The Application of Advanced Composite Technology to Marine Drilling Riser Systems: Design, Manufacturinagn d Test
Authors: Andersen W.F. , Anderson J.J. , Mickelson C.S. , Sweeney T.F. 
Published: October 2008

Life cycle costs are a key consideration in the economics of deepwater exploration and production. Lightweight structures, fabricated using advanced composite materials, have the potential to reduce life cycle costs for deepwater field development by virtue of their corrosion resistance, fatigue tolerance and their lower weight, as compared to steel. An Industry/University team, which includes ABB Vetco Gray, Deepstar, Reading & Bates, Northrop Grumman Marine Systems, Hexcel Carbon Fibers, and Offshore Technology Research Center, is applying advanced composite technololgy to Marine Drilling Riser Systems. Approximately one-half of the funding for the $4.8M, three-year project comes from the National Institute of Standards and Technology (NIST) Advanced Technology Program (ATP). The remainder of the funding comes from the team members in the form of cash, in kind labor and depreciation of facilities used in behalf of the project. The project work scope includes the design, fabrication and test of advanced filament wound composite marine drilling riser pup joints. The project start date was April 1995. This paper describes the progress to date on the design, fabrication and test of prototypes and also discusses the program plan for the remainder of the project.

Introduction

The potential life cycle cost benefits of the use of advanced composite structures in deepwater exploration and production programs have been identified in the literature (Refs 1,2,3 and 4). The identified benefits include corrosion resistance, fatigue tolerance and lower weight as compared to steel. Risers and Tension Leg Platform (TLP) tethers have been proposed, among others, as candidates for the application of advanced composite technology to achieve the potential life cycle cost benefits. The potential benefits increase significantly as the offshore oil industry moves out to deeper water projects and floating systems replace stationary structures.

While there have been past attempts at developing advanced composite exploration and production tubular products, cost-effectiveness and long term reliability have been major roadblocks which have not been successfully addressed. In addition, the development costs and development risk are of such a magnitude that no individual service or vendor company has been willing to step up, nor has an individual operator or driller been willing to sponsor a major development project for advanced composite tubulars.

In 1994, the National Institute of Standards and Technology (NIST), as an element of their Advanced Technology Program (ATP), issued a call for Program Ideas on advanced composite manufacturing. Amoco, Conoco and Shell representatives, with the support of the University of Houston, submitted a white paper on manufacturing composites for the offshore oil industry. NIST combined program ideas from the automotive, infrastructure and offshore oil industries and asked for proposal submittals on Manufacturing Composite Structures in July 1994 under program competition 94-02. The stated objective to be accomplished by proposed efforts for the offshore oil industry was to reduce the capital expenditures required for oil production from deepwater reserves by pursuing high-risk, high-payoff R&D projects which otherwise might not be pursued. The NIST ATP offers to form a partnership with industry-led teams by providing winning proposals up to one half of project funds in the form of a cooperative agreement.