Guidance Notes on Production Riser Life Extension

GUIDANCE NOTES ON

PRODUCTION RISER LIFE EXTENSION

JANUARY 2021

American Bureau of Shipping

Incorporated by Act of Legislature of
the State of New York 1862

 2021 American Bureau of Shipping. All rights reserved.

ABS Plaza
1701 City Plaza Drive
Spring, TX 77389 USA
Foreword

Foreword
These Guidance Notes provide technical recommendations and guidance on life extension applications for
subsea production risers attached to floating production installations (FPIs) that produce and/or store
hydrocarbons. These Guidance Notes outline the riser life extension process that includes inspection and
assessment of the riser structure and ancillary equipment for the entire subsea riser system. These Guidance
Notes are also applicable to subsea injection risers and import/export risers.
These Guidance Notes become effective on the first day of the month of publication.
Users are advised to check periodically on the ABS website www.eagle.org to verify that this version of
these Guidance Notes is the most current.
We welcome your feedback. Comments or suggestions can be sent electronically by email to [email protected].

Terms of Use
The information presented herein is intended solely to assist the reader in the methodologies and/or techniques
discussed. These Guidance Notes do not and cannot replace the analysis and/or advice of a qualified
professional. It is the responsibility of the reader to perform their own assessment and obtain professional
advice. Information contained herein is considered to be pertinent at the time of publication, but may be
invalidated as a result of subsequent legislations, regulations, standards, methods, and/or more updated
information and the reader assumes full responsibility for compliance. This publication may not be copied
or redistributed in part or in whole without prior written consent from ABS.

ii ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021

 Table of Contents

GUIDANCE NOTES ON

PRODUCTION RISER LIFE EXTENSION

CONTENTS
SECTION 1 Introduction ............................................................................................ 1
1 Overview ............................................................................................. 1
2 Scope and Application ........................................................................ 1
3 Abbreviations ...................................................................................... 1

SECTION 2 Riser Life Extension Process ................................................................ 3

1 General Riser Life Extension Process ................................................ 3
2 Simplified Process for Risers Managed in a RIM Program ................ 5

FIGURE 1 A High-level Riser Life Extension Process ............................... 3

FIGURE 2 General Life Extension Process with I3P Engagement ............ 5

SECTION 3 Inspection ............................................................................................... 7

1 General ............................................................................................... 7
2 Inspection ............................................................................................ 7
3 Inspection Technique .......................................................................... 8

SECTION 4 Assessment ............................................................................................ 9

1 General ............................................................................................... 9
2 Functionality ........................................................................................ 9
3 Corrosion............................................................................................. 9
4 Erosion and Wear ............................................................................. 10
5 Sealability .......................................................................................... 10
6 Strength............................................................................................. 10
7 Fatigue .............................................................................................. 11

SECTION 5 Modify, Repair or Replace ................................................................... 12

1 Modify................................................................................................ 12
2 Repair................................................................................................ 12
3 Replace ............................................................................................. 12

APPENDIX 1 Master Document Register (MDR) ...................................................... 13

1 Riser Life Extension Application Submitted to ABS .......................... 13
2 Documents to be Submitted for Review ........................................... 13

ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021 iii

 APPENDIX 2 Riser Life Extension Process in the U.S. ............................................ 15
FIGURE 1 Typical Riser Life Extension Process for Applications
Submitted to BSEE .................................................................16

APPENDIX 3 Riser Integrity Management Program ................................................. 17

TABLE 1 Example Risk Categorization Matrix .......................................18

FIGURE 1 Core RIM Process ...................................................................17

FIGURE 2 Example RIM Process.............................................................19

APPENDIX 4 References ............................................................................................ 20

iv ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021

 Section 1: Introduction

SECTION 1 Introduction

1 Overview
Many subsea production risers are approaching the end of their original design life. Those risers need to be
either decommissioned or be included in an application to the recognized Authority (if applicable) for an
extension of their original design life. Due to enhanced recovery or tiebacks from adjacent fields, more and
more existing fields are continuing to produce. As a result, life extension of those offshore assets including
production risers is becoming more commonplace.
For assessment of existing floating production installations, the ABS Guidance Notes on Life Extension
Methodology for Floating Production Installations provides guidance when the intended period of operation
at the original site or the accumulated operating time at both the original and relocated sites is extended
beyond the original design life period. This document focuses on risers attached to FPIs that produce and/or
store hydrocarbons.
These Guidance Notes are not intended to serve as a design standard, but rather to highlight the primary
activities of the life extension process for risers attached to FPIs. These Guidance Notes present a
methodology that can be applied in the riser life extension process for continued service. As such, they may
be applied to risers classed by ABS, not classed by ABS, or without class.

