LPS0265 DIP Brochure - SPE Offshore Europe
Transcription
LPS0265 DIP Brochure - SPE Offshore Europe
Diverless Installable Products Engineered Systems 2 Diverless Installable Products Contents Description Page No. Introduction 3 Company Profile 3 Vortex Induced Vibration Suppression Strakes 4 Thermal Insulation and Integral Strakes 4 Engineered Thermal Insulation Covers 5 Diverless Bending 6 Stiffener Connector (DBSC) ROV Clamps 7 Distributed Buoyancy Modules 8 ROV Releasable Buoyancy Modules 9 ROV Buoyancy Modules 10 Research and Development 11 ROVs were developed to aid inspections and operate in hostile waters where it would be unsafe or impossible to use divers. Before long, inspection ROVs were upgraded, fitted with manipulators etc, and became the workhorse for both Subsea inspections and basic intervention. Over the years ROVs have become more dextrous and operate in significantly deeper waters. They are now a necessity for Subsea intervention. Diverless Installable Products Introduction This publication is designed to present Trelleborg CRP’s diverless intervention products and solutions. Trelleborg CRP have completed a number of high profile contracts for the design, engineering and supply of products including buoyancy modules, thermal insulation covers, flange and pipeline protection, all of which have unique project specific design features. Trelleborg CRP is the largest and most experienced manufacturer of ROV buoyancy modules worldwide. Trelleborg CRP’s customer list is extensive and includes all the key ROV manufacturers. Trelleborg CRP has produced buoyancy modules for Halliburtons’ Pioneer, Examiner, Hercules and Warrior vehicles, Perry Slingsby Systems’ - MRV, Olympian, Spartan, Triton MRV and ST trenching vehicles, Stolt Offshores’ - SCV 3000 (see page 10), and Matis, plus a myriad of smaller vehicle builds including Seaeye Marines’ Puma and Sub-Atlantics’ Cherokee. By the end of 2004 Trelleborg CRP had supplied over 1000 modules on over 250 different vehicles. Trelleborg CRP is Proven to Perform. manufacture of buoyancy systems for AUV’s, manned submersibles, trenchers and deep sea rescue vehicles (DSRV’S). A relatively new type of subsea vehicle currently in great demand is deepwater ‘tracked' cable maintenance ROV's, or Trenchers. This in effect is a subsea tractor with wheels or track pads, but because of its size and weight in water, requires a substantial buoyancy pack depth rated accordingly, typically 3000 metres. Further more Trelleborg CRP have an extensive track record for the design and Company Profile With over 30 years of experience, Trelleborg CRP is a recognised leading designer, manufacturer and supplier of thermal insulation, buoyancy and cable protection solutions to the Offshore, Marine, Subsea and Telecommunication industries. With its headquarters in Skelmersdale, UK, the company started life producing polyurethane lifebuoys and lifejackets for the Marine industry, quickly earning a reputation for high quality manufacturing and product development. As a result of a continuous policy of product innovation and a programme of strategic growth, Trelleborg CRP embarked upon a number of material diversifications including syntactic foam, a material used in the construction of subsea buoys, ROV buoyancy and thermal insulation systems, which precipitated the company’s entry into the offshore market. Global Capabilities The company continued to expand throughout the 80’s and 90’s, moving into a purpose built manufacturing and office facility in 1990, heralding the start of a programme of continued expansion through both generic and strategic growth. By 1998 the company had further extended its site, more than doubling the manufacturing facility whilst adding a dedicated testing facility housing Europe’s largest hydrostatic pressure vessel for the testing of deepwater buoyancy modules. The group gained BS EN ISO 9001 certification (since superseded by BS EN ISO 9001:2000) and continued to invest in both its home and overseas operations. In 2000 the company acquired OCP Cable Protection Ltd and US based Emerson & Cuming Composite Materials, Inc. (ECCM). OCP, a specialist manufacturer of cable protection products, primarily servicing the seismic industry, complimented Trelleborg CRP’s product range and opened up new market sectors for the group. ECCM are widely regarded to have pioneered the development of syntactic foam buoyancy systems over 50 years ago and brought in-house production of high grade glass microspheres (Eccospheres®) to the group. This material has been used extensively in offshore thermal insulation applications together with a wide range of enhanced syntactic materials used heavily throughout Trelleborg CRP’s markets and also in aerospace, space and military applications. Continued Development February 2003 saw the acquisition of Houston based BGII, significantly