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Proceedings of the ASME 2014 33rd International Conference on Ocean, Offshore and Arctic Engineering

OMAE2014
June 8-13, 2014, San Francisco, California, USA

OMAE2014-24240

DEEPWATER PRODUCTION TTR DESIGN


Andrew Blaquiere Daniel Reagan
2H Offshore Inc. 2H Offshore Inc.
Houston, TX, U.S.A. Houston, TX, U.S.A.

Ricky Thethi
2H Offshore Inc.
Houston, TX, U.S.A

ABSTRACT the host platform. The additional payload requirements can


As the majority of easy access reservoirs have been dramatically increasing the size of the floating structure and
discovered, deep water exploration and production is at the thus the project CAPEX.
forefront of the Oil & Gas industry. Operators have utilized Top The weight associated with a single or dual casing system
Tensioned Riser (TTR) systems in deepwater on Spar and TLP is compounded when producing in ultra-deep water as the
platforms and are now well established in the US Gulf of overall riser system weight is increased to meet the water depth
Mexico (GoM), West Africa and Asia. However, new requirements. In addition, HP/HT reservoirs drive riser systems
reservoirs, particularly in the US Gulf, will be discovered in to have heavier wall thickness requirements resulting in
ultra-deep water (~10,000 ft) with high pressure (HP) (>15 ksi) increased overall system weight.
and high temperature (HT) (>284 F). In such conditions, the In order to manage the weight associated with ultra-deep
criticality and complexity of a production TTR system is water and HP/HT reservoirs, the use of high strength alloy
significantly increased. This paper addresses key design issues steels, threaded and coupled connectors and non-standard
and considerations including wall thickness sizing, material casing sizes are potential mitigations. These mitigations enable
selection, manufacturing capabilities, interface management the use of smaller wall thickness pipe with equivalent strength
and qualification testing. capacity and thus results in a decrease in the overall riser
system weight. The proposed mitigations to reduce the overall
INTRODUCTION weight of the system introduce additional challenges as it
The development of an Oil & Gas field from exploration to relates to sour service requirements, hydrogen embrittlement,
production takes on many phases. During the early stages of weldability, fatigue performance, interface complications to
field development, operators will determine how they intend to forged specialty joint components and qualification testing.
develop and operate the field using either dry tree or wet tree
systems. Field development plans that included multiple well ABBREVIATIONS
interventions and side tracking operations into different CAPEX Capital Expenditures
reservoirs have been shown to have a high level of success by GoM Gulf of Mexico
utilizing dry tree TTRs. HP High Pressure
Dry tree TTR arrangements may either be single casing or HRC Rockwell Hardness
dual casing systems, depending on functional requirements, HT High Temperature
reservoir pressure/temperature, water depth, economics and FT - Feet
safety and reliability considerations. ID Inner Diameter
As the industry moves into deeper water and produces JIP Joint Industry Project
from HT/HP reservoirs, the risk of unwanted hydrocarbon KSI Kilopound per Square Inch
release is increased. Regulatory bodies in the GoM are focusing LB Pound
on the implementation of dual casing configurations in order to LSJ Lower Stress Joint
limit the potential risks associated with deep water production. MASP Maximum Anticipated Surface Pressure
However, the implementation of a dual casing system in deep mT Tonne
water has a significant impact on the payload requirements on MWL Mean Water Level

1 Copyright 2014 by ASME


OD Outer Diameter hydraulic connector while the upper connection can be a
TTF Top Tension Factor flanged and bolted connection or integral style connector.
SMYS Material Yield Strength
SSC Sulfide Stress Corrosion Cracking Lower Stress Joint
T&C Threaded and Coupled The lower stress joint (LSJ) connects the riser to the TBC.
TBC Tieback Connector The LSJ is utilized to manage the high bending stresses and
TJ Tension Joint fatigue loading at this localized section adjacent to the point of
TLP Tension Leg Platform fixity at the seabed. The lower stress joint is typically
TTR- Top Tensioned Riser manufactured from a single piece forging and is considered a
primary class forging in accordance with API-RP-2RD [1]. The
TOP TENSIONED RISER (TTR) CONFIGURATION LSJ is typically a steel construction using grades such as A707
Dry tree Top Tensioned Risers (TTR) are systems which or F22 with 80 ksi minimum yield strength. The length of the
provide surface access to the subsea wells and consist of a joint is dictated by the bending loads due to vessel excursion
section of vertical pipe (i.e. riser joints) supported at the vessel and environmental offset, and can be shown to be in excess of
by an individual tensioner systems and connected to the subsea 50 ft. Long lengths forgings provide limitations on forging
wellhead via a tieback connector, Figure 1. suppliers due to weight, manufacturing process and final
machine capabilities.
The bottom connection can either be an integral flange
connection or an integral tieback connector profile with a
mechanical locking profile, as shown in Figure 2. The upper
connection can either be an integral flange connection or an
integral threaded connection.
Riser in Wellbay

