The oil and gas industry is one of the highest grossing sectors in the global economy, estimated by IBISWorld to be worth US$4.3tn in 2023. Although oil and gas workers are still dealing with the impact of the 2020 slump, they are generally positive both about the energy transition and sector growth (see the analysis on page 12).
This issue is packed with innovative technology, not least the cover story. This piece follows oil and gas giants BP and Chevron and their use of a mobile robot from Boston Dynamics that gathers data and warns of safety concerns on site (page 6). Another innovative technology, an AI filter from Qysea (page 52), promises to be of considerable assistance to subsea operations.
As one would expect there is also a big focus on safety including several articles on flame detection (pages 10 and 20), and an interesting product from Dropsafe that mitigates harm caused by dropped objects (page 44).
A detection system from Zelim (page 46) makes use of a tracking device, recorded video data collection and geolocation to track people that fall into the sea from offshore platforms.
We also cover several projects that have prevented unnecessary expenditure: a composite wrap from Belzona to repair a heavily corroded pipeline (page 32) and the Zetechtics Degraded Interface Adapter (page 54) which deals with degraded valve stems.
Do get in touch if you would like to feature your technology in the magazine or want to discuss areas you feel we should cover.
Nicola Brittain Editor
Electrical safety in low voltage switchgear
A guide to managing ambiguous specifications
Efficiency gains
How one cleaning technology has improved efficiency at a hydrogen plant
30 A stellar performance
Significantly reduced emissions came from this effective pipeline isolation tool
Composite cure
How a bespoke composite wrap was used to repair a heavily corroded pipeline
Smart inspector
A deep dive on a tool that simplifies the Ex/ATEX inspection process
PUBLISHER
Jerry Ramsdale
EDITOR
Nicola Brittain nbrittain@setform.com
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Dan Bennett, Jill Harris
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A creative challenge
How one assembly manufacturer has revamped design principles to meet demand
Reducing oil in water
The successful trial of a microbubble infusion unit
Streamlined gas analysis
How a process oxygen analyser calculates natural gas in real time
Withstand the elements
A product that uses a unique polymer to withstand severe elements
&
Mitigating drops offshore
A clever solution that eliminates the risk of dropped objects to offshore workers
Attention, person overboard!
An intelligent detection system providing automated detection and alerts
Managing complexity
A close up of a new 5G tablet that will streamline on-site operations
Castles in the sand
How one battery cell might be an industry game changer
A fish eye view
An AI filter that significantly enhances underwater visuals
Turning back time
A clever product that deals with degraded stem valves
Valve World Show
A lively Dusseldorf-based show
This Abu Dhabi-based show will run in November
Setform’s international magazine for engineers is published twice annually and distributed to senior engineers throughout the world. Other titles in the company portfolio focus on Process, Design, Transport, Mining, Energy and Power.
Siobhan Doyle explores how mobile robots are helping make the oil and gas industry safer and more efficient
Across the oil and gas sector, asset maintenance and worker safety are top priorities. Mobile robots are increasingly used to support these goals by capturing valuable on-site data while keeping employees away from hazards. Central to this work is American engineering and robotics design company Boston Dynamics and its canine-inspired robot, Spot.
Within the oil and gas sector, Spot can identify air and gas leaks, as well as other equipment maintenance requirements, from anomolies in temperature for example. Equipped with acoustic imagers, gas sensors and thermal cameras, Spot can identify potential hazards, identify equipment with degraded performance, and help ensure compliance for safer, more reliable operations, according to its developers.
In this article, we look at the ways in which this Massachusetts Institute of Technology spin-off company’s agile robot is helping energy companies inspect and maintain their equipment on-site, ultimately optimising site performance and helping operators make informed decisions.
ACROSS THE POND
Oil and gas companies are facing evolving market demands, regulatory pressures, and competition from alternative energy sources. Californiabased petroleum refineries company Chevron, has been responding to these pressures by adopting products and solutions that improve reliability and lower carbon emissions across their operations.
This has led to using Spot at its cogeneration facility in the Chevron Pipeline and Power Upstream Bakersfield, California location to validate several critical use cases. In the summer of 2023, the company expanded its fleet of Spot robots and deployed them to refineries in Pascagoula, Mississippi, and El Segundo, California. With this expansion, Chevron now owns more Spot robots than any other oil and gas company, marking a significant step toward incorporating advanced robotics capabilities throughout its asset portfolio.
“Mobile robotics have proven invaluable in our operations,” says Joshua Hofstatter, technology and
digital innovation manager at Chevron’s refinery in El Segundo, California. “Spot has the ability to walk into a facility and gather key data which can be presented into a fit-for-purpose dashboard. This really helps with decision making.”
Jason Bohr, Chevron’s enterprise process mining product owner, explains that Spot, equipped with various payloads, can monitor thousands of pieces of equipment at the refineries. This capability ensures that plant operators receive a continuous stream of real-time, accurate data to maintain smooth operations.
THE ROBOT HELPS WITH SAFETY INSPECTIONS
According to the team at Chevron, Spot can utilise an acoustic imager to detect anomalies and alert operations about potential air leaks, enhancing the efficiency of its refineries. Spot CAM+IR, a payload with purposebuilt cameras, can capture visual and thermal images of equipment and gauges. Chevron then processes these images through its own computer vision
Woodside Energy has integrated Spot into its operations to enhance safety at its largest LNG facility
programme to identify any anomalies.
Spot is not only aiding Chevron in existing inspection processes but also advancing them. Previously, operators would walk the sites and rely on their senses to analyse equipment, listening for unusual sounds or detecting excessive heat. “With Spot, we can take precise measurements of acoustics and temperatures, and then track that data over time,” says Zach Pringnitz, a robotics engineer at the Chevron Technical Centre.
Boston Dynamics also collaborated with Chevron to develop an industryspecific safety feature for Spot: a sensor that detects the presence of explosive gas. When Spot senses the gas, it immediately sits down and shuts off, reducing the risk of a spark from the robot igniting the gas. This new safety feature enables Chevron to use Spot autonomously in hazardous and electrically classified areas.
Chris McCasky at Boston Dynamics says that Chevron’s investment in Spot demonstrates the company’s commitment to technology and innovation. “Robotics have become essential to this industry – they
assist with worker safety, help clean up operations, and meet consumers’ energy demands. In short, robots are empowering more efficient and effective ways of working.”
THE ‘SPECTOR’ PROJECT
Located on a remote stretch of coastline in northwestern Australia lies one of the most technologically advanced liquified natural gas (LNG) production facilities in the world. The Pluto LNG facility is a towering maze of pipes, platforms, and machinery with capacity to produce 4.9 million tonnes of LNG each year from two offshore gas fields.
Given the scale of operations at Pluto LNG and the site’s critical importance to the region, it is important to reduce downtime. This requires early and frequent identification of potential problems before they escalate. Woodside turned to Boston Dynamics and Spot to help address this.
Woodside launched a data capture service at Pluto LNG featuring the robot, which Woodside calls ‘Spector’. It conducts routine inspections throughout the site and reduces the
exposure of operators to potential hazards. Images captured by Spector have helped experts at Woodside complete regulatory visual inspections for electrical equipment under the company’s performance standards.
The oil and gas production company has also partnered with Boston Dynamics and software company DroneDeploy to create a platform called ‘FUSE’. This platform – which combines Spector with Woodside’s in-house digital twin of the Pluto LNG facility – allows operators and analysts to pinpoint the exact location of issues within a virtual environment.
Before the Spector programme, it took up to 90 minutes to find equipment and complete an end-toend visual inspection. But experts at Woodside say that with Spector, inspectors can review images first to determine their response and then bring exactly what they need. “One of the biggest benefits of the robotcaptured images is that they can be used to identify issues before arriving in the field,” says Bruce Hill, electrical inspection coordinator at Woodside.
“This means we can bring spares and fix any issues as soon as possible, saving even more time.”
AN OFFSHORE JOURNEY
In 2020, British oil company BP pledged to reach net-zero emissions by the year 2050 while simultaneously boosting employee safety and operational efficiency. To achieve this, BP set out new ways to remove employees from potentially hazardous situations and environments. And although the company operates its facilities with a strong focus on safety, the work remains inherently risky. For example, since production sites are remote – in hard-to-reach locations such as the middle of the ocean – there is a risk in transporting employees back and forth.
STRATEGIC APPROACH TO DRIVING DIGITAL TRANSFORMATION
As highlighted by Adam Ballard, former facilities technology manager at BP, employing robots to inspect remote facilities is a strategic approach to driving digital transformation while enhancing employee safety on site. In this capacity, robots can undertake tasks traditionally carried out by personnel, including scanning for
BP is likely to use robots like Spot for new applications in future
abnormalities, monitoring corrosion, and checking gauges.
BP turned to Boston Dynamics and tested Spot multiple times before deploying one robot offshore. The initial phase involved a proof of concept (POC) at the Texas A&M Engineering Extension Service (TEEX) facility, replicating a typical production site. Tests included navigating various terrains and confined spaces to assess Spot’s mobility and autonomous capabilities. While initial trials revealed issues on grated stairs, Boston Dynamics quickly addressed these.
WORKING WITH VENDORS
Collaborating with BP, Boston Dynamics also connected with vendors to customise sensor payloads, including a methane sensor for high-
risk environments. Pleased with Spot’s performance, the BP team trialled the robot at its Whiting refinery in Chicago, where its performance improved with updates. This success gave the team the confidence to deploy Spot offshore.
ADVANCING SPOT’S PROGRAMMED CAPABILITIES
Ballard explained that the company’s strategy involves advancing the programmed capabilities of Spot, and said this helped the team develop a practical understanding of the site. “It’s about imbuing Spot with that experiential knowledge,” he explained. “Spot should possess the ability to observe, listen, detect odours, and scan to assess the plant’s status. Once fully integrated into our facility, Spot will require analytical reasoning to differentiate between normal operations and anomalies. In the near future, we envision robots like Spot becoming mobile inspectors capable of providing comprehensive insights into a facility’s condition.”
For
Spot the robot: Changing how companies operate ACROSS THE POND
Boston Dynamics’ most notable robot is changing how companies monitor and operate their sites, as well as how they ensure the safety of their teams, and make data-driven decisions. Spot is a compact, nimble four-legged robot designed with what the company calls ‘athletic intelligence’ - a form of artificial intelligence (AI) that allows it to walk, climb stairs, avoid obstacles, traverse difficult terrain, and autonomously follow preset routes with little or no input from users.
