Drilling & Wells Divis ion
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1 Drilling & Wells Divis ion Conor Gallagher Drilling and Intervention Riser Tensioner Load Modelling and its Impact on Wellhead Fatigue and Riser Loading Subsea 2012 Exhibition & Conference 8 th Feb
2 Introduc tion Wellhead & conductor fatigue loading key importance in offshore well design Deepwater oil and gas exploration (>10,000ft) Modern vessels Modern tensioning systems - Complex hydro-pneumatic systems Detailed tensioner model - Includes individual hydraulic and pneumatic components (DeepRiser TM ) Existing modelling and API recommended practices Accurate assessment of expected fatigue damage and riser loading 1
3 P res entation Outline Description of Riser, Wellhead and Conductor Systems Overview of Marine Riser Direct Acting Tensioners (DAT) Existing Industry Modelling Techniques for Wellhead Fatigue/Riser Loading Case Study #1 - Offshore Brazil (7,000ft Water depth) Riser Loading Case Study #2 - North Sea (4,000ft Water Depth) Wellhead Fatigue 2
4 Wellhead and C onductor S ystem High Pressure Wellhead (HPWH) 36 Conductor Rigid Lock Down 20 Casing Low Pressure Wellhead Housing (LPWHH) Conductor Connector (Weld & Body) Wellhead Weld Conductor Weld 3
5 Wellhead and C onductor S ystem 4
6 Direct Acting Tensioner System (DAT) Slip Ring Direct Connection Trip Saver Up to 5,000,000 lbs Capacity 50ft Stroke Capacity Manufacturer NOV N-Line, Aker MH Vessels 5 th & 6 th Generation 5
7 Direct Acting Tensioner System (DAT) PLC Shackle Connection to Vessel 4 Tensioner Stroke Signal Tensioner Cy linder - LP Side Flexible Hose 5 5 HP Air/Oil Accumulator 3 Anti-Recoil Valv e 2 Flexible Hose LP Nitrogen Accumulator 1 Air Pressure Vessels (APVs) Tensioner Piston and Rod Tensioner Cy linder - HP Side Shackle Connection to Tension Ring 6
8 Dynamic C harac teris tic s DAT S ys tem 8 m 200 bar kn 3 m/s Piston Velocity (m/s) xf ix - cy lsupport p - cy loilside F - cy lsupport v F ix - cy lsupport Piston Stroke (m) Cylinder Load (KN) Cylinder Pressure (bar) s
9 C ase S tudy #1 Offshore Brazil, 7,000ft Water Depth Location Offshore Brazil Water Depth (approx 7,000ft) Max Connected Seastate (based on 8m allowable vessel heave) Max Drilling Seastate (based on 5m allowable heave) Mud weight Max 12ppg Tensioning System 6 Cylinder DAT System rated to 3600 kips Key Requirements Maintain positive riser tension and keep wellhead loading to a minimum. 8
10 C ase S tudy #1 Top Tension Methodology API RP 16Q T min = T SRmin N/[R f (N-n)] Tension (kips) 1515 Mud (ppg) 10 T SRmin (kips) 1200 N 6 n 1 Rf 0.95 Detailed Tensioner Model Seastate Max Connected Tension (kips) 1920 Mud (ppg) 10 T SRmin (kips) 1200 N 6 n 1 Rf 0.75 Detailed Tensioner Model Iterate on top tension for given seastate to achieve positive tension at base of riser (factored up by 1.2 to account for 1 tensioner failure) 9
11 C ase S tudy #1 Top Tension V Wellhead Tens ion 2500 Wellhead Tension occurs when Top Tension > Weight Riser + LMRP + BOP Tension (kips) Hs (m) Recommended Top Tension 8.56ppg Recommended Top Tension 9ppg Recommended Top Tension 10ppg Recommended Top Tension 11ppg Recommended Top Tension 11.7ppg Wellhead Tension 8.56ppg Wellhead Tension 9ppg Wellhead Tension 10ppg Wellhead Tension 11ppg Wellhead Tension 11.7ppg 10
12 C ase S tudy #1 Wellhead Tension Variations Effective Tension (kips) kips 725 kips 1275 kips 75 kips Time (s) Max Connected, Top Tension= 1920 kips Max Drilling, Top Tension= 1920 kips Max Drilling, Top Tension= 1690 kips 11
13 C ase S tudy #1 Riser Stress Comparison Distance along the Riser (ft) Von Mises Stress Envelope (ksi) Max Drilling, Top Tension= 1920 kips Max Drilling, Top Tension= 1690 kips 12
14 C ase S tudy 1# Detailed Tensioner Model With API Top Tens ion Max Connected, Top Tension=1920 kips, 7000ft Distance along the Riser (ft) Compression Effective Tension Envelope (kips) Effective Tension (kips) Time (s) Max Connectd, API Top Tension=1515 kips, 7000ft 13
15 C ase S tudy #1 Shallow Water (1,000ft) - Wellhead Tensions Effective Tension (kips) kips 1125 kips Max Connected, Top Tension= 1920 kips, 7000ft Max Connected, Top Tension= 1050 kips, 1000ft Time (s) 14
16 C ase S tudy #2 North Sea, 4200ft Water Depth Location North Sea Water Depth 4,200ft Vessel 6 th Generation Tensioning System 6 Cylinder DAT System rated to 3600 kips Wellhead Stick-up 12ft Conductor System 36 x ft BML Soil Type Soft Objective Assess Fatigue Damage Detailed V Simplified Tensioner 15
17 C ase S tudy #2 E ffect of Tensioner Model on Fatigue Life (yrs ) Riser: SCF=1.3, DnV E Curve Conductor: SCF=5.0, DnV B1 Curve Location Detailed Tensioner model 0m offset 6.5m offset 13m offset Simplified Tensioner model 0m offset 6.5m offset 13m offset Drilling Riser LPWHH Weld inch Conductor Unfactored Fatigue Life 16
18 C ase S tudy #2 E ffect of Tensioner Model on Fatigue Life (yrs ) Conductor Connector Fatigue Life Riser Fatigue Life 60% Reduction m-0.5% offset-default Tensioner 1300m-1% Offset-Default Tensioner 1300m-Base Case-Default Tensioner Elevation w.r.t. Mudline (ft) Fatigue Life (yrs) m-Base Case-Default Tensioner 1300m-0.5% offset-default Tensioner 1300m-1% Offset-Default Tensioner 1300m-Base Case-Detailed Tensioner 1300m-Base Case-Detailed Tensioner m-0.5% offset-detailed Tensioner 1300m-0.5% offset-detailed Tensioner m-1% Offset-Detailed Tensioner Fatigue Life (yrs) 1300m-1% Offset-Detailed Tensioner Distance Above Mudline (ft) Telescopic Joint Location 17
19 K ey C onclusions Accurate Fatigue & Riser modelling must incorporate tensioner load variations Drilling & Intervention Fatigue Budgets Modern tensioning systems - Large wellhead tensions and stress ranges for large seastates Existing API top tension recommendations Riser compression Accurate seastate forecasting Reduce top tensions and risk of wellhead fatigue issues Tension primarily dependent on stroke velocity - Independent of water depth 18
20 Acknowledgements Dara Williams (MCSK) Donogh Lang (MCSK) John Greene (MCSK) 19
21 Thank you Thank You Any questions? Any Questions?
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