2 Scope and Application

These Guidance Notes provide technical recommendations and guidance on life extension application for
subsea production risers attached to FPIs that produce and/or store hydrocarbons. These Guidance Notes
outline the riser life extension process that includes inspection and assessment of the riser structure and
ancillary equipment for the entire subsea riser system. These Guidance Notes are also applicable to other
subsea risers in addition to production risers. The applicable riser types are:
• Production Risers
• Injection Risers
• Import/Export Risers
Drilling risers, workover and completion risers are not covered in the scope of these Guidance Notes.
These Guidance Notes should be used in conjunction with the following two ABS Guides:
• ABS Guide for Building and Classing Subsea Riser Systems
• ABS Guide for Classification and Certification of Subsea Production Systems, Equipment and Components

3 Abbreviations
ABS American Bureau of Shipping
ASME American Society of Mechanical Engineers
BPVC Boiler and Pressure Vessel Code
BS British Standards
BSEE Bureau of Safety and Environmental Enforcement
CVA Certified Verification Agent

ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021 1

Section 1 Introduction

DFI Design Fabrication and Installation

FMEA Failure Modes and Effects Analysis
FMECA Failure Modes, Effects and Causes Analysis
FPI Floating Production Installation
FPS Floating Production System
HAZID Hazard Identification
HAZOP Hazard and Operability Study
I3P Independent Third Party
LE Life Extension
MDR Master Document Register
OEM Original Equipment Manufacturer
RIM Riser Integrity Management
SCR Steel Catenary Riser
TTR Top Tensioned Riser
VIM Vortex-induced Motion
VIV Vortex-induced Vibration

2 ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021

 Section 2: Riser Life Extension Process

SECTION 2 Riser Life Extension Process

1 General Riser Life Extension Process

Riser life extension requires a life extension assessment created from collected riser characteristic data,
condition data, and operating data to confirm the integrity of the riser and its capacity for extended operations
under future operating conditions. The assessment may confirm that the riser is fit-for-service in its present
condition for the planned extended service life or call for a plan with repairs, component replacement,
additional inspection, additional monitoring, or a combination. A high-level riser life extension process is
shown in Section 2, FIGURE 1.

FIGURE 1
A High-level Riser Life Extension Process

For riser systems managed in a riser integrity management (RIM) program, riser characteristic data,
condition data, and operating data may be readily available for life extension assessment. For risers not
managed in a RIM program, additional efforts need to be called for to establish the current riser condition
for life extension assessment. For example, a design fabrication and installation (DFI) résumé should be
available to provide the data of the original design, including the design code and standards used, all design
assumptions, the intended design envelope, any non-conformances and any resulting modifications up to the
completion of installation or beyond. If this document is not available, extra efforts need to be called for to
obtain the design and as-installed data from the documentation management system. In addition, it is also
very important to obtain the production history and riser integrity data after the installation. If those data are
not available, conservative assumptions should be made for the life extension assessment, which may lead
to a decrease in the extended lifetime.
An inspection is necessary for risers not managed in a RIM program to establish the condition of the riser at
the time prior to the life extension assessment. The inspection should at least include the items listed in
Subsection 3/2.
Owners and operators generally require the review of the riser life extension by an independent third party
(I3P). Often the recognized authority (if applicable) requires an I3P engagement (note: in the U.S., the term
Certified Verification Agent (CVA) is used for verification of riser design, fabrication, installation, and life
extension). It is recommended to follow the three phases listed below for riser life extension. The earlier the
I3P/CVA engages in the process, the better the readiness of the life extension application.

ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021 3

Section 2 Riser Life Extension Process

i) Investigation phase
• Data collection and engineering evaluation
• Inspection
ii) Determination phase
• Assessment
• Provision of conditions for life extension, such as modify or repair
iii) Implementation phase
• Conditions implemented
Riser life extension application is usually required to be submitted to the recognized Authority (if applicable)
for approval. The recognized Authority (if applicable) may have specific requirements on the qualification
of an I3P. It is strongly suggested the Owner to communicate with the recognized Authority (if applicable)
for the requirements of riser life extension. The recognized Authority (if applicable) may review the riser
life extension application based on potential risks.
A recommended general process for riser life extension with I3P engagement is shown in Section 2, FIGURE
2. For riser life extension applications submitted to the recognized Authority (if applicable) with ABS
engagement as an I3P or a CVA, the document submittals are listed in A1/2.

4 ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021

Section 2 Riser Life Extension Process

FIGURE 2
General Life Extension Process with I3P Engagement

Appendix 2 is a dedicated section on riser life extension in the U.S. For U.S. applications, refer to Appendix
2 for details.

