400.000

Industry Funds $ US 1.200.000

RPSEA Matching Funds $ US 1.200.000

RPSEA RFQ Data Sheet Page 5 of 43

Title: Determine Remaining Life of Polyester Rope

BUSINESS INCENTIVE AND THEME (Why invest?):

SCOPE OF WORK (Work plan & schedule):

CONTRACTING PLAN: To be developed.

RELATED PROGRAMS (Linked Projects, JIPs & partners):

WHAT NEXT (Potential future work to advance/deploy technology)?

Technology Readiness Level (TRL) for this project technology.

RPSEA RFQ Data Sheet Page 6 of 43

Title: Determine Remaining Life of Polyester Rope

CTR BUDGET Hours / Rate Cost

TOTAL PROJECT COST $US 250,000

Industry Funds (Kind, & source to be identified in $ US 50,000

RPSEA Matching Funds $ US 200,000

RPSEA RFQ Data Sheet Page 7 of 43

Title: Riser & Flowline Crack Detection and Sizing Tool

WHAT NEXT (Potential future work to advance/deploy technology)?

Technology Readiness Level (TRL) for this project technology.

CTR BUDGET Hours / Rate Cost

TOTAL PROJECT COST US$7,000,000

Industry Funds (Kind, & source to be identified in $ US 1,400,000

RPSEA Matching Funds $ US 5,600,000

RPSEA RFQ Data Sheet Page 8 of 43

Title: Fatigue Performance of High Strength Riser Materials

BUSINESS INCENTIVE AND THEME (Why invest?):

RPSEA RFQ Data Sheet Page 9 of 43

Title: Fatigue Performance of High Strength Riser Materials

current practice of using knock down factors.

SCOPE OF WORK (Work plan & schedule):

RELATED PROGRAMS (Linked Projects, JIPs & partners):

WHAT NEXT (Potential future work to advance/deploy technology)?

Technology Readiness Level (TRL) for this project technology.

CTR BUDGET Hours / Rate Cost

RPSEA RFQ Data Sheet Page 10 of 43

Title: Fatigue Performance of High Strength Riser Materials

Phase 1 $US 1,000,000

TOTAL PROJECT COST $US 6,000,000

Industry Funds (Kind, & source to be identified in $ US-------------

RPSEA Matching Funds $ US-------------

RPSEA RFQ Data Sheet Page 11 of 43

Title: Composite Riser for Ultra-Deepwater High

BUSINESS INCENTIVE AND THEME (Why invest?):

RPSEA RFQ Data Sheet Page 12 of 43

Title: Composite Riser for Ultra-Deepwater High

SCOPE OF WORK (Work plan & schedule):

RPSEA RFQ Data Sheet Page 13 of 43

Title: Composite Riser for Ultra-Deepwater High

9. Evaluation of field trial test joints (post field trial)