increasing the group’s manufacturing capability whilst enhancing the scope of supply to the expanding Gulf of Mexico sector. In January 2006 all companies were acquired by Trelleborg AB through their Trelleborg Engineered Systems business area. Trelleborg is a global industrial group with over 22,000 employees operating in 40 countries. Their market leading positions are based on advanced polymer technology and in depth applications know how. As part of Trelleborg each company is able to benefit from a number of synergies including combined research and development programmes, cost efficiency initiatives, production flexibility and the sound financial platform that is provided by a large international conglomerate. Despite this rapid growth Trelleborg CRP has remained true to the principles of customer service and product innovation that launched the company over 30 years ago, continuing to offer engineered solutions that assist its customers to increase the efficiency, cost effectiveness and on-site safety of projects all over the world. 3 4 Diverless Installable Products Vortex Induced Vibration Suppression Strakes In deepwater applications, the use of steel catenary risers is increasing. These risers can be subject to the complex phenomenon of Vortex Induced Vibration (VIV). VIV causes accelerated fatigue damage and can give rise to problems such as pipe girth weld failure. Other applications prone to VIV are rigid steel flowlines unsupported over free spans and major deepwater field developments utilising a large number of thermally insulated pipelines, etc. For existing lines a VIV suppression system can be retrofitted by divers up to a pre determined limit or by ROV in deepwater. ROV Installable VIV Strake Covers Designed to established Trelleborg CRP design standards for VIV suppression strakes, Trelleborg CRP ROV installable strake covers are high performance composite covers with an attachable polymer strake profile incorporating the field proven hinge and ratchet locking mechanism (ROR - Remote Operated Ratchet) which allows the ROV to handle, open and securely close the covers around the pipeline. The strake covers are manufactured in two halves using a high performance GRP composite, providing a lightweight high-strength structure which supports a separately moulded rigid polyurethane strake, sized to suit each design. The covers are hinged down one side and fitted with a patented moulded ROR system on the other side with connection points. The covers are designed to minimise ROV intervention and incorporate accessible handles to afford easier installation. All these features can be incorporated at design stage with the cooperation of the ROV or installation contractor. The whole system is neutrally buoyant in seawater but can be adjusted to suit. Thermal Insulation and Integral Strakes On the majority of deepwater developments, for fields greater than 1000msw, thermal insulation is often required on all exposed pipeline structures, including subsea manifolds, Xmas trees and spool piece pipelines. As the outer diameter of the pipeline increases due to the additional insulation requirements the potential for VIV is also increased. Trelleborg CRP provide thermal insulation shells incorporating a “strake profile” which is moulded into insulation shells. This solution has been successfully used on a multitude of previous projects. With the increasing number of deepwater field discoveries it is anticipated the requirement for integral VIV strakes will increase accordingly. By adopting the integral strake principle with a thermal insulation requirement, Trelleborg CRP can design a dual function engineered product to suit clients exact thermal and VIV suppression requirements. Other variants are available and Trelleborg CRP’s experienced design department can develop project specific systems. Diverless Installable Products Engineered Thermal Insulation Covers Engineered Connector Insulation Often the most challenging piece in the flow assurance jigsaw is the insulation of the final connections. Risers, Flowlines, Jumpers, Manifolds and Trees can all be insulated prior to deployment, but once installed and successfully connected it is vital that those connection areas are adequately insulated in order to maintain the integrity of the completed system. Connections can take many different forms and may require completion via many different methods, from a diver installed flange connection through to a deepwater ROV installed stab and hinge over. Retrofitting insulation covers are often required. Trelleborg CRP has a wealth of experience in the design and manufacture of insulation covers to suit the broad range of complex and intricate assemblies in use today. Our design teams have extensive experience of developing bespoke solutions for one-off applications as well as working with the major