2 Simplified Process for Risers Managed in a RIM Program

It is preferred to have a RIM program in-place for riser life extension application. The RIM provides a
proactive process for demonstrating the integrity of a riser throughout its life on a fitness-for-service basis.
The integrity management process relies on gathering and collating information on the riser, periodically
evaluating the data, and using the evaluation to set a strategy for subsequent inspection and monitoring.
RIM is a continuous process throughout the service life of the riser. Key riser performance data is collected
continuously by robust and consistent monitoring devices. In addition, the riser condition data is collected
through scheduled maintenance, inspection, or planned modification and repair to the riser. If any initiator
is triggered, such as severe environmental events, accidental conditions, or life extension, the collected data
can be used to evaluate the fitness-for-service of the riser. Based on the evaluation, riser maintenance and
repair may be scheduled. Strategy plans and program work should be reviewed periodically. If needed, plans

ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021 5

Section 2 Riser Life Extension Process

and program should be adjusted to better manage the riser integrity. The details of riser integrity management
are illustrated in Appendix 3.
The riser systems may be managed in a RIM program and/or classed by a Class Society. ABS offers the
optional notation A1 Offshore Installation – Offshore Risers for subsea risers in the ABS Guide for
Building and Classing Subsea Riser Systems and CSS – Production for subsea systems in the ABS Guide
for Classification and Certification of Subsea Production Systems, Equipment and Components. For classed
riser systems, the riser life extension application needs to be submitted to both the Class Society that the riser
system is classed with and the recognized Authority (if applicable). Similar to the RIM program, the riser
“in-class” status is helpful to the life extension application submitted to the recognized Authority (if
applicable), and the Class Society is a natural choice of I3P/CVA, possessing all the survey records on hand
to support the life extension application submitted to the recognized Authority (if applicable). The
requirements for riser life extension submitted to the Class Society are essentially the same as those for riser
life extension submitted to the recognized Authority (if applicable), for which the Class Society will provide
help. The document submittals for riser life extension to maintain the ABS class notation are listed in
Appendix 1, Subsection 1.
As the recognized Authority (if applicable) may review the riser life extension application based on potential
risks, being managed in a RIM program or being classed by a Class Society benefits the riser life extension
application submitted to the recognized Authority (if applicable). For example, if the riser has been managed
in a RIM program in which the collected data shows the riser to be in very good condition and the fatigue
analysis report demonstrates the riser fatigue life exceeds the original design life plus the requested extension
lifetime, the life extension of this riser can be deemed as low risk. For a low-risk application with a short
requested extension lifetime (e.g., request of extension of 25% of the original design life), the review process
of the recognized Authority (if applicable) may be simplified.
The recommended general process for riser life extension denoted in Section 2, Figure 2 is also applicable
for risers managed in a RIM program, though some steps may be simplified. For example, the data collection
has already been carried out in the RIM program and the latest inspection report and data may be reused in
lieu of a dedicated life extension inspection.
Appendix 2 is a dedicated section on riser life extension in the U.S. For U.S. applications, refer to Appendix
2 for details.

6 ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021

 Section 3: Inspection

SECTION 3 Inspection

1 General
Regular inspection is normally included in the RIM plan or riser maintenance plan. The inspection program
should cover all inspectable components of the riser system. The inspection technology should be effective
enough to provide credible information of the condition of the riser system.
The inspection program can be prescriptive or risk-based and should include the visual inspection of the riser
system above water and below water. The inspection interval may be determined by the Owner based on the
experience of a similar riser or by original equipment manufacturer (OEM) recommendations. The
inspection interval can be established based on the guideline from API RP 2RD or API STD 2RD, however,
if any anomalies found in the riser system from the inspection are significantly different from those expected,
the inspection interval should be adjusted to accommodate the unfavorable situations. Details on risk-based
inspection for riser systems can be found in the ABS Guide for Risk-Based Inspection for Floating Offshore
Installations.
For riser life extension application, an inspection should be carried out before commencing the life extension
assessment. In some situations, if the most recent inspection can be agreed by the recognized Authority (if
applicable) as equivalent to a life extension inspection, the dedicated life extension inspection may be
waived.
If the risers are Classed, or a Class Society is nominated as the riser life extension I3P or CVA, Class Society
engagement should commence as early as possible.

2 Inspection
Inspection is critical to establish the condition of the riser system at the time prior to riser life extension
assessment. It is important to understand the current condition of an existing riser system compared to the
original “as-designed” condition and the original “as-built” installation survey.
The inspection should start with an inspection plan that covers:
i) List of the riser components in the riser system, including locations
ii) Inspection items and locations
iii) Contents requirement on the inspection report
iv) Principles to handle marine growth and debris
The inspection should include the following:
i) Visual inspection of the riser system above the water
ii) Verify the conditions of riser body.
iii) Verify important riser data (e.g., touch down location of the compliant risers).
iv) Confirm the conditions of internal/external corrosion and erosion, as well as coating and insulation.
v) Verify the condition of cathodic protection system.
vi) Confirm the condition of hang-off assembly, including riser porches or J-tubes, flex joints, or taper
stress joints, etc.
vii) Confirm the condition of vortex-induced vibration (VIV) suppression devices (e.g., strakes or
fairings).

ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021 7

Section 3 Inspection

viii) Confirm the condition of buoyancy modules, if any.

ix) Confirm the condition of riser support systems (e.g., riser guides, riser clamps, riser anchor supports,
mid-water arch, tether, and tether clamps), if any.
x) Confirm site soil or topography conditions have not changed much (such as scour, trench, etc.).
xi) The quantity and estimated weight of marine growth.
xii) For top tensioned risers (TTRs), confirm the condition of tensioner, topside jumper, riser joint
connections, and riser bottom connections.
xiii) For flexible risers, confirm the condition of armor wires, annulus, outer layer, end fittings, bend
stiffeners, bend restrictors, bellmouths, ballast modules, and movement restriction chain and
deadweight, if any.
Special attention should be paid to fatigue hot spots during the inspection. For TTRs, the fatigue hot spots
are generally:
i) Tensioner joint/topside buoyancy cans
ii) Subsea tiebacks connectors and stress joints
iii) Keel joints
iv) Joint connected to the stress joint
For Steel Catenary Risers (SCRs), the fatigue hot spots are generally:
i) Flexible joints
ii) Strakes
iii) Touch down regions and trenching
For riser systems designed for regular pigging operations, in-line inspection is strongly recommended to
confirm the riser internal conditions. The requirements of in-line inspection may be determined from the
results of the risk assessment. Details on risk assessment methods can be found in the ABS Guidance Notes
on Risk Assessment Applications for the Marine and Offshore Industries.

3 Inspection Technique
If deemed necessary, additional inspections should be carried out to further identify the anomalies in the
areas of interest. Detailed inspection technique can be found in the ABS Subsea Inspection, Maintenance,
and Repair Advisory.

8 ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021

 Section 4: Assessment

SECTION 4 Assessment

1 General
Engineering assessment is required to be carried out for life extension application to demonstrate fitness-for-
service of the riser system in the proposed extended service period. The assessment may start from a risk
screen and simplified analyses based on existing data to determine if additional monitoring, inspection,
sampling, or testing are needed. The differences between the design conditions and the actual service
conditions should be studied based on collected data to find the design margins for life extension. If the riser
condition does not support the requested extension lifetime, modification (including riser structures and
service conditions), repair, or replacement of the riser system should be considered. If this occurs, the
updated riser data need to be taken into account in the life extension assessment and an I3P/CVA review of
the modification/repair/replacement design, fabrication, and installation is usually required for life extension
applications submitted to the recognized Authority (if applicable). For the first life extension of a low risk riser
with a request for extension of up to 25% of its original design life at the same location, a simplified
assessment may be acceptable.
If marine growth levels are different than those expected during the inspection, its impact to riser components
functionality (e.g., VIV suppression devices), strength, and fatigue should be considered in the assessment.
Details of assessment method can be found in API RP 2RIM.

2 Functionality
The riser and all its components should be in a good condition to perform their intended function. Inspection
and/or testing should be carried out to detect damages or degradation which may impact the performance of
their intended function. Life extension assessment should confirm the fitness-for-service of the riser and its
components in their current condition, otherwise, action should be taken to restore the riser and its
components as fit-for-service. Particular attention should be paid to:
• Cathodic protection system
• Buoyancy modules
• Coatings and insulation
• VIV suppression devices
• Connectors/connections
For riser system life extension application, the effect of the reduced functionality of a damaged/absent
component during its possible damaged/absent period needs to be considered in the assessment. For example, if
fairings are inspected as not functioning properly, the riser fatigue life should be reassessed to consider this effect.

3 Corrosion
Corrosion is one of the most critical threats to subsea risers. Metal loss can occur with various depths and
irregular shapes in subsea risers due to corrosion, erosion, or wear. An inspection should be carried out to
obtain the actual amount of metal loss in the riser. It is very important to confirm that the metal loss is still
within the corrosion/erosion allowance specified in the original design, otherwise, the riser strength and
fatigue capability needs to be reassessed based on the reduced wall thickness and wall loss rate in accordance
with recognized industry standards. Modification, repair or replacement should be carried out if the
assessment concludes the riser’s fitness-for-service is not adequate for life extension. The repair needs to
follow established procedure, and an inspection on the repaired area needs to be performed to confirm that
the threat has been effectively mitigated.

ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021 9

Section 4 Assessment

If excess metal loss is found due to loss of or damage to coatings, anodes or their connectors, necessary
repair should be performed, and an inspection should be followed to confirm adequate corrosion protection
on the riser system. In addition, the effect of partial loss of corrosion protection on the riser fatigue life
should be taken into account in the engineering assessment of riser system. Meanwhile, the riser operating
parameters may be changed to reduce the future corrosion rates.
All repairs and modifications should have an I3P/CVA review for life extension applications submitted to
the recognized Authority (if applicable).

