Technip s Drilling & Refining Applications Division. Coflexip Flexible Steel Pipes for Drilling and Service Applications.

Transcription

1 Technip s Drilling & Refining Applications Division Coflexip Flexible Steel Pipes for Drilling and Service Applications User s Guide

2 User s Guide This User s Guide allows for a safe application of Coflexip flexibles pipes and is the extension to the Flexible Steel Pipe for Drilling and Services Applications brochure. Technip s Drilling & Refining Applications Division Coflexip - Flexible Steel Pipe for Drilling and Service Applications Coflexip flexible pipes for drilling and service applications are manufactured by the Drilling & Refining Applications Division of the Technip Group

3 Contents CONTENTS 0 GENERAL INTRODUCTION DESCRIPTION OF A COFLEXIP FLEXIBLE LINE DESIGN OF FLEXIBLE LINES NACE COMPATIBILITY END-FITTINGS Protection against corrosion Connectors Terminations Marking Handling collar ANCILLARY EQUIPMENT Bend stiffener Adapters/Cross-Overs Fire cover FLEXIBLE PIPE STRUCTURE Thermoplastic inner liner Interlocked Zeta layer Metallic reinforcement of the Zeta layer Intermediate thermoplastic sheath Double cross-wound steel armour Thermoplastic outer sheath Fire resistant layer Stainless steel outer-wrap MECHANICAL BEHAVIOUR OF COFLEXIP FLEXIBLE LINES FAILURE MODES OF COFLEXIP FLEXIBLE LINES GENERAL GUIDELINES STORAGE HANDLING INSTALLATION - CONNECTION WELDING OPERATING CONDITIONS FLUIDS TO BE TRANSPORTED Chemical compatibility of standard temperature rated lines Chemical compatibility of high temperature rated lines Exposure of high temperature rated lines to C0 2 combined with H 2 S Chemical compatibility of acid (HDPE) lines (former design) Sour service Flow rates TEMPERATURE RATINGS Standard temperature rated line (-20 C to +100 C / -4 F to +212 F) High temperature rated Line (-20 C to +130 C / -4 F to +266 F) High temperature Exposure Test of Choke and Kill Lines Acidizing/fracturing lines (-20 C to +65 C / -4 F to +149 F)

4 3.3 PRESSURE Rated working pressure OEM test pressure LIFETIME OF DRILLING AND SERVICE APPLICATION FLEXIBLE LINES REPAIR OF FLEXIBLE LINES INSPECTION AND TESTING OF LINES INTRODUCTION ROUTINE VISUAL INSPECTION External inspection Internal inspection FULL INSPECTION MANUFACTURER'S INSPECTION - MAJOR SURVEY FIELD PRESSURE TESTING (OPTIONAL) FULL PRESSURE TEST RECORDING OF INSPECTIONS AND TESTS PERIODICITY OF INSPECTIONS AND TESTS UNUSED LINES CHOKE AND KILL LINES DEFINITION Choke and kill lines Cement lines SOUR SERVICE COMPLETION FLUIDS VENTING PERIODICITY OF FIELD TESTING AND INSPECTION After installation pressure test Routine visual inspection (Section 6 - Para 6.2.1) Full inspection (Section 6 - Para 6.3) Manufacturer's inspection - major survey (Section 6 - Para. 6.4) Field pressure testing (optional) (Section 6 - Para. 6.5) Subsea (BOP stack) Choke and Kill lines TEST LINE APPLICATIONS "DST" AND "PTL" LINES DEFINITION SOUR SERVICE VENTING PERIODICITY OF FIELD TESTING AND INSPECTION After installation pressure test Routine external visual inspection (Section 6 - Para 6.2) Full inspection (Section 6 - Para 6.3) Manufacturer's inspection - Major survey (Section 6 - Para 6.4)

5 9 ACIDIZING AND FRACTURING LINE APPLICATIONS DEFINITION Handling Well service operations Dynamic operations Static operations SOUR SERVICE VENTING PERIODICITY OF FIELD TESTING AND INSPECTION Flushing of the lines Routine external visual inspection (Section 6 - Para. 6.2) After installation pressure test Full inspection (Section 6 - Para. 6.3) Manufacturer's inspection - Major survey (Section 6 - Para. 6.4) DRAG CHAIN OPERATIONS DEFINITION PERIODICITY OF FIELD TESTING AND INSPECTION After platform installation and hook up Routine visual inspection (Section 6 Para. 6.2) Yearly test SUMMARY OF INSTRUCTIONS

6 ABBREVIATIONS USED Abbreviations used ACD: BOP: CEM: C/K: DST: FAT: HDPE: VH: ID: LMRP: MBR: MWP: OD: OEM: Acidizing / Fracturing Blowout Preventer Cement Choke and Kill Drill Stem Test Factory Acceptance Test High Density Polyethylene Vickers Hardness Inner Diameter Lower Marine Riser Package Minimum Bend Radius Maximum Working Pressure Outer Diameter Original Equipment Manufacturer OEM. TP: Original Equipment Manufacturer Test Pressure PTL: QCDC: QDC: TP: WP: Production Test Line Quick Connect Dis-Connect Quick Dis-Connect Test Pressure Working Pressure 6

