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Tomorrow-Technip-September 2014
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Umbilicals Innovation at AngoflexCarbon Fiber Armors for Flexible PipesFLNG Cryogenic ProtectionLow Carbon Energy Solutions
TOMORROWA Technip Technology Publication - Issue 5 - September 2014
P. 10-11
P. 6-7Carbon Fiber ArmorsA Technip solution for ultra-deepwater and corrosive fluid
P. 4-5 Angoflex’s new world-firsts New carroussels and load-out path
Director of Publication: Christophe Bélorgeot
Chief Editor: Caroline Aurelle
Associate Editors - September 2014 issue:
Andrea Gragnani, Brian-A Roberts, Bruno Lequime,
Hallvard Hasselknippe, Jean-Louis Rostaing,
Jean-Philippe Martin, Laurent Decoret,
Laurent Pomie, Marie-Christine Charrier,
Sebastien Viale, Stéphane His, Sylvain Cabalery,
Vincent Douthe.
Design and production: Anne-Laure Seguette
The Group Communications Department would like to thank everyone who
contributed to this issue.
Technip - 89 avenue de la Grande Armée - 75116 Paris - France
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Low carbon energy solutions
P. 8-9 Joint industry program For FLNG cryogenic spillage protection
Tomorrow MagazineA Technip Technology PublicationIssue 5 – September 2014You can find the previous issues of Tomorrow
at: http://www.technip.com/en/media-center/
tomorrow-magazine
Your comments are always welcome:
[email protected] ISSN 2273-8703
Carbon Fiber ArmorsA Technip solution for ultra-deepwater and corrosive fluid
This document is printed on Heaven 42
This document is the property of Technip. Any modification, reproduction or commercial use of this document is prohibited.
“We are permanently maintaining our strong technological efforts, and our trusted teams are the driving force behind our innovation track record.”
Hallvard Hasselknippe President and Chief Operating Officer Subsea
I am happy to welcome you to this new issue of Technip’s technology and innovation magazine “Tomorrow”, this time mostly dedicated to some of our latest subsea innovations.
Technip, as a technology leader, has been able to drive numerous projects in the subsea business, throughout decades and all over the world. Yet, across this period of time, the environment in which we operate has significantly changed, increasing project complexity and pushing back
frontiers. Typically, in the 1990s, deepwater referred to projects operating at some hundred meters under the surface. Today deepwater
includes production operations up to 3,000 meters below sea level.
New frontiers require investment but first and foremost require technology, and much subsea progress has been made possible through innovation, most notably in risers and flowlines, as our latest developments in flexible technologies testify. From protection against H2S corrosion to carbon fiber armor making risers five times lighter and twice as strong as steel, Technip has shown that it is necessary to capitalize on research and development (R&D). This has enabled the Group to consolidate its position and win major contracts in key regions of the world, like Moho Nord in West Africa, or in less-explored areas such as pre-salt in Brazil.
R&D remains indeed more than ever a key driver for competitiveness at a time when our clients are looking to optimize their investments. Combined with early involvement and fit-for-purpose solutions,technology is critical to help them address ever-growing demand for hydrocarbons. In this regard we are permanently maintaining our strong efforts, and our trusted teams are the driving force behind our innovation track record.
Worldwide innovation and technology are two of the strategic axes that have allowed us to become a leader, from the deepest subsea oil and gas developments, to the largest offshore and onshore infrastructures, to date. We are proud of our achievements thus far which strongly contributes to fulfilling our vision: meeting the world’s energy challenge.
I do hope you enjoy reading this new issue of Tomorrow.
EDITORIAL
Low carbon energy solutions
Tomorrow-Technip-September 2014
Angoflex’s new carrousels and load-out path: new world-firsts
Back in 2004, Technip and Sonangol decided to open the first umbilical plant in Africa, through a Joint-Venture named Angoflex. This umbilical manufacturing unit is located in Lobito, 400 kilometers (km) south of Luanda, Angola and since its opening has delivered steel tubes umbilicals for operators present in the country. Adopting a national content approach, Technip is committed to supporting local development.
Crossing two rivers channels requiring one bridge of 55m with a trolley system, and one bridge of 26m
Crossing two roads, the first of 35m long with heavy load capacity for the crawler crane and the second of 25m long
Designing all the bends to accommodate the site constraints while remaining within the maximum bending radius of the umbilicals, anticipating what future designs would impose
Installing of an automatism system
Quick mobilization and demobilization of the complete equipment of the route with a temporary system
Limited quay availability to install tensioner and chute
The load-out path is the key element of this upgrade and was the most complex operation. Beyond the length, numerous challenges were met:
Challenges and success in project installation
The load-out activity consists of transpooling umbilicals from the carrousels located at the plant onto installation vessels located 1.2 km away. The plant is situated within the Sonamet yard (Sonangol), a fabrication facility extremely busy at the time of the upgrade; a challenge which required a minimum disruption of its activities.