subsea equipment suppliers to develop standardised solutions for the more common connection systems. In order to produce a cover that combines insulation efficiency with ease of installation a number of key factors need careful consideration. Trelleborg CRP engineers work closely with clients to adapt and modify existing solutions or develop project specific designs to meet particular requirements. Among the most important considerations are: • Materials • Sealing • Hinging and Latching • Buoyancy and Ballast • Installation Interfaces Thermal Insulation Shells and Doghouses are both installable by Remote Operated Vehicles (ROV). Installing any component in deep water via an ROV brings a multitude of challenges. Like the diver installed covers, units that are to be installed via an ROV need to be easy to handle and fool-proof to install. Unlike a diver an ROV operator has very limited and usually fixed visibility and relatively limited dexterity. The ROV installed cover therefore needs to be as simple a design as possible, with a great deal of emphasis placed on self-locating latching mechanisms and semi-automated operations. ROV time is very costly and as such the number of individual actions required to complete an installation are kept to a minimum. Each Engineered cover is unique as they are bespoke in design for their particular application. Our engineered covers have evolved over the years and during this period of time Trelleborg CRP have constantly improved their design. All modern covers incorporate a unique sealing arrangement which has been developed throughout rigorous testing and operational monitoring. 5 6 Diverless Installable Products Diverless Bending Stiffener Connector (DBSC) Dynamic flexible risers, flowlines, power cables and umbilicals may be connected to a rigid structure such as a subsea riser base or the turret exit of a floating production vessel. The presence of environmental loads will subsequently cause the “riser” to flex about this fixed location which, in combination with large axial loads, may cause damage to the riser structure due to overbending and fatigue. To prevent damage due to overbending the critical interface may be supplied with an integral bending stiffener (BS). The BS has a conical external profile with a hollow cylindrical section which allows it to slide over the end of the riser, adding local stiffness adjacent to a rigid connection to limit bending stresses and curvature to acceptable levels. Trelleborg CRP have the in-house capability to design and manufacture a wide range of steel interface structures to enable the BS to be connected to the adjacent rigid connection. The items often require complex interface engineering with riser suppliers, platform designers and installation contractors all wishing to have an input into the design process to ensure ease of construction and installation and integrity in service. For applications where the bending stiffener is prefitted to the riser prior to deployment and reeled off the laybarge before being pulled into the I Tube, Trelleborg CRP developed the Diverless Bending Stiffener Connector System. The Diverless Bending Stiffener Connector System (DBSC) assembly normally consists of the following components: • Female Interface (The main interface for the connection of the bending stiffener connector). • Diverless Bending Stiffener Connector (self activating and diverless). • Bending Stiffener. • ROV Removable Clamp (required during installation of the DBSC then removed). • Fixed Clamp/Backup Clamp (required during installation of the DBSC, remaining in place during normal service life then used to facilitate the removal of the BSC should it be required). The Trelleborg CRP DBSC is secured within the bore of the female interface via a fatigue resistant locking arrangement. The process is quick and reliable, with minimal ROV assistance required during installation. Diverless Installable Products ROV Clamps ROV Removable Clamp The ROV removable clamp is based on Trelleborg CRP’s typical buoyancy module internal clamp with a titanium strap surrounding a segmented syntactic body. The strap is modified to include ROV friendly fasteners and grab handles to enable removal by an ROV. A typical application for ROV removable clamps is within a Diverless Bending Stiffener Connector System. Each ROV removable clamp assembly consists of: • Clamp body • Circumferential strap • Tensioning assembly The clamp body has a cylindrical geometry and is split into individual segments to allow installation around the riser in a “drill chuck” arrangement. Rather than using a conventional bolting arrangement the required contact pressure between the riser and the clamp body is generated using a tensioned circumferential flat strap around the outside of the clamp body which is tensioned using a simple double cross bar and screw arrangement. Rotation