7 0. GENERAL INTRODUCTION General introduction This copy of the Coflexip FLEXIBLE STEEL PIPES DRILLING AND SERVICE APPLICATIONS USER'S GUIDE (hereinafter referred to as the Guide ) is revision 4 of the guide originally issued in 1989 revised in September 1990, and The main differences from revision 3 are an up-date of the product characteristics and compatibility charts made possible by the on-going tests performed as part of Technip's policy of continual research into the safe application of flexible pipes. Coflexip flexible steel pipe systems are manufactured by the Drilling & Refining Applications (DRAPS) Division of the Technip Group. The DRAPS Division recognises the fact that the majority of our clients have used Coflexip drilling application products for many years and have therefore built up a great deal of experience in their use. It follows therefore that much of the information contained in this Guide is intended primarily for those clients who are not familiar with the use of Coflexip products. For the purpose of this document, End User shall mean a person, a company, its and their co-contractors, co-lessees and joint ventures, its and their respective affiliates, and its and their respective officers and employees, including agency personnel (but shall not include any member of the Technip Group), who purchase, transport, handle, package, use or work with the Coflexip products as described in this Guide. The DRAPS Division relies on the feedback of all End Users to ensure the continued reliability of our products and to act as the basis for research into the flexible pipes of the future. We therefore welcome any comments on both the flexible pipes themselves and User's Guides such as this guide specifically written for Drilling and Service Applications. In producing this Guide, we have attempted to cover all aspects of both the design and safe use of our drilling and service application flexibles in normal, current applications. We are always available to answer questions from End Users. Any questions should be directed towards your local DRAPS Division office listed on the back cover of this Guide. The DRAPS Division MAKES NO REPRESENTATION ON WARRANTY IN CONNECTION WITH ITS DRILLING APPLICATION PRODUCTS SAVE AS EXPRESSLY AGREED WITH THE END USER(S) IN A DOCUMENT EXECUTED BY the DRAPS Division AND THE END USER. All information and data contained herein are subject to change without further notice, and are to be considered as RECOM- MENDATIONS in general or INSTRUCTIONS (when stated in the text) by the (Original Equipment Manufacturer) only. This document can be viewed and downloaded from our website at: 7

8 1. DESCRIPTION OF A COFLEXIP FLEXIBLE LINE 1. Description of a Coflexip flexible line This section will discuss the construction of a typical Coflexip flexible line and, according to the pipe construction, present the failure modes that might be caused by a possible misuse of the equipment. As shown in Figure 1, a typical Coflexip line is composed of: A length of flexible pipe Two end-fittings complete with handling collars Integral connectors Optional stiffeners Identification collars Connector Connector Termination Flexible pipe Stiffener Termination End fitting Identification collars Handing collars End fitting Figure DESIGN OF FLEXIBLE LINES All Coflexip Drilling Applications flexible pipes are designed in accordance with API 16C which is the only specific reference/regulation existing for Choke and Kill lines and/or API 7K for Rotary lines. Some of the API 16C requirements do not apply to other applications where our lines can be used (Acid/fracturing lines for example) when the resistance to H 2 S is not an issue; on the other hand all of our lines supplied for Choke and Kill applications are fully compliant with API 16C. 1.2 NACE COMPATIBILITY End-fittings: all steel materials used in the manufacture of a Coflexip end-fitting meet the requirements of NACE MR Steel wires: the carbon steel wires used for the Zeta, reinforcement wire and armour layers meet the NACE requirements in force at manufacturing date. The present steel wires have been tested according to TM 0284 and TM END-FITTINGS The end-fitting itself consists of the following: The termination which ensures the seal and the mechanical attachment of the end-fitting to the flexible pipe. The connector to allow the connection of the end-fitting to any other compatible connector. 8