Tendon Leg Platform

Tensioner System
Lower Stress Joint with Lower Stress Joint with
integral tieback connector integral flange connection
profile
Figure 2 Lower Stress Joint prior to Integration with TBC

Standard Riser Joints


StrakedRiser
Straked JointJoint Standard riser joints comprise the majority of the TTR
Stress Joint / TBC
from above the lower stress joint to the splash zone joint
Figure 1 Typical Gulf of Mexico Tension Leg Platform approximately 40-50 feet below Mean Water Level (MWL).
(TLP) Production Top Tensioned Riser Standard riser joints are typically seamless casing constructed
from steel with material yield strengths ranging from 80 ksi to
A detailed description of a typical top tensioned riser 125 ksi.
system is provided in Top Tensioned Riser (TTR) Engineering
Integrator Supply Model [10]. A brief overview of the key Splash Zone Joints
components is provided in the following sections. The Splash zone joints with greater wall thickness and
following description starts at the base of the riser and defines neoprene coating (to provide corrosion protection and impact
the system through the water column to the production resistance) are often utilized above the standard riser joints that
platform. terminate at approximately 40-50 feet below MWL.

Tieback Connector Standard and Splash Zone Joints Connections


The tieback connector (TBC) provides the interface The conventional method for connecting standard joints
between the riser and the subsea wellhead and subsea conductor and splash zone joints is weld-on threaded connections, as
casing. The connection to the subsea wellhead is generally a shown in Figure 3(a). An alternative construction method is the

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use threaded and coupled (T&C) connections, as shown in be either single or dual casing systems, depending on a range of
Figure 3(b). considerations including functional requirements, intervention
Confidence in the use of T&C connections for outer riser and workover requirements, reservoir pressure, water depth,
applications has increased due to deep water applications in economics and perhaps most importantly, safety and reliability
TTR risers as well as through JIPs [3]. considerations, [8].
The single casing riser system consists of a single casing
and internal production tubing. This arrangement offers the
lightest solution with lowest capital cost. The disadvantage of
this arrangement is the single casing barrier, which in some
developments can be insufficient. A critical phase is during
workover operations when the production tubing is removed
leaving only a single casing in place with the weight of
(a) Weld-on (b) T&C completion/workover fluid maintaining an overbalance pressure
Figure 3 Top Tensioned Riser Threaded Connections on the well. Any breach of the riser near the mudline and loss
of mud to the environment could result in an underbalance
Tension Joint condition in the well and in the extreme, a blowout event.
The tension joint connects the riser to the tensioner system, The risk associated with operating a single casing riser
which connects to the production platform. The tension joint is system in ultra-deep water with high pressure reservoirs has
utilized to manage the high bending stresses and fatigue loading been identified by Operators as a high risk operation.
at the localized section adjacent to the point of fixity at the Operational safe guards may be required prior to operating the
vessel. The tension joint is typically manufactured from a single field including no sidetrack drilling through the production
piece forging and is considered a primary class forging in riser, regular inspections and monitoring for wear, corrosion
accordance with API-RP-2RD [1]. The tension joint typically and fatigue of the casing. Alternatively to a single casing riser
consists of a steel construction using grades such as A707 or system, a dual casing riser system can be used. In a dual casing
F22 with 80 ksi minimum yield strength. A threaded section is riser system, two concentric casings are used as shown in
machined onto the exterior of the joint, which is used to Figure 4, with the production tubing run inside of the inner
interface the tension ring to the tensioner system. The length of most riser casing. In the event of failure of the inner casing
the joint is dictated by the high fatigue hotspot at the tension (primary barrier) during a workover scenario, the outer casing
ring fixity, which can be in excess of 50 ft. Long length is designed to retain the completion/workover fluids and
forgings provide limitations on forging suppliers due to weight, maintain the hydrostatic head and riser margin in the well, [8].
forging process and final machine capabilities.
The bottom connection on the tension joint can either be an
integral flange connection or an integral threaded connection. Tubing Inner
The upper connection on the tension joint is typically an Casing
integral mechanical connection to the surface wellhead. Outer
Casing
Tensioner System
Tension is maintained in the riser using a hydro-pneumatic
tensioner system or an aircan system that interfaces with the
platform and the tension ring on the tension joint. The tensioner
system provides global stability and motion performance
control and ensures that positive effective tension is maintained
at the base of the riser under all loading conditions.