4 Erosion and Wear

Internal erosion is normally caused by abrasive elements in the production fluid, such as sand, especially in
high-curvature areas. The sand concentration in the production fluid is recommended to be monitored during
the operation. If the sand concentration is more than the level assumed at the original design, the actual
erosion rate will exceed that specified in the original design. Measures should be taken to reduce the erosion
rate in this situation, such as changing operating parameters.
Wear is usually caused by repetitive contact between two or more surfaces. A typical example is a catenary
riser repetitively touching the seabed in the touchdown zone. Inspections should be performed to check the
high wear areas in the riser. Wear rates should be checked against the one defined in the original design. If
the measured wear rate is greater than the defined one, measures such as changing operating parameters may
be used to reduce the wear rate to normal.
Similar to corrosion, assessment should be carried out if the metal loss due to erosion/wear is greater than
the erosion/wear allowance specified in the original design. If the fitness-in-service of the riser system cannot
be confirmed, the riser system should be modified, repaired, or replaced. An I3P/CVA review of the
repair/modification is needed for life extension applications submitted to the recognized Authority (if
applicable).

5 Sealability
The sealing system should be inspected to confirm the possible wear/damage does not compromise its
pressure-containment function. For retrievable risers, the sealability assessment should follow the OEM
recommendations. For non-retrievable risers, visual inspections and/or pressure tests should be performed.
If the operation records show there are deviations to the original design parameters which may affect integrity
of the sealing system, an engineering assessment should be carried out to evaluate the possible adverse
effects on the sealing systems.

6 Strength
The strength assessment of a riser with reduced wall thickness should be carried out in accordance with the
original design standards or industry recognized standards such as API RP 2RD or API STD 2RD. The most
critical load conditions for normal operating, extreme, and survival conditions should be selected based on
load case matrix in the original design with updated environmental data. The wall thickness in the strength
analysis should be the wall thickness measured in the latest inspection less the extrapolated wall loss for the
remaining service life from the measured wall loss.
If the metal loss of the riser can be considered as uniform wall loss, global riser analysis using beam elements
may be acceptable. If the metal loss is localized and cannot be treated as uniform wall loss, component level
finite element analysis should be carried out to assess the critical sections of the riser. Fitness-for-service
analysis for a pipe with defects in accordance with recognized industry standards may also be acceptable.
If an inspection shows possible riser buckling or clashing, the related analysis should be carried out to assess
the fitness-for-service of the riser system in this situation.

10 ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021

Section 4 Assessment

7 Fatigue
The fatigue life assessment should be carried out unless the calculated fatigue life in the original design
analysis report exceeds the design life plus the extended lifetime and the inspection/testing data demonstrate
the riser system conditions meet the original design requirements. If the riser experienced loads/motions or
riser conditions have been changed to sufficiently impact the riser fatigue life, fatigue assessment should be
carried out using as many available measured/monitored data as possible such as environmental data, vessel
motions, riser motions, and riser conditions. The rate of wall loss should be considered in the fatigue analysis
based on inspection data and time of inspections. The greater the amount of measured/monitored data used
in the analysis, the more realistic the prediction of the fatigue life of the riser.
The fatigue assessments should consider all the fatigue loads experienced and to be experienced within the
total service life of the riser system (including the original design service life and the proposed extension of
service life). Riser fatigue damage is primarily composed of wave fatigue, vortex-induced motion (VIM)
fatigue and VIV fatigue. Using measured/monitored vessel motion, riser motion, and/or environmental data
may greatly benefit the analysis of the riser fatigue life estimation. Other cyclic loads, such as
thermal/pressure induced stress cycles and slug-induced vibration, may also be considered in the fatigue
analysis for riser systems if they are the concerns of the riser life extension.
For S-N based fatigue analysis, the same S-N curves and safety factors as those used in the original design
should be used for the riser fatigue assessment. If there are appropriate technical justifications based on
measured data, material fatigue testing, more advanced and calibrated analyses, and more favorable service
conditions, alternative S-N curves and safety factors may be acceptable. Alternative S-N curves may be
selected from recognized industry standards such as BS 7608, or through material fatigue testing based on
materials, environmental conditions, and the service condition. Alternative safety factors on fatigue damage
analysis should follow recognized industry standards with reasonable technical justifications.
For fracture mechanics-based analysis, the assessment should follow recognized industry standards. The
standard compliance cannot be a “mix-and-match”. For example, if API 579-1/ASME FFS-1 is selected as
the assessment standard, the entire fracture mechanics assessment should follow API 579-1/ASME FFS-1.
If BS 7910 is selected, the entire fracture mechanics assessment should follow BS 7910. The safety factor
of fracture mechanics analysis is usually less than that for the applicable S-N based fatigue analysis, and its
recommended value can be found in recognized industry standards, such as ASME BPVC Section VIII
Division 3.

ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021 11

 Section 5: Modify, Repair or Replace

SECTION 5 Modify, Repair or Replace

Modification, repair, or replacement should be carried out if the assessment concludes the riser’s fitness-for-
service is not adequate for life extension. All those activities need to be documented and reflected in the live RIM
plan. The life extension assessment may be resumed after the modification and repair with an I3P/CVA review of
the modification/repair design, fabrication, and installation required for life extension applications submitted to
the recognized Authority (if applicable). The as-built data/reports for the modification and/or repair of the
riser system need to be provided for its life extension application. The life extension process including
modification, repair, and replacement is illustrated in Subsection 2/3.
If the risers are classed, the Class Society will need to be involved in all these activities, from the design,
certification of materials, to the implementation, testing, and subsequent inspection.

1 Modify
All the modifications need to be documented and reflected in the RIM plan. Examples of modifications are:
 Modifications to the riser system
 Modifications to the host FPI that affect the riser system
 Modifications of the RIM plan, including additional monitoring and inspections, inspection intervals
 Modifications of operating procedures and major operation parameters
An I3P/CVA review of the modification design, fabrication, and installation is usually needed for life
extension applications submitted to the recognized Authority (if applicable).

2 Repair
In the event of damage to risers or components of riser systems affecting the integrity of the riser system, repair
may be carried out for safe continuous transportation of hydrocarbons. For the localized repair of non-leaking
minor and intermediate damage on risers or riser components, repair clamps may be utilized without the
need for an emergency shutdown to the riser system. For repair of riser components, replacement of the
retrievable components may be required without the need to retrieve the riser string. Non-critical repairs
which do not jeopardize the safety of the riser may form part of a planned maintenance program. Examples
of repair are:
 Corrosion coating repair
 Buoyancy module repair
 Cathodic protection repair
 VIV suppression device repair
An I3P/CVA review of the repair design, fabrication, and installation is usually needed for life extension
applications submitted to the recognized Authority (if applicable).

3 Replace
If repair of the riser or riser components is unable to bring the riser system back to its desirable condition for
the proposed extended service life, replacement of the riser string or riser system is an option for the life
extension application of the offshore assets including FPI and subsea equipment. The riser can be retrieved
and replaced. The replacement activity should be documented, and the RIM of the replacement riser should
start from design, fabrication, and installation again. For new risers, an I3P/CVA review of the design,
fabrication and installation is usually required by the recognized Authority (if applicable).

12 ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021

 Appendix 1: Master Document Register (MDR)

APPENDIX 1 Master Document Register (MDR)

1 Riser Life Extension Application Submitted to ABS

For riser life extension application to maintain ABS class notation, the following documentation should be
submitted to ABS for review:
i) An application document to propose life extension of the riser system including:
• Proposed continuing operation life
• Proposed continuing operation conditions including environmental conditions
• Inspected riser structure condition
• Environmental/geotechnical condition changes record
• Corrosion history, predicted corrosion rate and predicted end of life condition
• Proposed repair and replacement
• Future inspection/monitoring plan, inspection interval and acceptance criteria
• Proposed testing plan including pressure limits and testing interval
ii) Analysis reports for life extension of the riser system including:
• Strength assessment per inspected condition
• Fatigue damage accumulated based on previous operation history
• Strength analysis for the riser structure per riser structure condition at the end of proposed life
extension under proposed the worst environmental condition considering proposed repair and
replacement
• Remaining fatigue life per inspected riser structure condition and predicted corrosion under
proposed continuing operating conditions considering proposed repair and replacement

2 Documents to be Submitted for Review

The recognized Authority (if applicable) generally has specific requirements on the qualification of an I3P
or a CVA. The I3P/CVA is usually a third-party possessing technical capability with reasonable company size
and related experience. The personnel in the I3P/CVA team should not have served in the design team of the
original equipment/system.
For riser life extension to be submitted to the recognized Authority (if applicable) in which ABS is nominated
as I3P/CVA (subject to the approval from the recognized Authority (if applicable)), the following
documentation should be provided to ABS to carry out life extension I3P/CVA verification:
i) Riser life extension basis, including:
• Life extension methodology and forward-looking RIM plan for the riser system in the
application.

ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021 13

Appendix 1 Master Document Register (MDR)

ii) Inspection report, including:

 Conditions of riser body and riser data measurement (e.g., riser configuration data)
 Conditions of internal/external corrosion and erosion, as well as coating
 Condition of cathodic protection system
 Condition of hang-off assembly, including riser porches or J-tubes, flex joints or stress joints
 Condition of VIV suppression devices (e.g., strakes or fairings)
 Condition of buoyancy modules, if any
 Conditions of riser support systems (e.g., riser guides, riser clamps, riser anchor supports, mid-
water arch, tether, and tether clamps), if any
 Site soil or topography conditions (such as scour or trench)
 For TTRs, condition of tensioner, topside jumper, riser joint connections, and riser bottom
connections
 For flexible risers, condition of armor wires, annulus, out layer, end fittings, bend stiffeners,
bend restrictors, bellmouths, ballast modules, and movement restriction chain and deadweight,
if any
iii) Existing integrity management plan, inspection, maintenance, and repair data
iv) Input data for consumed fatigue life analysis:
 Riser design data, including sizing, weight, materials, coatings, and end connections
 Historical operational data, including pressure, temperature, internal fluid density, and sour or
sweet environment
 Historical environmental data, including monitored or assumed wave and current data and
floater motions
 Design analysis, including strength and fatigue analysis
v) Input data for remaining life analysis:
 Proposed riser data
 Proposed operational data
 Proposed environmental data

14 ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021

 Appendix 2: Riser Life Extension Process in the U.S.

APPENDIX 2 Riser Life Extension Process in the U.S.

ABS has carried out verification of several projects as a Certified Verification Agent (CVA) for the Bureau
of Safety and Environmental Enforcement (BSEE), the U.S. regulatory agency responsible for the approval
of riser life extension.
Based on the experience acquired from these activities, below is ABS’s understanding of the BSEE
requirements for the life extension process. It is the Operator’s responsibility to approach BSEE to confirm
the procedures in place.
An application needs to be submitted by the Operator to BSEE as follows:
1. Owner notifies BSEE of approaching end of design service life
2. Owner submits life extension application package, including verification plan and CVA nomination
3. BSEE approves verification plan and CVA nomination
4. CVA performs life extension assessment, conclude assessment work, and submits CVA Report
5. Owner communicates with BSEE and addresses comments
6. BSEE approves life extension application
The requirements on the life extension application package, verification plans contents, qualification of
CVA, CVA report contents are specified by BSEE. It is strongly suggested that the Owner communicate
with BSEE for those requirements proactively to prevent unnecessary delays.
BSEE has specific requirements for the qualification of a CVA. The CVA usually is a third-party possessing
technical capability with reasonable company size and related experience. The personnel in the CVA team
should not have served in the design team of the original equipment/system. The CVA should carry out the
life extension verification only after the CVA nomination is approved by BSEE.
As the approval process takes time, it is strongly suggested to submit the riser life extension application a
few years before the original permission expires. It is also strongly suggested that a RIM plan is in-place so
that the historical riser condition data, operating data, and environmental data are recorded continuously or
periodically. Those recorded data are very important for the assessment of the integrity of the riser system
at the time of submitting life extension application.
The CVA report should include the inspection findings, strength analysis, and remaining life analysis to
demonstrate that the integrity of the riser system can support the riser in the proposed environment under
proposed operational condition for the extended service life. All the safety factors used in the analysis should
be documented and justified. The overall conservatism can be represented by the combination of the safety
factors used for materials, occurrences, and analyses.
BSEE may review the riser life extension application based on potential risks. For example, if the riser has
been managed in a RIM program in which the collected data shows the riser to be in very good condition
and the fatigue analysis report demonstrates the riser fatigue life exceeds the original design life plus the
requested extension lifetime, the life extension of this riser can be deemed as low risk. For a low risk
application with a short requested extension lifetime (e.g., request of extension of 25% of the original design
life), the review process may be simplified (e.g., review the as-built data/report and latest inspection report,
etc.). For other life extension applications, the full process denoted in Section 2, Figure 2 may be applicable.
Riser life extension applications are usually submitted to BSEE in a life extension application package for
the whole offshore asset. BSEE may issue individual approvals for subsystems and a consolidated approval
letter for the whole system. As each subsystem may be granted different years of extended service life, the
consolidated approval letter is governed by the minimum allowed life extension for the subsystems.
A typical riser life extension process for applications submitted to BSEE is shown in Appendix 2, Figure 1.
The required document submittals for ABS as a riser life extension CVA is listed in A1/2.

ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021 15

Appendix 2 Riser Life Extension Process in the U.S.

FIGURE 1
Typical Riser Life Extension Process for Applications Submitted to BSEE

16 ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021

 Appendix 3: Riser Integrity Management Program

APPENDIX 3 Riser Integrity Management Program

The RIM program provides a proactive process for demonstrating the integrity of a riser throughout its life
on a fitness-for-service basis. It is very helpful to riser life extension assessment if a RIM program is already
in-place and the riser data, operational data, and environmental data are collected through periodic inspection
and continuous or periodic monitoring.
API RP 2RIM provides guidance on the integrity management of risers connected to a permanent FPI used
for the drilling, development, production, and storage of hydrocarbons in offshore areas. The RIM provides
the Owner a basis for the activities of inspection, maintenance, monitoring, and remediation to validate the
fitness-for-service of a riser system for its intended service throughout its service life.
Four important elements of RIM process are shown in Appendix 3, Figure 1: Data, Evaluation, Strategy, and
Program. If an initiator is triggered, such as life extension, assessment will be carried out to evaluate the
fitness-for-service of the riser for its intended application during its intended service life.

