Design Optimization and Stress Analysis of Subsea Jumper for Deep Water Systems: A Jubilee Field Application

In deepwater oil and gas production systems, a rigid subsea jumper is an essential flowline connector that moves hydrocarbons between subsea elements such as export systems, trees, and manifolds. To ensure safe and reliable operation, a thorough structural integrity assessment is necessary due to its multi-bend geometry, long unsupported spans, and exposure to high-pressure and high-temperature operating conditions. This study used Auto-PIPE Plus finite element analysis (FEA) software to evaluate the structural integrity and optimize the design of a rigid subsea jumper meant for the Jubilee Oil and Gas Field offshore Ghana. The multiphase flow meter (MPFM), a sample vessel, connectors, and the jumper assembly were all modelled under typical field conditions, which included a water depth of 1,700 m, a design pressure of 345 bar, an operating temperature of 110°C, and an ambient seawater temperature of 4°C. The resulting forces, moments, torsion, and stress distributions at crucial connection sites, such as the PLET/Tree and manifold interfaces, were assessed using finite element simulations. In compliance with ASME B31.4 design specifications, hoop, longitudinal, and combined stresses were evaluated. The results show that the jumper has satisfactory structural performance under the tested loading conditions. The maximum hoop and combined stress ratios of 0.78 and 0.68 remained below allowed code limits, indicating appropriate safety margins. However, node A29 showed a localized longitudinal stress ratio of 1.27, indicating overstress due to thermal expansion, geometric discontinuities, and support restrictions. Overall, the proposed rigid jumper design is structurally viable for the Jubilee Field, but localized design changes are needed to ensure complete code compliance and improve long-term operational reliability. To ensure long-term operational dependability and full code compliance, the research suggests reassessing design parameters, particularly wall thickness, bend geometry, and the potential integration of buoyancy modules.