O SH NS S 20 OW TA 10 ED VAN IT GE IO R N
OIL & GAS PRODUCT REVIEW ONS STAVANGER EDITION • SEPTEMBER 2010
CE R
T
RA
- ATEX - IECEx - IEC 61508 - EN13980 Quality System - Service Facility (equipment repair)
Training solutions covering Baseefa services, delivered to International audiences in the UK and abroad, plus online personal competency assessment to IECEx guidelines
INI N
G & COMPETE
TION ICA
Risk Assessment & Area Classification Legacy Equipment Assessments Plant Verification & Inspection Compliance Support (including ATEX)
TIF
Ex INSTAL LA T
S N O I
Y NC
Helping to make the world safer www.baseefa.com
KKI – still investing, still leading Koso Kent introl ltd armytage road, brighouse, West Yorkshire, hd6 1Qf W: www.kentintrol.com t: +44 (0)1484 710311 e: vector@kentintrol.com
With the neWs full of the events taking place in the Gulf of Mexico this year, even the lay person now has a good idea of the challenges facing engineers working on subsea projects. But for Koso Kent Introl, the problems and challenges of the unforgiving subsea environment are well known, and have been for many years. In fact, throughout its proud history, over 650 subsea valves have been designed and manufactured by the company. With significant future opportunities identified in development areas such as Brazil and the northwestern shelf of Australia, and growth expected in Alaska and the Gulf of Mexico, subsea valves are one of KKI’s major investment product areas in 2010. Originally established in 1967 as Introl the company rapidly achieved growth and a reputation of innovation that it still proudly maintains to this day. Over the years, ownership of the company has changed, but its location in the heart of Yorkshire in the UK, and its dedication to quality and product development has remained a core guiding principle. investment But the company’s leadership team is not happy to stand still, especially in the current climate of economic uncertainty. Denis Westcott, KKI’s Managing Director recognises that during periods
of increased competition, it is only those prepared to invest and look forward that will prosper and grow. “We used the economic downturn as an opportunity to look for prospects and are now increasing our focus on the upstream oil and gas side of the market. Our emphasis will be on FPSO, platform and subsea projects. Subsea activities will be a significant part of the market going forward and we aim to grow our influence in this area. Hopefully this will facilitate our expansion and cement our position as a specialist manufacturer,” said Denis recently. subsea solutions focus The KKI Engineering team, headed by Dr. Jonathan Lodge, is currently focused on the quality and operational efficiency of its subsea solutions. This team knows how important it is to create valves that can be relied upon; in the future, especially in the light of recent events, there can be no margin for error in subsea processes. It is only a rigorous approach to testing, quality control and assurance, and the utilisation of the company’s 20 years of subsea experience that will guarantee that its valves will operate successfully in such extreme environments. Therefore recently, much work has been done with regards to renewing the company’s API 6A PR2 accreditation, with the stringent requirements having been successfully met. Furthermore, investment in new equipment to allow a million step tests, and hyperbaric depth qualifications to 2400m depths (designed for 3000m depths) can further reassure customers about the absolute quality of the products they are ordering. As important to KKI and its customers as the quality of manufacturing is the quality of
KKI’s customers wIll be safe In the Knowledge that theIr chosen supply partner wIll stIll be delIverIng the hIghest qualIty solutIons to theIr valve needs
the design of subsea valves. The avoidance of the expense and inconvenience to customers of unscheduled repairs starts on the drawing board at KKI. The team designs against four core configurations: non-retrievable, diver-retrievable, ROV retrievable (remotely-operated vehicle) and ROT insert retrievable (remotely operated tooling). For this last option, at water depths of up to 1300m and external pressures of 240 bar, the pressure within the valves and actuators must be compensated to ensure their effective and continuous running. There’s no room for error, and so the team’s knowledge and experience of these hostile environments and working conditions is a reassurance to engineers and buyers as they select suppliers for subsea projects. Every KKI subsea valve is designed from scratch, according to the process it will be serving and the conditions in which it will be operating. Quality standards need to be adhered to (API 6A PSL 3G); material class requirements must be met (API 6A, EE, FF and HH), as must temperature class requirements (API 6A L to U standards, allowing for a temperature range of –46 degrees to +121 degrees centigrade). Trim configurations are a vital part of the design process, helping to avoid scenarios that might damage the valve during normal running and potentially lead to catastrophic failures further downstream. At KKI, these trim types include non-collapsible, bi-directional, single stage, multi-stage, velocity control and micro and multi-spine trims. Nothing is left to chance, and this is the secret behind KKI’s enduring success over the past forty years and more. other developments It is not only subsea markets that are a focus for KKI this year. The company is also investing heavily in the development of their Vector Labyrinth trim, and investment in quality standards such as APIQ 29001, ISO18000 and ISO29001 will further reinforce KKI’s reputation for excellence in the market place. aftercare Looking after our customers’ specific requirements doesn’t stop once a valve leaves the factory. The KKI philosophy of total quality is as embedded into aftercare as it is in the design and production of new valves. The service, spares and manufacturing teams often work together on aftercare client challenges. This combination of expertise ensures quality, reduces risk, controls cost and can provide a much faster turnaround than could be expected elsewhere. KKI’s longevity certainly helps in the delivery of an exemplary full product lifetime service. Records exist for every valve ever produced and serviced in the factory’s 40-year history. This unique record of the life of a valve, along with the service conditions in which it is operating, means that the team knows exactly what they are dealing with before they begin to service it. no service too severe So as 2010 progresses and the economic climate gradually improves, KKI’s customers will be safe in the knowledge that their chosen supply partner will still be delivering the highest quality solutions to their valve needs – whatever the application, however severe, wherever it is in the world.
3
Exposed: the dangers of benzene to seafarers Concateno 1A Harbour Quay 100 Preston’s Road London E14 9PH United Kingdom T: +44 (0)20 7712 8000 E: maritime@concateno.com W: www.concateno.com
FOLLOWING THE DEEPWATER HORIZON DISASTER, one of the largest operations in history is underway as attempts are made to clean up the tens of millions of gallons of crude oil spilled in the Gulf of Mexico. With such a large scale operation, which to date has involved some 5,400 response vessels and more than 25,000 people, the risk of exposure to the highly toxic and volatile chemical benzene is a significant threat. Benzene is a flammable liquid which occurs naturally in crude oil and natural gas. Crew onboard vessels involved in the clean-up efforts may be exposed to dangerous levels if their working environment is not carefully monitored and controlled. Seafarers can ingest benzene by inhalation, but also absorb it through the skin – even through indirect contact given its volatile nature. In the short term, exposure to low levels can cause numerous health problems including tremors, headaches and unconsciousness. Benzene is a significant cause of leukaemia and other blood-related illnesses, and exposure to high concentrations can cause death. Concateno, Europe’s most experienced chemical, drug and alcohol testing provider with 20 years’ experience in the maritime industry, has been providing its unique benzene urine test kits and exposure analysis for vessels involved in the oil spill clean-up operation. Concateno’s Benzene Exposure Biomonitoring (BEB) measures S-PMA (S-phenyl mercapturic acid), a benzene metabolite produced when benzene is absorbed into the body. The procedure allows rapid screening of at-risk individuals as required, which helps to identify and minimise potential exposure to hazardous substances therefore protecting the health of the seafaring crew. BEB uses state-of-the-art urine analysis to
4
rapidly identify exposure and trends. The benefit of using a urine sample is that it is easy to collect on board, and can determine all possibilities of exposure, either through inhalation or contact with the skin. Such monitoring can help determine the effectiveness of an organisation’s health and safety procedures and provide peace of mind for the crew. BEB technology is being adopted in the Gulf of Mexico by Norwegian shipping company Eidesvik, which is using Concateno’s sample collection kits to ensure that its seafarers are continually monitored for the presence of benzene. As is always the case onboard Concateno’s customers’ vessels, the health and welfare of all crew members is paramount. During this clean-up operation, Eidesvik is particularly mindful of the health risks of benzene exposure. The Concateno benzene kits provide marine companies with a simple method of testing its crew. Urine samples are taken using the vials supplied, and bio-packaged ready for dispatch to Concateno’s laboratories. Analysis takes a few hours and customers can have the results faxed or emailed back to them within two days. Since Concateno’s Maritime division added a low-cost, sensitive benzene test to its range of drug and alcohol services, the kits have been quickly taken up by shipping companies across the world, including the Norwegian shipping company Seatrans. Many vessels keep a stock of the test on board ready for instances such as the current operation in the Gulf of Mexico. The test provides a simple, fast and cost-effective means of determining exposure to this hazardous compound. Concateno’s network of staff across all the major shipping routes and international petrochemical locations ensures maritime organisations can benefit from the widest range of efficient, professional and responsive testing programmes in the market. Concateno’s experience, accredited processes and rapid turnaround times means its customers are guaranteed unsurpassed accuracy and integrity. The large-scale nature of the Deepwater Horizon disaster means that long-term exposure to highly toxic chemicals can be expected for many as a result. Concateno would urge any shipping company
CONCATENO’S MARITIME DIVISION Concateno provides comprehensive drug and alcohol testing to the maritime industry. The company boasts a wealth of experience, combined with accredited processes and rapid turnaround times, so customers can be sure that the accuracy and integrity of their drug and alcohol tests is unsurpassed. The Concateno Maritime Division team is solely focused on its clients’ drug and alcohol programme, ensuring that they get the best, most responsive service. With the most extensive range of tests in the market, Concateno provides drug testing panels to meet the major regulatory requirements that are fully supported by technical advice and customer service experience. Concateno works with its clients to provide innovative solutions; such as its benzene exposure biomonitoring service which was developed to meet the need for a simple method of monitoring occupational benzene exposure. Concateno has a geographical outreach covering all major ports and a network of over 600 fully trained collection officers. Their role is to ensure that the samples are collected and adhere to legally defensible chain of custody testing procedures with minimum disruption to the working life onboard.
working on the clean-up operation to consider adopting an effective benzene testing programme to ensure the safety of its crew. Aside from an employer’s duty of care to assess, monitor and manage risks on board, the shipping industry has witnessed an increase in the adoption of chemical testing and monitoring programmes due to the recent tightening of international regulations relating to benzene exposure and seafarer welfare. Changes to SOLAS regulation VI/ 5-1 regarding Material Safety Data Sheet (MSDS) provision for the shipment of MARPOL Annex 1 cargoes came into effect in January 2010. This information highlights the presence of benzene in crude oil, bunker oil and a number of other cargoes. It then details the actions required to reduce attendant risks from exposure to this substance. In addition, the new Maritime Labour Convention, which was adopted by the International Labour Organisation (ILO) in February 2006, has been designed to ensure the highest standards of healthcare, safety and welfare for seafarers. This is expected to come into effect in 2011.
When it matters most
Behind every test is a life Protecting the safety and wellbeing of seafarers and maritime workers is critical. Every crew member is responsible for ensuring that accidents at sea do not happen. Today’s maritime operators face some of their toughest challenges yet, including new international regulations for safeguarding health and welfare. With a worldwide client base, Concateno has more than 20 years’ experience providing the maritime industry with drug and alcohol testing programmes and hazardous chemical exposure monitoring.
Concateno Maritime Services •
Drug and alcohol testing
•
International sample collection service: •
Professionally trained network of officers
•
On board testing
•
24/7 collections
•
Legally defensible chain of custody procedures
•
Self collection service for post incident testing
•
Programme management, support and advice
•
Benzene exposure biomonitoring
Gulf Oil Spill: benzene exposure risks monitored by Concateno Health fears addressed amid clean-up operations Concateno has collected the first samples of its benzene exposure kits from vessels involved in the Deepwater Horizon oil spill clean-up operation. This procedure provides rapid screening to identify and minimise potential risk of exposure for seafaring crew.