DESIGN CONSIDERATION
The design of a TTR is specific to each field development.
The requirements associated with each field will vary based on Figure 4 Dual Casing Configuration
the environmental, regulatory requirements and reservoir
properties. The following sections discuss key design As previously discussed, ultra-deep water and HP
parameters of a TTR in ultra-deep water. reservoirs drive riser systems to use a heavier wall thickness to
resist the larger tension and pressure loads resulting in
Barrier Philosophy increased overall system weight and overall payload on the
A key design consideration for a production top tensioned production platform.
riser system is the selection of a single casing (one casing pipe While the weight increase associated with a dual casing
+ one tubing) or dual casing TTR system (two casing pipes + riser may be a disadvantage, a benefit of a dual casing system is
one tubing). Top tensioned risers for dry tree arrangements may

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that it offers an inherently improved thermal performing system
in deep water when compared to a single casing system. HT
reservoirs produced in ultra-deep water introduces thermal heat
loss due the interaction between hot hydrocarbons, cold
seawater and the long recovery distance to the production
platform. The secondary barrier steel volume in combination
with inhibited seawater or nitrogen in the inner annulus and
thermal gels in the outer annulus will typically reduce the rate
of heat loss during production. A single casing system will Figure 5(b) - External Seal of a T&C Connector
typically use inhibited seawater but may require external pipe
coatings such as wet thermal insulation to maintain the required The internal seal of a T&C connector is a metal to metal
riser temperatures during production. seal which is located on the pin of the connector and designed
Regulatory bodies overseeing the GoM are currently in the with tapered, radial or elliptical profiles which interface with
process of implementing regulations which require all the coupling. The internal metal to metal seal provides the
production TTRs installed in the GoM to be dual casing connector leak resistance, whereas the torque load shoulder
systems in order to minimize the risk of releasing hydrocarbons provides structural strength. To insure the proper make-up, the
during well completion and workover activities. The additional torque required to make up the connection is measured during
payload requirements of a dual casing riser system can installation to insure the metal to metal seal is properly
dramatically increasing the size of the floating structure and engaged. The make-up torque is determined by the connection
thus the project CAPEX. As the economics associated with type, size (i.e. outer diameter and inner diameter) and
field developments have to meet the Operators business model, qualification results.
different methods for to reducing CAPEX associated with T&C connections offer acceptable fatigue performance and
vessel payload must be evaluated. when supplied with a suitable external environmental seal offer
a lower cost and lower weight solution compared to a welded
Threaded and Coupled Connections pin and box connector.
Many TTR systems installed to date have used welded pin
and box connectors. As the connectors require welding, CASE STUDY
material yield strength of 80 ksi is at the upper bound of A case study considering a Production TTR in ultra-deep
material that can be utilized. As the weld on connectors limit water, 10,000 ft, with a high pressure reservoir, 15 ksi, is
the material yield strength, an alternative approach is the use of conducted to assess the weight savings when considering single
threaded and coupled (T&C) connections which do not require casing or dual casing system, standard and non-standard casing
welding, as shown in Figure 5 (a). A T&C connection allows sizes and the high yield strength materials. To show the
material yield strengths up to 125 ksi and results in thinner riser maximum weigh savings potential with high yield strength
wall thicknesses. materials, the reservoir conditions for the case study are
A potential issue associated with T&C connectors is assumed to be sweet service. However, for sour service
fatigue resistance from sea water ingress to the root radius of reservoir conditions, the maximum yield strength is 110 ksi due
the last few run-out threads. The ingress of sea water can lead material limitations described later in the paper.
to corrosion of the threads and ultimately result in a crack
initiation site for fatigue failure to develop. Therefore, outer Wall Thickness Sizing
casing T&C connections should incorporate a metal to metal The sizing requirements of the riser tubing and casings are
external environmental seal as shown in Figure 5 (b). The governed by the minimum inner diameter (ID) to pass
external seal will prevent seawater from reaching the root equipment and the wall thickness is determined using API-RP-
radius of the last few run-out threads. 2RD [1] that defines the outer diameter (OD). The tubing
contributes the smallest fraction of the total riser weight.
Therefore, a tubing ID of 4.375 is chosen as this is a typical
tubing diameter for dual casing TTRs. The inner casing is sized
to have a minimum drift diameter of 8.625. This ID is chosen
so that tools may pass through the inner casing during
completion/workover condition. The outer casing ID must be
large enough to accommodate the inner casing threaded and
coupled (T&C) connectors and the inner casing tie back
Figure 5(a) - T&C Connection connector. For this study, the inner casing tieback connector
will drive the drift diameter of the outer casing. An outer casing
drift diameter of 12.000 is required to allow the inner casing
tieback connector to drift through the outer casing during the
inner riser installation.