9 1.3.1 Protection against corrosion All steel materials used in the manufacture of a Coflexip end-fitting meet the requirements of NACE MR Coating protection of the end-fitting The whole surface, both inside and outside of a standard end-fitting is protected against corrosion, wear, abrasion and handling by a Nikaflex coating. The adhesion of the coating to the underlying steel is essential for the long term integrity of the protection. Various heat treatments are applicable for Nikaflex coated parts to improve that property. The DRAPS Division has selected the most effective process which is a long duration, high temperature heat treatment conducted between 600 C to 650 C (1,112 F to 1,202 F) for 10 hours. This process ensures diffusion of the coating into the steel, thus avoiding any possible scaling of the protection. The Nikaflex coating bears the following properties: The surface hardness of the coating is about 400 to 450 HV, in the range of most hardened steels, and this improves the end-fitting resistance against corrosion, wear, abrasion and handling. In particular, the end-fitting will resist long term exposure to internal flow of abrasive fluids. The inner coating is 75 thick; a visual inspection of the inner bore of the end-fitting showing that the coating is still present indicates the satisfactory integrity of those end-fitting parts subjected to the internal flow conditions. If the coating is damaged or cracked, traces of corrosion and rust may be visible and a complementary inspection should be completed. The Nikaflex coating is highly resistant against corrosion from marine atmosphere, sea-water and to H 2 S/C0 2 gases or other corrosive fluids which might be transported by the line Connectors The end-fittings can be supplied with most types of connectors, the most common being API hubs (formerly "CIW hubs"), hammer unions and API flanges. Generally the connectors are integral parts of the end-fitting avoiding buttwelding (with some exceptions for non-standard connectors). However, when used, the welding process is always completed BEFORE end-fitting mounting. Some restrictions on the type of connector used may apply e.g. API 16C does not allow the use of threaded connectors for choke and kill applications. Similarly it is not a DRAPS Division practice to fit a connector which has a higher pressure rating than the flexible pipe itself Terminations The termination will ensure the following functions: Mechanical attachment to the flexible pipe which will resist against internal pressure, traction and torsion Provides seal against inner effluent Provides seal against outer environment Mechanical attachment of the outer stainless steel carcass Marking The termination bears a permanent marking indicating: Manufacturer (*) Serial number of the line 9

10 Internal diameter of the line (inches) Application (*) Working pressure (WP bar or psi) of the line which is always inferior or equal to the maximum design pressure of the line structure Length of the line - face to face from one connector to the other (metres or feet) Date of the factory pressure test If applicable, a stamp of a certifying authority For repaired lines see section 5 (*) This information was optional before second quarter of 1990 Repaired lines If the line has been repaired by the mounting of a new end-fitting, it will bear the same marking as above, but the serial number of the line is changed on that end-fitting. Length and date of the factory pressure test are revised values marked on the new end-fitting. Although optional before the second quarter of 1990, The DRAPS Division recommends that the type of application be stamped where the information is missing, using the abbreviated classification as follows. In case of doubt, please contact the nearest DRAPS Division office. From the second quarter of 1990, the end-termination bears a revised marking as follows: Manufacturer Serial number of the line Internal diameter of the line (inches) Line application abbreviated as follows: C/K: Choke and Kill CEM: Cement PTL: Production Test Line ACD: Acidizing/Fracturing DST: Drill Stem Test Line length in metres (m) or feet (ft) Working pressure (WP bar or psi) Test pressure (TP bar or psi) Temperature range (continuous service: see section 3.2) The stamped test pressure is the OEM.TP (Original Equipment Manufacturer Test Pressure) Date of the factory pressure test (month/year) If applicable, a stamp of a certifying authority when required (For lines repaired by end-fitting replacement, see section 5) Example of marking COFLEXIP Manufacturer TR Serial number 3" - C/K m I.D./Application/Length WP psi Working Pressure TP psi Test Pressure TEMP: -20/+130 C Temperature range 02/2002 Test date (month/year) Any inquiry regarding the construction of the line and its end-fittings should refer to the serial number through which the DRAPS Division can trace the relevant information. 10

11 1.3.5 Handling collar A groove in the end-termination is fitted with a rotating handling collar with two symmetrical pad-eyes. This collar is designed to allow for safe handling of the flexible pipe. It is not designed to handle any other equipment which might be attached to the connectors. This collar is NOT designed for lifting more than the weight of the flexible itself. INSTRUCTION: for long lines (acidizing lines for example), typically lines longer than 25m (80'), the End User should refer to the DRAPS Division for advice on limitations in the use of the standard handling collars. Special collars can be designed for specific needs. For further details on Acidizing Applications see Section ANCILLARY EQUIPMENT Bend stiffener Figure 2 The bend stiffener is an additional device mounted on the flexible pipe during its manufacturing (see figure 2 above). It increases the local bending stiffness in the region of the end-fitting, producing a smoother transition from the endfitting to the flexible pipe structure. The bend stiffener is optional on most flexible pipes. It will allow the flexible pipe to better resist overbending: flexure damaging strength is increased by a factor of x3 when using this device. Made out of polyurethane, it is intrinsically resistant to corrosion. During the external inspection, check that the bend-stiffener is properly tightened on the end-fitting and is free of damage and cracks Adapters/Cross-Overs Adapters/Cross-Overs can be supplied if the End User needs to connect his flexible pipe to different or non standard connectors. These adapters are typically 0.3 metres or one foot long depending on the I.D. and rating. Represented is an API Hub / Weco adapter. 11

