CASE STuDY: Olympus TLP Tow-Out Marks Shell`s First use of
Transcription
CASE STuDY: Olympus TLP Tow-Out Marks Shell`s First use of
JU L Y 2 0 1 4 Com m e rcial marine applicat ions New Developments in Synthetic Rope Technology CASE STUDY: Olympus TLP Tow-Out Marks Shell’s First Use of Synthetic Rigging Finds Operational and HSSE Benefits Photo by Tim Burdick Photography Project Overview Transporting monolithic structures over long distances is a major undertaking that calls for fully engineered solutions. Towing the Olympus TLP—Shell’s newest and largest tension leg platform (TLP)—from the construction and integration yard in Ingleside, Texas to its new home in the Mars B field, more than 425 miles offshore in the Gulf of Mexico, was in planning for over two years. At more than 400 feet tall and weighing 120,000 tons, moving the platform is equivalent to moving a fortystory building that’s nearly a city block square. To make matters more challenging, it was hurricane season in the Gulf of Mexico. This was also the first time that synthetic lines were used exclusively to rig a tow-out and installation for one of Shell’s projects. During the in-shore portion of the tow-out in some areas only there was only 9 meters of clearance. The Situation The path to a decision to use synthetic lines had many tributaries, but throughout the process, Shell’s commitment to safety in all its operations was apparent. With 16 different ropes required for the inshore towout, the offshore tow, and positioning when on-site, personnel handling issues were a major concern. The decision to use synthetics for the tow-out rigging allowed simplified connection points (lugs versus padeyes), eliminated heavy shackles and jewelry requiring additional lifting equipment for attachment, and the pinch-points that come with the process. Re-rigging with heavy connection hardware in calm seas is challenging enough. In the kind of heavy weather that the Gulf often encounters during hurricane season, the chances of potential delays or even injuries rises exponentially. Synthetic lines were used for the critical inshore portion of the tow-out, as well as the offshore transport and the eventual positioning of the rig for installation. The result was faster, more efficient rigging and real benefits that eliminated health, safety, security, and environment (HSSE) exposure and operational considerations during design, fabrication, integration, transport, and installation of the platform. The reduction in installation time was due to the simplicity of the connection—lugs versus a padeye/shackle/ shear pin system required by steel-wire rope. The total number of fittings was reduced, along with the elimination of additional steel-wire ropes required just to handle the fittings. The rig’s design also influenced the choice. The TLP’s columns have limited space to accommodate additional hardware. The use of lugs and synthetic ropes rigged in a simple basket passed through the lugs required little additional space. The solution Because the use of synthetics in this application was new to Shell’s engineering team, they relied heavily on their selected vendors for information and assistance in selecting the highest integrity products, fabricated into the most efficient configurations to handle the requirements of the project. Engineers from Shell and their installation and transportation contractor, Heerema, worked with Samson’s master fabricating distributor in Houston, SWOS. Mike Poroo from SWOS handled the interface with Shell’s engineering team and Heerema during the planning stages, coordinated the fabrication of all the lines, and was on hand for the installation and rigging prior to the tow-out. Samson’s offshore technical sales engineer, Justin Gilmore assisted with appropriate line selection and design. Fabrication and testing of all the components was done at SWOS’ Houston facility. LEFT: Crowley tugs rigged for propulsion during the inland portion of the tow out Photo by Tim Burdick Photography CASE STUDY: Olympus Tow-Out..............1 TECHNICAL BULLETIN: Inspection & Retirement Pocket Guide.......................4 FROM ANOTHER DIVISION: KZ™100 Synthetic Crane Hoist Lines..............5 Samson Assists NASA on Space Station Exercise Project............... 