How to safely plan and conduct riser

replacement operations
November 26th, 2013
Xavier Heraudeau
 Introduction
Recovery risks management
Subsea 7 vessel capabilities
Agenda
Key points to plan for recovery
Lessons learned extract

27-Nov-13 Page 2
Introduction
What is a riser replacement operation ?
Reasons:
Field life extension
Riser life termination
Damage to product (accidental or fatigue)
New requirements (flow for flexibles, controls / power for umbilicals
/ cables)

Configurations mostly met for replacement scopes in North Sea:

Static risers in J-tubes
Dynamic risers

Steep wave Lazy wave (Reversed) Pliant wave Lazy S

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Introduction
What is a riser replacement operation ?
Overview of recovery operations: key steps
Topside end
disconnection from
floater
Transfer of topside end
from floater to vessel
Handling of topside end
through layspread
Wave un-shaping
Hold-down tether
disconnection and
counter-weight
management
Accessories removal
Subsea connector
break-off
Subsea end storage

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Introduction
What is a riser replacement operation ?
Overview of installation operations key steps:
Topside end
handling onboard
vessel
Transfer of topside
end to floater
Accessories
assembly
Counter weight
management
Wave shaping
Tethers connections
Subsea connector
installation

27-Nov-13 Page 5
Introduction
Subsea 7 Portfolio involving flexible risers replacement only

Project Client Year Riser Type and Quantity

Skuld Marine Installation Statoil 2012 1 x 11.5" Production Riser

Marulk Subsea Installation Statoil 2011 1 x 10.5" Production Riser

Njord A Riser Replacement StatoilHydro 2010 1 x 6" Production Riser

2 x 5" Production Risers and 1 x 8"
Snorre B Riser Replacement StatoilHydro 2009-2010
Production Riser
Visund Future Riser StatoilHydro 2009 3 x 6" Production Risers
Njord Gas Export Line & Riser Option 2 x 6" Production Risers and 1 x 10" Gas
Norsk Hydro 2007
Project Export Riser
Veslefrikk Riser Replacements Statoil 2003 1 x 8" Water Injection Riser, 1 x 4" Mud

Visund FPU Riser Replacement Statoil 2003 4 x 6" Production Risers

Vigdis WI Riser Replacement Statoil 2002 1 x 10" Water Injection Riser

sgard B Riser Replacement Statoil 2002 1 x 9" Gas Injection Riser

4 x 6" Gas Injection Risers, 1 x 6"
Njord FPU Riser Replacement Norsk Hydro 2002
Production Riser

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Introduction
Subsea 7 on-going projects involving Flex decomissionning in
Norway
Statoil Subsea Lines Modification project

Subsea 7 Portfolio involving Flex decomissioning worldwide

Apache Van Gogh flowlines Australia
Apache Ningaloo Vision flowlines Australia (on-going)
Total Moho Bilondo riser Congo
Suncor Terra Nova risers Canada
Nexen Scott & Telford flowline Scotland
...

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 Introduction
Recovery risks management
Subsea 7 vessel capabilities
Agenda
Key points to plan for recovery
Lessons learned extract

27-Nov-13 Page 8
Recovery risks management
Risk Consequence Some Mitigations
Limited knowledge of 1.Pollution from annulus 1.Annulus sampling tests
annulus with only visual 2.Burst due to localised 1.PPE ready on vessel
inspection of outer sheath pressure 2.Annulus venting
Flexible OD variations Bend stiffener not sliding Contingency procedures
Loose accessories
Flexible bore contents Pollution onboard vessel Dedicated storage system
(connection break-off) PPE
Contingency procedures
Pre/de-commissioning
activities tracability

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Recovery risks management
Risk Consequence Some Mitigations
BSLM release Delay in operation on Design that prevents locked
mechanism mal- SIMOPS BSLM
functioning Reversible procedures
Vessel dependance to Failure of winch may lead Plan for back-up procedures &
floater equipment to stand-by in close equipment onboard floaters
proximity
Closed I-tubes at 1.Dropped objects 1.Survey of I-tube
bottom ends with 2.Damage to product 2.Design at hang-off to avoid
potential debris when lowering dropped objects

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Operational risks management
Risk Consequence Some Mitigations
Extended operations in 1.Restricted activities 1.Qty of subsea operations
close proximity & onboard production units limitation
SIMOPS in restricted 2.Increased required 2.Reversible procedures
weather operational window
Extensive marine 1.Extended deck operations 1.Pre-survey
growth 2.Slippery working conditions 2.Working area designed
for marine growth material
2.Cleaning tools spares
Dropped objects Damage to existing subsea Risk assessments
infrastructures Shut-down

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 Introduction
Recovery risks management
Subsea 7 vessel capabilities
Agenda
Key points to plan for recovery
Lessons learned extract

27-Nov-13 Page 12
 Subsea 7 vessel capabilities
Skandi Acergy
Principal Particulars
400 Te AHC Knuckle Flexible Load-out 100 Te AHC Knuckle 1 off 32Te
Boom Crane Spread Boom Crane Initiation winch Length overall 157 m
Breadth 27 m
Depth to main deck 12 m
Draught 7.00 m
Deck area usable 2100 m2
Transit speed 15 kts
Maximum speed 18 kts
Accommodation 140
DP Class III