12 1.4.3 Fire cover As for the flexible pipe itself, it may occasionally be necessary, due to the working environment, for lines to include a greater degree of fire protection than standard. For such operating conditions, additional fire protection covers may be installed over the end-fitting assemblies. 1.5 FLEXIBLE PIPE STRUCTURE A typical Coflexip flexible pipe structure, for high pressure applications is shown in Figure 3 below. This construction is known as a non-bonded structure. From the inside out it is composed of the following: Thermoplastic inner liner 2 Aramid tape 3 Zeta spiral 4 Flat steel spiral 5 Thermoplastic intermediate sheath 6 Cross-wound tensile armours 7 Thermoplastic external sheath 8 Outer wrap interlocked steel carcass Figure Thermoplastic inner liner The thermoplastic inner liner makes the pipe leak-proof. This layer limits the upper service temperature of the line and the chemical compatibility to the various fluids which may be transported through the line. Various plastic materials are used to manufacture the inner liner, depending upon the service application of the line. This liner can be reinforced by aramid tapes depending on the application Interlocked Zeta layer This layer takes the hoop stress due to internal pressure and external crushing loads. The crushing resistance of a Coflexip line is similar to that of an API rigid pipe designed to withstand the same internal pressure. However, accidental crushing might damage the outer stainless steel wrap and reduce the lifetime of the line. It is the interlocking of the Zeta layer which will limit the bending radius of the line. If this limit is exceeded, irreversible damage to the flexible line will occur leading to perforation of the inner liner when under pressure Metallic reinforcement of the Zeta layer If necessary for extreme high pressure, the Zeta layer is reinforced by a flat steel layer which is not interlocked Intermediate thermoplastic sheath This sheath is a thin anti-friction layer which improves the dynamic behaviour of the line. This layer is not leak-proof. 12

13 1.5.5 Double cross-wound steel armour The double cross-wound steel armour wires will resist axial load caused by internal pressure, or external axial loads. It is also this layer which provides the flexible line with its resistance to torsion Thermoplastic outer sheath This layer is leak-proof. It will both: Protect the armour wires against corrosion and Protect the line against hydrostatic external pressure if the line is used subsea, as on LMRP BOP (Lower Marine Riser Package Blowout Preventer) stacks. (Note that test lines are vented through this outer layer and may not therefore be used subsea) Fire resistant layer For certain installations, e.g. permanently installed well control lines on fixed production platforms, it may be a requirement for essential service flexibles such as choke and kill lines, to be operable under fire conditions for long periods. The inclusion of a fire resistant layer installed after production of the standard pipe gives a working time at 700 C (1,292 F) and full working pressure, well in excess of 30 minutes. This layer is non-standard and would be the subject of a special order. Refer also to section 1 - Para for end-fitting fire protection Stainless steel outer wrap The stainless steel outer wrap (carcass) protects the thermoplastic outer sheath against mechanical damage caused by using the line in a harsh environment (impacts, wear, handling, etc.). This layer does not contribute directly to the mechanical resistance of the line. However, significant damage to this layer may lead to subsequent damage to the thermoplastic outer sheath causing either: Corrosion of the armour wires, and/or Collapse of the inner tube for subsea lines. 1.6 MECHANICAL BEHAVIOUR OF COFLEXIP FLEXIBLE LINES By design, a Coflexip flexible line is extremely resistant to: Internal pressure Dimensional changes under pressure are very limited; typical values are: Relative elongation at design pressure 0.15 to 0.25% Relative outer diameter change at design pressure < 0.25% The line is extremely stable under pressure. In particular, if bent it will not tend to straighten under pressure. No significant twist would occur. It will not pulsate or whip during high flow rate circulation. Tensile Forces Resistance to pulling forces ranges from about 50,000 dan for 2" ID to more than 100,000 dan for 3" ID (50 to 100 tons or 100,000 to 200,000 lbs). WARNING: you must be aware that a Coflexip flexible can be stronger than some of the pipework to which it is connected and that it will rarely be the "weak point" of a system. 13

14 Crushing The crushing resistance of Coflexip flexible pipes is similar to that of an API rigid pipe of the same design pressure Bending The line is resistant to bending, including frequent or continuous flexure with the imperative condition that the minimum bending radius is not exceeded. In the DRAPS Division's documents, the minimum bending radius is abbreviated as MBR. OD MBR d = (2 MBR minus OD) d is the minimum inside distance between the two surfaces Example: 2.5 Coflon 15 kpsi W.P. MBR = 0.86 m/2.81 ft OD = mm/52 inches d = 1.58 m/5.18 ft Figure 4 The minimum bending radius is an extremely important characteristic of a flexible steel line. As a rule of thumb, the minimum bending radius is roughly equal to: MBR = 12 x ID (ID: inner diameter of the line). Example: If ID = 3" then MBR = 12 X = 0.92 metre or 12 x 3 = 36", i.e. 3 ft. For specific DRAG CHAIN applications, the MBR for installed use is 1.1 x the storage MBR, as defined on the relevant data sheet. The accurate value of the MBR is part of the technical specification of the flexible line. 1.7 FAILURE MODES OF COFLEXIP FLEXIBLE LINES Coflexip flexible steel lines are extremely reliable due to: The design of the product The use of the highest standards applicable The use of the highest quality raw materials The Technip quality assurance system However, misuse might damage the line, and you must be aware that four main failure modes can occur: Corrosion of the armour wires - If the outer thermoplastic sheath is damaged, corrosion of the steel armour wires will occur. This will progressively reduce the thickness of the wires, causing a progressive decrease of the burst pressure. This failure mode may cause the line to burst catastrophically. 14