Angola is one of the most dynamic subsea market in the world, with deeper and deeper projects in an even more challenging environment.
With ultra-deepwater now referring to water depths over 1,500 meters (m) and close
to 3,000m below sea level, clients’ needs are thus more demanding and require bigger diameters and longer lengths of umbilicals. To respond to clients’ requirements, and to strenghen its position as a key technology leader on the market locally, Technip in Angola with its partner Sonangol decided to enhance the facilities available at Angoflex,
transforming it into one of the most capable umbilical plant of the world. This upgrade initiated in 2011, and completed in 2013, consisted of an extension to the Helix machine, two new 2,500 tons carrousels, the acquisition of two new under-rollers, and an unique load-out path to offload umbilicals from the plant to the quayside.
Trolley system to cross-over water
For further information, please contact [email protected]
4 - 5
A crawler crane is used to carry the Umbilical Termination Assembly (UTA) up to the installation vessel, all along the load-out path. It then requires perfect coordination between the vessel and plant teams to perform and complete the transpooling.
The first project executed thanks to these upgrades was the CLOV project for Total E&P Angola where the umbilicals were
entirely manufactured in Lobito. Three load-outs were carried throughout the year 2013, and were executed on schedule and without any safety issue despite the complexity of the operation. It was a world-first and a success since Angoflex received the CLOV Safety and Operational Award for the world’s longest and Africa’s first umbilical transpooling. This award is an acknowledgment of the extraordinary performance of the Angoflex, Technip
Umbilicals and Technip in France teams, and their capability to deliver this upgrade project, and execute three successful load-outs under extreme pressure.
Thanks to the upgrade, the Angoflex plant has now gained in competitiveness on the umbilical market, thus enhancing Technip’s key differenciating assets.
The recent award of Kaombo, where umbilicals will be manufactured by Angoflex, and transpooled with the load-out path reflects our clients’ confidence in Angoflex capability to deliver successfully such complex projects.
Successfully installing the load-out path
Overview of Angoflex manufacturing plant, Technip-Sonangol Joint-Venture in Angola
Tomorrow-Technip-September 2014
With the increasing water depth - 2,000 meters and beyond, and onset of corrosive fluids of offshore field developments, the suspended weight and the fatigue of dynamic risers became challenging. As a result, innovative tensile armors made of carbon fibers were developed with high mechanical performances and a weight up to five time lighter than steel.
Carbon Fiber Armors: a Technip solution for ultra-deepwater and corrosive fluid
Over the last twenty years, carbon fiber composites have progressed from laboratory curiosity to an industrial reality. Composite materials had already demonstrated great performance by weight savings for aircraft structures.
To address new market needs and continue to reinforce its offering of high-end flexible products, Technip started about 15 years ago a com-prehensive development research program to adapt this new technology for flexible pipe. This has demanded aca-demic support from universi-ties, laboratories and suppliers specialized in composite materials to develop specific test methods and/or benches.
A dedicated design methodologyhas also been developed. The key point of composite development was to qualify the material to sustain continuously during the full service life, typically twenty or thirty years, both mechanical loadings and degradation by aggressive fluids. The qualifi-cation has therefore included a full characterization of the composite material at small scale level (including fatigue,
aging, wearing etc…), and at full scale level including burst, impact, crushing, and fatigue tests. Recently, the success of a 9’’ ID fatigue test representative of a free hanging configuration in ultra-deepwater (UDW) Brazilian offshore area, including several severe extension phases, has confirmed the good behavior of the Carbon Fiber Armors (CFA).
With steel armors With carbon fiber armors
Carbon Fiber Armors in action
6 - 7
The industrial step is considerable. Throughout the 16 hours of preparation alongside the armoring machine, only two people assembled and adjusted 120 directional arms on two mounting wheels without perturbing the current steel production.
In less than one hour, those two 6-meter diameter and 10 tons wheels were positioned
on the armoring machine faces, allowing fast changes between steel armors and CFA production. These new types of armors provide an innovative comple-mentary solution to steel armors, and will in time enable clients to meet the challenges that come hand in hand with ultra-deepwater projects and new frontier developments.