According to Spot’s
developers, the robot is easy to use and learns intuitively, making it quick to deploy for both manual operations and autonomous missions. The robot has a payload of 14kg, is capable of moving up steps with a height of 30cm and a slope of ±30°, and has a maximum speed of 1.6m/s. The robot’s terrain sensing capabilities help with inspections and feature a 360° horizontal field of view, a range of up to four metres and a collision avoidance system allowing the robot to maintain a set distance from station obstacles. As for its
walking control system, Boston Dynamics has leveraged model predictive control (MPC), a strategy that predicts and optimises the robot’s future state in order to decide what action to take in the moment.
Spot can also operate at temperatures of between -20°C to 55°C, making it an ideal choice for environments such as oil and gas facilities. It also has an ingress protection level of IP54, meaning its electrical components are protected by dust and water that it is likely to encounter on site.
Helicopter and flare on offshore facility
OFFSHORE FLAME DETECTION
Dr Eliot Sizeland presents an innovative flame detection solution for offshore helidecks
The Civil Aviation Authority publication CAP 437
‘Standards for Offshore Helicopter Landing Areas’ has become an accepted worldwide source of reference. The latest edition, 8.2 July 2021[1], maintains its position as one of the go-to documents for helicopter safety offshore.
The requirements set out in the publication relate to fixed and mobile installations, whether they are operating in the oil and gas or renewable energy sectors. CAP
A triple IR detector has three sensors, each sensitive to a different IR wavelength
437 requires new build Normally Unattended Installations (NUIs) be fitted with deck integrated fire fighting systems (DIFFS), and existing NUI’s be retro-fitted with an alternative automatically activated fire fighting system.
DIFFS on NUIs should be integrated with platform safety systems such that pop-up nozzles are activated automatically in the event of an impact of a helicopter on the helideck where a Post-Crash Fire (PCF) is a foreseeable outcome. The overall
Table: FM tested and approved data[2]
design of a DIFFS should incorporate a method of fire detection, typically optical flame detection, and be configured to avoid spurious trips. The system should also be capable of remote override. This article discusses the latest advances in optical flame detection for this application.
TRIPLE IR FLAME DETECTORS
Triple IR (IR3) flame detectors are arguably the most used optical flame detector for hydrocarbon fires today.
A triple IR detector has three sensors, each sensitive to a different IR wavelength. The IR radiation emitted by a typical hydrocarbon fire is more intense at the wavelength accepted by one sensor, typically 4.5 microns, than the other two which monitor adjacent spectral bands (guard bands) for false alarms. “With other sources of radiation (e.g., heaters, lamps, sunlight) this is not the case, as. the intensity at 4.5 micron is no greater than the intensity of at least one of the guard bands. Electronic circuitry in the detector translates the information received into data that can be analysed for flame flicker analysis, threshold energy signal comparison, and mathematical ratios and correlations between various signals. Triple IR detectors are virtually immune to false alarms and can have extremely long detection distances to some fire types. There are, however, wide performance variations from brand to brand as no two triple IR detectors are the same.
The presence of exhaust (combustion) gases from helicopter engines is known to cause false alarms for some IR3 detectors, a special configuration, immune to these false positives, has been developed by FGD. False alarms offshore are a genuine concern for production and safety. Should a helicopter engine downdraft induce a false alarm on approach to a helideck, the firefighting system could activate automatically and create a safety concern for all onboard the aircraft.
The special FlameSpec configurations have been independently tested and approved by Factory Mutual (FM). The table[2] shows the response data for one such configuration.
A TYPICAL HELIDECK INSTALLATION
A typical helideck suppression system is activated by a standalone control system mounted close to the DIFFs skid in an ATEX-approved enclosure.
This system automatically monitors the helideck via three flame detectors, located at 120-degree intervals around the perimeter of the helideck.
One such flame detector has an embedded HD camera which can be viewed remotely from a control room or shore-based facility. This feature has been found to be particularly suited to remote NUI facilities.
Many operators have noted the benefit of having video and data of events stored quickly to non-volatile
memory locally for post incident investigation. Recordings start one minute before detection and continue for up to four minutes.
SUMMARY
In this article, we have presented an innovative solution to help reduce false alarms from triple frequency infrared flame detectors in applications where exhaust gases from helicopter engines can exist. We have also discussed how the use of an integral HD CCTV camera can provide a live video feed with realtime incident status to operators who can make informed decisions and direct responders accordingly.
[1] UK Civil Aviation Authority, Safety Regulation Group, CAP 437 ‘Standards for Offshore Helicopter Landing Areas’, Edition 8, amendment 02 July 2021
[2] FlameSpec IR3-HD manual, document number F101V0020.06, published June 2021
[3] NFPA 409, 2016 edition
Dr Eliot Sizeland is vice president of business development at Fire & Gas Detection Technologies Inc. www.fg-detection.com
REMOTE HELPER
A remote control that helps oil and gas engineers to manage actuators
Auma’s new explosion-proof RSTX 100 remote control offers safe and convenient operation of the company’s actuators, according to Auma.
Rugged yet ergonomic in design, the remote control will help on-site staff dealing with these actuators. The RSTX 100 is easy and intuitive to use, thanks to its large, high-resolution colour display with clear menu navigation and self-explanatory texts.
A 20-metre Bluetooth range ensures that on-site staff can operate their actuators from a safe distance. In addition, the remote control operates well when actuators are mounted in positions that are hard to reach, for example in pits or at a height.
Designed for use in potentially explosive atmospheres, the RSTX 100 remote control is ATEX and IECEx certified as intrinsically safe (ex ia), thereby offering utmost safety in areas where flammable liquids or gases may be present, according to the company.
The RSTX 100 provides all functionalities required to operate,
configure and commission AUMA actuators. Functions include opening and closing the valve, setting valve end positions, configuring operating parameters, updating the actuator firmware, and exporting actuator log data to CORALINK, the AUMA digital ecosystem, for analysis and diagnostics.
The RSTX 100 is compatible with
the products in the current AUMA actuator series: TIGRON, PROFOX-X, and SAEx and SQEx actuators with ACExC actuator controls.
OPTIMISM THROUGH CHANGE
Oil and gas workers expect sector growth as a result of transformation
Independent risk management company DNV recently released a survey called The Paradox of Petroleum in which 64% of oil and gas industry leaders said they thought the pace of the energy transition was accelerating, while 68% were optimistic about sector growth despite lingering sluggishness from the 2020 downturn.
Survey respondents also said that digital technologies and low-carbon innovations were driving the sector’s transformation. However, concerns remain among executives over investment in new oil and gas capacity,
highlighting difficulties with balancing demand and decarbonisation.
The confidence expressed by DNV survey respondents underscores the sector’s resilience as it tries to meet immediate demands with long-term environmental responsibilities.
The survey also shows the confidence of oil and gas workers following the 2020 downturn and helps demonstrate that the sector is serious about the transition to alternative energy sources such as wind, solar, hydrogen, carbon capture, utilisation and storage (CCUS), and biofuels. These investments are paving the way for new
revenue streams, despite challenges like higher interest rates and supply chain disruptions.
The survey gathered insights from nearly 450 senior oil and gas professionals to examine rapidly evolving trends and the near-term outlook for the sector.
For more information visit: www.dnv.com/powerrenewables/energy-industryinsights/the-paradox-ofpetroleum/
Reciprocating gas compressors are used in many applications and their operators demand excellent reliability. Unscheduled downtime can have significant financial costs for the business and operators should therefore employ a proactive maintenance regime. At the same time, sustainability is an increasingly pressing issue.
To that end, fugitive emissions from gas compressors represent a significant issue for operators. While leaks will not necessarily result in immediate problems or incur unplanned downtime, they might, and so should be addressed at the earliest opportunity.
CURRENT PRACTICE
Although gas leakage will not cause an immediate halt to the process, it tends to worsen over time and can cause other issues, such as a rise in operating temperature.
The key to the most effective solution is to look at the complete sealing system holistically.
During the compression process, the majority of leakage occurs at the piston rod packing, and this should be the primary concern for the operator. Tackling this issue and implementing a proactive maintenance program will not only ensure compliance with local environmental legislation, but deliver a more reliable compressor that costs less to run.
The integrity of these seals is determined by several factors including the ring design, material and the surface finish of the piston rod. For reciprocating compressors, increased wear rates and therefore seal leakage can be identified using measurement of gas leakage flow, or by identifying a change in the leaking gas temperature.
MODELLING THE SOLUTIONS
Currently, it is very difficult to obtain accurate data on gas leakage and to precisely predict the improvements
Tips on how to reduce compressor system downtime
that might be achieved by replacement parts based on modelling alone. But it is possible to demonstrate reduced leakage and improved reliability using real-world examples, and this is where Burckhardt Compression is leading the field.
In one situation, a dry-running compressor working with 90% hydrogen and 10% methane exhibited a very high leakage rate. Burckhardt Compression suggested a proprietary solution that included a set of multipiece rings made from Persisto 850, which had been developed by the manufacturer’s in-house team of experts. This enabled the packing to significantly reduce gas leakage and achieve a minimum lifetime of 8,000 hours.
Typically, when looking for technical support, the first port of call is the OEM and responses can vary depending on the age of the compressor and the ability of the manufacturer to deliver local support. Burckhardt Compression not only has decades of experience in working with compressors alongside numerous OEMs but can also provide in-person assistance and live, one-to-one support using advanced equipment.
DATA IS KING
As with any key equipment, process data from compressors is essential to establishing important operating characteristics. However, the amount of information available fluctuates wildly, depending on the operator.
The solution for situations where a minimal amount of data is available, is to temporarily install additional sensors and data recording equipment as part of the performance analysis to enable the current operating conditions to be established.
FUTURE CONSIDERATIONS
As national governments increase their focus on sustainability, operators may soon be required to provide evidence of the measures they are implementing to reduce emissions. As discussed, data is essential, and the ability to highlight improvements and demonstrate increased efficiency will be what provides them with a competitive advantage.
Careful inspection of compressor components is essential for identifying leaks
BRAZED VERSUS INDEXABLE TOOLING
A deep dive into the benefits of Boring and Trepanning Association (BTA) drilling
Deep hole drilling applications can be approached in several ways, but one of the most effective is often BTA drilling. BTA stands for Boring and Trepanning Association, although it is sometimes referred to as STS or Single Tube System drilling. Unlike gun drills or twist drills a BTA drill features an internal chip removal, which has advantages in both productivity and hole quality.
The BTA drill head has multiple carbide cutting edges and guide pads mounted to it. Open spaces are designed into the head for chip removal, and chips are evacuated through the drill tube the head is
The BTA drill head has multiple carbide cutting edges and guide pads mounted to it
threaded onto. Pressurised coolant surrounds the drill head in operation and is key to forcing chips through the head and out of the drill tube. This method of chip evacuation allows for a very clean and reliable process with excellent surface finish and high drill
feed rates – typically five to seven times faster than gundrilling at the same diameter. No peck cycles or feed interruptions are needed, resulting in reduced machine time while drilling extended depth-to-diameter ratios are even greater than 40:1.
