Flexible risers and flowlines are complex structures comprised of multiple layers, combining steel armor wires for strength and polymer layers for low relative bending to axial stiffness.
Flexlife made its name on our flexible riser inspection, monitoring, and repair technologies. However, it all started with best in class engineering in flexible riser design, specification, fatigue assessments, and life extension studies.
As independent domain experts, Flexlife’s team of flexible riser experts help operators with design and specification of new flexible pipes by combining our vast experience and expertise to select the best solution for the particular application.
We do this by utilizing Flexlife’s proprietary methods, software, and databases to ensure that we balance performance with cost efficiency.
Our approach has achieved up to a 50% cost savings for operators in new pipe procurement and installation costs for unbonded flexibles (see case study below).
FlexTracker, Flexlife’s proprietary database of used unbonded flexible pipes, tracks operator’s stored and unused flexibles.
Operators come to Flexlife when they need to quickly source unbonded flexibles for critical production applications or to save cost for short run production.
Unbonded Flexibles are the core to Flexlife’s DNA. However, we believe in choosing the right pipe for the job.
Thermoplastic Composite Pipe (TCP) and Reinforced Thermoplastic Pipe have made significant advances in recent years and offer significant procurement and installation cost savings.
Recognizing these advancements, Flexlife have carried out engineering studies to show that these bonded flexibles are indeed suitable in several applications to replace traditional unbonded flexibles, resulting in major cost savings for our customers.
Our engineers have more than 100 years’ combined experience in the specification, design and fabrication of flexible pipes and associated ancillary equipment.
We can assist with:
Working with Group company Umbilicals International, we can provide design reviews of flexible umbilicals, including:
We can undertake the following processes as part of the package management process:
We can assist with key tender documentation, including:
The client approached Flexlife for ITT support in the re-tendering of 7 flexible risers for a new project development.
Upon review, Flexlife found several gaps in the previous design philosophy. Overly stringent design considerations were causing unnecessary cost increases also leading to sole source supply and unnecessary fabrication risk.
Pipe Design Philosophy Gaps
Riser Configuration Gaps
After a detailed review of the original design criteria and riser configuration philosophy, Flexlife updated the specifications of the ITT, reducing the complexity of the design which allowed two additional vendors to bid on the pipe.
These changes resulted in ~$50 – 80 Million dollars in potential cost savings for the client’s flexible riser procurement.
Pipe Design Philosophy Recommendations:
Riser Configuration Recommendations
Our client required engineering support to confirm that the FPSO mooring hook-up analysis had correctly identified the principal risks for the pre-installed wet stored flexible riser system. The field development included:
The FPSO was permanently turret-moored above these with a 3×4 mooring.
Flexlife completed a scope of work, which included:
Flexlife was approached to design, fabricate and supply a riser system which included a flexible pipe, J-tube and associated clamps, for an existing field tieback in the East Irish Sea. The design had to take into account shallow water dynamic field infrastructure, ageing assets, a lack of survey data and restricted topside access.
We delivered a bespoke design within six weeks of commencing the project. A full integration analysis, flexible pipe global and fatigue analysis took placeand the systems were delivered in accordance with vessel schedules. The time from initial concept to installation was less than four months.
Flexlife has inspected, scanned, tested, dissected, and/or repaired 1000’s of risers. Utilizing this aggregated field service data, Flexlife has developed a feedback loop of insights into the unique characteristics and failure modes of risers from all of the manufacturers. This insight is not available anywhere else in the industry.
No. Flexlife is not a manufacturer of flexible pipe. We work with and have in-depth knowledge of all the flexible pipe manufacturers, including both unbonded and bonded pipes.
Yes RTP / TCP pipe has been used successfully to replace unbonded flexible pipe. However, it is dependent on the specific application.
RTP / TCP provide several advantages over traditional unbonded flexible risers. RTP / TCP pipe is much more cost effective from both a manufacturing and installation standpoint. Delivery times are often much shorter.
Here is a good example: An operator’s pipe was damaged beyond repair. The remaining production life of the well was nearing its end, but the operator wanted to produce for two more years. Replacing the riser with a TCP / RTP pipe enables them take advantage of the quick manufacturing turn-around to reduce lost production costs and reap the benefits of the manufacturing and installation cost savings.