15 Bending - If the minimum bending radius is exceeded, the Zeta layer may open; in which case, the inner tube is not properly supported and perforation will occur under pressure. Overbending generally occurs due to mishandling during installation. Particular attention must be paid at this time to the first metre or few feet of flexible pipe immediately behind each termination. An optional bend stiffener is available on request to improve the pipe's resistance to such overbending. This failure mode may cause the line to burst. Figure 5 shows how overbending may be caused, whether or not the line is under internal pressure. NO YES Figure 5 Ageing of the inner liner - The mechanical properties of the inner liner can be affected by ageing. This phenomenon causes the degradation of the long thermoplastic molecules and may be due to: Long exposure to high temperature, exceeding the maximum rated temperature Exposure of the internal surfaces to incompatible chemicals The degradation of the material could make it brittle and the tube may break when bent with or without internal pressure, leading to a leakage. This failure mode can result in a burst, or more often, in a high pressure leak. Collapse of the inner liner - If damaged, the outer sheath may not be leak-proof. For subsea lines, the external hydrostatic pressure will be applied on to the inner liner which may collapse. This can lead to the rupture of the liner and failure of the line. This failure mode may cause the line to burst. 15

16 2. GENERAL GUIDELINES 2. General guidelines 2.1 STORAGE Storage in general does not require specific precautions regarding the environment or duration of storage. Depending on length, the best ways to store a line are either: In a straight line (up to 6 metre or 20 ft long) Coiled to its MBR, attached to a wooden pallet or crate Installed in a DRAG CHAIN prior to hook-up and start of operations Coflexip flexible lines are shipped with protection on the connectors. INSTRUCTION: a similar protection should be reinstalled when the line is disconnected. It may consist of a metallic blind flange that fits the connection, which is preferable, or of a good wooden protection. This protection must ensure that: > The inner bore of the line is closed to avoid accidental intrusion of any foreign material; > The connector, especially the seal area, is properly protected against impacts, etc. INSTRUCTION: if stored below minimum rated temperature, ensure that no handling is done before the line is brought back to the minimum rated temperature. INSTRUCTION: the inner bore of a Coflexip line should be thoroughly flushed with fresh water prior to long term storage. 2.2 HANDLING INSTRUCTION: only qualified and trained personnel should handle flexible lines such as those manufactured by the DRAPS Division. Whilst we make every effort to assist End Users whenever possible on the methods of handling to be deployed, the final decision on the best methods for local conditions and capacities rests with End Users or their appointed agents, either of whom should have their own procedures for such handling operations. Any rigging should be suitably adapted to the specific flexible line in question, as mishandling can be dangerous to operations, surrounding personnel, equipment and property. The line must never be bent below the minimum bend radius (MBR), as this may damage it. As a rule of thumb, the minimum bend radius is equal to: MBR = 12 x ID The accurate value of the MBR of the line is part of the technical characteristics of the Coflexip structure and will have been supplied to the original End User: it can be obtained from the nearest DRAPS Division office. The MBR must be respected at all times, whether the line is under pressure or not. User should avoid bending the flexible just behind the end-fitting. As a rule of thumb, a straight length of about 0.6 to 0.9 metre (2 to 3 feet) should be used as a safety distance. See section FAILURE MODES OF COFLEXIP FLEXIBLE LINES The use of wire ropes or chains may damage the anti-corrosion treatment of the end-fitting. If so required, use a shackle connected through the eye of the handling collar. Never use wire ropes or chains directly against the stainless steel outer-wrap. If force needs to be applied to the body of the flexible line itself, use soft slings. Moving flexible line on the ground 16