Cartridge mounted insert BTA head
FORMS OF BTA DRILLS
BTA drills are generally available in two forms: brazed or indexable; and tool selection is dependent upon several factors. As the name implies, brazed tools involve brazing a carbide insert and guide pads onto a steel body, while indexable BTA drilling tools have carbide inserts either directly mounted to the head with a retention screw or seated in a cartridge that is mounted to the tool. Hole diameter is the initial consideration when determining whether to use brazed or indexable BTA drills. For small hole diameters – generally 12 to 20 mm in diameter – brazed tools are often the first choice as it’s difficult to make small inserts and screws strong enough to withstand the torque and forces of BTA drilling (manufacturers of BTA drilling tools continue to make improvements in indexable BTA heads as small as 8 mm in diameter, however).
BRAZED TOOLS
Brazed tools offer extremely close tolerances and excellent surface finish as the insert and guide pads are mounted and then ground to the specified diameter, providing almost perfect concentricity and cylindricity.
Ease of use is also a benefit – simply attach the head to the drill tube and discard it when it has dulled or failed. If you experience a tool failure, the investment in drill head isn’t as costly as repairing or replacing an indexable drill head. Finally, an indexable BTA head can only be as accurate as the tolerance of the inserts themselves; but a brazed head has been ground to a very precise tolerance from the manufacturer.
By contrast, hole diameters starting at approximately 20 mm favor indexable tools, primarily for economic reasons. Replacing larger diameter brazed tools is expensive, whereas indexing an insert and guide pads gives an easy extension to the tool’s life. Indexable insert manufacturers also offer an exhaustive range of carbide grades, coatings and chip breakers for application-specific advantages.
INDEXIBLE INSERTS
The placement of the indexable inserts on a BTA drill head varies by diameter and by manufacturer and can include one or multiple inserts mounted directly to the head or set in a heat-treated cartridge which is then mounted to the head. Guide pads are typically mounted
on the head to counter the drilling forces and burnish the hole during drilling. Indexing, or rotating, a direct-mounted insert is as simple as loosening the retaining screw and turning the insert to expose a fresh cutting edge. If the insert and pocket were made with tight tolerances, your cutting diameter should remain reasonably consistent.
Cartridge-mounted inserts, however, typically incorporate a shim or other adjustment system to allow for a much more precise diameter setting after indexing inserts and guide pads. This process does require additional equipment, however, such as a micrometer and stand or tool presetter – as well as the skills needed to accurately make the necessary adjustments.
Whether you select brazed or indexable BTA drills for your deep hole drilling application, you will be rewarded with high feed rates and process reliability, along with minimal centerline deviation and excellent hole quality.
Diagram demonstrating BTA deep hole drilling
ADVANCED DETECTION
The unique challenges of offshore environments make visual flame detectors a good choice, here we explore why
Floating Production Storage and Offloading (FPSO) units are vital in the oil and gas industry, since they enable the extraction and processing of hydrocarbons in deepwater environments. However, the complex operations and harsh conditions of offshore environments pose significant safety challenges. Among these, fire hazards are paramount owing to the presence of highly flammable materials. Addressing these risks requires advanced fire detection technologies. One such innovation is the intelligent visual flame detector, which has proven to be the technology of choice for FPSOs.
ADVANCED DETECTION CAPABILITIES
Traditional flame detectors often struggle with the unique challenges presented by offshore environments, such as reflections from the sea, varying light conditions, and the presence of other heat sources. Intelligent visual flame detectors, however, utilise advanced machine vision (MAVIS) technologies to accurately identify flame characteristics. These detectors can differentiate between actual flames and false alarms caused by sunlight reflections, hot CO2 emissions, or blackbody radiation from process equipment, thereby enhancing the
The complex operations and harsh conditions of offshore environments pose safety challenges
Intelligent visual flame detectors are faster
reliability of fire detection systems on FPSOs.
The core technology involves highresolution visual sensors combined with MAVIS. These sensors capture visual data, which is then analysed onboard in real-time by MAVIS algorithms trained to recognise the specific spectral signatures and behaviours of flames. This ensures that only genuine fire incidents trigger alarms, reducing downtime and maintenance caused by false positives.
PLUG AND PLAY RELIABILITY
A significant advantage of intelligent visual flame detectors is their plugand-play nature. These detectors are designed to work straight out of the box, requiring no calibration for each specific facility. This feature is crucial for FPSOs, where operational efficiency and ease of integration are paramount. Once installed, these detectors can immediately start providing reliable fire detection, capable of dealing with all process or environmental challenges onboard.
ENHANCED SAFETY AND RESPONSE
Safety is paramount on FPSOs, where rapid and accurate fire detection can mean the difference between a controlled incident and a catastrophic
event. Intelligent visual flame detectors are faster and more accurate that traditional methods, enabling quicker response times and preventing fire escalation.
These detectors can integrate with Safety Management Systems (SMiG) to automate emergency responses. Upon detecting a flame, the system can activate suppression systems, shut down critical equipment, and alert personnel. Additionally, it can provide live video of the incident and help operators direct personnel during emergencies, ensuring coordinated and effective responses and enhancing the overall safety of the crew and facility.
ADAPTABILITY TO OFFSHORE ENVIRONMENTS
Intelligent visual flame detectors are designed to withstand harsh weather conditions, corrosive atmospheres, and mechanical vibrations typical of FPSOs. Their robust construction ensures long-term reliability and minimal maintenance, which is crucial for operations in remote and hard-toreach locations.
PROVEN TECHNOLOGY WITH A TRACK RECORD
Intelligent visual flame detection is
not a new technology. It has been available since the mid-1990s and been widely adopted, with thousands of installations worldwide. This extensive track record demonstrates the reliability and effectiveness of these detectors in various industrial settings, including the demanding environments of FPSOs. Their proven performance over decades provides operators with confidence in their ability to safeguard personnel and assets.
COST EFFICIENCY AND OPERATIONAL BENEFITS
There is a perception that intelligent visual flame detectors are more expensive than traditional systems, but this is not the case. The initial investment is comparable, and the long-term benefits far outweigh the costs. The reduction in false alarms translates to fewer operational disruptions and lower maintenance expenses. Moreover, the enhanced detection capabilities and high false alarm immunity contribute to overall operational efficiency and safety, potentially saving millions in avoided downtime and damage.
Intelligent visual flame detectors come equipped with high resolution visual sensors
A FLEXIBLE SUBSEA VALVE
This innovative ball valve is helping to address the industry’s demand for speed and reliability
In the dynamic world of subsea engineering for the Oil and Gas industry there is an ongoing demand for speed and reliability. Valve manufacturer JB Valves has released a new patented, qualified, configurable subsea ball valve to help meet these needs. The company claims that the design reduces manufacturing lead times by an impressive 70%.
VERSATILE CORE DESIGN
The foundation of the company’s innovation is a robust core valve design that can be configured as either a two- or three-way valve. This versatility means the valve can meet various operational requirements with zero customisation to the core design. This streamlined design means the product combines flexibility with reliability, enabling clients to tailor the valves to specific needs without compromising performance. Qualified to API 6A 21st Edition 2018 PR2F and API 17D 3rd Edition 2021 for sour service the core design has been through its paces.
OPERATORS
Recognising the unique demands of each application, the company developed Lever and Bucket operators that can be specifically configured. These ensure good performance, compatibility, precise control and efficiency across operational environments that include highpressure gas systems, shallow and deep water or just specific mounting requirements.
ENHANCED TORQUE RESISTANCE
A key innovation includes a low torque heavy duty ROV (Remotely Operated Vehicle) bucket that increases the torque to damage ten-fold. This was designed so that the valve would not be damaged in the event of accidental over-torque, even if the ROV torque
JB Valves’ new subsea ball valve is 10-20% lighter than previous designs
tool is set for a higher-rated operator. This enhancement ensures that valves can withstand the rigorous forces encountered in demanding subsea applications; this improved durability extends operational lifespan. Similarly, the increased torque resistance reduces the risk of operational failures, ensuring reliable performance under extreme conditions.
LIGHTWEIGHT AND ROBUST
Weight reduction is crucial in some subsea pieces of equipment. By integrating a new polymer bucket, JB Valves decreased the valve weight by 10-20% while maintaining existing mounting configurations. This lighter design facilitates easier handling and installation, contributing to overall operational efficiency. Despite the weight reduction, the valves retain their strength and durability, offering a perfect balance between weight saving and robust performance.
MEETING CLIENT EXPECTATIONS
The optimised delivery times allow clients to maintain their project timelines and achieve significant cost savings. With reduced lead times, clients can stay on schedule and avoid costly delays, ensuring
projects proceed smoothly from start to finish.
RELIABILITY
Customers that have taken up the valve – which satisfies API 17N TRL Level 7 and beyond - report troublefree performance, underscoring their reliability and effectiveness, according to the company.
LISTENING TO CUSTOMERS
JB Valves reiterates the fact that its designs are not set in stone and that it is responsive to customer needs. “A customer-centric approach ensures that we continue to innovate and deliver products that exceed expectations,” says managing director Jonathan Balmforth.
He continues: “Our flexible subsea ball valve design represents a significant advancement in subsea engineering. By focusing on configurability, enhanced performance, and reduced manufacturing lead times, we set new industry standards and help clients meet their operational goals.”
AN INDUSTRY STAPLE
Why a solid state MRU and MGC from one technology manufacturer has seen industry-wide take up
The maritime industry utilises a spectrum of applications that require precise attitude, heading and position data, as well as reliable performance over time. The use of technology manufacturer Kongsberg Discovery’s solid-state Motion Reference Unit and its Motion Gyro Company (MGC) has therefore become the de-facto industry standard.
Here we explain how the company has spent the past three decades harnessing the understanding of inertia to develop the highly versatile sensing technology that underpins these technologies.
“In 1986, we embarked on a mission to simplify and commercialise inertial navigation technology for the maritime market at an affordable cost. Our engineers spent six years honing the technology, and in 1992 we launched our first MRUs. They deserve huge credit as pioneers,” says Vidar Bjørkedal, vice president SEATEX sales at Kongsberg Discovery.
KEY LEGACY
With over 20,000 MRUs installed and the product name now known as
an industry-wide generic term, the Kongsberg MRU has had considerable influence on the industry. Following the success of the MRU line, the MGC was first released in 2014 and more recently, the company launched the miniMRU.
The company’s MRUs feature a cluster of highly tuned accelerometers and Kongsberg-developed MEMS gyros that deliver precise measurements of rotations and accelerations with incredible accuracy. Based on this, the MRUs can calculate speed, attitude and many other parameters. The MGCs, with their north-seeking gyros, also bring true heading output. Particular benefits include a high output data rate, high reliability, compact size, light weight and low power consumption. Neither the MRUs nor the MGCs require any maintenance as there are zero wear-out parts. For most applications, recalibration is also a thing of the past.