New frontiers for ultra-deepwater
Mounting wheel
The many years of R&D and industrialization effort have now brought to life the CFA concept, delivering a new cutting-edge technology taking flexible pipe further.
For further information, please contact [email protected]
Sample of a carbon fiber armor flexible pipe
The emergence of light-weight composite materials used as tensile armor wires, with high strength/weight ratio, high fatigue performance and corrosion free, has opened new frontiers for UDW to dramatically reduce the suspended weight and increase the service life of flexible risers.
For instance, lazy wave configurations commonly used in ultra-deepwater fields with structures made of steel can be advantageously replaced by a simpler, more stable, interference-friendly as-installed riser configuration such as free hanging. Another opportunity for application of CFA is the replacement
of steel armour wires on large diameter flexible pipe used for oil transfer from a FPSO (Floating Production and Storage Off-loading) to shuttle tankers leading to weight saving and a more stable configuration, without the requirement of buoyancy elements.
The onset of this technology also needs the development of specific non-destructive test means, and monitoring systems. The acoustic emission which has been qualified for pipes made of steel armor wires has been installed on fatigue samples to test the composite technology. Other systems are also currently under study to integrate optical fibers in the CFA and monitor the flexible pipe behavior throu-ghout service life. To follow the trend of
new offshore developments, technology qualification is continuously extended to document further the performance of the CFA with the most corrosive fluids and develop new composite solution for high temperature.
At manufacturing plant level, the composite also required specific industrial means and processes to be laid on the flexible pipe. The objective was to integrate CFA on existing machines dedicated to steel armors. After four years of designs, tests and adaptations on the armoring equipment, a first full scale set-up was performed at the beginning of 2014. The first trial for a full scale manufactured CFA flexible pipe will take place in the coming months.
Tomorrow-Technip-September 2014
Current passive protection solutions against cryogenic spillage impacts are derived from classical passive fire protection materials with the objective to extend their performances domain. Consequently, duplex protection systems have been qualified and certified in accordance with Technip clients’ requirements to address both fire and cryogenic resistance.
Safety scenarii to prevent the risk of cryogenic leakage on offshore assets are quite specific in offshore facilities design. Stakeholders and all the different involved disciplines within Technip (Offshore Structure, Process, HSED, Material…) concurred to the necessity to initiate a research and development (R&D) program involving all the partners to develop a shared approach, methodology, tools and protection solutions to improve management of these risks, in light of Technip’s leading position on FLNG.
In 2011, Technip’s offshore product line launched a call for sponsors to all of the FLNG value chain actors to set up a Joint Industry Program (JIP). This call has shown a wide interest and most major opera-tors, engineering contractors, OEM and classification autho-rities decided to join in, and to actively support this initiative.
To define a cryogenic hazard rating criteria
To carry out a baseline survey of the different Cryogenic Spillage Protection (CSP) material technologies
To qualify experimentally a 3D Computational Fluid Dynamics (CFD) model “EOLE”, in collaboration with a software developer PRINCIPIA, to accurately model LNG accidental releases from leak point to rejection at sea, to better assess the extent of area to be protected with CSP
Industry program for FLNG cryogenic spillage protection
Preventing spillage of cryogenic material (e.g. LNG) is essential especially when operating offshore, in restricted environments, to ensure both personnel safety, as well as asset integrity. With world firsts led by Technip such as FLNGs, ensuring safety is a key priority. In line with Technip’s commitment to protection a joint industry program has been developed, dedicated to cryogenic splliage protection.
Attendees at the Kick off meeting of the joint industry program in Cybernetix, Technip’s subsidiary in Compiègne
This program, gathering sponsors and protective materials vendors, has been kicked off in 2012 with the following objectives:
Innovative product design for protection of cryogenic liquid accidental release
Material engineering
HSE Design (safety engineering and risk quantification)
Computational Fluid Dynamics Modeling
Experimental testing (Cybernetix Center of Technip - Compiègne)
Complex physical phenomena are addressed during these qualifications:
Low and high pressure jet fragmentation, rain out and coalescence
Pool spreading and vaporization on sloped surface and on various substrates
Cryogenic media spreading and vaporization on water
Once qualified, Technip along with PRINCIPIA will propose to their clients, EOLE services for CFD simulation of LNG accidental release.