5 CURRENT NEWS:......................6 Samson in Action Behind the Lion JU L Y 2 0 1 4 CASE STUDY: Olympus Tow-Out continued Gilmore reports, “SWOS was the key contributor to the success of this project. Shell leveraged the technical and fabrication expertise of SWOS from design to installation. With SWOS located in the heart of Houston, they are the perfect partner for projects in the Gulf. They inventory a big selection of our products, handle all of the custom fabrication and testing, and were on-site to get first-hand knowledge of how the ropes were going to be used and oversee the installation; ensuring the best possible outcome for Shell.” The Inshore Tow-out—No Room for Error The inshore portion of the tow-out was critical. At times, there were as little as nine meters of clearance in the channel from the Ingleside integration facility to open water. The channel transit required eight tugboats—two for propulsion, two for braking, and two for steering, plus two more on standby. The two propulsion tugs and the two steering tugs were tethered to the rig using wing lines fabricated from Samson Quantum-12, a 12-strand line made with 100% Dyneema® HMPE fiber with Samson’s patented DPX™ technology incorporated into the surface strands. The line is designed to have an enhanced coefficient of friction for better grip on H-bitts and capstans. All lines were fabricated with an eye on each end, and protected from chafe with Samson’s Saturn Dynalene. A sliding chafe sleeve of Samson DC Moor-Gard that could be easily moved along the line to the location of the lugs was also fitted to prevent chafe at the attachment points through the lugs. The Offshore Tow Once the rig was clear of the channel and in open water, the tugs were repositioned in the offshore tow configuration. Again, an easy changeover without the need for additional equipment was critical. Rigging in open water can be challenging, but lightweight, high-performance synthetics that are easily handled by manpower alone made rigging changeovers quick and efficient. Photo by Tim Burdick Photography The offshore portion of the tow-out. Four tugs were used for the offshore tow; three towing the rig astern using Samson Saturn-12, a 12-strand, 100% Dyneema® fiber line. Saturn-12 has the strength of steelwire rope, along with a proprietary coating that significantly reduces both internal and external abrasion. The result is ultimate strength and reliability in a line that will outperform and outlast other lines with up to 20% longer service life in critical applications. These lines were rigged in advance, with two of them designed to double as a positioning bridle during anchoring and installation. These lines were also fabricated with an eye at each end, protected with Saturn Dynalene and a sliding sleeve of DC Moor-Gard to be positioned at the center of the line through the lug to protect from rotational abrasion caused by potential sea swells during the 10-day tow-out. Photo by Tim Burdick Photography Positioning the rig during installation. Positioning and Installation Arriving at the installation site, the four transport tugs were again repositioned; one at each of the four quadrants of the rig. Each was tethered by a positioning bridle fabricated from the same Saturn-12 construction as the offshore tow lines. The bridles were rigged prior to the tow-out. Since the Olympus platform is installed in relatively close proximity to the existing Mars platform, positioning operations were critical. In each case, the lines were rigged quickly and efficiently by a minimum of POSITIONING BRIDLES crew and without additional handling equipment. Early Photo by Tim Burdick Photography engineering and design took into account using synthetic Olympus TLP and AHV during installation; positioning bridles visible from rig. lines for the eventual tow-out and installation stages later in the process. That allowed standardization of the towing lugs and the ability to replace unique and complex one-off components required for steel-wire rope with a much simpler, yet robust, design. After the project the ropes SWOS’ Mike Poroo reports on another benefit to using were returned to SWOS lightweight, high visibility synthetic lines for the positioning for inspection, proofportion of the project, “An unanticipated advantage not loading and recertification. covered in the report was explained to me during my last They are currently stored visit with Shell. They could look down from any point on the platform and clearly see the Saturn-12 lines while in controlled conditions moving the platform into position. Wire rope would have and ready for use on the been too dark in color and too far under water to see. This next Shell project. helped keep the vessels clear of the lines and helped prevent a tow-line from snagging on the preinstalled tendons/tension legs.” Key Benefits Samson’s high-performance synthetic lines made with Dyneema® fiber are, size-for-size, as strong as wire rope with similar elongation characteristics, yet weigh 85% less and they float. The advantages include quick and easy rigging using only manpower in most cases, rather than heavy equipment. This results in safer worksites with fewer strain injuries from excessive weight, a significant reduction of potential pinch-points, and elimination of injuries from broken, “fish-hooked” strands common with wire rope. In addition, exposure to potentially dangerous situations with additional heavylift equipment and personnel was virtually eliminated. Shell found that transitioning to synthetic ropes for tow-outs and installations furthers their aim of achieving Goal Zero and strengthening their commitment to safety. 