Capacities
Flexible/Umbilical installation
Riser installation
3 off 10Te FLS (125Te Flexible Lay 2 off ROV (DP work
Spool/Jumper Installation
deck winches System). class).
+ 7.2x7.2 m Moonpool Deployed through Structures/Manifold Installation
moonpools Protection structures
3000Te Below Deck
Carousel

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 Subsea 7 vessel capabilities
Skandi 7
Principal Particulars
Length overall 120.7 m
Breadth 23 m
Depth to main deck 9m
Draught 7m
Deck area usable 1125 m2
Transit speed 12 kts
Maximum speed 16 kts
Accommodation 114 persons
DP Class III

250 Te AHC Knuckle VLS (260Te Vertical Lay 2 off ROV (DP
Boom Crane System) work class)
Capacities + 7.2 x 7.2 m Moonpool

Flexible/Umbilical installation
Riser installation
Spool/Jumper Installation
Structure/Manifold Installation
Inspection and maintenance work
Support vessel operation

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 Subsea 7 vessel capabilities
400 Te AHC Knuckle 100 Te AHC Knuckle
Normand Oceanic Boom Crane Boom Crane

4 off 12Te
deck winches

Principal Particulars Capacities 2 off ROV (DP work

class).
Deployed by A-frames
Length overall 157 m Flexible/Umbilical installation
Breadth 27 m Riser installation
Depth to main deck 12 m Spool/Jumper Installation
Draught 7.00 m Structures/Manifold Installation
Deck area usable 2100 m2 Protection structures
Transit speed 12 kts
Maximum speed 17,6 kts
Accommodation 140
DP Class III
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 Subsea 7 vessel capabilities
7 Pacific

Principal Particulars
VLS (260Te Vertical Lay
250 Te AHC Knuckle System). Length overall 134 m
Boom Crane + 7.2 x 7.2 m Moonpool
Breadth 24 m
Depth to main deck 12 m
Draught 7.00 m
Deck area usable 978 m2
Transit speed 12,5 kts
Maximum speed 13,5 kts
Accommodation 100
DP Class II

Capacities
Flexible/Umbilical installation
Riser installation
Spool/Jumper Installation
30 Te AHC Knuckle 2 off ROV (DP Structures/Manifold Installation
Boom Crane work class).

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Subsea 7 vessel capabilities
Skandi Acergy - Storage
24m OD / 6m high under-deck carousel
RDS possible on deck:
Flowlines: up to 6-slots
Risers: up to 5 slots

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Subsea 7 vessel capabilities
Skandi Acergy - Lifting equipment

Present flexlay vessels, 1 slide per vessel,

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Subsea 7 vessel capabilities
Skandi Acergy Containment
All below can be generic to any vessel
IBC tanks with pumping system
Closed volume around hang-off area
PPE for marine growth: same as working under rain.
PPE for pipe contents:
Integral rubber suit for pipe contents
Rubber gloves & boots
Face shield + protection glasses
Mask

Skandi Acergy Subsea equipment

LARS - Safe til Hs=6m
Up to 270kg lifting capacity

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 Introduction
Recovery risks management
Subsea 7 vessel capabilities
Agenda
Key points to plan for recovery
Lessons learned extract

27-Nov-13 Page 20
Recovery operations key points to plan for
Platform operations
Contingency procedures in case of difficult disconnection or equipment
failure
Function testing performed

Vessel operations
Thorough planning of containment operations
Thorough planning of operations at working area while heavy cleaning
SIMOPS (onboard vessel) due to installation of aids
Reversible installation or recovery operations to be aimed while
SIMOPS in closed proximity
Schedule re-visited after preliminary visual survey (marine growth)

Subsea operations
Counter weight connection Use of permanent clamp if possible
ROV installation of aids on product to be limited as much as possible
Trials to be planned for subsea installable aids
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Recovery operations key points to plan for
Design requirements
All utilization of temporary installation aids to be designed in view
of recovery operations
Assessment of aids design with permanent features (anodes)
Permanent accessories design: interfaced with Installation
Contractor for aids connection and riser installability
Riser configuration (buoyancy section mainly) to be optimised for
restricting use of counter weights
Topside BSLM selection for use at end of life
Monitoring of annulus and pressure release systems
Re-use of permanent equipment to be thouroughly assessed
according to as-found conditions of equipment.

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 Introduction
Recovery risks management
Subsea 7 vessel capabilities
Agenda
Key points to plan for recovery
Lessons learned extract

27-Nov-13 Page 23
Extract of list of Lessons extra learned on how to
address safely this operation worldwide
Lesson # Description
LL-09599 Top tension variation evaluation at vessel during pull out
with flexible pipe rupture at production unit
LL-10533 Use of buoyancy module ballast cages
LL-10201 & Marine Growth Removal Collar for Flexible Recovery
LL-03755
LL-10202 Flexible Recovery - Product Packing
LL-00987 Positioning of vessel during MWA Buoy preparation and
recovery works
LL-01983 Precom - management of pigs during product recovery
LL-03699 Wire Deflector for riser pull-in
LL-03781 Use of variable weight DMA
LL-03788 Positioning of RDS & reel cradles for recovery operations
LL-06647 Bend Stiffener Stopper Clamp and Tip Support

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