8- 9
A large part of the program has been focused on the assessment of the CSP performances of several material technologies and proposes viable and reliable solutions. Technip has developed a specific test bench and associated testing procedures “CSP Technip proof
test” which has been reviewed and approved by the Cryogenic Test Lab of the NASA Kennedy Space Center. This testing protocol is under conversion to an ISO committee draft for which the work group is led by Technip. Ongoing discussions are engaged with
class authorities to incorporate hazard ranking criteria in the new revision of FLNG classification rules. To date, the qualification of the 3D CFD model is still on-going and most of experimental validation trials are carried out on the test platform of Cybernetix with the target to be completed in 2015.
For further information, please visit http://www.technip.com/en/our-business/offshore/flng or contact [email protected]
FLNG: a Technip first
Test bench for jet fragmentation
When safety matters, Technip is at the forefront of the industry by doing the right thing.
The program is managed byour Innovation and Technology Center and involves several in-house disciplines:
Tomorrow-Technip-September 2014
Courtesy of Shell
Low Carbon Energy Solutions
The CANSOLV CO2 Capture System
In 2013, Technip and Shell Cansolv forged a strategic alliance to market CCS projects globally leveraging respective expertise. Together the alliance offers leading edge “one-stop-shop” CCS projects to power clients around the world, and includes collaboration of respective experts seeking to improve current offerings aiming for the highest efficiency CCS solution.
Lower regeneration energy and superior kinetics compared to conventional amines
High loading capacity combined with ease of regeneration
Improved resistance to oxidative and thermal degradation
Advanced solvent and technology development
Proven constructability
CANSOLV CO2 CAPTURE SYSTEM BENEFITS
and NO2 emissions.
Shell Cansolv’s CO2
capture technology is highly adaptable to a wide variety of industrial applications, gas flow rates and carbon dioxide (CO2) concentrations.
The system employs a regenerable solvent and utilizes a proprietary amine technology which captures the CO2 from the flue gas and releases it as a pure stream. The pure CO2 product output by the Shell Cansolv technology enables Enhanced Oil Recovery (EOR), Carbon Capture and Storage (CCS) or Carbon Capture and Utilization (CCU) downstream of the plant.
In post-combustion CO2 capture, the CO2 is chemically removed from the flue gas after the combustion of the fossil fuel, so the emission control system is segregated from the production facility, unlike some alternative CO2 capture technologies.
The system is essentially standalone and, therefore, ideal for retrofit scenarios.The technology can help refiners, utilities and other industries to lower their carbon intensity and meet stringent greenhouse gas abatement regulations by removing CO2
from their exhaust streams, with the added benefit of simultaneously lowering SO2
Shell Cansolv 150MW SO2 / CO2 Capture retro-fit plant for SaskPower in Canada
and reduced scale-up risk
The Peterhead Carbon Capture and Storage Project
Today, Technip’s office in Milton Keynesserves as a “centre of excellence” for the development of end-to-end solutions for carbon capture and storage projects.
Shell U.K. Limited, with strategic support from SSE Generation Limited, proposes to establish the world’s first commercial-scale full-chain gas carbon capture and storage (CCS) demonstration project at SSE’s power station at Peterhead in Aberdeenshire, Scotland.
Around one million tonnes per year of carbon dioxide (CO2) emissions could be captured from the power station and then transported by pipeline and stored, approximately 100km offshore in the depleted Goldeneye gas reservoir, at a depth of more than 2km under the floor of the North Sea.
Technip’s operating centre in Milton Keynes, UK, in association with Shell Cansolv, executed a pre-FEED study for the Peterhead CCS project during 2012. Currently the Milton Keynes office is executing the onshore FEED for this next phase of the project.
The Cansolv patented technology is designed and guaranteed for bulk CO2 removal up to 90%. The key process steps are:
An innovative technology
The onshore FEED scope includes a grassroots carbon capture, conditioning and compression plant and modifications to an existing combined cycle gas turbine power plant.
For further information, please contact [email protected]
Feed gas is quenched and saturated in a circulated water pre-scrubber.
Gas contacts the lean amine solution in a counter-current mass-transfer packed absorption column.
CO2 is absorbed and the treated gas exits to atmosphere.
Midway through the column, partially loaded amine is removed from the tower, cooled and reintroduced over a layer of mass transfer packing.
CO2-rich amine from the absorption column ispumped through a lean–rich amine heat exchanger and then on to the regeneration column.
Rising, low-pressure saturated steam in the column regenerates the lean amine solution. CO2 is recovered as a pure, water saturated product.
Lean amine is pumped from the stripper reboiler to the absorption column for reuse in capturing CO2. The CO2 is directed to by-product management systems.
10- 11
The Peterhead Power station with the areas where the carbon capture and compression facilities will be built
Tomorrow-Technip-September 2014
First RFCC unit for BP in Kwinana, Australia
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