2 JU L Y 2 0 1 4 CASE STUDY: Olympus Tow-Out continued SWOS and Samson representatives were on hand for the initial rigging for the tow-out. Each line in the system was purpose-built and fabricated to specification at SWOS’ Houston facility. Each is tagged with a unique serial number and can be tracked using the Field ID database that maintains a full record of the lines’ construction details, current certifications, and logistics. Photo by Tim Burdick Photography With the installation now complete, the lines have been returned to the SWOS facility in Houston. They have been fully inspected, proof loaded, and recertified, and are being stored in controlled conditions, ready for use on the next Shell project. HSSE Benefits In addition to the operational efficiencies of using Samson high-performance synthetic lines for tow-out, the switch from wire was consistent with the design philosophy that proven, safe solutions are better than designing one-off, complex solutions. Transitioning to synthetic lines for tow-outs and installations furthers the aim of achieving Goal Zero, a program that captures the belief that they can operate without fatalities or significant incidents despite the often difficult conditions. Lightweight, high-strength synthetic ropes have been proven to significantly eliminate weight-related injuries as well as handling injuries while reducing operational times. Challenges Encountered Since the platform connections had been designed to accommodate synthetics, the attachment points had been engineered from the start. The connections to tugs from two different tug operators—Crowley and Signet—were only a little more problematic. Crowley was supplying two brand new ocean-going tugs that were placed in service just prior to the tow-out. This would be their first operation. Signet provided four tugs. Each had different configurations of deck hardware and equipment to account for in designing the connection from the tug’s tow wire to the synthetics attached to the platform. One unexpected benefit — the highly visible Saturn-12 and Quantum-12 lines improved safety. The Results In this case, an offshore project worth more than $1 billion was delivered and positioned safely for installation with a significant savings in time. In addition, there were no safety issues to personnel or damage to the rig itself in the process. The Samson Advantage In the case of the Olympus TLP tow-out, SWOS and Samson engineers brought not only superior products to the project, but also the full knowledge-base Samson has developed over its 135-year history. A history of manufacturing innovative cordage products that industries rely on for the biggest challenges. Products that can change the way critical work is done on the most complex projects. SWOS’ expertise in dealing with the offshore industry’s unique problems, combined with the test data and engineering expertise of Samson’s Research and Development and Sales Engineering departments, help to produce the best outcomes. More efficient operations, safer work environments, well-engineered products: it all adds up to a real, significant advantage on complex, demanding applications. We call it The Samson Advantage. Our customers call it peace of mind. There’s a lot riding on your mainline… …and your bottom line. Delivered with every Samson towing system is a service package that ensures long service life and low total cost of ownership. We call it The Samson Advantage. Our customers call it peace of mind. SamsonRope.com INSTALLATIONS INSPECTIONS TRAINING DOCUMENTATION RETIREMENT CRITERIA Dyneema® is a registered trademark of Royal DSM N.V. Dyneema is DSM’s high-performance polyethylene product. 3 JU L Y 2 0 1 4 TECHNICAL BULLETIN: Inspection & Retirement Pocket Guide A new way to talk about synthetic ropes The visual inspection of synthetic ropes before use is critical in most industrial applications. The residual strength of a rope, the prime indicator of its useful and safe remaining working life, must be assessed before committing the rope to continued use. With high-performance synthetics like HMPE replacing steel-wire ropes in many applications, the need for a method to determine the state of a rope is more critical than ever before. The problem is that there is no common, standardized language or reference scale to describe the state of a rope. To date, judgment on the state of the rope has required a synthetic rope expert to complete an inspection on-site. The alternative is removing the rope from service and testing the rope to destruction in order to evaluate residual strength. d Inspection ancket Po t en em ir et R Guide SINGLE BRAIDS The detailed photos and information make inspection quick and accurate. NA L This information is provided as a guideline. If