UNRIVALLED MOTION COMPENSATION TOOL
MRUs can be used as embedded sensors in just about any piece of equipment or working platform that requires accurate motion stabilisation,
from offshore jack-up operations, dynamic positioning (DP) systems, riser monitoring and motion damping for fast ferries, to helideck monitoring and even motion compensation for beds on cruise ships. Typical Active Heave Compensation (AHC) applications include offshore cranes, gangways, winch systems, Launch & Recovery Systems (LARS) and hoisting equipment in drilling draw-works.
The MRU feeds data to the controller that regulates the motion compensation system. “Customers can select from more than 350 variables for a particular application, making these units extremely flexible,” says Bjørkedal.
HIGHLY VERSATILE SINGLE SENSOR
Kongsberg’s type-approved and wheelmarked MGCs go on to provide not only simultaneous motion compensation for multiple onboard applications but also replace conventional gyrocompasses for navigation of all ship types. “We’re one of very few vendors globally that can supply a single type-approved sensor that can cater to all applications
The company’s MRUs feature a cluster of highly-tuned accelerometers and Kongsberg-developed MEMS gyros
The MGC was first released in 2014
onboard a vessel – for navigation, cranes, DP, you name it. That is revolutionary,” says Bjørkedal.
Similar to the MRU family, the MGCs are scoped to cater for different use cases and accuracy requirements.
The MGGs are built using a different gyro technology, with ring-lasers (RLG) replacing the MRUs’ MEMSbased gyros. These gyros are so sensitive they are able to detect the Earth’s rotation, enabling the MGC to calculate true north.
SIMPLIFYING NAVIGATION
For vessel navigation, the stability of the MGC can be translated to less rudder usage and thus reduced fuel consumption and emissions. “This is
because fewer course adjustments are necessary, which reduces the impact of the rudder and extends the lifespan of the steering system. That also goes for high-speed vessels,” Bjørkedal says.
The exceptional north-seeking capabilities of the MGC outperform conventional gyrocompasses, and this is especially visible in high latitudes.
“This capability is beneficial not only for dedicated Polar ships but will also be very relevant if northern sea routes are used amid retreating Arctic seaice,” Bjørkedal adds.
The latest generation of MRUs and MCGs is built on the legacy of more than 30 years of experience.
“Customers report that the units just keep on working, which is a clear testament to their reliability and
durability,” Bjørkedal says.
He adds that both product families are “bottom-line sustainable” due to their maintenance-free design. By eliminating the need for regular servicing and the associated downtime, they ensure continuous operation. This not only removes the necessity for service engineers to visit the vessel but also results in substantial cost savings. Consequently, the uninterrupted performance and reduced operational expenses directly enhance the financial health and efficiency of the operations.
ACCURACY IS KING
The MRU and MGC form the core of Kongsberg Discovery’s Seapath platforms targeting complex hydrographic surveys and seabed mapping. The latest Kongsberg EM2042 MBES brings the miniMRU fully embedded to simplify installation and create a unified INS and multibeam system. The inertial sensor works together with state-of-the-art multifrequency GNSS receivers and processing algorithms to provide the best possible position, velocity, attitude, time and heading data. All available GPS, GLONASS, Galileo, Beidou and QZSS satellites are used in the position solution.
CUSTOMISED TO REQUIREMENTS
In summary, inertial technology is critical for robust and accurate maritime operations and all Kongsberg Discovery’s MRU/MGC solutions are uniquely flexible. “The segments we serve tend to be bespoke, so in addition to providing standalone units for integration into thirdparty systems, we also collaborate directly with customers to adapt the technology to their unique challenges.” Bjørkedal says.
You can also watch ‘Inertial’ by Kongsberg on YouTube here
For more information visit: www.kongsberg.com/ discovery/campaign/inertial/
The MiniMRU provides a SWaP-C of high-end inertial sensors
ELECTRICAL SAFETY IN LOW VOLTAGE SWITCHGEAR
A guide to managing ambiguous specifications
Electrical safety in low voltage switchgear is not a new topic, since the dangers associated with the manual operation of any electrical switchgear, particularly on-load switching, have always been present. Through personnel training and certification, all certified electrical technicians/engineers will be aware of the risks to both personal safety and operational assets during electrical switching.
However, without a defined international standard for LV products to provide arc-fault containment (IEC TR61641:2014 is still only a test report) the requirements defined by end-users or in specifications can be varied or ambiguous as the natural reaction is often to default to the most onerous possible requirement without fully understanding the options available. The result is often provision of a premium solution which may not give the end-user the best fit in terms of maintenance and/or operational safety. A good overview of Arc-Fault capability was provided back in 2017 by GAMBICA in their guide which is still available on-line for free.
For new projects Blackburn Starling & Co. Ltd are often asked to provide solutions which can include one or more of the following features:-
• LV switchboards/MCC specified to comply fully with IEC/TR61641:2014. These can be provided as a premium product to comply with arcing classes (A,B or C) as detailed within the test report. The GAMBICA guide is again recommended to select the relevant arc class for containment to provide purely personnel protection (Class A) through to containment within individual functional units or sections (Classes B or C) when related to Form 4 switchgear.
• Fully insulated busbar systems to preclude an arc-fault occurring within the low voltage panel, this is to provide compliance with section 6.1 of the test report.
• OEM products to incorporate safety features including:Air-circuit breakers which include maintenance modes to limit the fault level of the circuits whilst an engineer is switching the ACB for maintenance.
Arc-flash detection equipment where the protection relay has a fibre-optic cable installed throughout the length of the busbar chamber within an LV panel to provide a high-speed trip to the main circuit breaker upon detection of an arcflash incident.
• The supply of remote operator panels or pendants to allow the switching of the circuit breakers to be carried out without the need to have an engineer standing in front of the panel thereby reducing the risk of any injury from arc-fault incidents.
Once installed on site the PPE category, incident energy and safe working distance for the switchgear should also be calculated to allow this information to be displayed on each section of the LV equipment. All manufacturers should be able to assist with these calculations, Blackburn Starling & Co. Ltd use a licensed software package for this purpose with data both from our own installed equipment and details of the external field cabling, transformers etc. As with all bespoke equipment it is always recommended to have the conversation as early as possible in the design phase of a project to allow the LV switchgear supplier to advise on their recommendations and options. Following a review of the options available, the client can choose the most appropriate method for their site and operations teams to provide the optimum solution.
Off-Site build of a modular LV electrical switchroom
Liebherr Intelligent Maintenance
www.liebherr.com Maritime
EFFICIENCY GAINS
This case study outlines the efficiency gains delivered to a hydrogen plant following installation of an innovative cleaning technology
Anew robotic convection section cleaning technology has demonstrated significant efficiency gains in Steam Methane Reformers (SMRs) since 2017.
SMRs are crucial in hydrogen production for refineries, with capacities ranging from 5,000 to over 300,000 nm3/h. The process involves desulfurisation, prereforming, and primary reforming in a radiant wall SMR, followed by CO shift reaction and purification.
The radiant wall SMR is the heart of the hydrogen plant, operating at high temperatures of up to 900°C. IGS offers free heater evaluations, studying possible changes in radiant and convection sections. Their services typically show benefits ranging from 1.5% to 5.0% in energy savings or production increase.
The following case study highlights how IGS’s Tube Tech’s robotic convection section cleaning technology delivered a 4.9% radiant efficiency gain, with efficiency enhancement from 40.3% to 42.3%, and a payback period of just three months.
The project, in Southern Europe, involved a twin-cell side-fired primary hydrogen reformer facing high bridgewall temperatures, limiting production. IGS Cetek high emissivity refractory coatings were applied to all radiant surfaces in 2017, increasing emissivity from 0.34 to 0.92 and allowing additional hydrogen production without approaching temperature limits.
The coating was reapplied in 2023 owing to its gradual loss of emissivity over time. Throughout the six-year run, the highest reported bridgewall temperature was only 1055°C under more than 110 knm3/hr hydrogen production rate, demonstrating the coating’s longevity and reliability.
The projects executed during the 2017 and 2023 turnarounds provided immediate payback and operational
KEY CASE STUDY HIGHLIGHTS:
• 4.9% radiant efficiency gain
• Efficiency enhancement from 40.3% to 42.3%
• Payback within 3 months
• Hydrogen production rate increased from 108 to 116 (knm3/h)
flexibility. Furnace performance evaluation revealed a significant radiant efficiency enhancement (40.3% to 42.3%) with a corresponding bridgewall temperature reduction of more than 50°C. This enhancement increased the hydrocracking unit’s capacity, resulting in an additional production margin of about €4.8m per year.
The 4.9% radiant efficiency gain led to less fuel firing required to produce the same amount of hydrogen, equivalent to an 18,400 MTPA CO2 emission reduction. The achieved radiant efficiency enhancement can be utilised to reduce fuel consumption and CO2 emissions or to increase throughput/severity under the same firing rate.
The IGS Cetek application brought an immediate radiant efficiency gain,
as predicted, and post-project analysis corresponded with the pre-project technical evaluation. The refinery now has the option to save fuel or increase throughput under the same firing rate during high-demand periods. IGS continues to closely monitor the unit’s performance for the lifetime of the applied coating systems.
IGS Tube Tech’s technology had a significant impact on improving efficiency, reducing emissions, and increasing production capacity in SMRs, contributing to more sustainable and cost-effective hydrogen production across the entire refining industry.
High emissivity coating applied to refractory lining
A STELLAR PERFORMANCE
This pipeline isolation tool significantly reduced emissions on an innovative project in Scotland
Tools and services supplier to the energy industry, Stats Group, and its partner National Gas have been awarded the IGEM/EUA Gas Industry Award for Product of the Year for their work to reduce emissions on a strategically important pipeline replacement project.
This award recognised National Gas’s use of Stats Group’s Remote Tecno Plug (RTP) during the Lochside IJ Replacement Project at St Cyrus, Scotland. This marked the first operational use of the RTP on the national transmission system.
Following this successful deployment, the RTP will be added to the range of standard solutions available to National Gas for repair and maintenance projects, helping to reduce project timelines and emissions across their pipeline network.
The RTP is an innovative pipeline isolation tool that provides a leaktight double block and bleed isolation. This enabled the 48” diameter pipeline to remain fully pressurised at 55
bar for 56 km during replacement of an insulation joint and was used instead of traditional venting or recompression operations.
Neil Mackay, group senior business development manager at Stats Group, said: “In collaboration with National Gas and third-party validation from Pipeline Integrity Engineers and DNV, we’ve proven this technology can greatly reduce venting emissions for pipeline maintenance activities.