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Field hydrotest conditions are not allowed to drive the wall
thickness as these are conducted to confirm riser joint and Table 2 Pros and Cons of Standard Casing Sizes
connection integrity only and are shown to be the Maximum Pros Cons
Anticipated Surface Pressure (MASP) plus 500 psi in May not be feasible or has
accordance with [11]. The inner and outer risers are considered Multiple suppliers
increased weight
at the full reservoir shut-in pressure of 15 ksi. The inner casing High likelihood of
can see the maximum pressure in the event of a tubing leak qualification test data Over designed component
during a shut in condition. The outer casing can see the available
maximum pressure in the event of an inner riser leak during a Threading profile may not
completion/workover condition. Field proven with extensive
be qualified with an external
The A annulus, annulus between the tubing and the inner track record
seal
riser, is filled with a heavy completion fluid with a density of
12 ppg. The B annulus, annulus between the inner riser and Table 3 Pros and Cons of Non-Standard Casing Sizes
outer riser, is filled with treated seawater with a density of 8.5
Pros Cons
ppg. The TTR considers a nominal top tension factor (TTF) of
Requires manufacturing of
1.5. The TTF is defined as the tension applied to the top of the
Optimal design specialty manufacturing
TTR divided by the wet weight (including surface equipment)
equipment (long lead items)
of the TTR.
Most likely no previous
The first sizing case assumes both casing barriers are Weight savings
qualification test data
constructed from 80 ksi material. The minimum required wall
thicknesses are calculated for both standard and non-standard May be only solution in
casing sizes. design frontier (high
Limited track record
The wall thickness calculations using drift diameters of pressures, high temperatures,
8.625 for inner casing and 12.000 for outer casing show that exotic materials)
the required wall thickness is in excess of one (1) inch which is
greater than the standard API casing sizes. The hoop stresses in Material Grade
both the inner and outer casing from the high internal pressures The material selection for the inner casing is assessed
drives the wall thickness requirements higher than standard API using non-standard casing sizes using T&C connectors. An
casing sizes. If, for example, an Operators preference is to use outer casing of 80 ksi yield strength is assessed with a range of
80 ksi material grade to accommodate weld-on connections for inner casing with material yield strengths of 80 ksi, 95 ksi
the outer casing, then the use of non-standard casing sizes is (T95), 110 ksi (C110) and 125 ksi (Q125). Figure 6 shows the
required. minimum required wall thickness sizing for the inner casing
The wall thickness sizing results for non-standard casing with varying material and Figure 7 shows the weights savings
sizes with 80 ksi material grade are shown in Table 1 below. in weight wet. As discussed previously, the inner casing of a
dual casing is equivalent to the outer casing of a single casing
Table 1 Wall Thickness Sizing Summary for Non- system; therefore only the dual casing system results are
Standard Casing with 80 ksi Material Grade presented for the remainder of the study.
ID WT OD Wet Weight The maximum reduction in wall thickness for the inner
Pipe
(inch) (inch) (inch) (lb/ft) riser reduces from 2.15 to 0.87 when increasing the material
yield strength from 80 ksi to 125 ksi. To maintain a constant
Tubing 4.370 0.560 5.489 30 inner riser bore diameter from the topside equipment (surface
Inner 8.625 2.150 10.805 113 wellhead) to the subsea equipment (subsea wellhead), the
Outer 12.000 1.579 14.366 167 reduction in wall thickness will reduce the OD of the inner
casing.
The selection of non-standard casing sizes can decrease the The in water weight savings when increasing from X80 to
riser weight by minimizing additional unnecessary wall Q125 material is 138 pounds per foot (lb/ft). The total weight
thickness and outer diameter. Non-standard casing sizes are savings per risers in 10,000 ft of water depth is 629 mT or 34%
readily achievable for most casing suppliers; however there is of the total riser weight. If an Operator is considering a
the potential for an increased cost and lead time over standard production system with 15 TTRs, the total payload savings of
casing sizes. The non-standard casing tooling used during the production platform is up to 14,140mT.
manufacturing is not an off-the-shelf commodity and
therefore will likely require fabrication prior to production. The
pros and cons to standard casing sizes are presented in Table 2
and the pros and cons of non-standard casing sizes are
presented in Table 3.