Tel: +44 (0)20 7712 8000 Email: maritime@concateno.com www.concateno.com
Concateno Harbour Quay, 100 Preston’s Road, London, E14 9PH, UK
CGP7433 Ed.002
To find out more about our benzene exposure biomonitoring service for your company please contact us.
Undetected Sensor Failure Maintenance
With over 40 years experience in portable and fixed gas detection, Crowcon knows the pitfalls and problems you need to avoid. From South American steel mills to North Sea oil rigs, our reputation has been earned by delivering on the trust of those that we protect. Drift
www.crowcon.com
sales@crowcon.com
Flexitallic innovations improve asset reliability and longevity Flexitallic Ltd Scandinavia Mill Hunsworth Lane Cleckheaton BD19 4LN United Kingdom T: + 44 (0)1274 300300 E: flangerescuegasket@flexitallic.eu W: www.flangerescuegasket.com
FLExiTaLLiC To THE rESCUE WiTH FrG Set to revolutionise offshore asset maintenance, Flexitallic has launched the first-ever solution to sealing damaged flanges without the need for replacement or machining – the Flange Rescue Gasket (FRG). The FRG is a unique invention developed in response to customer demand for a sealing solution to reduce the lengthy and costly process of flange maintenance in corrosive offshore environments. The FRG actually negates the requirement for flange replacement or machining, so dramatically reducing downtime. Utilising Flexitallic’s revolutionary sealing technology, highly compressible Sigma® ensures the FRG conforms to damaged flange surfaces to seal and prevent further deterioration. Sigma®, restructured PTFE is bonded to the high integrity serrated metal ring, providing a leak-free seal and blow out resistance. The bright, easily identifiable FRG has a PTFE coated body, which is corrosion resistant and features integral bolt holes for ease of installation and ensures correct location. Superior mechanical integrity allows the use of the full range of torque, reducing the risk of operator error to meet stringent HSE standards. The FRG is the ultimate corrosion management tool, proactive in helping inspection and reactive in enabling repair. By reducing leaks and slowing corrosion, the possibility of shut-downs with associated HSE visits are dramatically reduced, as is the huge loss of revenue associated with a stop in production. From corrosion management to health and safety, through environmental impact to incident avoidance, the FRG is poised to dramatically change flange inspection and maintenance forever. Flexitallic’s approach to the problems experienced by the oil and gas offshore industry has resulted in high numbers of enquiries from engineers globally. Many enquiries involve the use of the FRG to both shorten the time of unplanned maintenance and also the reduction of the damaging effects of corrosion on new and replacement equipment, both having major implications for engineers. Russ Currie, Flexitallic’s applications engineering manager reports: “The FRG offers engineers an exciting solution for upgrading equipment and processes, especially when faced with the challenges that increased demands from
8
health, safety and environmental legislation bring. “Engineers and asset managers are instantly identifying that the FRG offers an opportunity to increase production up time, reduce maintenance down time and positively affect past and future corrosion damage to ultimately improve the profitability especially on ageing offshore assets. Feedback on the FRG from the industry includes many positive comments on the simplicity of the design, material development, innovative use of available technology and ease of installation.” Phil Kelshaw, sales and engineering director at Flexitallic comments: “The Flexitallic team has designed and manufactured an incredible product in the Flange Rescue Gasket. In line with the long list of the FRG’s features and benefits, Flexitallic has invested in a sophisticated marketing campaign to brand and launch the new gasket, to maximise awareness amongst engineers and asset managers to impact the gasket industry globally. Aspect Design & Marketing gave the flange rescue gasket a unique brand – a highly identifiable industrial styled FRG “stamp” logo and created a distinctive design style for use across all marketing communications. “We maintain our position as an industry leader in sealing solutions through engineering expertise, pioneering gasket design, materials development and setting industry standards. With strong, valued, long-term partnerships with customers, who rely on our knowledge of current health and safety and environmental issues affecting the industry. We work with them to identify problems and provide fast, innovative solutions. FRG is a great example of Flexitallic’s commitment to offering a superior sealing solutions package.” The FRG is the latest in a long line of sealing technology innovations from Flexitallic, from the spiral wound gasket to the flexible Sigma range of high integrity, low maintenance gaskets. THErMiCULiTE® – rEvoLUTioNary MaTEriaL For UNrivaLLED rESULTS Exclusive to Flexitallic, Thermiculite® is a truly revolutionary material. Developed for use in Critical Services, Thermiculite® gasket material maintains integrity from intense heat to extreme cold and was developed by Flexitallic to provide a successful seal across the widest spectrum of chemical processing technologies. Developed over a 15 year period, Thermiculite® provides industry with a high performance, technologically advanced yet easy to use material that has no rival. Comprised of thermally and chemically restructured Vermiculite, a non-
asbestos, versatile, non-toxic, non-hazardous mineral, Thermiculite® demonstrates remarkable versatility. When combined with various other materials such as Aramid or Steatite, Flexitallic’s unique and innovative manufacturing processes allow Thermiculite® material to be incorporated into many product forms. Capable of sealing at temperatures ranging from cryogenics to in excess of 1000oC, even in oxidising environments, applications inlude Petro Chemicals, Fertilisers and OEM, all of which require extreme process temperatures. Flexitallic’s team of experienced engineers use the versatility of Thermiculite® to create bespoke sealing configurations in equipment and piping systems to increase operational up-time for customers. This truly remarkable product has proven itself as an effective long-term sealing solution in over 500 of the most demanding industrial sealing applications. Recent testing has proven the material’s low leak rates - thousands of times tighter than the requirements of Germany’s air quality standard (TA Luft VDI 2440). Offering a single solution, Thermiculite® replaces the need for a range of sealing products. Inventory reduction, emissions compliance, increased gasket life and reduced misapplication all equate to major cost savings. The Flexitallic Group is the international market leader in the manufacture and supply of high quality, high value industrial static sealing products. Developer of the spiral wound gasket in 1912 in the US, Flexitallic continues to innovate with materials and products including Thermiculite®, Sigma® and the FRG. Flexitallic’s global customer service network of owned manufacturing facilities, licensees and global distribution network ensure local demand is met quickly, with a combination of the highest product quality and customer service. With a varied product offering that includes spiral wound gaskets, semi-metallic gaskets, RTJ gaskets, FlexproTM kammprofile, sheet gaskets and dynamic and static packings, the Flexitallic Group draws upon its past and present day mixture of leadership, quality, service and technology to develop sealing solutions for industry globally.
Dual Sealing Reusable Plug
Lee's Dual Sealing AFO Plug provides a leak tight metal to metal seal in high pressure manifold applications but also incorporates an O ring in order to vent air from a product when filling it with oil or to safely release trapped high pressure gas. ● Seals up 56,000 psig ● Floating Seal Self-aligns ● Stainless Steel construction ● NACE compliant materials available on request For more information, contact Lee Products Innovation in Miniature
Tel: 01753 886664 Fax: 01753 889588 www.leeproducts.co.uk e-mail: sales@leeproducts.co.uk
Lee Products Limited, 3 High Street, Chalfont St Peter, Bucks SL9 9QE
Rotaflow - the flexible joint specialists ROTAFLOW FV LIMITED Rotec House Bingswood Trading Estate Whaley Bridge High Peak SK23 7LY T: 01663 735003 F: 01663 735006 E: sales@rotaflow.com W: www.rotaflow.com
ROTAFLOW FV LTD DESIgnS AnD MAnuFAcTuRES high quality swivel joints for a wide range of applications in the chemical, oil & gas, processing and food industries. Swivel joints are a key element in Loading Arms, rotating drums and filters and for relieving torque in hoses. The patented design of Rotaflow swivel joints allows 360 degree rotation under pressure without leakage. With a clear bore, any fluid passing down a pipe will also pass through a Rotaflow swivel joint without restricting the flow pressure. The SK Series features Rotaflow’s
unique roller system and wide spaced bearings, to give a robust and reliable design. This range is ideal for the oil and gas industry, process plant applications, wash system designs, slowly rotating drums, filters and applications where offset loads are a problem. The large block seal allows free movement with low torque. The ‘F’ series of swivel joints in hardened carbon steel or ‘FS’ series in 316 stainless steel is designed for small bore applications from ¼” to 2” (DN6 to 50). We design and manufacture swivel joints in both carbon steel and 316 stainless steel and “specials” in any grade of metal to suit customer specification including the larger diameters. Every joint is tested and additional specific testing including coded welding, rigorous pressure and NDT etc is available on request. More and more we are rising to the challenge of the demands of quality paperwork with FAT. Rotaflow is also certified to PED Module H for the design, manufacture and repair of swivel joints.
9
The Need For Subsea Leak Detection NeptuNe OceaNOgraphics Ltd sapharey house, sturt road, charlbury, Oxon OX7 3sX, united Kingdom t: +44 (0)8453 707177 F: +44 (0)8704 581979 e: chris@neptune.gb.com W: www.neptune.gb.com
NepTuNe OceaNOgraphicS LTD is a global leader in the field of detection of leaks from subsea pipelines, risers and control systems and has made, and continues to make, significant technical advances in this field. Neptune has developed several new leak detection systems based on fluorometric, acoustic, differential temperature, MEG and direct hydrocarbon detection techniques. FLuOrOmeTry In the past detecting subsea pipeline leaks has relied on ‘black light’ (unfiltered ultraviolet light) to visually detect leaked fluorescent dyes either by diver or underwater camera, however, this method is very inefficient and relies on high dye concentrations and optimum visibility and tidal flow conditions for any chance of success. More recently, deploying submersible ‘tuned’ fluorometers that send data up to the attendant vessel providing a real time visual display has largely solved these problems. These submersible fluorometers are capable of measuring concentration levels thus allowing the operator to ‘home in’ on the highest values found at the leak source. They are very sensitive and will detect dye at concentration so low as to be invisible to the naked eye or underwater camera. However, with normal submersible fluorometers spatial coverage is poor and the dye has to be in contact before it is detected. To overcome the problem of spatial coverage and the need for dye contact with the fluorometer, Neptune Oceanographics has developed a family of ‘Long Ranger’ leak detection systems that detect tracer dyes remotely. The ‘Long Ranger’ sensors have forward facing ‘tuned’ light sources (like torches) producing beams of excitation light. The fluoresced light generated by leaking fluid is detected by the sensor without the need for contact. Because the sensors have high spatial coverage and long range, quick and easy scanning for leaks is achieved without needing to consider tidal flow direction to ‘capture’ dye. The latest versions of Neptune’s ‘Long Ranger’ leak detection sensors have the potential to detect leaking fluorescent dyes and crude oil, etc. at distances of up to 20m. Other significant advantages of the ‘Long Ranger’ include the detection of leaks from risers while working at safe operating distances and detecting leaks within confined structures such as manifolds where ROV access is not possible or too hazardous. For many years the fluorescent dye typically used for leak detection has been Fluorescein, however, this is being phased out of general use as it no longer complies with the latest legislation for discharges at sea. Other tracers such as Castrol’s SPF, Champion Clear Dye and other clear UV dyes, MacDermid’s Oceanic range of fluids, Rhodamine, Roemex’s 9022 red dye, etc., have been tested to demonstrate their compliance with the latest
10
legislation and are now widely used. Neptune’s family of ‘Long Ranger’ fluorescent leak detection sensors are capable of detecting these dyes and by deploying the UV version can detect crude oil, lubricating oil and hydrocarbon based control fluids such as Castrol’s Brayco fluid. acOuSTicS Hydrophones are effectively underwater microphones that can be tuned to ‘listen’ for ultrasounds generated by fluids leaking under pressure. For small leaks these leak generated signals tend to be at frequencies well above the audible range, i.e. above 20kHz, thus requiring sophisticated sensors and software to reliably determine the difference between leak generated and ambient ‘noise’. The major problems with this method are the sounds caused by the attendant (ROV) and other vessels in the vicinity. In collaboration with Aquatec Group, Neptune Oceanographics have produced an acoustic leak detection sensor that incorporates a directional hydrophone with a high pass filter that significantly reduces the effects of non leak generated sounds. The sensors have been tuned to respond in the range of frequencies known to be emitted by high pressure leaks through small apertures. Acoustic signals are sent to an onboard PC via an ROV umbilical or diver cable where acoustic intensity is displayed graphically and also recorded for later playback. Typical applications are detection of leaks of gas from subsea installations, locating fluid leaks from buried pipelines and from pipe within pipe configurations. More recently, Neptune Oceanographics supplied a modified acoustic detection system complete with acoustic modem that successfully monitored the opening and closing of a large control valve during pipeline maintenance and replacement operations.