of the screw using a defined torque causes it to rotate, pulling the crossbars together and hence generating the required tension. ROV Installable and Removable Clamp The ROV installable and removable clamp is a steel multi-segment clamp. The segments are required to cope with the riser OD tolerance, expansions and contractions. Each segment is held together using ROV friendly fasteners. A hinge connects two segments and swing bolts which allow the clamp to be initially installed as a hinged two part clamp. Once in place on the riser, the ROV engages and begins to torque up the swing bolts and the other fixed fasteners as per a typical multi-segment clamp. Prior to ROV installation guide wires are installed at surface which take the weight of the clamp during installation and removal. ROV Installable Clamps Trelleborg CRP design and manufacture a complete range of clamping systems. With over 20 years experience in the offshore industry and an unrivalled knowledge and expertise in polymer-composite materials, Trelleborg CRP are the world’s leading clamping system supplier. To complement our range of standard systems we offer a complete ‘concept to completion’ service Rigid Riser Clamps During the life of a fixed production platform it is often necessary to fit additional risers to the structure. Any connections between the riser and the platform structure must be capable of subsea assembly and be able to carry both static and dynamic loads throughout the design life. Connections of this nature may be made using rigid riser clamps. Riser Clamps Floating production platforms are normally connected to the subsea facilities by flexible risers and umbilicals. In these systems it is often necessary to support the umbilicals directly from the risers. Umbilicals may be secured to dynamic risers by installing clamps at discrete intervals. 7 8 Diverless Installable Products Distributed Buoyancy Modules More specifically in Floating Production scenarios, dynamic risers, rigid steel export risers, cables and umbilicals often require to be held subsea in a geometric configuration known as a stable catenary from vessel or platform to the riser base or export tanker. To achieve this shape one must apply a distributed buoyant load to the relevant riser section, this can be achieved with Trelleborg CRP’s “Distributed Buoyancy Modules” (DBMs). DBMs are usually deployed from a vessel at surface level but following installation it may become necessary to apply additional buoyancy to the stable catenary. In this case further DBMs can be installed to the stable catenary at subsea level using an ROV. This is known as a ROV installed “retrofit buoyancy solution”. ROV installed DBMs have a slightly different configuration to surface-installed DBMs. An existing DBM with integral internal clamp can be easily modified to enable ROV installation. Buoyancy Element The buoyancy element, which generates the upthrust to the flexible riser/cable/umbilical consists of the following: • Syntactic Foam Core • Robust outerskin • Integral clamp • Fastenings • Installation frame including ballast The buoyancy element itself is split into two identical halves which allow it to be fitted around the riser/cable/umbilical. Clamp Clamping onto the riser/cable/umbilical is via a pliable integral clamp fixed to the internal bore of the buoyancy elements. Fastening System The fastening system consists of a hinge arrangement and a ROV operable latching and tensioning assembly. The hinge arrangement holds the two halves of the buoyancy elements together, allowing the entry of the riser/cable/umbilical. Tensioning Assembly The tensioning assembly is designed specifically for ROV use. The first operation is engagement of the latch which is achieved automatically as the two halves of the buoyancy element are brought together fitting by latch hooks onto the adjacent bar. The tensioning assembly can then be torqued up by the ROV. Installation Frame For installation using ROV, an installation frame can be utilised which performs two functions, firstly to control the opening and closing of the module elements around the umbilical during installation, and secondly to hold the ballast in place during installation. The frame can then be removed by turning ROV friendly throughbolts to release the ballast from the module and the frame can be re-used if desired. Diverless Installable Products ROV Releasable Buoyancy Modules When installing heavy large diameter pipelines offshore, especially in deepwater, the tensions generated on the installation vessel can be extremely high. To reduce the weight of the pipeline during installation, discrete buoyancy modules can be strapped to the pipeline onboard the vessel or on land in the case of a shore pull. Trelleborg CRP pipeline buoyancy modules are manufactured for surface and deepwater operations. In many cases each