“We’re honoured to receive this award recognising the RTP’s innovative design and significant emissions reduction capabilities.”
Compared with traditional recompression methods used, the RTP reduced emissions on the Lochside project 24 fold – discharging just 9.5 tonnes of gas instead of the projected 233 tonnes of emission if venting had been used.
The carbon savings are estimated to be the equivalent of switching off 1,760 gas boilers for a year or taking 1,000 cars off the roads in the UK. The installation and testing process
also took only 24 hours versus six weeks for pipeline recompression operations.
In addition to the compelling emissions benefits, the RTP improves safety by enabling critical repairs while keeping the pipeline pressurised. It also reduces maintenance time and costs.
Kirsty McDermott, senior engineer at National Gas, says: “The Remote Tecno Plug exemplifies the type of innovative technology that will be critical for the gas transmission industry to meet its net-zero targets. We’re proud to collaborate with STATS to lead adoption of this gamechanging solution.”
With over 40 potential future applications already identified on the national transmission system, the RTP is poised to make a significant impact on pipeline emission reductions in the UK and beyond.
❝ The carbon savings are estimated to be the equivalent of switching off 1,760 gas boilers for a year or taking 1,000 cars off UK roads
STATS Group personnel monitoring a 48in Remote Tecno Plug, St Cyrus, Montrose
STATS Group’s 48in Remote Tecno Plug in situ at St Cyrus, Montrose
MAN MET: INTERNATIONAL OIL & GAS ENGINEER AUGUST EDITION ADVERT 29-7-24
LEADING THE WAY WITH CUTTING-EDGE PRODUCTS AND SERVICES
We pride ourselves on delivering products and services that cater to the varied needs of industries. With a commitment to excellence and innovation, we have established ourselves as industry leaders providing cutting-edge solutions backed by exceptional customer service.
Our metrology products:
– Portable Arms, Laser Trackers and Scanners, Accessories and Probes: Our products give customers access to cutting-edge technology.
– Resellers of Leading Brands: We proudly offer products from renowned brands such as peel 3D, PMT Measuring Arms, REFLECON Scanning Spray, PolyWorks, Aberlink and CyberGage360, providing solutions to meet every need.
In 2023, we invested in training our staff at the PMT headquarters to repair and service PMT measurement arms of which we are the official UK reseller.
Contact our team of experts on 0161 637 8744 or visit manchester-metrology.co.uk.
Manchester Metrology Ltd
Unit 3, The Wellington Centre, Whitelands Road, Ashton-under-Lyne OL6 6UY 0161 637 8744 | manchester-metrology.co.uk
Our range of services:
– Subcontract Inspection
– Equipment Hire & Leasing
– Laser Scanning & Reverse Engineering
– Alignment & Inspection
– Robot Calibration & Floor Marking
– 3D Printing
– Comprehensive Training
COMPOSITE CURE
How a clever composite wrap from Belzona was used to restore a heavily corroded pipeline
At a Refinery in Spain, an underground oil pipeline of 872 metres (2860.8 ft) was suffering from severe corrosion. Left unchecked, this would have caused severe metal loss and potentially disastrous financial and environmental consequences.
STEEL PIPELINE IN NEED OF PROTECTION
The carbon steel pipeline, measuring 55.9 cm (22 inches) in diameter, needed to be repaired promptly to prevent further damage being incurred. Additional substrate corrosion may have resulted in oil leakage and environmental problems.
One potential solution was to completely replace the pipeline, however, this would have been extremely expensive considering its length. Furthermore, this would have incurred a significant carbon footprint.
According to an article by Carbon Clean in 2021, for every ton of steel produced, nearly double the amount (1.85 tons) of CO2 is released back into the atmosphere. In addition, the process of removing and disposing of the damaged pipeline would have significantly increased the carbon footprint even further.
As well as the environmental impact of replacing the damaged pipeline, this process would have required a lengthy period of downtime. This, combined with
the expense of buying a new steel pipeline, made replacement too expensive an option.
COMPOSITE WRAP: AN ALTERNATIVE TO PIPELINE REPLACEMENT
In order to bypass the drawbacks associated with replacement, the customer decided to repair and protect the pipeline using a combination of polymeric technology.
Following an inspection from Elena Expósito Fernández, AMPP (NACE) Certified Coating Inspector Level 2 and Technical-Commercial Delegate at authorised Belzona Distributorship
Rodator Composites, the following systems were specified and applied:
“The 2-part epoxy paste, Belzona 1111 (Super Metal), was specified to fill in any gaps in the weld seams to ensure the pipeline had a smooth profile. For heavily corroded areas, plate bonding was required using steel plates which were 50 cm x 60 cm (19.9 in x 23.6 in) in size, with a thickness of 5 mm (0.2 in). These were bonded into place using the epoxy structural adhesive, Belzona 7311. To reinforce the pipeline, the composite wrap, Belzona SuperWrap II, was specified. Finally, the anticorrosion coating, Belzona 5811 (Immersion Grade), was chosen to provide long-term corrosion protection.”
MINIMISE ENVIRONMENTAL IMPACT
By repairing and protecting the pipeline with a combination of polymeric technology, the customer was able to successfully bypass the drawbacks associated with complete pipeline replacement. In addition to making considerable financial savings, they were also able to significantly minimise their environmental impact.
Application of anti-corrosion coating over Belzona SuperWrap II
Elena Expósito Fernández, TechnicalCommercial Delegate at Rodator Composites
SMART INSPECTOR
A North Sea operator has adopted an advanced tool to simplify the Ex/ATEX inspection processes
Oil and gas operators regularly say that improved Ex/ATEX-inspections would significantly reduce explosions and increase efficiency. Companies are using various solutions to help with this, and one of these is software.
BETTER EX/ATEX INSPECTIONS
A new product from AG Consultancy, the SAP solutions specialists, will be of interest to these operators. The company claims is the ‘first tool of its kind’ designed to overcome challenges posed by the implementation of global health and safety standards and Ex/ ATEX inspections in the oil and gas industry and wider energy sector.
Following the launch of the solution by the Aberdeen-based company in May 2024, North Sea operator Spirit Energy, which provides primary energy to fuel homes and businesses across the UK and Europe, became the first to adopt the solution.
Its platform ‘Smart Ex’ allows businesses to undertake Ex/ATEX inspections internally within their SAP tool without the need for thirdparty products - the difficulties and inefficiencies related to managing multiple IT solutions lacking a ‘single source of truth’ is well documented.
According to its developers, the fully integrated solution is an end-to-end tool which encompasses planning, execution and analysis and covers the full life cycle of Ex/ATEX inspections.
“For the oil and gas sector, the problems posed by the use of multiple platforms when undertaking Ex/ ATEX Inspections are significant and the challenges for companies can be demanding,” says Deepal Ratnayaka, director SAP consultancy services at AG Consultancy.
“Smart Ex allows businesses access to mobile, real-time updates on a single system providing insights for informed decision making by
bringing together work management and inspection management needs. This negates the need for two separate IT solutions.”
ARTIFICIAL INTELLIGENCE AND MACHINE LEARNING
The software is designed to be regularly updated with the latest technology including artificial intelligence and machine learning. In addition, it manages various types of inspections including integrity inspections, compliance checks, tool calibrations and maintenance checklists. It also complies with safety standards IEC60079, NEC500/505 and ATEX and has a digital auditing trail allowing for full traceability of inspections.
REDUCES DUPLICATION
According to its developers, the system can help reduce manual, duplicate efforts in system updates,
saving technicians’ time, and allowing for better insight into operations. It also helps with compliance via audit trails and analytics.
“Ex/ATEX inspections are an important business process and critical to the safety of staff and ongoing operations, we believe this tool can be revolutionary for organisations that are currently grappling with how best to address the challenge with multiple IT systems,” Ratnayaka adds.
“Our industry knowledge in oil and gas and energy, combined with our SAP proficiency, allows us to tailor SAP solutions to specific business needs. The successful implementation of ‘Smart Ex’ for Ex/ATEX inspections at Spirit Energy is a prime example of our expertise.”
Dashboard of the smart inspection tool
A CREATIVE CHALLENGE
How one metallic bellows assembly manufacturer revamped its design principles to meet customer demand
The pressure relief valve market requires specific bellows operating parameters for each individual valve installation. As such they require the manufacturers of metallic bellows assemblies to be acutely aware and responsive to their requirements.
In recent years the required operating parameters for pressure relief valve bellows has increased, and this looked like it might be an issue for leading bellows manufacturer Senior Bird Bellows given its existing design principles.
EXISTING DESIGN PRINCIPLES
Senior Bird Bellows has been designing and manufacturing metallic bellows assemblies for nearly 50 years. The assemblies were originally supplied as expansion joints for oil and gas pipelines and then further developed for use in pressure relief valves.
In trying to understand how the company could meet these higher requirements, it discussed the costly and time-consuming introduction of an alternative method of producing the bellows, but this would not have suited small production runs across many different bellows designs.
It was then that the engineering team decided to challenge the long-
standing design principles to see if the new requirements could still be met with its current manufacturing process.
Existing design principals were based around the guidelines set by the industry standard EJMA (Expansion Joint Manufacturers Association) as well as the experience of selling to this market..
In revisiting these principles when applied to pressure relief valves, it became clear that pressure is exerted on the bellows in a way which is different to how pressure is applied to an expansion joint. Since no specific data existed for this pressure application, a development programme to produce a specific set of guidelines was initiated.
NEW GUIDELINES
Senior Bird Bellows utilised their specialist in-house test facility to run an extensive test programme to produce specific parameters for a wide range of bellows designs.
An initial test campaign of pressure and fatigue tests was run, and the results were compared with data generated from existing design guidelines. The data clearly showed that existing bellows designs tested in this way could achieve much higher operating parameters than existing data predicted.
From this initial test data, a more
comprehensive test programme was developed, increasing the number of bellows designs across different bellows materials. The follow-on test data once again confirmed higher operating parameters were achievable with the current manufacturing process.
Senior Bird Bellows has now fed this information back into the design guidelines thereby enabling the company to meet the higher demands being specified by the valve market.
THE FUTURE
The Senior Bird Bellows engineering team are now using the same approach to challenge existing design principles for bellows usage in cryogenic applications, given the increased interest in using hydrogen as a fuel source. Building on their in-house test capability, modifications have been made enabling bellows testing to be carried out at cryogenic temperatures and an ongoing test programme is now under way to generate specific design guidelines for these extremely low temperature applications.
The process of challenging existing guidelines has enabled Senior Bird Bellows to meet changing market needs, while still being able to offer the advantages of quick turnaround times facilitated by their production process.