FIGURE 1
Core RIM Process

The RIM plan can be risk-based, prescriptive, or a combination of the two. Risk-based RIM is recommended
as it optimizes the activities of inspection and monitoring. If the RIM plan is on a prescriptive basis, a risk
assessment for the riser system is strongly recommended to be carried out, and the RIM plan should include
managing the identified risks of the riser system accordingly. An example of risk category based on the
combination of likelihood of failure and consequence of failure is listed in Appendix 3, Table 1. More
advanced risk assessment technique or more complicated risk category matrices can be used in the RIM plan
to manage the risks of the riser system more efficiently.
The ABS Guidance Notes on Risk Assessment Applications for the Marine and Offshore Industries provides
the guidelines for defining the concept of risk, describing the methods available to assess risk, and in
performing successful risk studies. Since the objective of the risk assessment is to demonstrate the fitness-
for-service of the riser system and its associated structure and subsystems via risk screening, the assessment
should clearly define the risk categories (e.g., risk matrix) and acceptable risk levels.

ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021 17

Appendix 3 Riser Integrity Management Program

The riser potential failure modes should be assessed and identified by the suitable technique (e.g. FMEA,
FMECA, HAZID, HAZOP, etc). The objectives of the failure mode analysis are to:
• Identify and provide recommendations to eliminate or mitigate the effects of common failure modes
• Demonstrate effective redundancy
• Identify potential “hidden” failures and determine the effects of a second failure

TABLE 1
Example Risk Categorization Matrix
Consequence of Likelihood of Failure
Failure Low Medium High
High Medium High High
Medium Low Medium High
Low Low Low Medium

The details of assessment methods and riser assessment process can be found in API RP 2RIM. An example
of RIM process for a SCR system is shown in Appendix 3, Figure 2.

18 ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021

Appendix 3 Riser Integrity Management Program

FIGURE 2
Example RIM Process

Initiator triggered?

Measured & Inspected Data:

* Routine & automated:
- Vessel 6 DOF motion
- Hang off angles & top tension
- Current profile & other metocean data
- Production data (temp, pressure, etc.)
* Offshore ROV inspection:
- Confirm anomaly/repaired/modified
- Establish new baseline inspection

Assessment, Digital Technology Based:

Base Digital Model: - Update of digital model Recommendation:
- As-built data (riser) - Simulation - ROV inspection, if req’ed.
- Baseline inspected data - Simulation/measurement data analysis - Measurement device update
- Calibrated motion data - AI based Condition Assessment consider
* Offshore ROV inspection results
* Updated simulation results

STRATEGY
Yes Overall inspection
Fit for Service?
philosophy, strategy, and
criteria for offshore in-
service inspection
No

DATA
Modify or Replace
Repair, Modify, or Replace Managed digital system for
Repair
archival/retrival of RIM data
& records

ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021 19

 Appendix 4: References

APPENDIX 4 References
1. ABS, Guidance Notes on Life Extension Methodology for Floating Production Installations, 2017.
2. ABS, Guidance Notes on Risk Assessment Applications for the Marine and Offshore Industries, 2020.
3. ABS, Guide for Building and Classing Subsea Riser Systems, 2017.
4. ABS, Guide for Classification and Certification of Subsea Production Systems, Equipment and
Components, 2018.
5. ABS, Guide for Risk-Based Inspection for Floating Offshore Installations, 2018.
6. ABS, Subsea Inspection, Maintenance, and Repair Advisory, 2019.
7. API 579-1/ASME FFS-1, Fitness-For-Service, Third Edition, 2016.
8. API RP 2RD, Design of Risers for Floating Production Systems (FPSs) and Tension-Leg Platforms
(TLPs), 1998, reaffirmed in 2006, with Errata 2009.
9. API RP 2RIM, Integrity Management of Risers from Floating Production Systems, First Edition, 2019.
10. API STD 2RD, Dynamic Risers for Floating Production Systems. Second Edition, 2013.
11. ASME Boiler and Pressure Vessel Code (BPVC), Section VIII, Division 3: Alternative Rules for
Construction of High Pressure Vessels, 2019.
12. BS 7608, Guide to Fatigue Design and Assessment of Steel Products, 2014, with amendment 2015.
13. BS 7910, Guide to methods for assessing the acceptability of flaws in metallic structures, 2019.

20 ABS GUIDANCE NOTES ON PRODUCTION RISER LIFE EXTENSION . 2021