17 Do not attach slings directly to the end-fitting - use the handling collar provided. Always connect slings to both eyes in order to have the pulling force in a straight line through the main axis of the flexible pipe. Prevent abrasion of the flexible line against the ground; use wooden supports or planks. If a forklift has to be used to lift a flexible line, soft slings must be used to prevent damage, and to prevent the flexible line from falling off the forks (see the DRAPS Division Handling schematics inside the rear of this Guide). End User assumes all responsibility for essential safety precautions to avoid injury or death in connection with these operations. 2.3 INSTALLATION - CONNECTION The preferred installation for a Coflexip flexible line is with the pipe positioned in a J or U configuration, with the end-fittings pointing up in a vertical position. See Figure 6. If, due to the rig equipment, this configuration is not feasible, special care must be taken when securing a non-vertical connection that overbending behind the end-fitting is avoided. Connection of the flexible line to other pipework requires: Supporting the weight of both the end-fitting and the line Correct alignment of the end-fitting MBR INSTRUCTION: The best way to achieve this is to support the weight of the line through the use of the handling collar, then control the alignment with a non-metallic rope or sling attached about 0.9 metre (3 feet) behind the end-fitting. See Figure 7. Figure 6 Never do the reverse, i.e.: Do not support the weight immediately behind the endfitting; Do not align the line from the end-fitting itself. 2.4 WELDING A flexible steel line is a mixed construction of steels and thermoplastics. It must be recognised that because of the heat diffusion that occurs during any welding process, the thermoplastic layers may suffer irreversible damage leading to an unsafe line. When used, welding processes are only completed during the original manufacturing process of the line at a stage where the operation cannot affect the other components. Consequently, any field welding repair of a flexible line, involving either the end-fitting (including the stainless steel ring groove) or the stainless steel outer carcass, will render the line unsafe and unusable. Such lines will must be withdrawn from service and stamped "NOT-REUSABLE". Figure 7 17

18 3. OPERATING CONDITIONS 3. Operating conditions Although similar in appearance, the construction of Coflexip lines for different drilling applications such as Choke and Kill lines, Acid lines or Test lines differ significantly. INSTRUCTION: these lines must never be used for any purpose other than the original for which the line was supplied and which is stamped on the end-fitting identification collar (see section 1.3). In case of doubt, contact the nearest DRAPS Division office for information on guidelines to be respected. 3.1 FLUIDS TO BE TRANSPORTED Generally, all kinds of drilling muds and oil production fluids, or chemical additives, may be transported through flexible lines depending upon the applications. The compatibility tables included in this Guide give an indication on the behaviour of the liners with most common chemicals. Due to the number of chemicals used, often in concentrated forms, and the infinite number of possible combinations, it is virtually impossible to guarantee the behaviour of our products in all circumstances. INSTRUCTION: in case of doubt please contact the nearest DRAPS Division office. All components of the end-fittings in contact with the inner fluids are adequately protected against corrosion. In most cases it is the internal liner made of thermoplastics that will limit the chemical compatibility of the flexible line. They are different for: Standard temperature rated line (-20 C to +100 C / -4 F to +212 F) or High temperature rated line (-20 C to +130 C / -4 F to 266 F) or Acid line (HDPE) (-20 C to +65 C / -4 F to +149 F). (Former designs, no longer in production i.e. typically pre-1998 although some later examples may have been supplied). Tables I, II and III give a limited list of the different chemicals relevant for drilling and service applications and their effects on the flexible line. In case of doubt, contact the nearest DRAPS Division office Chemical compatibility of standard temperature rated lines The inner lining of these lines is made of RILSAN, which is a grade of polyamide II material. It must be noted that Standard Temperature Rated lines (-20 C to C / -4 F to +212 F) are not designed to handle any acidified effluents and/or heavy metallic salts such as zinc or calcium bromides. See Table I 18

19 TABLE I Chemical compatibility of standard temperature rated lines. Exposure resistance of RILSAN inner lining at given temperature ranges. Concentration 0 F -18 C 75 F 24 C 150 F 66 C 200 F 93 C 250 F 121 C Hydrochloric acid HCl 15% F F F F F 30% F F F F F Hydrofluoric acid HF 3% F F F F F 7.5% F F F F F Xylene C 6 H 4 (CH 3 ) 2 100% S S S S NR Methanol CH 3 0H 100% S S L NR NR Zinc bromide ZnBr 2 saturated F F F F F Calcium Bromide CaBr 2 saturated L L L L L Calcium chloride CaCl 2 saturated S S L L L Methane CH 4 100% S S S S L Diesel 100% S S S S L Crude oil 100% S S S S L Sodium hydroxide NaOH 50% S L NR NR NR Hydrogen sulphide H 2 S (pure gas) < 20% S S S S L Hydrogen sulphide H 2 S (condensate) < 20% L* L* L* L* L* Water Presence L* L* L* L* L* S: Satisfactory NR: Not Recommended L: Limited use** F: Forbidden * The PH value of the fluid may greatly influence the behaviour of Rilsan inner lining ** Technip s DRAPS Division to be consulted for exact exposure time Chemical compatibility of high temperature rated lines The inner lining of these flexible lines is made of COFLON, a fluorinated thermoplastic: Polyvinylidene fluoride (PVDF) material. See Table II TABLE II Chemical compatibility of high temperature rated lines. Exposure resistance of COFLON inner lining at given temperature ranges. Concentration 0 F 75 F 150 F 200 F 250 F -18 C 24 C 66 C 93 C 121 C Hydrochloric acid HCl 15% S S S S S 30% S S S S S Hydrofluoric acid HF 3% S S S S S 7.5% S S S S S Xylene C 6 H 4 (CH 3 ) 2 100% S S S S S Methanol CH 3 0H 100% S S S S S Zinc bromide ZnBr 2 saturated S S S S S Calcium Bromide CaBr 2 saturated S S S S S Calcium chloride CaCl 2 saturated S S S S S Methane CH 4 100% S S S S S Diesel 100% S S S S S Crude oil 100% S S S S S Sodium hydroxide NaOH 50% S S L NR NR Hydrogen sulphide H 2 S < 20% S S S S S S: Satisfactory NR: Not Recommended L: Limited use F: Forbidden 19