For more information visit: https://sabird-bellows.co.uk/
Senior Bird Bellows product
REDUCING OIL IN WATER
A microbubble infusion unit that was successfully trialled to significantly reduce oil in water levels
Adaptive Process Solutions (APS), a produced water treatment specialist, has completed a highly successful field trial of its new Microbubble Infusion Unit (MiFU) technology, achieving a near five-fold reduction in oil in water (OiW) levels in combination with a synergistic production chemical.
A SUCCESSFUL TRIAL
The full-scale trial, conducted aboard a floating production, storage and offloading installation (FPSO) in the North Sea, took place over a six-month period. The trial achieved the required positive outcome for the client and confirmed that the new technology will help an industry facing increasing OiW levels in produced water.
In common with other operators, produced water separation had been a long-standing challenge for this client. Several different technologies had already been trialled unsuccessfully before APS proposed its patented MiFU, which had already produced impressive results in preliminary offshore laboratory testing.
A RETROFITTABLE ADD- ON
Designed as a retrofittable add-on to existing water treatment systems, MiFU was configured to meet the specific conditions and fluid chemistry at the asset, with before and after results confirming the potential for five-fold improvements in OiW results.
Paul McAlister, managing director of APS, said the MiFU was developed to address the industry-wide issue faced by operators to efficiently and effectively clean produced water so that it meets strict regulatory standards before it can be discharged back into the sea.
“This is a notoriously challenging problem for operators,” he said. “The North Sea is a mature oil and gas province and the industry discharges millions of tons of water into the sea
each year. This is exacerbated because the existing separation systems were designed to process smaller volumes of produced water resulting in a bottle neck that slows production.”
He continues: “Our technology can head off the challenges encountered by FPSO operators when they can no longer rely on additional ‘slop tank’ separation in heavy seas, as a fallback to meet demand. In both cases, MiFU boosts overall environmental performance and productivity.
HOW IT WORKS
MiFU uses infused micro bubbles which attach to very minute particles of oil and fine solids in the produced water which can then be easily removed by the asset’s existing separator process. While underlying technologies have already been proven, MiFU is unique through its implementation of a patented multipass process which directly injects size and quantity-controlled gas microbubbles into target points in a contaminated water stream.
SUPERIOR BUBBLE SATURATION
MiFU’s superior bubble saturation and variable bubble size range is also a first in the produced water rental services industry.
This optimisation means MiFU is capable of processing between 1,000 –100,000 barrels of water a day, reducing up to 90% of oil and contaminants and eliminating the requirement for further costly downstream filtration and material management.
As it scales up for strategic growth, APS is beginning construction of a second MiFU rental skid and projects increasing its headcount to 20 by the end of this year in response to new business enquiries from the North Sea, Norway, West Africa, Gulf of Mexico and Brazil.
The company is also working on designing units for onshore sectors such as whisky distilleries, municipal water treatment and wastewater.
The MiFU technology leads to a five fold reduction in oil in water levels
STREAMLINED GAS ANALYSIS
A new process oxygen analyser precisely calculates natural gas, biogas and other gas streams in real time
With over 40 years of experience of providing liquid and gas phase on-line continuous process analysers to the oil and gas industry, Houston-based manufacturer Analytical Systems Keco has introduced another analyser that conducts real-time and continuous oxygen analysis of natural gas, biogas, and other gas streams.
Utilising optical quench luminescence technology for gaseous sampling, the OxyHound analyser conducts precise oxygen measurements in a gaseous phase (ppmv and % on a molar basis) with no cross-sensitivity with CO2, H2S, NH3 or SO2, sulphate or other ionic species.
HOW IT WORKS
The OxyHound analyser uses advanced optical quench luminescence, tailored for precise oxygen measurement in process streams. This technology hinges on the phase modulation of an oxygen-specific luminophore’s luminescent decay time, enabling accurate calculation of oxygen’s partial pressure.
OxyHound measures the phase shift and intensity variation between the excitation light and the fluorescent response. From these measurements, the oxygen concentration is precisely
calculated by the on-board computer in the analyser in real-time.
With a user-friendly and lowmaintenance design, the OxyHound eliminates the need for electrolyte changes or membrane maintenance. Utilising Keco’s Cloud Connect service, users can remotely monitor the analyser on any web-connected device using LTE-M.
According to its developers, these features and its versatility to work as an O2 analyser or oxygen meter (data logger) make the OxyHound an ideal replacement for older technologies like paramagnetic analysers, electrochemical cells, and in some instances, zirconia and Tunable Diode Laser (TDL).
REAL APPLICATIONS
Built for Division 2 and Zone 2 hazardous locations, the OxyHound operates in a range of environments with contaminants such as H 2 S, CO 2 , H 2 , propylene, methanol, and ethanol mixtures.
The gas analyser can be used in various industries, including natural gas pipelines and refineries. For example, in the oil and gas sector, the process gas analyser can measure traces of O2 levels in various operations from vapor recovery units (VRUs) to enhanced oil recovery processes
OxyHound measures the
The OxyHound oxygen (O2) gas analyser has a long sensor life, with low maintenance and no moving parts
WITHSTAND THE ELEMENTS
Infrastructure on offshore oil platforms, in underground mines or petrochemical plants must often withstand severe environmental conditions, meaning there is a high risk of corrosion. To last in these conditions parts require specifically designed materials.
The Flameproof Ex d Envirobox junction box from Pratley Manufacturing and Engineering is one such part. It received the prestigious ‘Award of Excellence for Technical Innovation’ from the South African Flameproof Association (SAFA) at its 2023 awards evening. “Pratley’s Flameproof Ex d Envirobox junction box is a major milestone for the electrical hazardous areas industry. It is a product unlike any other,” says Eldon Kruger, Pratley Marketing Director.
THE JUNCTION BOX
Made from a specially formulated, robust engineering polymer the
junction box is designed to withstand severe environmental conditions. It is ideal for use in offshore oil platforms, underground mines or petrochemical plants since these are areas with a high risk of corrosion.
The polymer is unique to Pratley and has exceptional mechanical properties including strength, stiffness, creep, dimensional stability and more, according to the company. This ensures that the junction box can withstand 2 x 20-joule impact tests in a -40°C environment.
Flameproof equipment is designed to ensure that internal ignition within a flammable atmosphere is prevented from transmitting outside the protective enclosure. However, traditional directentry flameproof junction boxes made from steel, cast iron or aluminium are likely to corrode over time when used in very harsh environments.
This is not the case with Pratley’s Flameproof Ex d Envirobox since it has been third-party tested to a
This innovative product uses a unique polymer to withstand severe environments
4,000-kilopascal internal pressure. Additionally, it is IP66/68 certified for continuous underwater depths of up to 300m, making it water, dust, and gas tight. The lid and base have an accurately machined flamepath.
The junction box can be supplied with either 4 x 20mm or 25mm entries or smaller on request and can accommodate Pratley Ex d flameproof cable glands and accessories. Each box is supplied as a standard two-way box with 2 x flameproof blanking plugs.
The internal bosses are drilled and tapped to provide an earthing point for terminal mounting rails or earth lugs and these are integrated to the box entries providing complete earthing continuity.
Boxes can be fitted with an N35 terminal rail, a Pratley patented cranked rail, an inverted cranked rail, or piggyback rails. Pratley Kwikblok terminals and pre-cut lengths of cable with glands can also be factory fitted to customer requirements.
The box has an optional external earthing point and is supplied with 4 x M6 nuts and washers as well as a 1 x M6 spring washer. It also has threaded mounting M5 holes and is able to accommodate a mounting plate that can be purchased separately if required.
FULLY CERTIFIED
The Flameproof Ex d Envirobox is fully certified to SANS, EN and IECEx Standards, including ATEX for use on surface and underground mining applications (Ex db I/IIB+H2 T6..T5 Mb Gb, Ex tb IIIC T85..T100 Db) in Zone 1, 2, 21 & 22, and an ambient temperature range of -40°C to +55°C.
“Pratley’s goal was to produce the only direct entry junction box that is fully corrosion resistant. Our Flameproof Ex d Envirobox is a world-first product from Pratley,” concludes Eldon.
The Flameproof Ex d Envirobox from Pratley is made from robust polymer
MITIGATING DROPS OFFSHORE
A clever solution that helps to eliminate the risk of dropped objects to offshore workers
In the oil and gas industry, dropped objects are a significant safety hazard. Offshore environments, with their complex structures and harsh conditions, make this risk even more pronounced. Equipment and fixtures at height can become loose or corroded due to constant exposure to weather and vibrations. These incidents can lead to costly operational disruptions, severe injuries, and even fatalities, making preventive measures essential for maintaining safety.
A REAL-LIFE INCIDENT: LESSONS FROM THE FIELD
Consider a February 2019 incident on an offshore facility. A 15-kilogram fixture fell 15 metres owing to corrosion and extreme weather. This incident, which could have been fatal
for workers below, highlights the critical need for proactive measures. It underscores the importance of addressing dropped object hazards before they result in profound consequences.
EFFECTIVE SOLUTIONS: THE HIERARCHY OF CONTROLS
Addressing the risks of dropped objects requires a structured approach based on the hierarchy of controls. The hierarchy of controls is a systematic approach to hazard mitigation, prioritising elimination as well as, engineering and administrative controls:
1. Elimination: First, assess if fixtures need to be positioned at height. Relocating has the potential to eliminate the risk entirely.
2. Engineering controls: When relocation is not feasible, secondary retention solutions, such as safety nets, are crucial. These nets enclose and tether fixtures, preventing them from falling should primary supports fail.
3. Administrative controls: Regular inspections are vital. Routine checks allow for early detection of degradation, enabling timely maintenance and repairs.
A WELL-ENGINEERED SOLUTION
Dropsafe offers an immediate and reliable solution to mitigate dropped object risks, which is the best choice when elimination of the risk is simply not possible.
Dropsafe Nets provide instant protection, preventing fixtures of any size from falling and the company
Dropped object prevention solution
has developed the Trisafe carabiner to aid with site safety and is used across all their safety securing devices. The carabiner’s triple action operation prevents accidental opening, while the auto locking mechanism reduces human error. The
introduction of this triple action, autolocking Trisafe technology enables Dropsafe to offer a high standard of worksite safety, according to the company. Designed to be easy to install and inspect, Dropsafe Nets require no maintenance or on-site
modifications, making them a simple and effective solution. The American Bureau of Shipping (ABS) have also certified all Dropsafe Nets with DOPP+ type approval.
ENSURING SAFETY WITH DROPSAFE NETS
Incorporating Dropsafe Nets into offshore operations significantly enhances safety by offering an immediate and reliable solution to prevent dropped incidents. By following the hierarchy of controls (prioritising elimination, employing engineering controls, and conducting regular inspections) offshore facilities can protect their workers and maintain operational integrity.