Typical screen display
Long Range Sensor: Two blue excitation light beams are visible. Fluoresced light produced by the dye shows as a green cloud at the leak location. Tracer dye is Fluorescein. Leak detection system output is graphically displayed on the onboard PC.
DirecT DeTecTiON OF hyDrOcarbONS Hydrocarbons in liquid form such as crude oil can be detected using a ‘Long Ranger’ leak detector, however, a different method is required for gas. A direct reading hydrocarbon sensor has been added to the range of Neptune Oceanographics leak detection systems. This sensor is essentially a methane detector but it is equally a general hydrocarbon detector that will respond to most hydrocarbons, however, the potential for oil contamination on the sensors membrane make it less suitable for oil detection but good for gas detection. The very high sensitivity of the sensor also makes it ideal for the detection of gas leakages, gas in trapped in structure voids, seepage from the seabed, etc. DirecT DeTecTiON OF mONO eThyLeNe gLycOL (meg) A new addition to Neptune’s subsea leak detection capability is a MEG (Mono ethylene glycol) sensor. This sensor detects leaks of MEG from the subsea systems without the need to add tracer dye. By eliminating tracer dye, leak detection can be accomplished with no additional environmental downside. DiFFereNTiaL TemperaTure meaSuremeNTS Under some circumstances such as with water injection flow lines, leaks can be identified using the temperature difference between the surrounding seawater and the water leaking from the flowline. The flowline water temperature is normally above ambient seawater temperature due to the high pressure pumping required. Neptune has developed a differential temperature technique that can detect very small temperature changes. The sensors comprise fast, high precision thermistors connected through the Neptune leak detection system to the ROV umbilical for onboard display and recording. The 2 channel on-board PC displays data as a colour time series plot in real time allowing the operator to easily see changes in signal that indicate the presence of a leak. The software also allows the user record data and set alarm levels. OTher NewS During 2006 Neptune Oceanographics formed a strategic alliance with Aberdeen based Dynamic Positioning Services (DPS) who provide full workshop facilities, equipment deployment, technical expertise and experienced offshore engineers to support Neptune’s global leak detection operations. Neptune’s growing list of agents includes established companies in:- Norway, Singapore, Houston, India and UAE
‘NeptuNe OceaNOgraphics Ltd is a gLObaL Leader iN the fieLd Of detectiON Of Leaks frOm subsea pipeLiNes, risers aNd cONtrOL systems.’
Leaks in your subsea pipeline installations? Neptune Oceanographics can find them for you.
Leak Detection Techniques Include:➤ ➤ ➤ ➤ ➤ ➤
Long range fluorescence for tracer dyes Detection of liquid hydrocarbons Detection of gaseous hydrocarbons Differential temperature measurement Acoustic listening Detection of Mono Ethylene Glycol (MEG)
Neptune continuously strive to improve and develop new and better techniques for detection of leaks in subsea pipeline systems and provide leak detection systems and offshore engineers who can mobilise and conduct leak detection surveys anywhere in the world at very short notice.
Neptune Oceanographics Limited Tel: Fax:
+44 (0) 8453 707 177 +44 (0) 8704 581 979
Email: Web:
info@neptune.gb.com www.neptune.gb.com
Neptune Oceanographics Ltd is an ISO 9001 : 2008 certified company • First Point registration number 20436
Economical, safe and environmentally friendly. Phil Carter Business Development Manager – Oil & Gas Hayward Tyler Ltd T: +44 (0) 7881 913062 E: subsea@haywardtyler.com
WHaT ELsE MakEs fLuiD-fiLLED MOTOr TECHnOLOGy sO sPECiaL? Electric motor technology has evolved tremendously over the last century. As early as 1908 Hayward Tyler designed and manufactured the first submersible electric motor for marine salvage and this has been continually developed for over a century to meet the evolving demands of complex operating environments. One of the many design challenges faced was how to remove heat generated in motor windings and bearings. This was met with the design of the fluid-filled electric motor. The mix of water-glycol in the motors, removes the internal heat and the internal circulation system maintains a low copper temperature in the winding wire and at the bearings, resulting in greater longevity, it also maintains a good lubrication film in the hydrodynamic bearings. With water being an abundant, efficient, low cost and environmentally friendly cooling medium, it is the preferred choice for the fluid-filled motor. With space at a premium on offshore platforms, Hayward Tyler introduced water-filled submersible driven pumps to offer smaller, lighter solutions than conventional air-cooled shaft driven units, with no impact on desired output. WHy DO HayWarD TyLEr usE WaTEr/GLyCOL-fiLLED MOTOrs? Dry wound motors are a familiar option for topside offshore applications, however if you tried to use this dated technology anywhere below the surface let alone at sea depths in excess of 2,000-3,000 metres, the results would be immediate, catastrophic failure. We know that usually water and electricity don’t mix, however Hayward Tyler have developed a unique way of using the very latest in subsea motor technology to develop a water/ glycol fluid-filled electric motor for deep sea applications. Water/glycol is a commonly used control fluid but it allows subsea motors to run at operating speeds up to 4200rpm. This is due to the lower frictional losses across the unit resultant from the coolant and its combination with modern bearing technology. COOLEr OPEraTiOn To promote efficient cooling of the subsea units, Hayward Tyler has developed a high efficiency impellor situated inside the motor casing which is directly connected to the motor shaft. This circulates the water/glycol mix around the motor windings and bearings and then out to parallel circuit spiral heat exchangers. The heat
12
exchanger has been designed to give the maximum cooling effect on motor fluid to provide both longer operational life and thermal stability. The seawater temperature, typically 4ºC, depending on the depth and conditions, then cools the mix before re-entering the motor casing to start the cycle again. The water/glycol mix not only cools the motor but it provides the lubrication for the bearings. With extensive qualification testing to give the assurance of a long operational lifetime, Hayward Tyler also use a particular corrosion inhibitor to prevent any internal parts, which might be susceptible to corrosion, from failing. Each unit is assessed individually on size, materials and duty to determine the possible deterioration of any of the internal parts. HV POWEr suPPLy The motor is housed in a pressure casing that is designed for an internal overpressure, which can be in the region of 350 bar, again depending on the operating conditions and depth. The difficulty of connecting the electrical power connectors to the subsea motor is overcome by a terminal box fitted on the seawater side of the motor pressure boundary, which is filled with a suitable medium
to enhance electrical protection. As previously mentioned, technology with a qualified proven track record should be identified and used to minimise the risk of possible failure. A terminal box filled with transformer oil is an excellent medium to make the high voltage (HV) electrical connections. Of course failure of the terminal box seal had to be considered. In this case the actual connection of the copper cable end and terminal stalk is electrically insulated. This is achieved by use of an insulation material (typically XLPE cross linked polyethylene) bonded on the terminal stalk and cable. Operational thermal dimension change also needs to be considered. In passive mode the motor temperature will be that of the ambient seawater temperature; around 4ºC. The design temperature of the terminal box, taking into account the electrical heating effect and motor operating temperatures, can be in the region of 60ºC. The challenge is to design the insulation around the connection which can accommodate this thermal cycle from the cold standby to hot operating duty. The major design hurdle is the electrical penetrator. This component is in fact the terminal stalk that crosses the pressure boundary to deliver power to the motor windings. Hayward Tyler had to accommodate three major design parameters: electrical insulation, differential pressure and thermal cycling. Of these it is the challenge of thermal cycling and the mix of materials involved in providing the physical strength, the electrical insulation and the copper itself. The amount of material required for the mechanical strength dictates the physical dimensions and in turn, results in an inherently highly electrically insulated penetrator. Extensive qualification and testing is required to prove this is the case, however complexity of the different thermal properties of the materials used presents the biggest challenge. Subsea conditions are complex and demanding and require practical well engineered and reliable solutions. Fluid- filled subsea motors offer a robust long term solution for the deepest and most hazardous conditions. These motors offer a time between overhauls of at least 40,000 hours, with an exceptional continual operation of up to eight years. This is essential for subsea installations where the total cost of intervention is significant. The demand placed by this sector is high and Hayward Tyler is at the forefront of fluid- filled subsea motor technology and the ongoing development of this technology ensures that customer needs will continue to be met.
fluid filled electric motors & pumps custom designed to meet the most demanding of applications and environments
• Seawater Lift • Firewater Pumps • Boiler Circulating Pumps and Motors • Subsea Motors • Submersible Generators www.haywardtyler.com
Est.1815
WELCOME Designed to provide direct marketing for the offshore industry, the Oil & Gas Product Review magazine has continued to keep abreast of the latest developments through all levels of technology involved in this ever-changing market. With our presence at the important trade shows through the industry calendar and with the publication being released quarterly, we are now at the forefront of Offshore marketing.
CONTENTS
“Our philosophy is to provide companies with the chance to let their relevant industries know about their products and services in their own words. We do not use journalists but rather publish editorials and press-releases and in doing so, can provide a less expensive alternative for the advertiser. With our circulations being controlled to the senior buyers and specifiers (named individuals), we can ensure that companies’ details are seen by the right decision-makers”
2 4 6 7 8 9 9 9 10 12 15 15 16 17 18 20 21 21 22
DIRECTOR OF SALES
DUNCAN SMITH
Director of Sales Duncan Smith Tel: +44 (0)1634 301 418
Koso Kent Introl Concateno Crowcon Detection OSEA Singapore Flexitallic Rotaflow Cengar Lee Products Neptune Oceanographics Hayward Tyler Advanced Components Michel Le Mack Benoil RAE Systems Bedford Opto Technology James Walker Able Instruments Darchem
Production Martin Anastasi Tel: +44 (0)1634 301 418
Design and pre-press Vortex Creative Ltd +44 (0)1322 319 344 www.v-creative.co.uk
23 24 26 27 27 28 30 32 34 35 35 36 38 39 40 42 44 45 46 46
Cutting Underwater Sonar Equipment Corrosion Solutions Futuretec Dynamic Ceramic Belleville Springs BS&B Ross Offshore BPP Tech Walton Engineering Proserv Mechtool Engineering Werma Converteam Hawke International Valeport GL Group Wessington Cryogenics John Crane Bowers Metrology
Telephone: +44 (0)1634 301 418 Fax: +44 (0)1634 301 428 Web: www.globalmediadvertising.co.uk Email: sales@globalmediadvertising.co.uk PO Box 738, Rainham, Kent ME8 9NR
The Oil & Gas Product Review and other titles are produced by Global Media Advertising Ltd. Published quarterly and for major events throughout the year.
14
Miniature Piloting Solenoid Valve Lee’s Miniature Solenoid Valve has been designed for demanding, high pressure sub sea applications.
Your global partner for moisture, hydrocarbon dew point and gas analysis • • • •
Gas production Fiscal metering Natural gas storage Power generation plants Discover more – visit www.michell.com
� 12 or 28 v.d.c. � 3000 and 5000 psi standard designs � Higher pressures available as specials � Single and Dual Coils � Low Power Consumption � Multi-Seal - eliminates o-rings and back-up rings TM
Innovation in Miniature
Dew Point - Humidity - Oxygen
Michell Instruments Limited 48 Lancaster Way Business Park, Ely Cambridgeshire CB6 3NW United Kingdom T: 01353 658000 E: uk.info@michell.com
SEND FOR OUR FREE PRODUCT CATALOGUE
Tel: 01753 886664 Fax: 01753 889588
www.leeproducts.co.uk e-mail: sales@leeproducts.co.uk Lee Products Limited, 3 High Street, Chalfont St Peter, Bucks. SL9 9QE.
