Offshore Malaysia Flexible Riser Annulus Testing
2H delivered a comprehensive flexible pipe annulus testing campaign, interpreted test findings and provided integrity recommendations for 14 flexible risers offshore Malaysia.
An operator with multiple flexible risers on a platform in East Malaysia in an unknown condition, was concerned about the long-term integrity of the flexible pipe. 2H was tasked with conducting a comprehensive annulus testing programme for 14 flexible risers, which had been supplied by three different flexible pipe manufacturers.
The programme needed to include vacuum testing and positive pressure testing as well as general visual inspection of topsides equipment, an end fitting vent port flow test, and annulus gas sampling to establish annulus system integrity and composition of the permeated gases.
Annulus Testing Campaign
2H conducted the entire scope of the flexible riser annulus integrity and condition testing using its in-house, custom-built annulus test kit, FlexTest. The rigorous test programme was completed in accordance with API recommendations, industry best practices and proven methodology developed by our flexible pipe specialists. The test kit works with a variety of interfaces, such as multiple riser/jumper end fitting designs from various flexible vendors, offshore facility interfaces and gas sampling bottles from third-party vendors.
This project took 10 weeks (accounting for COVID-19 quarantines) from initial discussions with the operations team to completion of the offshore campaign by 2H personnel. Pre-mobilisation planning was critical in achieving the client’s objectives safely and on schedule, and this included identifying interfaces, procuring project-specific equipment, and developing a customised work pack and procedure.
2H engineers provided round the clock coverage offshore to conduct the testing safely and efficiently.
Once the testing programme was completed by our offshore engineers, we were able to establish the current condition of each of the 14 flexible riser annuli as well as identify several specific integrity issues that needed to be addressed. Test results were reviewed back onshore by our flexible pipe experts who developed a report with recommendations for follow-on actions, inspection and testing. This provided the client with clear diagnostics of the risers’ integrity condition and allowed them to optimise their engineering assessments and rationalise maintenance work.
How 2H added value
This was a collaborative effort with expertise and insight provided by our flexible pipe specialists, offshore engineers and integrity engineers to deliver a holistic approach to testing and a comprehensive engineering appraisal and recommendations report.
We leveraged our independence from flexible riser suppliers to offer an unbiased, fit-for-purpose approach for the on-going management and maintenance of the different risers.
Our FlexTest flexible riser annulus test kit is the most advanced on the market offering tests that other do not, such as the vacuum testing, positive pressure testing and annulus gas sampling which were critical in establishing system integrity in this campaign.
Our many years of experience designing riser systems for this region meant we knew the types of conditions these risers had been operated under and gave us insight into what to test for and the most appropriate remediation measures for continued operation.
Not only was the condition of each riser established, but a comprehensive post-testing analysis and appraisal reporting was delivered to the client to safeguard the on-going operational integrity of the risers.