20 3.1.3 Exposure of high temperature rated lines to CO 2 combined with H 2 S Under certain conditions, exposure to relatively high concentrations of CO 2 combined with H 2 S, can lead to damage of the COFLON liner. For this reason, the following limitations are to be respected: PRESSURE TEMPERATURE FLUID CONDITIONS 1035 bar/15,000 psi 130 C (+266 F) CO 2 + H 2 S < 10 % 690 bar/10,000 psi 130 C (+266 F) CO 2 + H 2 S < 30 % 690 bar/10,000 psi 110 C (+230 F) CO 2 + H 2 S < 50 % Chemical compatibility of acid (HDPE) lines (former design) The inner lining of these flexibles is made of high or medium density polyethylene (HDPE) which is a polyolefinic material (no longer used as an inner lining in standard production flexibles). See Table III TABLE III Chemical compatibility of acid (HDPE) lines. Exposure resistance of HDPE inner lining at given temperature ranges Concentration 0 F -18 C 75 F 24 C 150 F 66 C 200 F 93 C 250 F 121 C Hydrochloric acid HCl 15% S S S F F 30% S S S F F Hydrofluoric acid HF 3% S S L F F 7.5% S S L F F Xylene C 6 H 4 (CH 3 ) 2 100% S S L F F Methanol CH 3 0H 100% S S S F F Zinc bromide ZnBr 2 saturated S S S F F Calcium Bromide CaBr 2 saturated S S S F F Calcium chloride CaCl 2 saturated S S S F F Methane CH 4 100% S S L F F Diesel 100% S S L F F Crude oil 100% S S L F F Sodium hydroxide NaOH 50% S S S F F Hydrogen sulphide H 2 S < 20% S S S F F S: Satisfactory L: Limited use F: Forbidden Sour service All components of the end-fittings and of the flexible pipe, in contact with the inner fluids, meet NACE-MR edition As well as those internal surfaces which come into direct contact with the inner flow, due to gas diffusion, some other flexible pipe components may be in contact with low concentrations of sour gas. The carbon steel wires used for the Zeta, reinforcement wire and armour layers meet the NACE requirements in force at manufacturing date. The wires used at present have been tested according to TM 0284 and TM Depending upon the application, Coflexip pipes are classified either: Permanent sour service, or Temporary sour service See Sections 7 to 10 for the different applications of Coflexip pipes. In case of doubt, contact the nearest DRAPS Division office. 20

21 3.1.6 Flow Rates The maximum continuous flowrate for all smooth bore i.e. thermoplastic inner sheathed lines, is 15 metres per second. Many lines, particularly those for acidizing / fracturing applications, have been subjected to flow-rates well in excess of this figure for relatively short periods of time without any damage being sustained. This is entirely dependent on the abrasive properties of the flow medium, therefore maximum short term flow-rates cannot be quantified for all flow conditions. Extreme flow rates and abrasive fluids can cause erosion in the end-fittings. It is common practice to change the end-fittings when these show severe scoring or pitting. Experience has shown that for those types of lines subjected to severe abrasive conditions (fracturing operations), the end-fittings can be replaced twice before the flexible pipe itself should be considered not fit for further use. 3.2 TEMPERATURE RATINGS Standard temperature rated line (-20 C to C / -4 F to F) Continuous service Standard Coflexip Choke and Kill lines are designed for -20 C to +100 C / -4 F to +212 F continuous service, with no time limit (within the lifetime of the whole line). Higher temporary service temperature Standard Coflexip flexible pipes may be used up to +130 C / +266 F, maximum temperature of the transported fluids for a maximum of one month, continuous or cumulative service. Lines exposed to temperatures higher than +100 C / +212 F but no more than +130 C / +266 F for continuous or cumulative service of 1 month must be removed from service and stamped not reusable following this exposure. Survival conditions All Coflexip flexible lines (C/K, DST, PTL) are designed to resist to +160 C / +320 F maximum inner temperature of the contained fluids for a duration in excess of one hour. A copy of the qualification test report is available upon request from all DRAPS Division sales offices. Standard temperature rated Coflexip flexible lines are deemed not reusable for further service after sustaining a temperature above the temporary rating of +130 C / +266 F. Lines exposed to temperature higher than +130 C / +266 F must be removed from service, properly stamped not reusable, and replaced by a new line High temperature rated Line (-20 C to +130 C / -4 F to +266 F) Continuous service High temperature rated flexible pipes are designed for -20 C to +130 C (-4 F to +266 F) continuous service, with no time limit (within the lifetime of the whole line). Note: under certain fluid conditions, there may be limitations on pressure and/or temperature ratings (Refer to Section 3 - Para ). Higher temporary service temperature High temperature rated flexible pipes are not designed for a higher temperature than the maximum continuous temperature rating. Survival conditions All Coflexip flexible lines are designed to resist to +160 C (+320 F) maximum inner temperature of the contained fluid for a duration in excess of one hour. A copy of the qualification test report is available upon request from all DRAPS Division sales offices. High temperature rated Coflexip flexible lines are deemed not reusable for further service after sustaining a temperature above the continuous rating of +130 C (+266 F). Lines exposed to temperatures higher than +130 C (+266 F) must be removed from service, properly stamped not reusable, and replaced by a new line. 21