HEAD OFFICE : sales@adcomtec.co.uk Tel : 00 44 (0) 8707 576664 www.adcomtec.co.uk U.S. OFFICE : sales@adcomtec-us.com Tel : 713 780 3997 www.adcomtec-us.com
15
KENNY MACK Oilfield Consultant
STUCK PIPE PROBLEM!
Specialist Drill Retrieval
CALL: KENNY MACK AIExpE “THE LEADING BACK-OFF EXPERT IN THE INDUSTRY” 3/4” BACK-OFF & FREEPOINT 1” BACK-OFF & FREEPOINT
PATENTED Kenny Mack, (AIExpE) is a well known figure on the oilfield scene and has over 30 years experience in the specialist retrieval of stuck drill strings and associated tools and equipment. He has developed and patented the LE MACK, a Safety Side Entry Drive Sub which is used to control the well pressures during various wireline, slickline or coiled tubing operations that permits the fluids to be circulated for well control or pump down operations particularly in HP, HT & highly deviated wells. Kenny has a proven track record and all the tools and experience to provide his customers with the expertise to recover drillstring and associated equipment when all other options have been exhausted.
KENNY MACK Oilfield Consultant
Specialist Drill Retrieval
LE MACK is used to control well pressures during various wireline, slickline or coiled tubing operations and permits fluids to be circulated for well control or pump down operations particularly in high deviation or high pressure wells. It is compatible with all sizes of wireline and is suitable for Top drive, Side Drive or Kelly Drive Systems. LE MACK allows right or left handed radial and axial movement of the drill string with the wireline or coiled tubing installed, eliminating wear and damage to the wire, Top Drive and drilling equipment. It avoids hazadous and time consuming removal of the washpipe, bullplug and mud screens. The split grease tube sealing system can be readily checked for wear and enables rig up, rig down, tool and cable head changeover times to be kept to a minimum. Additionally, wireline and tool recovery to the surface can be achieved under pressure conditions. Extra entry ports are provided in the upper end plate for a second wireline entry, coiled tubing or for the introduction of drilling fluids, cement or special fluids.
KENNY MACK Oilfield Consultant
Specialist Drill Retrieval
The LE MACK tool maximises safety during these recovery operations and provides many additional time saving and cost cutting benefits to the overall operation.
SAFETY MAXIMISED IN: • WELL PRESSURE • FLUID CIRCULATION • PUMP DOWN OPERATIONS SIMPLIFIES: • SENSOR ACCESS • STRANDED WIRE • WIRELINE ACCESS • TOOL CHANGE OUT • • ADDITIONAL ACCESS • COILED TUBING ACCESS • CABLE & HEAD CHANGEOVER • • DRILL STRING AXIAL MOVEMENT • DRILL STRING RADIAL MOVEMENT • ELIMINATES: • WASH PIPE REMOVAL • GOOSENECK REMOVAL • BULL PLUG REMOVAL • • MUD SCREEN REMOVAL • MUD DISPLACEMENT TO RIG FLOOR • RIG TONGS TO HOLD OR APPLY TORQUE • DAMAGE TO DRILLING EQUIPMENT •
APPLICATIONS: 1. Perforating 2. Gyro Surveying 3. Drilling/Logging Measurement 4. Running Free Point Indicator Tool 5. Back Off Operations 6. Explosive Cutting 7. Chemical Cutting 8. Drill Collar/Drill Pipe Severing 9. Pump Down Operations 10. Tubing Conveyed Perforating 11. Plug Setting 12. Cement Bond Logging 13. DST Latched Inductive Coupling 14. Depth Determinations 15. Multi Finger Caliper Logging 16. Temperature Logging 17. Slimhole Drilling 18. Slickline Operations 19. Sandline Operations 20. Cementing 21. Severing/Cutting Coiled Tubing 22. Tough Logging Conditions (T.L.C) 23. Snubbing 24. Fishing Operations 25. Coiled Tubing Operations
KENNY MACK Unit 8 Piper Alpha Centre, Badentoy Place, Badentoy Industrial Estate, Portlethen, Aberdeen AB12 4YF T/F: 01224 783898 Home T: 01569 731879 Home F: 01569 731891 M: 07860 112653 E: mrkennymack@aol.com
Kennet Building, Trade Street, Woolton Hill, Newbury RG20 9UJ, United Kingdom Contact +44 (0) 1635 253412 E-mail sales@benoil.com www.benoil.com
Using Wireless Gas Monitors for Confined space entry During plant turnarounds rae systems Central and northern england peter J. Bratt T: +44 (0)1865 408368 M: +44 (0)7730 952901 F: +44 (0)1865 408 301 e: pbratt@raesystems.com rAe systems - scotland, eire, n. ireland scott Wilkie T: +44 (0)1865 408368 M:+44 (0)7714 999268 F: +44 (0)1865 408 301 e: swilkie@raesystems.com
When poWer plants, oil refineries, food processing, pharmaceutical, chemical, paint or plastic plants need to have major service, be upgraded or retrofitted this is called a plant turnaround. These times of zero production are both high stress and high cost both in terms of labor and lost production revenue. Many times repairs need to be made in the “confined spaces” of pressure vessels, separators, feeders, storage tanks and valve systems. These limited access, limited ventilation confined spaces present a challenge to both worker safety and retrofit time. A “confined space” as defined by OSHA, has limited or restricted means of entry, exit or ventilation, is large enough for a person to enter and perform work, and is not designed for continuous occupancy. Confined space entry is inherently dangerous, and in the high intensity environment of a plant turnaround, it becomes especially challenging to manage worker safety against the need for efficiency and the economic pressures of getting the plant back on line as quickly as possible. The atmosphere in a confined space can become hazardous for a variety of reasons. Welding operations can produce toxic fumes, and decomposing organic material can release chemicals such as hydrogen sulfide or methane. Heavier than air gases like carbon dioxide can sink to the bottom of
a confined space and reduce the level of oxygen to fatal levels. Oxygen can also be consumed by many chemical processes such as the formation of rust or bacterial action in the fermentation process. There may also be residual chemicals from the production processes that can include volatile organic compounds (VOCs), or hydrocarbons, which are both toxic and flammable and potentially an explosion hazard. The presence of VOCs immediately calls for the use of either a dedicated photoionisation detector or a multi-gas monitor that includes a PID. In the last several years 5-gas monitors have been available in both handheld and wireless configurations. As a turnaround work-shift begins each of the confined spaces on the facility would need to be monitored prior to entry. OSHA requires that confined space entry permits be reissued every twelve hours or when a new shift starts. This has traditionally been a manual process, and it takes several hours to revisit the work sites, resample the environment, and then reissue the permit. Hours of downtime during each shift of a plant turnaround can cost companies thousands of dollars. After each work break the confined space in question would again have to be monitored before work could resume. In addition to the work crew a “spotter” would be assigned to each hole or worksite. This person would be responsible for making sure that the working atmosphere of the work site did not pose a safety threat. Typically the spotter would be issued a hand held monitor that might include a drop line of extended tubing to actually sample the work area. If there was a problem it was the spotter’s job to clear the worksite, begin ventilation and then eventually give the approval to return to work. This presented two problems, the spotter had to know how to interpret the alarm and had to get help if workers were endangered. Often, the spotter became tired or distracted and could make mistakes in judgment
when reading alarms on monitoring equipment. Initially, site safety officers began deploying wireless monitor as a back up to the fixedgas systems that were turned off during the service cycle. They soon realized that they could also provide a back up to the spotter, and even continuously watch the hole when the spotter was not there. The advent of wireless gas detection has given facility operators and safety officers a new approach to this solve “hole watch” problem. Using wireless gas detection networks with sensors at each confined space worksite and a central command center, safety officers could continuously monitor a work site, even when workers where not present. Procedures were developed so that if a work site had not alarmed during the break, then is could be assumed that it was safe to re-enter the work site immediately. This cut the wait time after each break and provided a cost effective way to safely increase productivity. One of the early adopters of wireless gas diction was an oil refinery that needed to bring down each of six major areas for 60 days at a time. Significant time was saved by not having to recertify confined spaces for each work shift. This is done by using wireless gas monitors to monitor continuously and only required recertification if there has been an alarm. The Wireless MoniTor DeployMenT The facility has six independent wireless networks that are linked to local control rooms. Data from each of the six control rooms is uploaded to an offsite data server that integrates all of the site data. The master control room monitors all six production areas through the web-based terminal viewer. The viewer provides visibility to all 36 deployed wireless monitors as well as real-time maps showing the location and alarm data for all units. AlArMs Alarm notification is handled in three layers: ➤ Individual monitors provide local alarm notification at the work site. ➤ The local control room is notified (visually and audibly) of an alarm over the wireless network and is displayed on the remote base station so that a response can be initiated if necessary. ➤ As a backup – Email alerts are issued whenever any wireless monitor on site goes into alarm. As each local control room uploads the real time data over hardwire Ethernet cable onto the secure offsite data server, data is also monitored “real-time” on secure web terminal in the Master control room. The use of wireless toxic gas monitors has come of age. Today’s monitors are quick to deploy or reconfigure and offer the ability to use global positioning satellite technology to know exactly where and alarm is coming from. Wireless gas monitors have been found to provide both a better worker safety net and significant cost savings to industrial facilities that must continually improve their production and manage their costs.
18
w w w. r a e s y s t e m s . c o. u k
Bedford Opto Technology Limited Bedford Opto Technology 1 Biggar Business Park Market Road Biggar ML12 6FX Scotland T: +44 (0)1899 221221 F: +44 (0)1899 221009 E: lorna@bot.co.uk W: www.bot.co.uk
BedfOrd OpTO TechnOLOgy specialise in the design,development and manufacture of ATEX/IECEx certified Opto Couplers.The current range consists of 3 products;10kv tubular OPI 110/1264 series with phototransistor output and CTR’s of up to 100% minimum at 1mA If;the OPI1000L series phototransistor output giving 40% min CTR at 1mA If in surface mount configuration supplied taped and reeled:the OPI2000M with a High Speed Logic output coupled to a high speed IR emitter operating up to 2MHz with very low propagation delays,supplied in surface mount
or through board configuration. A new surface mount ATEX/IECEx coupler,the OPI5000 is under development that will comply with the Lead Free directive and be compatible
A new surfAce mount AteX/IeceX coupler, the opI5000 Is under development thAt wIll comply wIth the leAd free dIrectIve And be compAtIble wIth the solderIng temperAtures AssocIAted wIth the chAnges to solderIng processes. SS BOT Plex
23/1/06
3:11 pm
with the soldering temperatures associated with the changes to soldering processes.Samples are available now.All BOT ATEX products meet the RoHS directive and are now IECEx certified. Luxion type high luminous flux white LED arrays are available to customers requirements,ideal light sources in hazardous environments. • For further information,data,samples and pricing please contact Bill Stott or Lorna Wyllie on 01899 221221(Ph) or 01899 221009(Fax) or visit our NEW Web site www.bot.co.uk
Page 1
BEDFORD OPTO TECHNOLOGY LIMITED
IECEx CERTIFICATION APPLIED FOR
Design, development and manufacture of ATEX certified Opto Couplers. Through board or surface mount in tape and reel. High speed logic output. Special selections and lead forms readily available.