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mT or 37% of the total riser weight. If an Operator is
considering a production system with 15 TTRs, the total
payload savings of the production platform is up to 10,290 mT.

Figure 6 Wall Thickness Sizing for Dual Non Standard


Casing with Varying Inner Riser Material

Figure 8 Wall Thickness Sizing for Dual Non Standard


Casing with Varying Outer Riser Material

Figure 7 Wet Weight for Dual Non Standard Casing with


Varying Inner Riser Material

The final assessment is to increase the material yield Figure 9 Wet Weight for Dual Non Standard Casing with
strength for the outer casing. For maximum weight reduction, Varying Outer Riser Material
the inner casing material is selected at 125 ksi (Q125) and the
outer casing material is assessed at 80 ksi, 95 ksi (T95), 110 ksi Combining the three weight saving strategies (non-
(C110) and 125 ksi (Q125). Figure 8 shows the minimum standard sizes and the selection of Q125 material for the outer
required wall thickness sizing for the outer casing with varying and inner casing), the reduction in the in-water weight per riser
material and Figure 9 shows the weights savings in mass per in 10,000 ft of water depth is up to 71% of the total riser weight
unit length. using standard casing in 80ksi. If an Operator is considering a
The maximum reduction in wall thickness for the outer production system with 15 TTRs, the total payload savings of
riser reduces from 1.58 to 0.83 when increasing the material the production platform is up to 24,430 mT.
yield strength from 80 ksi to 125 ksi. To maintain a constant It is noted that the use of C110 or Q125 as an outer riser
outer riser bore diameter from the topside equipment (surface casings or a Q125 inner riser casing has not been utilized to
wellhead) to the subsea equipment (subsea wellhead), the date on a Spar or TLP development currently operating.
reduction in wall thickness will reduce the OD of the outer Advancements in manufacturing, testing and adjustment to
casing. industry codes have increased the industrys confidence to use
The wet weight savings when increasing from 80 ksi to high strength materials for production TTR systems in ultra-
125 ksi yield strength material is 100 lb/ft per unit length. The deep water and HP/HT reservoirs. The following sections
total weight savings per risers in 10,000 ft of water depth is 457

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identify components that must be evaluated in order to NACE TM01777-2005 test Method A or test Method D on a
implement higher yield strength materials in a production TTR. sample material with a mean hardness of 29 HRC or higher.
The updated code provides both the manufacture and
Sour Service Requirements operators the ability to considering high strength steels
Typically the well fluids in ultra-deep water reservoirs can combined with sour service wells as the requirements are
be extremely corrosive and can degrade the casing material clearly defined.
over the life of the well. Operators will define the sour service
requirements for the material based on the acidity and hydrogen Hydrogen Embrittlement
sulfide partial pressures of the well fluid, as shown in Figure Exposure to hydrogen, specifically for high strength steels,
10, [12]. may cause the steel to become brittle and ultimately fracture,
also called hydrogen induced cracking (HIC). If hydrogen is
introduced during the manufacturing process, the hydrogen will
diffuse into the micro-structure of the steel and create pressure
pockets. During the service life of the steel, the increased
exposure to hydrogen can decrease the material ductility and
tensile strength and result in HIC. However, tight controls on
the manufacturing process, heat treatment and material
hardness can reduce the risk of HIC.
The micro-structure for seamless casing must be within the
requirements put forth in API 5CT, [2], which requires the grain
size for T95 material to be ASTM of 5 or better and for C110
material to be ASTM of 6 or better. The reduction in grain size
in combination with tight controls on the chemical
compositions of the material will reduce the possibility of
introducing hydrogen into the manufacturing process.
Figure 10 Sour Service Criteria The heat treatment of the material will control the
hardness, strength and brittleness of the material. The heat
Many casing suppliers offer their own proprietary material treatment includes a quench to increase the through-wall
grades which meet the requirements of NACE MR0175/ISO material hardness and a temper to reduce the brittleness and
15156-3, [12]. With the selection of higher material yield reduce the likelihood of HIC. API 5CT recommends the HRC
strengths such as 110 ksi or 125 ksi, the sour service resistance values for C110 material to be maximum of 30 HRC, to reduce
is reduced. The sour service requirements are achieved by potential failures for both SSC and HIC. API 5CT 9th edition,
dictating the hardness of the material during the manufacturing [2], includes new references to NACE TM0284-2003 for HIC
and heat treatment process. Increasing the yield strength will criteria and testing methodology within Annex K.
increase the material hardness, which reduces the resistance to Considering the improvements and control to the
sulfide stress corrosion (SSC) cracking and corrosive manufacturing processes, casing supplier test data has shown
environments. that higher material yield strengths with hardness values of 30
Due to technological advancements in the manufacturing HRC are not susceptible to HIC.
capability of seamless pipe mills, the chemical compositions of
the raw material being supplied is more controlled. The Weldability
improvements in controlling the chemical composition allow The selection of higher strength steels greatly reduces the
seamless pipe suppliers to provide products which have been weldability of the material. The high material hardness
tested and shown to have resistance to SSC as well as einsure associated with high strength steels make production welding
complete through wall hardening. Additionally, seamless challenging and requires lengthy and expensive weld
manufacturing creates an even and consistent micro-structure, qualification programs. Additionally, if the material is required
which is most desirable for resisting SSC cracking. to be resistance to corrosive environments (i.e. sour service
Previously, there was minimal industry standard literature compatible) the weldability may be further reduced. The
that defined the acceptance criterion for SSC cracking or testing material hardness is the critical input to sour service resistance
requirements for higher yield strength materials. However, the and during welding significant heat is introduced into the
9th and newest edition of API 5CT, [2], includes standards for material. The heat affected zones will create localized
SSC criteria and tests for high strength steels including C110 hardening, higher than the allowable criterion, and the material
and Q125. Section 7.14 recommends using NACE will not meet the SSC requirements. If the localized hardening
MR0175/ISO 15156-3, [12], as guidance for C110 material. is not tempered the material may reach failure during
Additionally, the code states the manufacturer of C110 material operations
shall meet or exceed the minimum SSC requirement using Based on the above, when considering high strength casing
for the standard and splash zone joints (i.e. T95, C110 or