you are unsure of the condition of your rope/sling, please contact your sales or technical support representative. st* period of time will racteristics of hile others will. ons that should be Email: [email protected] Cut Strands theseconditions, eforedecidingto ce, RepaIR oR ReTIRe What > Two or more cut strands in proximity Cause > Abrasion Compression NoT peRMaNeNT— RepaIR What > Sharpedgesandsurfaces > Cyclic tension wear ved damage ge is over ernational Guideline Criteria: Guidelines 2004. CorreCtive aCtion If possible, remove affected section and resplice with a standard end-for-end splice. If resplicing is not possible, retire the rope. Cause Pulled Strand Melted or Glazed Fiber NoT peRMaNeNT— RepaIR > Visible sheen > Stiffnessreducedbyflexing the rope > Nottobeconfusedwithmelting > Often seen on winch drums What > Fibermoldingitselftothe contact surface under a radial load CorreCtive aCtion Work back into the rope. Cause > Strand pulled away from the rest of the rope > Isnotcutorotherwisedamaged > Snaggingonequipmentor surfaces What Cause > Fusedfibers > Visiblycharredandmeltedfibers, yarns, and/or strands > Extreme stiffness > Unchangedbyflexing > Exposure to excessive heat, shock load,orasustainedhighload CorreCtive aCtion If possible, remove affected section and resplice with a standard end-for-end splice. If resplicing is not possible, retire the rope. CorreCtive aCtion Flex the rope to remove compression. Discoloration/Degradation Inconsistent Diameter Abrasion RepaIR oR ReTIRe RepaIR oR ReTIRe RepaIR oR ReTIRe RepaIR oR ReTIRe What Cause > Fusedfibers > Brittlefibers > Stiffness > Chemical contamination CorreCtive aCtion If possible, remove affected section and resplice with a standard end-for-end splice. If resplicing is not possible, retire the rope. What Cause > Flat areas > Lumps and bumps > Shockloading > Broken internal strands CorreCtive aCtion If possible, remove affected section and resplice with a standard end-for-end splice. If resplicing is not possible, retire the rope. msonRope.com What Cause > Brokenfilamentsandyarns > Abrasion > Sharpedgesandsurfaces > Cyclic tension wear CorreCtive aCtion Consult abrasion images* and rate internal/ external abrasion level of rope. Evaluate rope based on its most damaged section. n Minimal strength loss (continue use) n Significant strength loss (consult Samson) n Severe strength loss (retire rope) *Refer to images on opposite side. 2090 Thornton Street, Ferndale, WA 98248 USA Tel 01.360.384.4669 Fax 01.360.384.0572 SamsonRope.com © 2013 Samson Rope Technologies, Inc. All rights reserved. 3/2013 #1021 {108283} 12.5K The Pocket Guide includes information on proper rope inspection techniques and corrective action steps, plus a visual scale for external and internal abrasion. Understanding Abrasion EXT ER N AL EX T ERNA L EX T E R N AL 1 2 3 IN T ER N AL I NT ERNA L I N T E R N AL E XT E R N AL E XT E R N AL E XT E R N AL E X TE R NA L There are two types of abrasion: internal abrasion caused by the relative movement of internal and external yarns, and external abrasion caused by contact with external surfaces. An unprotected rope moving over a rough surface, such as a poorly maintained chock can be subjected to both. Upon inspection, it’s easy to see that the external strands are abraded by a rough surface: often, fibers can be left behind on the surface that caused the abrasion, and the surface of the rope readily shows abraded yarns. Compare surface yarns with internal yarns. Inspect for internal abrasion. The same rough surfaces can also cause internal abrasion due to the movement of the internal strands relative to each other. When the rope’s surface strands pass over rough surfaces, they are slowed relative to the strands next to them, causing friction. Heat is created from friction— and heat is among the biggest enemies of synthetic ropes. This information is based on testing performed by Samson and is provided as a guideline. If you are unsure of the condition of your rope, please contact your Samson representative. The Samson Inspection and Retirement Pocket Guide is designed to alleviate this problem by establishing a common language and a reference scale to describe the current state of a rope. The Pocket Guide is based on a statistical analysis of several years of lab testing reports of ropes used in a variety of different applications and tested to destruction in the Samson R&D labs. All testing in the Samson labs is well documented with photos of the samples tested and pre-test assessments of the general state of the rope. The type of damage, its extent, and any mitigating conditions (like chafe gear) are all properly noted. The rope is then tested to destruction to determine the actual residual strength of the sample. The resulting guide provides a means of estimating the state of the rope and whether it should be repaired or retired from use. The Inspection and