BEDFORD OPTO TECHNOLOGY LTD. 1 BIGGAR BUSINESS PARK, BIGGAR, LANARKSHIRE ML12 6FX TELEPHONE: 01899 221221 FAX: 01899 221009 E-MAIL bill@bot.co.uk www.bot.co.uk
20
Reusable Plugs Lee’s A.F.O. Plug (Axial Force Only) provides a leak-tight, metal to metal seal in high pressure/high temperature manifold applications.
● ● ● ●
Reusable-allows easy access to sealed passageways Seals to 60,000 psi and 600˚F All stainless steel constructionno sealants or O-rings Floating seal self-aligns
Innovation in Miniature
SEND FOR OUR FREE PRODUCT CATALOGUE
Tel: 01753 886664 Fax: 01753 889588
www.leeproducts.co.uk
e-mail: sales@leeproducts.co.uk
Lee Products Limited, 3 High Street, Chalfont St Peter, Bucks. SL9 9QE.
21
Cutting Underwater Technologies Ltd Cutting Underwater Technologies Ltd CUT HQ, Aberdeen Science and Energy Park Claymore Drive, Bridge of Don Aberdeen AB23 8GD Scotland T: +44 (0)1224 222950 F: +44 (0)1224 826006 E: info@cut-group.com W: www.cut-group.com
CUT, THE DIAMOND WIRE CUTTING SPECIALISTS have, over the last 12 months, been able to demonstrate the effectiveness, flexibility and reliability of their technology through the adoption of a number of innovative solutions to cutting requirements across a number of very different industries. CASTELLATED CUTTING During the pre-planning phase of a major project, which required the deconstruction of a 10,000 tonne steel jacket in the North Sea, concerns were raised regarding how best to maintain the integrity of the structure as it was deconstructed. Thus CUT was faced with the seemingly unachievable task of performing severance cuts on the jacket legs whilst retaining both strength and stability in the members. The solution developed by CUT was termed “Castellated Cutting” which necessitated the design and build of a specialist ‘modular’ diamond wire cutting
machine able to accommodate the 120inch diameter of the jacket legs. The design of this machine allows any cut to be made in both horizontal and vertical planes in one operation. Thus the castellated profile of the finished cut means that, whilst the leg is severed, the upper and lower sections of the leg retain both stability and strength in any plane. DRYER SIZE REDUCTION PROJECT 2008/2009 The nuclear, like the oil & gas industry offers a totally different set of parameters to companies working within their confines. This is especially true when working in a “hot”, highly radioactive environment. Working in the United States CUT were required to develop a diamond wire cutting system which would reduce the size of a steam dryer which formed part of the boiling water reactor plant. The particular scope of work was to reduce the size of the dryer structure such that it would be able to store the severed sections in anti-radiation containers in dedicated storage areas. Moving away from their more traditional hydraulic power and operating systems a new electrical powered DWCS was developed that could be assembled, prepared and operated on site by CUT operatives working in full nuclear protection suits. Such was the success of the CUT equipment that additional work of this nature in Europe and the Far East has been secured. CUT, working closely with their Genoa based parent company, Tecnospamec, are able to offer their
Onshore
patented Diamond Wire Cutting Systems across diverse industries because of their ability to provide both standard and bespoke systems. Thus cutting packages can be tailored to offer solutions to particular project requirements without compromising either efficiency or safety. This ‘no compromise’ approach means that clients can be assured of a successful project carried out without incident, with the minimum site timescales, and at the lowest cost. Additionally CUT’s technology offers negligible environmental impact with the only residue produced from the cutting operations being the ‘fines’ produced by the actual cut itself. With over 3000 operational cuts carried out in more than 500 completed projects CUT proudly offer their motto, “Any Cut – Anywhere – Any Time – Any Industry” to all their clients; whatever their requirements.
Bespoke Solutions
“The” Diamond Wire Specialists Offshore Oil & Gas
Offering Any Cut
Nuclear
-
Any Where -
Any Industry
info@cut-group.com Norway
Houma USA
www.cut-group.com
Aberdeen Group HQ
Brazil
Singapore 23
Sonar Equipment Services specialize in the rental, sales and manufacture of leading marine survey equipment for the global offshore industry. Our mission is to provide our customers with a competitive edge by providing cost effective solutions and services with flexibility and support along the way. Offering over 50 years combined experience, the SES engineering and sales team provides the highest level of customer focussed support around the clock from project planning to completion. With extensive technical and manufacturing expertise in the field of sidescan sonar and sub-bottom profilers, SES has been providing innovative engineering solutions to the Oil and Gas Industry, Construction Industry and Renewable Energy Sector for over 15 years. Continued investment in the rental pool offers our customers the latest survey equipment to support offshore and near-shore operations. SONAR EQUIPMENT SERVICES LTD Tel: 01493 443363 Fax: 01493 443387
Units 3 & 4 Enterprise Court, Gapton Hall, Great Yarmouth, Norfolk NR31 0ND
E: enquiry@sonar-equipment.com W: www.sonarequipmentservices.co.uk
AREAS OF PRESERVATION CONSTRUCTION/ NEW BUILDS ♦ Protection of equipment & systems from procurement to commissioning DECOMMISSIONING ♦ Protection of capital equipment until disposal or re-commissioning OPERATIONS ♦ Process stream inhibition SHUTDOWNS ♦ Drilling rig/packages ♦ Individual systems MAINTENANCE ♦ Electrical enclosures ♦ Deluge systems (ultra safe chemical cleaning & preservation) ♦ Bolt preservation ♦ Corrosion under Insulation (chemical & dry air systems) ♦ Oilfield spares (onshore & offshore) ♦ Corrosion under tubing clamps
info@corrsol.co.uk
26
High Strength Safety Screens The Lee Hi-Bar safety screens are machined from a single, solid bar of aluminium or stainless steel. Uniform holes from 75 to 400 microns are then drilled using a unique process, enabling the finished screen to withstand pressure differentials up to 7500psid without bursting or collapsing. It is, simply, the most reliable safety screen in the world. It’s backed by hundreds of cumulative years of engineering experience and the toughest standards in the business.
Innovation in Miniature
SEND FOR OUR FREE PRODUCT CATALOGUE
Tel: 01753 886664 Fax: 01753 889588
www.leeproducts.co.uk e-mail: sales@leeproducts.co.uk Lee Products Limited, 3 High Street, Chalfont St Peter, Bucks. SL9 9QE.
Dynamic-Ceramic Limited Dynamic-Ceramic Limited Crewe Hall Enterprise Park, Weston Road, Crewe CW1 6UA United Kingdom T: +44 (0)1270 501000 F: +44 (0)1270 501423 E: sales@dynacer.com W: www.dynacer.com
DYNAMIC-CERAMIC LIMITED, an innovative manufacturer of world beating ceramic solutions is pleased to announce the completion of a substantial investment program that has expanded manufacturing and office facilities by 50%. “This significant investment will enable us to respond effectively to our customers’ needs,” states Harry Hodgson, Managing Director of DynamicCeramic. “We have invested in the latest grinding and inspection technology which has enabled us to stream-line our production processes and offer even greater levels of customer service.” Advanced ceramics developed by DynamicCeramic are playing a major role in improving the efficiency of components at oil and gas industry sites around the world. Its “transformationtoughened” Technox® zirconias and other ceramics offer greater resistance to the effects of wear, corrosion, erosion, abrasion and heat than conventional materials such as metallic alloys and polymers. Advanced ceramics are also electrical insulators and transparent to electromagnetic
waves. Typical applications in downhole and oilfield installations include parts in MWD and LWD tools, fluid metering systems, valve plugs, stems, seats, retainers, cages and trims, moveable orifice and ball valves, mud pump nozzles and pistons, and turbo-drill components. Photograph 1 shows a Technox 3000 valve plug after service; note the damage to the steel work but the light polishing of the ceramic. Photograph 2 shows part of an alumina cyclone. Dynamic-Ceramic, which won the Institute of Materials 2006 Gold Medal, develops products to deal with specific issues of wear and corrosion or electrical or thermal insulation. Ceramic powders are compacted and then shaped using computer numerical control (CNC) machine tools. Firing at high temperatures (above the melting temperatures of most metals) bonds the powder particles together densifying the material and developing the unique combination of high strength, hardness and toughness. Machining of the now ultra-hard material is carried out by diamond grinding, with finished tolerances of ±1µm being achieved. High Photograph 1
Photograph 2
degrees of flatness and surface finish are obtained by lapping and diamond polishing. Wear-resistant Technox® materials are also suitable for oil refinery applications, especially in the highly erosive environment of air grid nozzles within the fluidised catalytic cracking unit (FCCU). A specialised fixing method – patented by Dynamic-Ceramic to solve problems caused by ceramic and steel having different coefficients of thermal expansion – extends the working life of nozzles, providing a more consistent fluidised bed and reducing turnaround costs. Catalyst withdrawal tubes made from Technox® materials have lasted ten times as long as a refractory liner in the same application, giving a more controllable flow through the discharge port and causing less wear damage to local pipe and valve areas, reports the company. Other components within the FCCU, such as orifice plates and feed injectors, have, it says, also had their performance and service life increased when made from Technox® materials. According to Managing Director Harry Hodgson, “the number of possible uses of advanced ceramics within the oil and gas industry is unlimited but it is up to companies such as ours to inform engineers and designers of the capabilities of modern advanced ceramics and help them choose the correct ceramic for their particular application”.
27
Is it a Belleville washer or a precision disc spring? BELLEVILLE SPRINGS LTD Arthur Street, Lakeside, Redditch, B98 8JY, United Kingdom T: 01527 500500 F: 01527 517039 W: www.bellevillesprings.com E: info@bellevillesprings.com
WHEN JULIAN BELLEVILLE patented his conical spring disc in 1861 it is unlikely he had any idea that it would have such wide-ranging applications. Unlike the conventional helical compression spring that has a linear force/deflection
characteristic, the same characteristic in a disc spring is a function of the variable cone-height to thickness ratio. This is often a useful feature: for example, the seal on a spherical ball valve requires a spring force back-up to achieve sufficient seating stress which must be maintained throughout a significant amount of seal face wear. A disc spring with a cone height approximately 1.5 times the material thickness, offers a near constant force for a range of deflections. A constant force characteristic is also desirable in joints or bolting systems subject to thermal expansion and contraction. STACKING While the variation of cone height to thickness ratio can be employed to produce characteristics of a progressive, linear, or regressive nature, the full realisation of the versatility of the disc spring emerges with ‘stacking’ into spring columns. A disc spring ‘nested’ inside another – i.e., convex face placed to concave face (same way up ) – is described as two disc springs assembled in parallel. This arrangement results in a force
Stacking
1 Single Disc Spring
Total Force = Force of single disc spring
Total Force = 2 x Force of single disc spring
Total Deflection = Deflection of single disc spring
Total Deflection = Deflection of single disc spring
3 Disc Springs in series
28
2 Disc Springs in parallel
4 Disc Springs in series and parallel
Total Force = Force of single disc spring
Total Force = 2 x Force of single disc spring
Total Deflection = Deflection of single disc spring
Total Deflection = Deflection of single disc spring
capacity double that of a single disc spring, yet the deflection capability remains that of a single disc. It is a misconception that the resultant force from two disc springs assembled in parallel is equal to the force of a disc spring that is twice the thickness of the single disc. Not so, due to the fact that disc spring thickness is raised to the power of three in the force calculation formula. For example, for identical inside and outside diameters, the force to flat of a single 2mm thick disc may be 5,423N and the force to flat of a single 4mm thick disc is 26,697N. Having multiplied the force of a single disc spring by nesting further disc springs of the same dimensions in parallel, it is possible to multiply the deflection by adding further nested units to the column which are apposed to one another, - i.e. ‘back-to-back’. Single disc springs of the same dimensions can also be stacked back-to-back, termed stacking in series. When disc springs are employed in series or parallel stacks, or a combination of both, Fig 1, friction occurs at the bearing points of opposed springs in series stacking, and to a greater degree across the interfaces of parallel nested discs. Often the hysteresis due to friction is advantageous for those applications requiring a damping effect. A ‘rule of thumb’ for guidance on length of disc spring stacks to minimise friction, is that, in the unloaded condition, the stack length should not exceed 2.5 times the disc springs outside diameter. DISC SPRING SELECTION Precision disc springs, produced to the DIN standards 2092 and DIN 2093, are pre-stressed (scragged); machining and radiusing of edges also removes stress raisers, which could otherwise reduce fatigue life. The term Belleville washer generally applies to the lower cost, less precise form of conical spring disc, normally used on applications of a less critical nature. Scragging is omitted and the inside and outside diameters are not machined. Select therefore disc springs to DIN 2092/2093 for critical loading or dynamic applications and the Belleville washer for static applications where some setting and /or loss of force can be tolerated. BELLEVILLE SPRINGS LTD. Using computer software and our many years experience of the disc spring industry, Belleville springs are perfectly placed to help you select the correct component for your application. Whatever your questions give us a call.