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Q125), the use of weld-on threaded connections are not capacity to maneuver the joint and a lathe that can
recommended and therefore non-welded T&C connections are accommodate the joints diameter and weight.
the preferred connection method. Although a weld-on The tolerances associated with premium threaded
connection can still be utilized on the specialty forged joints, connections utilized for a TTR are extremely tight
typically constructed from 80 ksi yield strength material, the compounding the manufacturing problem even further. The
interfaces between the components must be properly managed. number of machine shops capable of performing this type of
fabrication with the equipment capability, technical capability,
Interface Challenges track record and working relationships with T&C suppliers is
The physical interfaces challenges on a Production TTR limited.
system are the connections between the standard joints and the The interfaces can be further complicated depending on the
specialty forged joints (i.e. lower stress joint and tension joint). procurement strategy of the operator or riser integrator
The connections at these locations must be as strong as the pipe contractor. The operator can select a turnkey supplier capable of
and be capable of withstanding the strength and fatigue loading providing all TTR components or utilize a riser engineering
due to vessel excursions and environmental loading. integrator that selects individual suppliers for each component
Considering the case study detailed above, the specialty based on technical capability and optimal interface solutions
forged joints are constructed using F22 or A707 (80 ksi yield) [10]. If the riser integrator model is selected and three (3)
material and the casing with the optimal weight savings is different suppliers are selected to procure the tension joint,
constructed from Q125 (125 ksi yield) material. The high standard riser joints and stress joint, the operator or engineering
strength material results in thinner walled pipe while contractor must determine the optimal connection to place on
maintaining an equivalent strength capacity to the forging the both specialty forgings.
material. With the selection of Q125 material, the use of weld-
on connections is eliminated due to the weldability limitations. Interface Management
Therefore, T&C connections must be selected for the standard To manage these interface challenges, it is important to
riser and splash zone joints. As the specialty forged joints are understand the potential solutions associated with each
80 ksi material they can either use a weld-on threaded connection type. Due to the material yield strength mismatch
connector, a weld-on or integral compact flange or an integral between the forging and casing material, the use of a crossover
T&C connection with a similar design and size as the standard joint will likely be required. The use of crossover joints will
riser joints. manage the material transition for any connection type.
The advantage of using weld-on connections (threaded or Depending on the selected connection type, the crossover joint
flanged) on the specialty forged joints is the manufacturing may be a forged joint or a seamless casing joint.
process is simplified. Multiple suppliers are capable of welding For an integral threaded connection is selected for the
80 ksi materials and the welding can be performed in multiple specialty forgings, the potential for two (2) seamless casing
environments and positions. The disadvantages of using weld- crossover joints is required. The T&C connection design uses a
on connections are the weld and fatigue qualification program specified make-up torque to achieve the optimal pre-load in the
is lengthy and expensive, a second connection type is seals as well as in the thread profiles. The optimal make up
introduced into the system and additional tooling may be torque for each connection is proportional to the materials
required offshore. yield strength. In the case of material yield strength
Alternatively, if an integral T&C connection is used on the mismatches, high torque loads required to make up high yield
specialty forged joints, then there is only one connection type strength connections can over stress and damage the lower
along the entire TTR system. However, the interface yield strength material. Damage to the connector can increase
management of must be addressed as detailed in the next the stress amplification factor (SAF) and thus cause fatigue
section. For T&C connectors, the pin is generally the weakest failures through the life of the project.
point in the connection. If an integral T&C connection is used To limit the potential over torqueing of the lower grade
on the specialty joints, the capacity of the connection may still material, a crossover joint with intermediate yield strength that
meet the system load requirements even though the specialty meets the torque requirements for both the low and high
joint is a lower yield strength material. strength materials can be selected. Typically material mismatch
If the connection is a similar design and size as the for T&C connectors should not exceed 15 ksi. Therefore to
standard riser joint connection, the T&C connector qualification transition from the forging material (80 ksi) to the casing (125
program may be reduced when compared to a welded option. ksi), two (2) crossover joints may be required with yield
The key disadvantage of using an integral T&C connection is strengths of 95 ksi and 110 ksi. Using wall thickness sizing in
there are a limited number of suppliers globally with the accordance with API-RP-2RD, [1], the crossover joints may
capability to thread a long length, heavy and large OD forging. have varying diameters to the standard casing, which requires
The specialty forgings can extend up to 60 ft, weighing up to different sized T&C connections at each interface.
15,000 lbs and have outer diameters up to 18. The supplier If a flange connection is selected for the specialty forgings,
must have a machine shop with adequate space to it is most ideal to use a short (~6 ft) forged crossover from 80
accommodate the length, an overhead crane with enough ksi yield material with an integral flange connection. The