of the pipeline buoyancy modules have to be released and recovered, a task which can be carried out by divers, an ROV or an acoustic release mechanism. Trelleborg CRP design, engineer and manufacture a complete buoyancy system to suit all project requirements. A number of standard cylindrical or square section buoyancy modules are available “off the shelf ” but usually clients request Trelleborg CRP to produce a project specific design. For mid-water and deepwater pipeline buoyancy modules, Trelleborg CRP use a composite syntactic foam formulated to match the maximum operating depth. Typical water depths are 500, 1,000, 1,500 and 2,000 metres but syntactic foams for greater water depths are available if required. The fast and efficient installation and subsequent release of buoyancy modules are essential to the overall success of any pipeline project. Trelleborg CRP provide a range of banding systems to secure the modules with project specific attachment/release mechanisms, where ROV releasable systems have been used successfully on many recent deepwater projects. Flexifloat Flexifloat is designed to remove the project specific nature of pipeline buoyancy modules. Nearly every installation has a different buoyancy requirement due either to a change in the pipeline diameter or by installation depth of the pipeline. Flexifloat comprises a series of discrete tubular buoyancy elements which are interlocked together by a Flexilink connector. This allows the buoyancy to hinge around the main pipeline to provide a close fitting low profile buoyancy system. The Flexifloat system can be supplied to generate 1,0005,000kg buoyancy per element and is rated for water depths of 30-1,000msw. It can be secured using conventional carbon steel ripaway straps or by a dedicated Quick Release Mechanism (QRM) and reusable Kevlar/EVA coated straps. Ancillary Equipment Trelleborg CRP provide a range of ancillary interface equipment to facilitate the attachment of existing buoyancy modules on to new/alternate pipeline/carrier systems including interface saddles and securing straps (including ROV releasable securing straps) Non Standard Buoys Trelleborg CRP can offer a complete design, engineering and manufacturing service to clients who have a specific “subsea” problem to solve. If standard Trelleborg CRP buoyancy units are inappropriate, development of a bespoke solution will be offered. Trelleborg CRP have produced a variety of “non standard” subsea buoyancy modules with unique design features, including ROV “ball grab” connection buoyancy modules with depth rating up to 3,000 metres. 9 10 Diverless Installable Products ROV Buoyancy Modules Trelleborg CRP have been manufacturing syntactic foam buoyancy modules for ROVs for nearly 20 years. During this time the size and complexity of modules have increased significantly. Buoyancy modules of up to 10,000kg nett buoyancy are now commonplace with the average water depth requirement up to around 3,000 metres. Trelleborg CRP have the material technology and design experience to manufacture highly sophisticated buoyancy modules using either a cross-linked co-polymer foam, typically for water depths up to 600 metres or a syntactic foam, depth rated to over 7,000 metres - full ocean depth. Clients are asked to send their preliminary enquiry to Trelleborg CRP to be carefully assessed by our Subsea Engineering department. Inserts One of the more complex issues relating to ROV module design is the location and incorporation of metallic inserts. These are usually provided as lifting points or for the attachment of additional equipment. However they can make a straightforward technical issue extremely complicated unless dealt with correctly at the design stage of a particular enquiry. Trelleborg CRP have a vast amount of experience in dealing with this very important subject. Protection Coatings ROV reliability is an essential requirement and ROV deepwater buoyancy modules can be vulnerable to handling damage, usually during deployment and recovery. Simultaneously applied impact and hydrostatic effects can compromise operational reliability. To address the problem and enhance module strength, a unique “hard shell” outer skin is incorporated within all Trelleborg CRP deepwater ROV buoyancy packs. The “hard shell” is homogeneous within the composite core and outer layers of the polyurethane elastomer skin. Following extensive impact testing the “hard shell” system proved to be 3 times stronger than a conventional outer skin. Diverless Installable Products Research and Development Testing Capability Testing and product development are at the heart of Trelleborg CRP’s material advances and product solutions. Whether this be within the laboratories, witness testing or ongoing research and development, testing is a major focal point for Trelleborg CRP. Trelleborg CRP believe that continuous