‘UNLIKE THE CONVENTIONAL HELICAL COMPRESSION SPRING THAT HAS A LINEAR FORCE/DEFLECTION CHARACTERISTIC, THE SAME CHARACTERISTIC IN A DISC SPRING IS A FUNCTION OF THE VARIABLE CONE-HEIGHT TO THICKNESS RATIO.’
Belleville Springs is a member of the Springmasters速 Group
Consultancy, Design, Manufacture and Distribution...
Your complete solution for DISC SPRINGS AND BELLEVILLE WASHERS Arthur Street, Lakeside, Redditch, Worcestershire B98 8JY. Tel: +44 (0)1527 500500 Fax: +44 (0)1527 517039 info@bellevillesprings.com www.bellevillesprings.com
BURST ALERT® MAGNETIC SENSOR SYSTEM - Designed to Provide Fast Detection of an Activated Bursting Disk B16.5 (Classes 150, 300 and 600), EN (PN 10 through 40(), and JIS (PN 10 through 40). Safety head material options include stainless steel 316, Hastelloy and carbon steel.
Bs&B Safety Systems Ltd Raheen Business Park Limerick, Ireland T: +353 (0)61 227022 F: +353 (0)61 227987 E: sales@bsb.ie W: www.bsb.ie.com
THE BURST ALERT MAGNETIC SENSOR uses a type BAM or BAML magnetic activation assemblies (see figure 1) and a magnetically activated type RBS sensor switch that is connected to a monitoring system. The magnetic activation assembly is installed at the downstream side of the bursting disk, between the disk and its safety head. Inserted once, the RBS sensor switch becomes closed circuit whenever a new BAM or BAML magnetic activation assembly is present. When the bursting disk activates, it causes the magnetic activation assembly to arc away from the RBS sensor switch causing it to change state to an open circuit from which an alarm signal can be generated. The RBS sensor switch is reusable and external to the process, automatically reset without the need of electrical work after initial installation. The sensor is installed to a blind threaded hole in the outlet of a BS&B type SR-7R safety head. OPTIONS AVAILABLE The Burst Alert Magnetic activation component Sensor, Type BAM, is approved for BS&B bursting disk models SKr, S-90 and RLS. For low pressure applications, Type BAML is designed for use with BS&B disk model LPS. The RBS sensor switch, which has an extended ambient temperature option (RBS-ST) and a high temperature option (RBS-HT) is the same for use with both BAM and BAML activation components.
The BAM and BAML assemblies are not influenced by back pressure conditions at the outlet side of the bursting disk. It requires the movement of the bursting disk during activation to push the BAM or BAML module aside, causing the RBS switch to change from ‘open circuit’ to ‘closed circuit’. In the case of the low pressure LPS bursting disk, the BAML engages the full diameter of the LPS bursting disk when it bursts, ensuring sensing of low pressure disk function. SR-7R SAFETY HEAD The SR-7R safety head, designed for use with the Burst Alert Magnetic sensor system, accepts BS&B reverse buckling bursting disk types S-90, RLS, SKr and LPS. An internal ‘bite seal’ located in the safety head inlet provides the best possible ‘metal-to-metal’ seal to the bursting disk. The bite seal is activated by application of the recommended companion flange bolt torque. The SR-7R is fitted with side lugs to pre-assemble the disk and safety head before final installation between companion flanges. The unique shape of the SR-7R flange adapter ring, which is permanently attached to the safety head inlet, is designed to properly center the bursting disk device inside the bolt circle of the companion flanges. A correctly centered bursting disk device is required to provide the expected flow characteristics, as confirmed by the certified flow resistance factors of the bursting disk type (Kr value(s)). A slight offset will diminish flow capacity and increase pressure drop which must be below 3-percent for applications where a bursting disk is applied at the inlet of a safety relief valve. The SR-7R is available to suit standard companion flange specifications from nominal pipe size 25mm to 250mm according to ASME /ANSI
BS&B MONITORING SYSTEMS Type RBS-ST/HT Sensors with BAM/BAML Activation Assemblies are designed for connection to most monitoring systems. BS&B offers both hard-wired and wireless monitoring options: ➤ Detec-Saf hard wired monitoring and alarm systems are available in modules to support from 1 to 15 bursting disk devices complete with back up battery power and intrinsically safe barrier protected circuits. ➤ Rupture Disk Manager to optimize the safety, integrity and total cost of ownership of bursting disk devices. The RDM collects pressure and temperature data at the bursting disk device and analyzes the information for characteristics detrimental to safety while providing immediate indication when a bursting disk has burst using a Burst Alert® sensor. ➤ BS&B SmartDisk® wireless monitoring system that connects up to 32 bursting disks to one monitor without the expense of cable, informing the user immediately when a bursting disk has activated. ➤ BS&B Wireless A2B System for communication of Burst Alert® sensor information wirelessly from point ‘A’ to point ‘B’ for connection to the users instrumentation system. Both standard and A heavy-duty ver sions are is provided for applications required to meet both non hazardous and hazardous service NEC Class I Division I or ATEX Zone 1 requirements. ABOUT BS&B SAFETY SYSTEMS BS&B Safety Systems Ltd. is the leading global manufacturer of bursting disk pressure relief devices, buckling pin relief valves, explosion protection systems and wireless monitoring devices that are marketed throughout Europe and world markets. The company is the inventor of the bursting disk and has shaped the growth of pressure relief technology for over 75-years. BS&B is an ISO-9001 certified manufacturer with manufacturing facilities in Limerick, Ireland, as well as Tulsa, Oklahoma. USA; Minneapolis, Minnesota, USA; Monterey, Mexico; Suzhou, China; Chennai, India; Edmonton, Canada; and Sao Paulo, Brazil.
‘BS&B SAFETY SYSTEMS LTD. IS THE LEADING GLOBAL MANUFACTURER OF BURSTING DISK PRESSURE RELIEF DEVICES, BUCKLING PIN RELIEF VALVES, EXPLOSION PROTECTION SYSTEMS AND WIRELESS MONITORING DEVICES THAT ARE MARKETED THROUGHOUT EUROPE AND WORLD MARKETS. THE COMPANY IS THE INVENTOR OF THE BURSTING DISK AND HAS SHAPED THE GROWTH OF PRESSURE RELIEF TECHNOLOGY FOR OVER 75-YEARS.’ 30
Offshore support and onshore rebuild facility. Offshore support and onshore rebuild facility. Ross Offshore has over thirty Ross Offshore has over thirty years heat exchanger experience years heat exchanger experience in the oil and gas industry. in the oil and gas industry. We supply a We supply a complete heat complete heat exchanger service exchanger service to the Oil, Gas and to the Oil, Gas and Power Generation Power Generation sectors and sectors and provide users of heat exchangers provide users of heat exchangers with a repair, re-tube, rebuild and with a repair, re-tube, rebuild and replacement service, on and replacement service, on and
REX REX
THE HEAT EXCHANGER THE HEAT PEOPLE. EXCHANGER PEOPLE.
offshore, for most types of offshore, for most types of exchangers. These can range in size exchangers. These can range in size and types from small Oil Coolers, and types from small Oil Coolers, large Fin Fan and large Fin Fan and Generator Radiators to High Generator Radiators to High Pressure Shell and Tube Gas Pressure Shell and Tube Gas Coolers and Plate Heat Exchangers. Coolers and Plate Heat Exchangers.
Contact: Kenny Erskine or Toby Ross Contact: Kenny Erskine or Toby Ross
Peterseat, Altens, Aberdeen, Scotland T +44 (0)1224 877774 F +44 (0)1224 876066 Peterseat, Altens, Aberdeen, Scotland T +44 (0)1224 877774 F +44 (0)1224 876066 E-mail: toby@rossoffshore.com www.rossoffshore.com E-mail: toby@rossoffshore.com www.rossoffshore.com
Heat Exchangers, Coolers, Radiators and Plate Packs.
Our service also includes des Offshore Site Surveys and Turnaround/Shutdown overhauls which our own labour which can also be integrated with the ich employ em client’s lab labour force. Ross Offshore is support service that is flexible and efficient.
Contact: Kenny Erskine or Toby Ross
REX
THE HEAT EXCHANGER PEOPLE.
Peterseat, Altens, Aberdeen, Scotland T +44 (0)1224 877774 F +44 (0)1224 876066 E-mail: toby@rossoffshore.com www.rossoffshore.com
BPP-TECH
DISCOVER AN OCEAN OF KNOWLEDGE
BPP-TECH bpp@bpp-tech.com www.bpp-tech.com 0845 217 7000 BPP-CaBlEs cables@bpp-cables.com www.bpp-cables.com 0845 217 7000
BPP-TECH Has launCHEd a new company “BPP-Cables” to capitalise on our expertise in cable technology. BPP-Cables is a company that provides cable technology – from design, analysis, procurement, installation and service support.
VESSELS STRUCTURES UMBILICALS BILICALS RISERS & FLOWLINES CABLES CABLES HOSES VESSELS RISERS ELS STRUCTURES UMBILICALS MaRKETs The main markets will be for marine and the offshore oil & gas LS RISERS & FLOWLINES CABLESrenewables, industries. LES HOSES CABLES RISERS VESSELS WHY BPP-Cables? VESSELS STRUCTURES UMBILICALS Providing subsea cable engineering to purchasers will reduce their BILICALS RISERS & FLOWLINES CABLES risk when buying. Most cables will CABLES HOSES VESSELS RISERS last significantly longer than the warranty period, ELS STRUCTURES UMBILICALS manufacturer’s but not necessarily for the required life for the project. Installation LS RISERS & FLOWLINES CABLESdesign and repairs to subsea cables is an ICALS CABLES HOSES VESSELS RISERS extremely expensive operation. BPP-Cables provide a validated VESSELS STRUCTURES UMBILICALS service in designing a cable for the BILICALS RISERS & FLOWLINES CABLES specific conditions. BPP-Cables will also analyse designs independently CABLES HOSES RISERS to provide the buyer a service life assessment. BPP-Cables offer subsea cables that are lighter and have a longer life, at a lower cost.
See what you're missing www.bpp-tech.com
Innovative engineering in energy technologies
The possible issues that face subsea cables could include: • Design flaws • Incidents during transportation or installation
• • • •
Incorrect usage Fatigue Manufacturing problems Damage from shark attacks and marine growth • Accidental damage BPP-Cables will design, procure and install cables or analyse designs with the following failure modes in mind: • Excessive axial tension or torque • Excessive bending • Crushing by excessive external pressure • Hose/tube bursting by excessive internal pressure • Layer separation and instability • Birdcaging • Loop formation and kinking • Mechanical degradation - wear and fatigue • Material degradation-exposure to adverse agents, temperatures and pressures • Problems with terminations In summary BPP-Cables offer the following services: • Cable design • Dynamic and fatigue analyses • Service life assessments • Reviews of subsea systems and architecture • Umbilical and cable design and engineering including bespoke AC and DC cables • Concept and feasibility studies • Cable and material qualification testing • Due diligence • Product development for new and existing applications • Procurement and QA/QC • Insured risk and failure analysis Take a look at our BPP-Cables website: http://bpp-cables.com or email us at cables@bpp-cables.com for your copy of the cables brochure.