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opposite end of the forged component can easily be threaded by
the T&C connection supplier and a coupling can bucked on if
required. The forged crossover can then be made up onto the
stress joint or tension joint in a controlled environment,
hydrotested, drift tested and then delivered offshore. However,
additional crossover joints will be required to transition from
the short forged crossover to the high strength casing. The
additional crossover joints will follow the same design as
detailed above for the integral threaded connection.

High Yield Strength System Overview


A stack-up drawing showing a single casing Production
TTR system with a flanged connection on the forgings, a forged
crossover and Q125 standard casing is provided in Figure 11.
The same system with integral T&C connections at all
interfaces is provided in Figure 12.
Whether forged or seamless casing crossover joints are
selected, these components would be a limited order for the
supplier and therefore may be costly and include an extensive
lead time. Additionally, the complexity of these interfaces
requires multiple material yield strengths to be used on single
system. If the operator preference is to use T&C connections on
the entire system, the next decision will be what qualification
program is required to accept the T&C design.

Figure 11 Production TTR Stack Up with Flange


Connections on Forgings

9 Copyright 2014 by ASME


Qualification Test Program
Qualification test programs for Production TTR
components may be necessary to confirm the design,
manufacturing and fabrication are acceptable for the
components to meet the projects design criteria and
manufacturing specifications. A typical qualification program
for T&C connections may include, but is not limited to,
sealability testing in accordance with ISO 13769, [9], fatigue
testing and make and break testing. For each qualification test,
the test setup and test parameters proposed by the T&C supplier
should be reviewed by the operator and/or riser engineering
contractor. The test setup is critical to confirm the test will
represent real project scenarios and are not under conservative
or unrealistic. Improper test setups may yield test artifacts or
generate results that are unrealistic. Any test results which are
anomalies shall be investigated and may require extensive
project resources to determine the root cause.
For fatigue and sealability testing, there are no industry
standards for accepting previous test data for a T&C connection
in a different size (i.e. OD and wall thickness) or material grade
(i.e. F22, T95, C110, Q125, etc). Most T&C connector
suppliers will have selected product sizes and material grades
that have previously been tested to the typical industry standard
requirements and are available for review. When considering
either standard or non-standard casing sizes, it is the operators
choice to either accept fatigue testing results from other casing
sizes of the same grade material that bound the project selected
casing size or conduct a new qualification testing program.
Using previous test data will reduce time and cost to the overall
qualification test program, but depending on the size and
material grade may not satisfy the operators and/or engineering
contractors project requirements.
The Production TTR system shown in Figure 12 will
include four (4) T&C connections with different grades and
potentially different sizes depending on wall thickness
requirements. Each interface with the associated components
and material yield strengths (SMYS) are detailed in Table 4.