Retirement Checklist section of the Guide describes the seven common forms of damage: cut strands, compression, pulled strands, melted or glazed fiber, discoloration/degradation, inconsistent diameter, and abrasion. It provides a visual reference for each and a determination of the cause and possible corrective action that can be taken. Abrasion Of all the forms of damage that a rope is subjected to, the most commonly observed are abrasion and cutting. Both result in broken filaments in the rope and in a potential reduction in strength. Cutting is characterized as a highly concentrated density of broken filaments localized in one or several strands at one particular position on the rope. Cutting is generally easier to assess than abrasion in terms of the volume of broken filaments in relation to the size of the rope. 4 IN T E R N AL 5 IN T E R N AL 6 IN T E R N AL In Ret 7 SIN I NTE R NA L ropes that are dragged against rough surfaces without proper chafe protection, or experience repeated bending over sheaves and across fairleads, the surface fibers are slowed in relation to the internal fibers, causing fiber-on-fiber abrasion. The effect of abrasion on the residual strength of the rope is more difficult to assess than cutting or other forms of physical damage. To help assessment in the field, the second side of the Pocket Guide is devoted to a visual comparator of the various states of both internal and external abrasion. The Abrasion Comparator The Abrasion Comparator shows a ® 12-strand HMPE rope —AmSteel Blue—in a range of abrasion states from new rope to rope ready for retirement. The images represent a scale numbered from 1 through 7 that ranges from minimal strength loss (steps 1 and 2), significant strength loss (steps 3 through 5), to severe strength loss (steps 6 and 7). Each is further tagged with an action—for ropes with significant strength loss, consult Samson; for severe strength loss, retire the rope. Images are provided for both external abrasion and internal abrasion. When consulting your Samson dealer or representative you now have a ready reference to accurately describe the state of the rope in question. Abrasion is characterized as a low density of broken filaments distributed across a larger volume of rope, both along the length of the rope as well as among the various strands at any position along the rope. Abrasion can be both external—along the surface of the rope, and internal, within the structure of the rope itself. The comparator is an easy reference that can be used in the field to help assess the state of a rope. Small and easily held in the hand while performing an inspection, it helps establish a guideline and a common language when discussing the state of a rope. It is printed on extremely durable synthetic paper that is resistant to tearing and comes packaged in a vinyl sleeve to make it ‘pocket friendly.’ It is easy to visualize how external abrasion occurs—ropes dragged across rough surfaces can easily break surface fiber filaments. Internal abrasion is caused by fiber filaments rubbing against one another, or by the ingress of grit or gravel into the braid of the rope. In For a complete description of the methodology used in preparing Samson’s “Inspection and Retirement Pocket Guide,” see the technical paper “Inspection Criteria for HMPE Rope” available in the Resources and Literature section of SamsonRope.com 4 JU L Y 2 0 1 4 NEWS FROM ANOTHER DIVISION: Synthetic Crane Hoist Line & NASA Samson KZ™100 Synthetic Crane Hoist Line: The first rope designed specifically for use on mobile cranes In an industry where safety is the no. 1 priority, KZ™100 is a lightweight alternative to traditional steel-wire hoist ropes. With the same load pull and load chart as wire, KZ™100 can be used with a 5:1 safety factor. It is 80% lighter than the wire it replaces for easy handling, simplified reaving, and faster installations. Synthetic KZ™100 does not rust and requires no lubing. The unique construction eliminates kinking, bird caging, and damage caused by diving on the winch drum. With a torque-neutral construction, KZ™100 eliminates load spin and cabling. Manitowoc and Samson joint development KZ™100 is a product of joint application development between Samson and Manitowoc, supported by fiber supplier DSM Dyneema®, and ushers Samson into the crane industry. “Together, we were able to leverage the experience and technical expertise of both Research and Development teams to bring the market something completely new that offers many benefits to the end user,” said Michael Quinn, Samson’s director of new market development. The product debuted at ConExpo 2014. Mike Herbert, director of product planning and marketing for Manitowoc, said “…dealers, customers, and even everyday crane enthusiasts will see what a leap in technology this first synthetic hoist rope is for the lifting industry. Partnering with Samson on this “…dealers, customers, application development resulted in a lighter and and even everyday crane more innovative product that ushers in a new era enthusiasts will see what of hoist ropes.” a leap in technology this first synthetic hoist rope is for the lifting industry. Partnering with Samson on this application development resulted in a lighter and more innovative product that ushers in a new era of hoist ropes.” MIKE HERBERT, Manitowoc director of product planning and marketing KZ™100 was tested in the lab to characterize tensile strength, tension fatigue, bend fatigue, and the effects of temperature on the rope’s performance. These tests were performed at four different testing labs—two Samson labs and two third-party labs, and required more than 4,000 hours of machine and sample preparation time to complete. More than 4.6 miles of rope was manufactured for testing and field trials over the course of this project. Manitowoc conducted reliability tests over more than 280 hours and 14,000 cycles. The rope, sold exclusively through Manitowoc, will be available as an option on all Grove rough-terrain cranes in late 2014. The initial launch at ConExpo 2014, together with Manitowoc’s grove RT770E rough terrain mobile crane, generated serious interest within the industry. KZ ™100 is 80% lighter than the wire it replaces with the same load pull and load charts. Torque neutral construction eliminates load spin and cabling. Photo © Manitowoc Cranes Developed jointly by Samson and Manitowoc KZ ™100 ushers in a new era in hoist ropes. International Space Station Crew Stays Fit with Samson Crewmembers on the International Space Station (ISS) need to maintain their preflight muscle, bone strength, and endurance. The Advanced Resistive Exercise Device (ARED) helps them do just that. Developed by engineers at NASA, the exercise device simulates a free-weight training regimen that is hard to duplicate in zero gravity. Cable-based exercises use a rope interface. The engineers at NASA had at first specified 1/4" Validator- 12 for its low elongation, high strength, and no creep, but the splice was too long and the splice area too big to work efficiently with their system of pulleys. They tried to develop a shorter splice, but it was unreliable. The rope needed to be replaced every three months. At the cost per minute of time on the space station, a reliable replacement needed to be found. NASA’s team included a sailor who recommended Samson’s XLS as a candidate. XLS was put through their complete lab test series and was found to outperform Validator-12 in this application. The XLS was put into service on ISS. When the splice began to pull out, it was time to call in the experts. Samson R&D was consulted—the best solution was to lockstitch the splices in the XLS to keep them from pulling out. Problem solved. XLS is performing well and is expected to last more than four times longer before replacement is needed. Samson sent Danielle Stenvers from R&D to consult with the NASA ARED team. She returned with a list of follow-up questions from NASA engineers. In appreciation for the work Samson does to support the mission of the ISS, Danielle was treated to a personal tour of the facilities and labs by one of the ISS astronauts. 5 JU L Y 2 0 1 4 Current News from Samson BEHIND THE LION SAMSON LOGO 130th ANNIVERSARY James P. Tolman chose the trademark (issued July 4, 1884 — the nation’s oldest continuously registered trademark) as a symbol of brute power encountering its match. In Tolman’s mind, the strength of Samson was something to be equated to the strength of his braided rope. Tolman’s sister had been struck by the paintings of Samson and the lion she had seen in her tours of European art galleries and suggested adapting the biblical story as the basis for a trademark. His mother and wife are also listed in the family annals as contributors to the design. This July Samson’s trademark celebrates 130 years of service to the company! Samson high-performance winch lines GO DEEP SAMSON IN ACTION U PCOMI N G EVE N TS See Samson at these upcoming events: MOORING > IMPA September 17–18: London, United Kingdom OFFSHORE > OSEA December 2–5: Marina Bay Sands, Singapore TUG > International Workboat December 3-–5: New Orleans, Louisiana Perdido Spar Project: Lightweight traction winch on a cantilevered deck holds 9,200 feet of 2-1/2" diameter Quantum-12 and lifts up to 90,000 pounds. STRONG RELIABLE EFFICIENT Samson high-performance winch lines go deeper than steel wire: > 85% lighter than same > Greater capacity in size steel wire ultra-deep water > Reduces deck weight > Neutrally buoyant Talk to the experts at Samson and put their experience and extensive testing to work on your next winch line or heavylift project. CONTACT SAMSON EMAIL: [email protected] ONLINE: SamsonRope.com PHONE: 1.360.384.4669 FAX: 1.360.384.0572 MAIL: 2090 Thornton Street Ferndale, WA 98248 USA 6