Project1:Layout roject1:Layout 11 21/01/2010 21/01/2010 09:23 09:23 Page Page11
WALTON WALTONEngineering Engineeringhas hasbeen beenaaleading leadingmanufacturer manufacturerof of3-way 3-way
Temperature TemperatureControl ControlValves Valvesfor forover over60 60years. years.These Thesevalves valvesare aresold sold world-wide world-wideininMarine, Marine,Power PowerGeneration, Generation,Offshore Offshoreand andIndustrial Industrial sectors. sectors. Manufactured Manufacturedininaawide widerange rangeof ofmaterials materialsWALTON WALTONValves Valveshave havebeen been engineered engineeredto tomeet meetthe theincreasing increasingdemands demandsof oftoday’s today’smarket. market.Of Ofrobust robust construction constructionthey theyare aresimple simpleto tooperate operateand andprovide providean anextremely extremelycost cost effective effectivemethod methodof oftemperature temperaturecontrol. control. An Animportant importantFeature Featureisisthe theability abilityto to“hand” “hand”the thevalves. valves.This Thisprovides provides flexibility flexibilityininselecting selectingthe theconfiguration configurationbest bestsuited suitedto tothe thepipework pipework arrangement. arrangement.Manual Manualcontrol, control,at atthe thevalve, valve,isisstandard standardfor forthe themajority majorityof of valves. valves. We Weoffer offeraaprogramme programmefor forconverting convertingexisting existingDirect Directoperated operatedvalves valvesto to Pneumatic Pneumaticor orElectric Electricoperation. operation.This Thiscan canbe beachieved achievedininmany many instances instanceswithout withoutremoving removingthe thevalve valvecasing casingfrom fromthe thepipework. pipework. Quality Qualityisisimplicit implicitthroughout throughoutthe therange rangeof ofWALTON WALTONValves Valvesand andto tothis this 2008 end endthe thecompany companyhas hasbeen beenassessed assessedby byNQA NQAto toBS BSEN ENISO ISO9001:2000 9001:2000
WALTON WALTONEngineering EngineeringCo CoLtd. Ltd. 61 61London LondonRoad, Road,St StAlbans, Albans,Herts HertsAL1 AL11LJ 1LJ Tel: Tel:01727 01727855616 855616(2 (2lines) lines) Fax: Fax:01727 01727841145 841145 Email: Email:sales@waltonengineering.co.uk sales@waltonengineering.co.uk Website: Website: www.waltonengineering.co.uk www.waltonengineering.co.uk
Over 40 years at the forefront of fire, blast & acoustic protection worldwide MechTool Engineering Limited Mech Tool House, Whessoe Road Darlington, Co Durham England DL3 0QT T: +44 (0)1325 355141 E: sales@mechtool.co.uk W: www.mechtool.co.uk
FoR 40 yEaRs MECH-TooL EnginEERing LTD (MTE) has been at the forefront of the design and manufacture of products that provide fire, blast and acoustic protection to personnel and equipment across a range of industry sectors, notably offshore and onshore oil and gas, nuclear, renewables, chemical and petrochemical. Accreditation to ISO 9001 and employing over 150 highly skilled staff. The organisation and manufacturing facilities are based in Darlington in the North East of England with additional quayside manufacturing and assembly facilities located in nearby Middlesbrough. Mech-Tool’s ongoing commitment to continuous business improvement has lead to the company restructuring into three product based business units enabling greater focus within the varying industries and product sectors.
• MTE Modular Products Fire and blast rated accommodation modules, packaged equipment modules and control rooms designed to meet clients’ specified explosion, thermal, fire and acoustic performance criteria. Modules are manufactured and supplied complete with all electrical, HVAC and packaged equipment systems preinstalled, tested and commissioned. • MTE acoustic Products Acoustic packages for power generation and compression equipment, silenced gas turbine intake & exhaust systems, acoustic enclosures for rotating equipment, vent discharge & safety valve silencers, acoustic mitigation services for existing industrial facilities and offshore
locations. Design, engineering, manufacturing and technical services are available to support the supply of noise control ancillary equipment.
• MTE Fire and Blastwall Products Firewalls & blastwalls carry Lloyds type approved certification from A60 to H120 fire and jet fire up to 60 minutes. Full scale blast testing has been carried out up to 4 bar. Windwalls, Heatshields / weather protection systems to drilling derricks and blast relief systems designed and manufactured to meet customers specified requirements. Mech-Tool has recently earned RoSPA’s prestigious President’s Award after collecting ten consecutive gold awards. The RoSPA award scheme is designed to reduce the number of accidents and cases of ill health at work, but also examined the Health and Safety Management Systems at Mech-Tool’s head office and two fabrication centres in Darlington and Teesside, as well as its offsite operations. The award took place alongside Safety & Health Expo 2010.
“PRoTECTing PERsonnEL in FiRE anD BLasT RaTED MoDuLaR BuiLDings” Mech-Tool Engineering Ltd is a recognised specialist in the design and manufacture of modularised buildings required to withstand significant blast overpressures. Mech-Tool Engineering, Ltd is pleased to announce the successful completion of a major contract to design, manufacture and install a fire and blast rated modular office block building to a leading UK refinery. The building was manufactured in 6 modular sections with the addition of a link corridor that formed an office block measuring 28 meters long x 15 metres wide x 4 metres high when placed on site. With one of the key project drivers being to minimise the impact on site during installation and with the complexities of lifting, positioning and weather proofing modules of this size within a live oil refinery, the modular sections were trial assembled at Mech-Tool’s quayside facility in Middlesbrough prior to delivery in two phases. “oFFsHoRE LQ PRoTECTED WiTH MECH-TooL’s FiRE anD BLasTWaLLs” Mech-Tool Engineering Ltd has successfully completed the design, engineering, manufacture and supply of 5000m2 of stainless steel external fire wall cladding for a new living quarters platform for BP Norge AS, this is part of the
36
Valhall Oil Field re-development. The £4 million contract included the supply of doors. Mech-Tool’s fully certified range of firewalls, blastwalls, heatshields, blast relief systems and fire and blast rated doors have been an integral feature of fixed and floating offshore platforms for more than 35 years. Design engineering on the Valhall project was carried out at Mech-Tool’s research and development offices in Whessoe Road, Darlington. The cladding was manufactured at Mech-Tool’s factory in the Albert Hill area of Darlington and delivered to Lowestoft by road. The cladding was manufactured in 4m x 2.5m stainless steel panels typically A60 and H60rated. This will provide at least 60 minutes of fire protection in the even t of an evacuation. In addition to the above, Mech-Tool also designed, engineered and supplied 1950m2 of windwalls and 1450m2 of heatshields.
£1.4M noisE ConTRoL ConTRaCT sHouTs LouDLy FoR noRTH-EasT EnginEERing EnTERPRisE Mech-Tool’s Acoustic Division has expertise in interpreting the noise exposure risk assessment and producing practical and economic solutions for the protection of the personnel at risk. The company has recently successfully executed a £1.4 million contract for the BP Valhall Oil Field. In mid-August 2009 four large compressor units were shipped ready for installation from Teesside directly to BP’s North Sea fabrication facility in Holland. Built by MAN Turbo AG, the compressors were encased in stainless steel acoustic enclosures, capable of noise reductions of up to 45 decibels, which had been designed and manufactured by Mech-Tool Engineering Limited, of Darlington. The compressors and enclosures were to have been fitted together in Holland, but Mech-Tool’s role on the project – initially only for the design and manufacture of enclosures and associated ventilation and gas detection systems – was expanded to include the installation of the enclosures onto the compressor skids and fully commission the fire and gas systems, ventilation systems and all electrical hook ups. The installation onto the compressors was undertaken in Mech-Tool’s fabrication centre at the North Sea Supply Base in Middlesbrough. The packaged skids on completion, weighing between 80 to 130 tonnes were loaded directly onto sea transport for transshipping to the fabrication yard in Holland, where one lift to their final position on the platform facilitated immediate interconnection to the process systems.
ENGINEERING LTD
Global supplier of industrial noise control products, packaged equipment modules and passive fire and explosion protection solutions Mech-Tool provides a complete design, project management and supply service for: Modules • Accommodation modules • Packaged equipment / control rooms • Switchgear & instrumentation modules Fire & Blast Protection Systems • Firewalls & blastwalls • Radiant heatshields & windwalls • Blast relief systems Industrial Noise Control Systems • Acoustic packages for power generation & compression sets • Acoustic upgrading of on/offshore facilities • Acoustic studies & mapping of on/offshore facilities Capabilities • In-house design & engineering capability • State of the art 3D engineering • Quayside facility to build and load out modules exceeding 3000 tonnes • Acoustic mitigation services • Lloyds / DNV certified fire resistance to J60/H120 & blast up to 4 bar Mech-Tool Engineering Ltd. Mech-Tool House, Whessoe Road, Darlington, Co. Durham, DL3 0QT Telephone: +44 (0) 1325 355141 Fax: +44 (0) 1325 487053 Email: sales@mechtool.co.uk Website: www.mechtool.co.uk
ATEX
Converteam, the power conversion company, provides customised solutions and systems converting electrical energy into productive performance. These solutions are built around three core components: rotating machines, variable speed drives, automation and process controls. Our scope covers consulting, design, manufacture, system integration, installation, commissioning and a broad range of services. Our worldwide workforce remains fully committed to one overriding goal: to bring you the best in technology, backed up with truly effective service in all markets. Many hundreds of ships have been fitted with Converteam’s electric propulsion systems, with extensive experience in FPSOs, dive support vessels, OSVs/PSVs and many other vessel types. Converteam are world leaders in integrated electric power and propulsion solutions.