22 3.2.3 High temperature Exposure Test of Choke and Kill Lines All Coflexip Choke and Kill lines have been tested in accordance with the latest edition of API 16C and are in full compliance with the highest standards imposed. These standards include the following destructive testing: Flexible Line High Temperature Exposure Test This test is intended to determine the maximum temperature that a flexible Choke and Kill line will withstand for a short duration when exposed to the rated working pressure. This test represents severe, survival conditions and should not be used to define the temperature rating of the line. It is imperative that both the line structure and the end terminations be exposed to the temperature excursions during the tests. Successful completion of verification testing qualifies the size and pressure rating of the flexible tested, together with smaller sizes of equal or lower pressure ratings and temperature of equivalent design and construction. Upon reaching the manufacturer s rated working pressure and maximum temperature, the temperature is raised at a rate not to exceed 5 F (2.8 C) per hour to 350 F, +10 F, (177 C +5.5 C) and held for one hour. The temperature should be measured, either at the fluid inside the line or at the inside wall of the line. At the end of one hour, the temperature is raised at a rate not exceeding 5 F (2.8 C) per hour until failure. Failure is defined as a visible fluid leak in the end connection, the body of the line or burst of the line. The total time of exposure to 350 F (177 C) and above should be recorded together with the temperature and the failure mode of the pipe: leak and its location, or burst and its location. Acceptance criteria will be sustaining the 350 F (177 C) hold period, at rated working pressure, for one hour with no visible leakage. The pressurization fluid can be water, or heat transfer oil. The fluid may be static or flowing. Because the objective of the testing is to simulate, as closely as possible, service conditions, line heating should be from the inside. In connection with flexible pipes, a "burst" is defined as the catastrophic failure of the pipe assembly, either by loss of a complete end fitting, or by rupture of the complete assembly such that no flow is possible between the opposing end connectors. A leak is defined as a loss of pressure integrity in the flexible pipe assembly, but which allows a significant quantity of flow between the opposing end connectors enough to allow a continued temporary limited use in its intended service. The Coflexip line survived the above destructive testing procedure for a total period in excess of 20 hours, and to a final temperature of 232 C(450 F). Failure mode was a leak as defined above, no bursting occurred Acidizing/fracturing lines (-20 C to +65 C / -4 F to +149 F) Coflexip HDPE acidizing/fracturing lines are designed for -20 C to +65 C (-4 F to +149 F) continuous service, without time limit (within the lifetime of the whole line). As acidizing/fracturing lines are normally only used to pump into well formations, it is unlikely that there will be the requirement to operate lines at temperatures higher than ambient and for this reason there are no other temperature ranges, temporary or survival. These lines are not designed for flowing produced well fluids. Coflexip Coflon acidizing lines have the same temperature limitations as the high temperature rated lines (see section 3.2.2). 3.3 PRESSURE Rated working pressure The working pressure stamped on the end-fitting must be understood as the maximum operating pressure to which the line may be permanently subjected. It is not the manufacturer's responsibility to define allowances for eventual surges that may occur through the lines. We insist that Users acquaint themselves with guidelines, specifications, or limitations issued by Certifying Authorities or regulatory bodies OEM test pressure All new Coflexip flexible lines are pressure tested at the factory prior to supply. Test pressures are as follows: WP OEM. TP 345 bar/5,000 psi 690 bar/10,000 psi 690 bar/10,000 psi 1035 bar/15,000 psi 1035 bar/15,000 psi 1550 bar/22,500 psi Test duration: all factory pressure tests last a minimum of 24 hours after stabilisation at ambient temperature. Note: the standard DRAPS Division FAT (Factory Acceptance Test) is well in excess of the minimum requirement of API 16C. 22