and extensive testing is the only way to remain at the forefront of material development and continue to offer solutions that expand production possibilities and improve operating efficiency. facility. Although a similar size chamber, this vessel is rated to 3,400msw. Load Testing In order to verify the performance of the product Trelleborg CRP will typically perform various function tests. These tests will be tailored to the product in question to satisfy both Trelleborg CRP and the client that the product is fit for purpose. Typical tests performed are as follows: • Proof load testing • Destructive load testing Hydrostatic Pressure Testing Hydrostatic testing is probably the most common and regular form of testing undertaken by Trelleborg CRP engineers. To assist with the thorough and comprehensive testing of buoyancy modules, Trelleborg CRP have numerous pressure vessels rated up to 17,000bar and have installed one of the largest hyperbaric test chambers in Europe. Rated to 3,000msw, it has an overall height of 8.8m and inside diameter of 3m, enough to accommodate some of the largest buoyancy modules. • Fatigue load testing To complement this impressive fully instrumented test facility, a second test chamber is fully operational at our Houston Fatigue testing can be set up for products being used in high dynamic environments. The fit up and ease of assembly and timing • Simulated installation tests The proof load test is subjecting a fully assembled product to the calculated maximum in service loading for a defined time period, then examining the product for any signs of damage. The destructive load test includes a first proof load test, before increasing the load until failure of one or more of the elements occurs. The failure load is recorded and compared to the load anticipated by calculation methods. will be verified through simulated installation testing prior to the product leaving the factory. Facilities Trelleborg CRP have all the necessary equipment and personnel to conduct a wide range of materials testing and factory acceptance testing. All products and materials are subjected to a rigorous programme of qualification and process control. Trelleborg CRP also have contact with and access to external testing houses. In addition to hydrostatic testing the company has a comprehensive physical test laboratory and a calibration system fully compliant with BS 5781 Part 1/ISO 10012-1 standards. The company also designs and constructs full scale test rigs for new product design verification with the testing carried out at Trelleborg CRP and witnessed by clients or third party inspection as required. Extensive chemical laboratory facilities are available for analysis of the full range of polymer materials employed in the product range. 11 NORTH AMERICA EUROPE Trelleborg CRP Business Unit Stanley Way Skelmersdale Lancashire WN8 8EA UK Trelleborg CRP Ltd. Stanley Way Skelmersdale Lancashire WN8 8EA UK Tel: +44 (0)1695 712000 Fax: +44 (0)1695 712111 Tel: +44 (0)1695 712000 Fax: +44 (0)1695 712111 Trelleborg CRP Business Unit 114 rue Saint Lazare - BP20609 60476 - Compiegne cedex 2 France Email: [email protected] Website: www.trelleborg.com/crp Tel: +33 (0)3 44 23 03 50 Fax: +33 (0)3 44 23 03 49 Trelleborg CRP Business Unit Norsea Dusavik Bygg 1 PO Box 138 4001 Stavanger Norway Tel: +47 51 54 38 00 Fax: +47 51 54 35 00 Email: [email protected] Website: www.trelleborg.com/crp Trelleborg OCP Ltd. 3 Peter Green Way Barrow-in-Furness Cumbria LA14 2PE UK Tel: +44 (0)1229 842070 Fax: +44 (0)1229 842071 Email: [email protected] Website: www.trelleborg.com/ocp Trelleborg CRP Inc. 1902 Rankin Road Houston TX 77073 USA Tel: +1 (281) 774 2600 Fax: +1 (281) 774 2626 Trelleborg CRP Inc. 3131 West Little York Road Houston TX 77091 USA Tel: +1 (713) 956 0435 Fax: +1 (713) 290 0211 Email: [email protected] Website: www.trelleborg.com/crp Trelleborg Emerson & Cuming, Inc. 59 Walpole Street Canton MA02021-1838 USA Tel: +1 (781) 821 4250 Fax: +1 (781) 821 0737 Trelleborg Emerson & Cuming, Inc. 24 Teed Drive Randolph MA02368 USA Tel: +1 (781) 963 6794 Fax: +1 (781) 963 6788 Email: [email protected] Website: www.trelleborg.com/eandc The information contained in this publication is for guidance only and does not constitute a specification. All figures are nominal. This document discloses subject matter in which Trelleborg CRP Limited has proprietary rights. Neither receipt nor possession thereof confers or transfers any right to reproduce or disclose the documents, any information contained therein, or any physical article or device, or to practice any method or process except by written agreement with Trelleborg CRP Limited. Trelleborg CRP Limited is committed to further development of all its products. The right is reserved to alter this specification without prior notice.
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