Unbonded flexible pipelines for deep water field applications are subject to elevated hydrostatic constraints; bore pressure being dropped brings high compressive stresses due to reverse end cap effect. If the external sheath is unsealed, the axial compression loads transmitted to the tensile armors induce their radial expansion, which can lead to their buckling. Specific layers shall be added in order to maintain armors in place: anti-buckling tapes. These layers, designed with high performance fibers, have been introduced in the early 1990's when the use of flexible pipe has grown in deep water. Various failure modes are expected and observed depending on the fiber characteristics, tape construction, tensile armors properties and annulus environment. For each pipe design, an optimum has to be found between the anti-buckling tapes loads and the compressive stress in the armor layers in order to ensure sufficient safety margins against both tapes breakage and different buckling modes of the armors. Anti-buckling tape interaction with the tensile armors and annulus environment main influencing parameters will be explained in the light of full scale tests performed on flexible pipes in hyperbaric tank. Specific laboratory devices have also been developed to be representative of the operating behavior of both armors and high strength tapes. In parallel, this paper will present qualification tests performed in compliance with the requirements of 2014 editions of API standards 17J and 17B. The tests showing tape resistance and flexible pipe behavior have enabled to establish a robust design rule. This process is being scrutinized by an Independent Verification Agent and aims at leading to Type Approval Certification according to the latest edition of API 17J.

Spread moored FPSO (Floating Production and Storage Offloading) vessels are generally used for the large West African oil fields. The oil is transferred from the FPSO to shuttle tankers via an Oil Loading Terminal (OLT). 2 to 3 large diameter flexible lines are connecting the FPSO to the OLT. The final connection between the OLT and the shuttle tanker is made by floating hoses. The single length of each flexible pipe can be typically 2,300 meters or higher, and the internal diameter is generally very large in the order of 15_23″ to minimize the pressure drop and the offloading time. Conventional flexible pipe is the most suitable solution for this application. However, its long length and large diameter require a large number of buoyancy modules which are necessary to support the substantial weight generated by the steel armor wires. An alternative to steel is Carbon Fiber Composite (CFC). This material is not only twice as strong and five times lighter than a high strength steel but it is also characterized by its exceptional performance in fatigue. As the weight of the composite armor flexible pipe is significantly reduced, the use of buoyancy is no longer necessary. The pipe can also be manufactured in a single length without intermediate connection. A qualification program based on a 19″ internal diameter prototype has been launched. This is the first time that a large internal prototype with Carbon Fiber Composite Armor (CFA) and end-fittings have been designed and manufactured. The main goals are to confirm the suitability of the CFA flexible pipe for oil offloading application in accordance with the design tools. The mechanical behavior responses of the CFA are monitored by strain gages when the flexible pipe is in straight and curved positions under internal pressure and bending cycles. The paper will present the main mechanical properties and the overall performance of the flexible pipe designed and tested. The economic viability will be demonstrated by showing how the CFC material cost is positively offset by the removal of the buoyancy modules and a faster offshore installation.