Cladtek MLP in Operation on Mero 1 FPSO for Ultra-Deep Dynamic Riser and Flowline Service

Cladtek delivered 96km of 6″ and 8″ MLP for Brazil’s Mero 1 Project in 2021, the first full MLP deployment for ultra‐deep dynamic riser flowline service. The pipes used in the rigid riser and flowline system to connect 13 wells (6 production wells and 7 water alternate gas injection wells) in the pre‐salt field Mero 1, part of the Libra reservoir. Mero 1 is the first pre‐salt project to use Mechanically Lined Pipe from top to bottom of the riser section, including the fatigue sensitive sections.

Mero 1 risers follow an innovative concept, using Mechanically Lined Pipes from platform to seabed, whilst installed by Reel‐Lay. Pipeline design counts with the liner stiffness to counter its tendency to “wrinkle” during installation – as opposed to pressurized installation previously used. Refinements in pipe‐end design during project execution caused a part of the MLP scope carried out with the application of additional CRA reinforcement on top of the transition from clad to liner. This preventive action further guarantees no such feature will occur during installation, as validated during full‐scale validations.

The team faced technical challenges such as HTHP conditions, ultra‐deep waters (2100m), sour service (CO2/SSC), stringent tolerances and acceptance criteria, and additional engineering and technical alignment between parties to ensure pipeline integrity. Despite the challenges and uncertainties posed by the COVID
situation, the team remained collaborative and committed to ensuring safety, quality, and integrity.