Designed with high standards at the forefront, Dropsafe’s clients can trust the product to protect their workforce and maintain operational integrity.
For more information visit www.dropsafe.com
Dropped object netting on an off-shore platform
Zelim’s Zoe technology records a 10-second clip of the person overboard incident
ATTENTION, PERSON OVERBOARD!
How an intelligent detection system on a jack-up rig provides automated person overboard detection and alerts
Workers on offshore rigs have to contend with severe weather and rough seas, and ensuring their safety in these conditions is a key concern for oil and gas operators. Although accidents such as falling overboard are infrequent, they remain a potential risk. To prevent such incidents, one of the world’s largest offshore rigs in the North Sea, the Valaris Stavanger, has adopted an AI-powered system from solutions company Zelim that automatically detects and tracks persons overboard at sea.
AN INTELLIGENT AI SOLUTION
Called Zoe, Zelim’s solution is a person in water (PIW) technology that helps search and rescue operations in the ocean. It uses a suite of cameras and sensors to monitor the area around a vessel, raising alerts if someone falls overboard.
Zoe was deployed on the jack-up rig Valaris Stavanger in February this year, and installed a tailored solution that included seven infrared and optical cameras placed around the vessel, allowing the entire rig to be monitored. Following an initial
trial period, Valaris will evaluate the suitability of the system for use on other assets in their fleet.
“The harsh weather in the North Sea can change quickly. Traditionally if someone falls into the water, the alarm is raised, and a person acts as a spotter to maintain visual contact. We have been totally reliant on line of sight,” Glen Spearman, offshore installation manager onboard Valaris Stavanger, explains. “However, now Zoe gives us a 360-degree view from the rig at any one time. It will reduce our response time and improve the chances of a successful rescue in the event of an accident.”
HOW IT WORKS
When someone falls overboard, Zoe transmits an automatic alert to the radio operator, who can view a 10-second clip taken when the alert was triggered while simultaneously viewing live footage. Zoe continues to track the person in the water, thereby increasing the chance of a successful rescue.
MAYDAY CALL GEOLOCATION
The system then logs the position of the vessel and the person overboard at the point of detection for mayday call geolocation, before providing the radio operator with a mayday script and actions checklist, ensuring fast and accurate reporting.
“Zoe has been designed and developed in collaboration with the US coast guard,” says Doug Lothian, chief technology officer at Zelim. “The system has been through extensive testing in adverse conditions and given a 96.8% successful detection rate of up to 337m, above standard requirements. We worked closely
The system has been through extensive testing in adverse conditions and given a 96.8% successful detection rate up to 337m, which is above and beyond standard requirements
with Valaris on this project in their working environment. This meant we were quickly able to understand their specific customisation requirements.”
DATA COLECTION
Data from Zoe is processed onboard the vessel for security and full functionality with no internet connection. The system’s AI models have been built on a dataset of over 4.9 million labelled maritime rescue images across a wide range of ocean conditions. According to Zelim, the technology could be used
in many other settings, including automatic security threat detection and alerting as well as red zone monitoring.
Alongside Zoe, Zelim is developing hardware to aid search and rescue operations, including a rescue ‘conveyor’ called Swift and, additionally, an unmanned rescue vessel called Guardian.
For more information visit: www.zelim.co
MANAGING COMPLEXITY
Benedikt Eckert, channel distribution manager from i.safe Mobile explains how to get the most from the company’s new product
The maintenance of oil and gas plants is extremely complex - it must consider safety in explosion hazard areas (and the impact on employees and the environment), as well as minimising production downtimes and saving operational costs. Planning, carrying out and documenting maintenance sessions efficiently is a complex process. Maintenance planners, engineers, safety inspectors and project managers on site should be able to access all information such as documentation, statistics, detailed drawings and diagrams anywhere on the company site. Powerful ATEX/ IECEx certified mobile devices such as the new 5G Android tablet IS940.1 from i.safe Mobile are made for these complex requirements.
OPTIMISING IS940.1 USE FOR MAINTENANCE TASKS
Maintenance planners can use the device to get an overview and check upcoming maintenance tasks. Detailed plans of the system, circuit diagrams and calculation documents for all areas can be clearly displayed on the tablet, which has a highresolution 10-inch display.
The tablet can also help with resource allocation. Maintenance teams are set up and the planner assigns tasks to the respective technician on site in advance and ensures that the necessary tools and spare parts are available by the agreed maintenance date or that orders can be entered and placed directly in the system. The large screen enables easy multitasking, e.g. the simultaneous display of several documents or applications.
As far as compliance with important safety protocols is concerned, safety checklists can be called up digitally in real time and updated at any point.
During maintenance itself, technicians on site carry the tablet with them and have access to the
The IS940.1 tablet is an indispensable tool for maintenance planning in the oil and gas industry
latest instructions and plans anytime, anywhere on the company premises. In this way, sources of error can be minimised, and dangers averted.
The tablet’s wireless connection (Wi-Fi 6) allows all team members to communicate with each other at any time and stay in real-time contact with the control centre. This enables quick problem solving in the event of incidents and therefore minimises downtime. To document activities, work is entered directly onto the tablet and can be immediately synchronised with notes, photos and necessary signatures with the central system.
SAFETY INSPECTORS
Safety inspectors can use the IS940.1 tablet, for example, to check work on site and to compare and verify
the maintenance work carried out with plans. Inspection reports can be created directly on the tablet with embedded images and annotations and can also be immediately forwarded to all parties involved for review and approval.
The IS940.1 tablet is an indispensable tool for maintenance planning in the oil and gas industry, especially in the hazardous areas of Ex zone 1. Its large screen, durability and safety features make it a good solution for accessing and interacting with complex technical documents and improving overall maintenance efficiency and safety.
Jupiter Class 4 to Petrobras Style
Degraded Interface Adapter
The Jupiter Degraded Interface Adapter (DIA) has a Petrobras Style output, ISO 13628-8 Rotary Docking Class 4 input, and comprises easily interchangeable gripper fingers to suit a range of stem sizes.
The DIA is designed to allow the operation of Petrobras Style interfaces where the effects of corrosion, wear and historic misuse mean that close-fitting or other types of fixed sockets are ineffective.
If a Jupiter Torque Tool is used to supply the drive input, the Jupiter Software can be configured to provide repeated automated torque pulses to help overcome residual breakout forces.
A potential use case for SubCtech’s technology
CASTLES IN THE SAND
How new products including an industrial battery cell and an energy storage system could be a game changer for the industry
In the ever-evolving realm of underwater technology, innovation is vital. Companies involved in the sector manage and build equipment structures located on, below, or buried in the seafloor. Lines include production risers, flow lines and associated production control systems.
One of the key players, SubCtech, is known for its innovation and both divisions of the company focus on new technologies but have quite different customer bases - the divisions comprise Ocean Power, dealing with subsea Li-Ion batteries and power equipment; and Ocean Monitoring, focusing on vessel underway equipment and ocean climate change analysis.
THE OCEAN MONITORING BUSINESS UNIT
The Ocean Monitoring business unit makes up 10% of the company’s operations and supplies mainly to scientific institutes, research vesselbased scientists and ocean race sailors. The monitoring equipment covers surface and underwater greenhouse gas monitoring and microplastic samplers. The Autonomous Underway Measurement System (AUMS) is designed for pCO2 monitoring on ships (‘FerryBox’) and can be further upgraded via various available sensors: e.g. Meteo TopBox for meteorological and sea-air exchange flux measurements and any third-party instrument.
The latest Microplastic Sampler, for example, enables monitoring on any type of sea vessel and can detect even the smallest presence of microplastics in the water, down to particles single parts per m3, without the need for large nets or complex filter systems. The next-level robust and waterproof design provides accurate sampling even on high-speed boats travelling at more than 30kn or underwater up to 3,000m water depth.
OCEAN POWER PRODUCT DIVISION
The Ocean Power Products division makes up 90% of the company’s operations and supplies primarily to customers within energy sector, monitoring stations/moorings,
subsea applications and autonomous underwater vehicles (AUV) as well as remotely operated vehicle (ROV) manufacturers. The Li-ion battery systems range from standard common off the shelf (COTS) subsea to customised vehicle batteries with and without battery-management systems (BMS) and chargers. The advancedprecision titanium housing is fully customised and can be designed for full ocean depth.
Subsea batteries for gas (LNG) production, for example, allow highperformance for a design life of 25 years with the electronics and Li-ion cells meeting specific and meticulous safety standards. In these cases, the rechargeable Li-ion batteries provide robust subsea uninterruptible power supplies (UPS). They are perfect for marine and offshore technology applications, offering next-level safety, reliability and availability.
The company’s PowerPacks automatically protect themselves via built in safety features. Some of the advantages of Li-ion batteries are the high current and standby operationality features, the ability to function at low to high temperatures and that they are able to cope with high currents/peaks. Furthermore, the corrosion-free titanium housings reduce OPEX costs down to almost zero and offer designs capable of operations in more than 6,000m depth.
According to SubCTech’s CEO Stefan
Marx, the company’s Ocean Power unit offers both standard batteries and bespoke solutions: “We are able to offer solutions that fit our customers’ specifications and this is the service that has enabled our growth to date. Apart from advanced technology, trust from long-term relationships is key.”
SAFETY OF LI-ION BATTERIES
Battery cells with SubCtech’s Li-ion technology offer huge advantages in terms of energy and power density in combination with safety, according to the company. However, all Li-ion or Lipol cells are sensitive to overcharging, deep discharge and can be damaged by excessively high currents or temperatures. For safe operations and a long service life they need appropriate protection.
Their special industrial cells already have several built-in internal safety features: an overpressure valve, shortcircuit protection, a steel housing and, in the case of the high-energy cells, a special temperature protection jacket around the electrodes. Although some of these properties may be found in ‘no-name cells’, only high-quality industrial cells offer the required failure rates of typically 1 in 10 million during their entire lifetime - the risk of failure according to FMEAs is extremely low.
The battery is primarily divided
into safe battery modules. These can be scaled up and are monitored and controlled by a high-level controller battery-management system.
2 MWH RECORDBREAKING ENERGY STORAGE SYSTEM (ESS)
Many years ago, SubCtech recognised the ever-increasing demand for power and increasing capacity within the subsea sector for UPS, backup solutions or to support long tiebacks in brownfields. Its latest response is a new series of Li-ion batteries specifically aimed at large subsea energy storage facilities, vehicle propulsion and and the electrification of energy production locations.
The aim is to make global energy supply more reliable while also minimising production down time.
The resulting innovation is already making waves across the industry, according to the company. The Subsea 2 MWh Energy Storage System (ESS), is fully qualified according to API17F and is already reaching TRL 6. The storage system is now being deployed underwater for operational use.