www.converteam.com
www.harshandhazardous.com
CABLE GLANDS
World leading range of hazardous area and industrial cable glands, providing unrivalled safety
GRP ENCLOSURES
Extremely robust anti-static Exe enclosures, providing extreme corrosion and impact resistance
UK Office Hawke International Oxford Street West, Ashton-under-Lyne, Lancashire 0L7 0NA. UK. Tel: +44 (0) 161 830 6695 Fax: +44 (0) 161 830 6698 E-mail: sales@ehawke.com
Singapore Office Hawke International 130 Joo Seng Road, #03-02, Olivine Building, Singapore 368357 Tel: +65 (6282) 2242 Fax: +65 (6284) 4244 E-mail: asia@ehawke.com
OFFSHORE PLATFORMS
ENGINE ROOMS
HARSH
www.ehawke.com
STAINLESS STEEL ENCLOSURES
Extensive range of stainless steel Exe enclosures, with global certification options
EX CONNECTORS
Complete range of Exd Instrument, Control and Power connectors, allowing for greater flexibility
USA Office Hawke International
4140 World Houston Parkway, Suite 130, Houston, TX. 77032 USA. Tel: 00 (1) 281 445 7400 Wats: (800) 354 9189 Fax: 00 (1) 281 445 7404 E-mail: america@ehawke.com
CONNECTION SOLUTIONS FOR GLOBAL APPLICATIONS
PETROCHEMICAL REFINERIES
H AND HAZARDOUS AREAS
In Our Element Valeport Limited St Peter’s Quay Totnes Devon TQ9 5EW UK T: +44 (0)1803 869292 F: +44 (0)1803 869293 E: sales@valeport.co.uk W: www.valeport.co.uk
ESTabLiShED in 1969, Valeport design and manufacture instrumentation for the oceanographic / hydrographic community, with a worldwide customer base that includes the environmental, military, oil & gas, renewable, construction, dredging and civil engineering sectors. Key to our reputation for supplying high quality, reliable instrumentation is our philosophy of retaining all aspects of the development and manufacturing processes in-house. Our riverside premises in the picturesque town of Totnes in the southwest of the UK houses all our facilities for designing, CNC machining, environmental testing, assembly, calibration and servicing of all our instruments. This philosophy gives us complete control over every aspect of our products, allowing us to provide our customers with the right tools to do their jobs, with minimum fuss and maximum confidence. Now into the 41st year providing the oceanographic, coastal and hydrographic community with surveying and monitoring equipment, Valeport are maintaining their position as the UK’s leading manufacturer in this market area. Back in the early 70s, the company grew steadily making current meters and new products
were introduced like CTDs and Tide Gauges. The pioneering days of North Sea exploration in the 80s allowed the 600 series CTD to become a firm favourite in the survey and seismic market, indeed this is still the case worldwide and is now known as the Midas CTD. A move into Tide Gauges during the 80’s proved to be the right decision for Valeport as the BTH700 and VTM710 became a familiar site in many ports and harbours both UK and worldwide. The portable Model 740 introduced in the mid 90’s allowed both large and small survey companies to enjoy a powerful, yet cost effective solution to tidal monitoring and has proved to be another “industry standard” for tidal measurement. With the oil and gas exploration market entering deeper water, Valeport had to follow suit. The introduction of a 3000m depth rated CTDs allowed the monitoring necessary to support required operations. Today, we deploy both CTD, Multi-Parameter CTD’s and SVP instruments to 6000m as standard whilst technology drives us forward. The late nineties saw a new phase in development with the introduction of Wave Recorders and Sound Velocity instruments. The Model 730 Directional Wave Recorders using the well documented PUV measurement method and linear wave theory for data processing, allowed coastal monitoring projects to safely achieve data collection where a traditional wave buoy could not operate. The addition of extra parameters
‘Monitoring of sound velocity has traditionally been done via coMputed ctd data and still undertaken when salinity and density are required. these days direct MeasureMent via valeport’s range of Mini sensors and profilers, which utilise the latest in high technology coMposite Materials and digital circuitry, provides users with an un-beatable accuracy. a coMbined ctd/svp, the Midas svX2 has quickly becoMe the professional choice within the oil & gas survey coMMunity in the last few years.’
42
such as turbidity proved a powerful tool in the sediment transport and coastal erosion studies. Monitoring of sound velocity has traditionally been done via computed CTD data and still undertaken when Salinity and Density are required. These days direct measurement via Valeport’s range of mini sensors and profilers, which utilise the latest in high technology composite materials and digital circuitry, provides users with an un-beatable accuracy. A combined CTD/SVP, the Midas SVX2 has quickly become the professional choice within the oil & gas survey community in the last few years. For bathymetric products, the Midas Bathypack and miniIPS (intelligent pressure sensor) combine well to give users the best in density corrected depth measurement with simple to use topside software. Completing the survey equipment range is the Midas Surveyor, a portable, single beam, dual frequency GPS echo sounder. The Surveyor allows one unit to log and output multiple parameters saving valuable space on small craft. As we move forward, product development is key to our future. Our products come from our customers; the skill is translating a market-led idea into a specification that can be met by our team of mechanical, electronic, firmware and software R&D engineers. Quality in the manufacturing process is paramount, from the mechanical parts from our CNC machine shop, through rigorous environmental and batch testing of pcbs in our ESD protected factory, to final assembly of the sensors and instruments we offer. The sale of an instrument is the start of our relationship with a customer, not the end. With facilities including a tow-tank, ultra-stable temperature and salinity baths, high accuracy temperature bridges and standards, and pressure test vessels for all our products, our Service and Calibration staff are able to keep your instrument performing as new for many years. That is why we offer a 12 month warranty on all services – to give you the same confidence in our products that we have. Valeport’s strength is in our customer service and the policy of continuous product development. Our aim is to maintain a high level of innovation and support for many years to come.
The UK’s leading manufacturer of hydrographic and oceanographic instrumentation. • Tide Gauges • Wave Recorders • Current Meters • Echo Sounders & Bathymetry • Sound Velocity • Ocean Engineering • CTD & Multiparameter
Tel: +44 (0)1803 869292 E Mail: sales@valeport.co.uk Web: www.valeport.co.uk
The global independent technical advisor
A global network with a local presence Assurance Advanced Engineering and Consulting Marine Operations Project Execution
15873_NS 14.07 2010
Software Solutions
www.gl-nobledenton.com
Š GL Industrial Services UK Ltd. All rights reserved.
Email: glnobledenton@gl-group.com
Wessington Cryogenics - A World Class Manufacturer of Cryogenic Storage Vessels Wessington Cryogenics 2 Gadwall Road Rainton Bridge South Houghton le Spring Tyne & Wear DH4 5NL United Kingdom T: +44 (0)191 512 0677 F: +44 (0)191 512 0745 E: info@wessingtoncryogenics.co.uk W: www.wessingtoncryogenics.co.uk
WESSINGTON CRYOGENICS is a manufacturer of a broad range of cryogenic storage vessels from small general purpose dewars to multi-coded vessels, bespoke road tankers, custom build trailers and 10ft & 20ft ISO framed tanks for the global Oil & Gas Industry. In 2009 Wessington Cryogenics celebrated its 25th year and during the last 15 years has become recognised amongst the best in the world for quality and reliability, vessel design and manufacture. In addition to this, Wessington Cryogenics is able to offer a full tank and frame refurbishment program and re-certification service at its UK factory. Wessington can also offer a vessel repair and testing service (on-site) and is ISO 9001:2000 and ASME registered. Wessington has proven technical expertise and design capability to build to all current international
standards including: ADR & RID (Transport), PED & TPED, DNV 2.7.1 (Offshore), EN 12079/13530, CSC, IMDG (Container Transport and Maritime), Worksafe Australia, ASME VIII & US DOT (Transport America). Wessington Cryogenics is also the preferred supplier to many of the major organizations in the Oil & Gas Industry including the international Oilfield Service Companies and cryogenic Tank Rental & Leasing Companies. Many of these companies placing multiple repeat orders for 10ft and 20ft ISO containers – year after year, for delivery into some of the most hostile environments all over the world. Wessington has made substantial investment in production, training, and the implementation of lean manufacturing techniques in the last two years and with a new 70,000 square ft production facility have doubled its production capacity, for the standard 10ft ISO offshore tank. This new facility gives us an additional 30,000 square ft (production capacity) allowing the company to take on large scale manufacturing projects and custom designed cryogenic vessels and trailers. The company remains a family run business with the directors having a combined experience of more than 75 years in cryogenic engineering & manufacturing and with more than 80% of its annual total production, being exported globally. In 2008 and 2009 Wessington Cryogenics was recognized for outstanding achievement by a panel
of industry leading experts and awarded Company of the Year, International Business of the Year and Exporter of the Year by respected independent organizations in the UK. This success has come from continued growth with global partners within the Well Service Industry. The majority of our 10ft and 20ft offshore tanks are being used in coiled tubing, nitrogen pumping and well intervention services by most of the major international operators. Wessington Cryogenics is a truly international company, but remains strongly committed to its traditional manufacturing routes in the North East of England and is passionate about its people, strong business heritage, and cryogenic manufacturing expertise… • 10ft ISO framed units, 20ft ISO framed units, 2000, 3000, 4000 and 5500 gallon capacity, Dual Certified ISO units, cryogenic road tankers, custom build trailers.
45
False economy? John Crane explains why equipment should be returned to the original manufacturer for service and repair key to this issue – and to the warranties that are offered on refurbished products. Access to the original drawings and expertise used to create the equipment is essential if it is to be returned to a 100% as-new condition. No other manufacturer will have access to these drawings, or to the component tolerances and assembly instructions that are necessary to refurbish to the original design standards. Materials are also crucial. Those used by John Crane are invariably selected, tested and approved The UK has Few oil reFineries leFT, specifically for an individual seal and are often the last one originally built in 1964. Ageing qualified in the original design, development and process plants like these are creating a growtest work. No other manufacturer can know what ing demand for reliable support from equipment material grades and test regimes were used to manufacturers. With plant operators under great reach the approved standard. Some of the compressure to keep their facilities constantly running, ponent designs may also be protected by patents. there is a temptation to have equipment serviced This causes substitutions to be made, compromisor repaired by someone other than the original ing the equipment’s original design and opening manufacturer - a strategy that is fraught with risk. the door to reliability problems and increased risk In order to minimise risk of disruption or downto the customer. time for the customer, critical equipment must The original manufacturer is also likely to have operate efficiently and reliably. To achieve this, it a far deeper understanding of both the equipment must be refurbished and serviced as effectively itself, and equally importantly, the part it plays as possible and no one is better placed to do in the wider operating process. John Crane’s this than the original manufacturer. John Crane extensive expertise allows it to not only repair an goes to great lengths to ensure that it can always item that has failed, but also to investigate further provide a fully comprehensive support capability and identify the root cause of the failure. Because to all its customers. the company has a wide portfolio Repair capabilities offered by John Crane are 109396_Oil_and_gas_Ad_125x180.qxd:Layout 1 25/6/09 16:14 of products Page 1 John Crane UK 31 Nash Road Trafford Park Manchester M17 1SS T: (+44) (0)161 872 2484 F: (+44) (0)161 872 1654 E: enquiries@johncrane.co.uk W: www.johncrane.co.uk
ranging from mechanical seals and engineered bearings through to filtration systems, it is able to take an experienced and holistic view of the entire process. That makes it far easier to identify and eliminate the root cause of any failure – which may lie well away from the failed equipment itself in another part of the process - and so help prevent repeat failures in the future. The implications here for reducing risk, downtime and lost revenue are enormous. Accessibility is also key to this issue. John Crane operates a global network of service centers which covers over 50 countries and so provides customers with genuinely local access. This greatly simplifies the logistics of returning parts for servicing, ensures local availability of genuine spares, reduces turnaround times and eliminates language barriers. These facilities are also constantly upgraded, which ensures that the level of servicing provided is always as high as possible. With service capabilities continuing to play an increasingly important role in the early stages of a purchasing decision, it makes good sense to ensure that the supplier you choose can provide the type of service and repair capability that is essential in today’s market. John Crane believes that it is able to do exactly that and to deliver significantly reduced risk plus greater reliability, uptime and revenues streams to its customers as a result.
METROLOGY SOLUTIONS THAT PERFORM…. As exclusive UK distributor, Bowers can deliver Gagemaker’s industry-standard thread inspection product range
Bowers’ range of flexible and adaptable bore gauges are perfect for use in the most demanding environments
Bowers has launched some great Special Offers across its range of Precision Measuring Solutions. For more information visit www.bowers.co.uk/current-offers
Partners in Precision Unit 15, Bordon Trading Estate, Bordon, Hampshire GU35 9HH Telephone: 08708 50 90 50 Fax: 08708 50 90 60 www.bowers.co.uk offshore@bowers.co.uk
46
10 0 S 25 N t OG 70 a s t u tand i s Vi S
A unique combination of products and services John Crane is a global leader in delivering world-class products, services and support to customers in a wide range of industrial sectors. We are also committed to achieving the highest levels of customer satisfaction in the process. Our success is backed by our emphasis on customer support. We work in partnership with our customers to provide bespoke solutions that satisfy individual requirements, supported by our global network of service facilities.
• Dedicated global service engineering team • 24/7/365 emergency response team • Specialist asset management services • Present in 53 countries with over 200 sales and service facilities
Mechanical Seals • Fluid Control Systems • Power Transmission Couplings Filtration Systems • Advanced Hydrodynamic Bearings
www.johncrane.com