Table 4 Interfaces with T&C Connections


SMYS SMYS
Interface Component Component
(ksi) (ksi)
1 LSJ Forging 80 Crossover 1 95
2 Crossover 1 95 Crossover 2 110
3 Crossover 2 110 Standard 125
4 Standard Casing 125 Standard Casing 125
5 Standard Casing 125 Crossover 2 110
6 Crossover 2 110 Crossover 1 95
7 Crossover 1 95 TJ Forging 80
1) Assumes interface 5, 6 and 7 are same as 3, 2 and 1, respectively.

Figure 12 Production TTR Stack Up with Integral T&C In order to acquire acceptable statistical test data, the
Connections on Forgings industry standard for fatigue testing T&C connection is to test
six (6) samples per connection type. The six (6) samples will be

10 Copyright 2014 by ASME


tested at different stress levels and different cycle times, as Connectors Product Line for Outer Production Riser
detailed in Table 5. and Single Barrier Riser Applications in Deepwater
and Ultra Deepwater. OTC Brazil, 2011
Table 5 Fatigue Testing Samples for Connections [5] OilPatch Technologies NF2000 Product Data Sheet
Samples Stress Cycles [6] NORSOK Materials Selection. NORSOK
Standard M-001, Rev. 3, Nov 2002
2 Low High [7] Walters, D, Thomas, D, Hatton, S. Design and
2 Medium Medium Optimization of Top Tensioned Risers for Ultra Deep
2 High Low Water. Floating Production Systems Conference,
2004
Based on this practice, if six (6) samples were tested for all [8] Offshore Magazine Risks and concerns of single-
four (4) connection types, a total of twenty four (24) samples casing riser systems versus dual casing risers. Volume
would require testing. The testing program would be expensive, 71, Issue 7, July 2011
time consuming and may not be practical with respect to [9] ISO Procedures for Testing Casing and Tubing
project schedule due to testing facility availability. Also, the Connections. ISO 13679, 1st Edition, December 2002
extensive testing program may generate additional unforeseen [10] Padelopoulos, P, Thethi R Top Tensioned Riser
problems, which could lead to further costs and potential (TTR) Engineering Integrator Supply Model. 2012
schedule delays [11] Oil and Gas and Sulphur operation in the outer
Alternatively, the operator and/or engineering contractor continental shelf 30 CFR 250 2012
can develop a methodology on a project basis for accepting test [12] NACE - Petroleum and natural gas industries -
results from similar material grades and casing sizes or Materials for use in H2S-containing environments in
previous test data. The approach may consider testing only the oil and gas production - Part 3: Cracking-resistant
critical connections based on analytical FEA results by the CRAs (corrosion resistant alloys) and other alloys
T&C supplier. Verification of other connector may be done by ASNI/NACE MR0175/ISO 15156-3, 2nd Edition,
comparing the FEA analysis vs the test data to verify the December 2010
modeling and analysis techniques.

SUMMARY
The production of hydrocarbons in ultra-deep water in
HP/HT wells is pushing conventional TTR design and
equipment to the limits. Regulatory requirements to incorporate
dual casing systems into TTR designs for the Gulf of Mexico
will increase riser system weights and require vessel payload
capacities to increase. Utilization of higher yield strength
material and non-welded T&C connections will help to manage
these additional payload requirements. Industry specifications
are now addressing the manufacturing and testing requirements
needed for high strength steel for use in dynamic production
riser applications. Interface management, supply chain models
and the required qualification test requirements are critical
inputs in the decision making process in order to utilize high
strength steel riser joints.

REFERENCES
[1] API Recommended Practice for Design of Risers
for Floating Production Systems and TLPs. API RP
2RD, 1st Edition, June 1998, Reaffirmed May 2006
[2] API Specification for Casing and Tubing. API
5CT, 9th Edition, July 2011
[3] Walters, D, Thethi, R, 2H Offshore Inc A Step
Change, Application of Threaded and Coupled
Connections. OPT USA, 2002
[4] Sches, C, Dekervel, A V&M Tubes, France, Caron, O,
V&M USA Corporation, Houston Development
and Validation With Testing of a High Strength Steel
Fatigue Resistant Threaded & Coupled Premium

11 Copyright 2014 by ASME

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