Completion and Workover Riser Connection Qualification for HPHT Applications

Abstract This paper describes the design and development process and details the successfully completed qualification work of an industry-first rotary-shouldered connection that is 20,000 psi working pressure rated as per American Petroleum Institute (API) Standard 17G1. This connection is used in a Drill Pipe-Based Riser (DPBR) that can be used in a Through-BOP Intervention Riser System (TBIRS)1 or in an Open Water Intervention Riser System (OWIRS)1. The design and qualification of the connection while navigating the different challenging requirements from several industry standards are described, along with valuable lessons learned. Failures Modes Effects and Criticality Analysis (FMECA) was performed using a collaborative process between various stakeholders and used to create a detailed qualification program. Finite Element Analysis (FEA) was used to determine the static, functional and cyclic capacities of the threaded connector in accordance with API 17G1, API 17TR82 and ASME Boiler and Pressure Vessel Code (B&PVC) Section VIII Division 35. Physical testing consisted of validating the connector capacities by performing make- and-break (functionality) testing, sealability testing, and cyclic fatigue testing. Independent Third Party (I3P) witnessing, and review was completed on all relevant design and qualification activities as per the Bureau of Safety and Environmental Enforcement (BSEE) requirements for High Pressure High Temperature (HPHT) equipment. The drill pipe type connection used to complete this fit-for-purpose design and subsequent API 17G qualification for a 20,000 psi riser is a versatile product that reduces the total cost of ownership. It enhances operational efficiencies in offshore completion, intervention, and workover activities, allowing for multiple trips without repair. After successful completion of the qualification program, the product improves endurance capacities without compromising pressure sealability.