Development of a 14-inch ID High-Pressure Hybrid Riser for SBOP Drilling

This paper discusses the development of a 14-inch ID high-pressure hybrid riser (10 000 psi) for surface BOP drilling in ultra-deep water (10 000 ft). The high-pressure hybrid riser system is obtained by adapting and combining two existing technologies, previously developed by the IFP for other applications: – the Clip connector, a double breech-block type connector to provide a quick and safe connection for riser joints; – hybrid pipe technology, a steel pipe hoop-wound with tapes of carbon fibers impregnated with polyamide thermoplastic resin. IFP has developed a new 14-inch ID HP Clip connector for the hybrid riser application. The connector is capable of withstanding a 2.8 million pound tension and a 10 000 psi operating pressure. In addition, a 16-inch nominal OD hybrid riser pipe has been designed to replace the steel riser pipe with a thinnerwalled hoop-wound steel pipe. The significant weight savings that can be achieved with the hybrid riser pipe make it possible to design an effective riser architecture to withstand the high pressure and deep water requirements. Pursuant to design studies, a 14-inch ID prototype assembly consisting of two hybrid riser pipe sections with a high-pressure Clip connector was manufactured. A test program, including burst and collapse tests as well as cyclic fatigue testing, was formulated and carried out to qualify the performance of the Clip connector and hybrid riser pipe system. Completion of hybrid pipe additional fatigue testing and realization of a scale-one field testing of the hybrid riser are considered as the next steps of the project. To date, the main test results (burst, collapse, fatigue resistance) confirm that the Clip connector and the hybrid pipe technologies are well suited for ultra-deep sea drilling with a surface BOP. However, the fatigue resistance of hybrid riser pipes still needs to be better characterized.