5 MWh Energy Storage System (ESS)
A FISHEYE VIEW
The need for frequent inspection and maintenance is greater than ever with the increase in offshore oil and gas facilities. Underwater robots, whether remotely operated underwater vehicles (ROVs) or autonomous underwater vehicles (AUVs), have proven to be an asset for offshore operators in these areas, creating a cost-efficient solution that cuts out the need for humans to dive down to the seabed.
However, to inspect the structures placed on the seabed effectively, manufacturers must equip ROVs and AUVs with cameras that provide the best possible visuals. The better the visuals, the more informed operators will be when making decisions. This is something Chinese robotics
company Qysea Technology had in mind when developing its FiFish E-Go underwater robot.
Developers at Qysea equipped the robot with an industry-first 176° ultrawide fisheye lens, delivering a 146° field of vision underwater to capture a wide range of elements in a single frame. With a macro adjustment capability, the FiFish E-Go focuses underwater at a 10cm distance, allowing for clear observation at extremely close distances, according to the company. It also features 10,000 lumens of underwater lighting and a 160° wide illumination angle, ensuring clarity under dark and turbid oceans.
AI-DRIVEN UNDERWATER OPERATIONS
Qysea’s self-developed AI Vision Lock function enables FiFish to achieve adaptive stabilisation and locking of target objects underwater with a simple touch on a control screen. Furthermore, its AI plankton filtering algorithm automatically optimises visuals, ensuring clearer underwater scenes for professional underwater monitoring tasks. Its AI Dehazing Algorithm automatically identifies and filters out the snowflake effect caused by underwater suspended particles, enhancing image clarity, and improving
decision-making efficiency for underwater operations. “A clearer vision underwater offers significant advantages for [oil and gas] operators,” the Qysea technical team tells IME “This includes enhanced visual data for detailed assessments, optimised time and cost efficiency of inspections, as well as increased diver safety when monitoring underwater maintenance operations.”
UNDERWATER ALGORITHMS
The Qysea technical team explain that techniques such as dehazing, contrast enhancement, and natural color correction, mean these algorithms optimise underwater images, helping operators obtain better quality and more realistic visuals for comprehensive inspections. When complimented by add-on tools, FiFish can use traditional laser scaling and AI automation to measure underwater dimensions of objects accurately and efficiently, identifying damaged areas in underwater structures, including oil and gas facilities offshore, with high precision, experts at Qysea say.
BUILT FOR PURPOSE
Inspired by the hammerhead shark, E-Go’s biomimetic tail fin stabilises the machine during underwater operations, minimising water flow disturbances. Additionally, the T-shaped fin design enhances operator mobility, enabling swift one-handed handling and rapid deployment, according to Qysea.
The E-Go also features a modular design with detachable components for its motor, lighting, camera, and battery. Module replacement operators can restore the E-Go to its underwater operable state quickly. With extensive expansion capabilities, it can accommodate up to six tools simultaneously.
Qysea claims that the new robotics system will provide a wide range of subsea operations and scenarios with increased power and propulsion
The FiFish E-Go optimises visuals
The E-Go has a modular design
TURNING BACK TIME
How one product helps overcome degraded valve stems in ageing fields
Offshore subsea production systems are fitted with valves to control fluid or gas flow in standard operating conditions as well as the operation of valves during shutdown, intervention, maintenance, and the eventual decommissioning of the field. These valves are accessible via external stems that are designed to be operated by Remotely Operated Vehicles (ROVs)
Valve stems deteriorate over time as a result of corrosion, wear or historic misuse and this can lead to a situation where close-fitting or other types of fixed sockets used are no longer effective.
Subsea control specialist Zetechtics designs and manufactures subsea control systems and tooling for subsea intervention operations and the company’s design and engineering team have developed the Jupiter Degraded Interface Adapter (DIA) to overcome the increasingly common issue of degraded valve stems in ageing fields.
HOW THE DIA WORKS
The tool is ROV mountable. It also interfaces with the existing Jupiter Class 1-4 Torque Tool, controlled by a Jupiter 2 Subsea Control System, to provide the DIA with the feedback and control required to perform the
valve operation accurately, within the allowed torque and turns range.
In addition to the benefits of the Torque Tool, the DIA seamlessly integrates with the Jupiter 2 Subsea Control System and is supplied with a pre-configured Jupiter Software Setup file (*.JUS) for operation.
The DIA is designed to operate interface stems with geometry that varies from an original hexagon to a more cylindrical shape or stems featuring slightly raised edges and other non-uniform features.
Consequently, the Adapter provides a way of operating a degraded valve or actuator into a known state using a standard Class 4 Torque Tool.
The tool is supplied with a variety of gripper fingers which are easily changed over on deck to suit the size and characteristics of the degraded interface. The fingers open to allow the DIA to work with stems with raised edges. The clamping finger mechanism has inherent compliance which allows the fingers to adjust to surface irregularities as the actuator is operated. Once fully engaged, the fingers allow for a close-fit engagement around the degraded stem.
When using a Jupiter Class 1-4 Torque Tool to supply the drive input, the Jupiter Software can be configured to provide repeated automated torque pulses to help overcome residual breakout forces.
The DIA seamlessly integrates with the Jupiter 2 Subsea Control System
FEATURES AND BENEFITS:
• Petrobras Style output and ISO 13628-8 Rotary Docking Class 4 input
• Designed to allow the operation of Petrobras Style interfaces, with an API 17D add-on option available upon request
• Simple on-deck configuration allows quick change over of gripper finger pieces
• A range of gripper fingers to suit different stem sizes
• Gripper fingers available with different surface profiles to allow for various types of degradation. Custom profiles available on request
• Hydraulic operation allows large engagement force and positive disengagement
• Maximum Torque: 2,711N.m (2,000lbf-ft)
• Heavy Duty Paddle Handle option
• Size: 613 x 260 x 214mm
• Weight: 36.9kg (air), 28.8kg (water)
• Environmental: -10 to 50°C
• Maximum working depth: 4,000msw. The product offers an excellent solution for operators facing the problem of corroded sockets or valve stems.
VALVE WORLD EXPO: EXPECT A LIVELY EXCHANGE
Delegates at Valve World Expo, to take place between the 3rd and 5th of December in Dusseldorf, can expect hands-on technological innovations, international encounters and a lively exchange of information. Valves are indispensable to the oil and gas and many other industries since they control fl ows and separate media from each other, thereby preventing liquidity and gas transfers as well as leakages.
435 exhibitors from 31 countries (correct as of July) will demonstrate that this sector is booming and showcase a plethora of innovations and solutions for the global energy transition, construction industry, water and sewage, the chemical and petrochemical industries, the shipbuilding and marine sector, food and pharma as well as the classic
fossil fuel sectors of oil and gas.
Exhibitor numbers demonstrate that this trade fair is one of the most international events in Messe Düsseldorf’s portfolio since 341 international and 91 German companies are due to attend. At this point in time over 14,000 square metres are already booked in halls 1 and 3.
European companies from Italy, UK, Spain and Turkey are strongly represented. In addition, overseas exhibitors will be travelling to Düsseldorf from China, India, South Korea, Taiwan and the USA.
Attendees from the oil and gas industry will find products relevant to oil and gas conveying / constructing pipelines; the onshore / offshore industry; refining; the petrochemical sector; the plastics industry; chemical plant construction
and further processing and conditioning.
The great innovative power boasted by this industry in 2024 is reflected not only in the international KCI conference but also by the line-up at the Expo Forum in hall 3 and the presentation of the Valve Stars Awards.
The accompanying Valve World Conference in hall 1 will ensure a well-balanced knowledge transfer between theory and practice with keynote presentations, technical sessions, workshops and panels, a young engineer programme, and live demonstrations. You can read the advance programme here
Over 14,000 square metres are already occupied in halls 1 and 3
ADIPEC: ACCELERATED ENERGY PROGRESS
ADIPEC 2024, one of the longest running trade shows for the oil and gas industry, will take place in Abu Dhabi, UAE, between 4th-7th November 2024.
The trade show builds on 40 years of energy leadership, and aims to unite communities, nations and industries across the world who are looking to create affordable, secure and sustainable energy, according to the organisers.
Over four days, ADIPEC aims to facilitate critical dialogue and collaboration across diverse sectors, including energy, technology, maritime and logistics, with a view to advancing the energy transition and fast-tracking climate action.
The organisers expect the show will attract 184,000 energy
professionals with an interest in the latest strategies and technologies. The conference programme spans 10 categories including energy, finance, technology, manufacturing, transport, and construction with over 350 sessions providing a stage for more than 1,600 speakers to address urgent global challenges. Speakers will include ministers, global energy heads and technology pioneers among others. Attendees are encouraged to source products and services from the 2,200 or so exhibiting companies – including global NOCs, IOCs, NECs and IECs.
Running in parallel, ADIPEC will host specialised industry areas for decarbonisation, maritime & logistics and digitalisation to expose attendees to new business opportunities across the full spectrum of the energy industry.
There will also be 30 international pavilions for energy industry professionals from around the world to convene and explore the latest developments within the global energy ecosystem.
The 12th edition of Young ADIPEC will also be run from the show under the patronage of Sheikh Nahayan Mabarak Al Nahayan, UAE Minister of Tolerance and Coexistence, with the support of the Abu Dhabi Department of Education and Knowledge (ADEK). ADIPEC 2024 will host the 12th edition of Young ADIPEC.
The programme aims to foster an inclusive, collaborative environment and serve as a learning platform to engage high school and university students with an interest in Science, Technology, Engineering, and Mathematics (STEM).
HAMPRO® HIGH-PRESSURE PROCESS TECHNOLOGY
The high-pressure pumps of the HAMPRO® series are used in the Oil and Gas Industries to pump a very wide range of fluids, meet the stringent requirements of the relevant safety and reliability regulations and are characterized by a robust design and careful use of resources.
Our experienced team of experts will be happy to help configure the perfect solution for your individual application.
RECIPROCATING PUMPS TO API 674
- Glycol pumps - Leak test pumps
- Methanol pumps
- Produced water injection pumps
- Sea water injection pumps
Pressure: 50 – 4000 bar
Flow rate: 0,1 – 256 m³/h
Hammelmann GmbH
Carl-Zeiss-Straße 6-8
(0) 25 22 / 76 - 0 pp@hammelmann.de
D-59302 Oelde www.hammelmann-process.com
Reliable Gas Detection
At Gas Clip Technologies, we believe that quality and budget-friendly should go hand-in-hand, which is why we create top-of-the-line gas detection solutions that have a low cost of ownership. Each detector is compliance-based and designed to withstand the roughest treatment in the harshest environments.
All of our products are available through distributors worldwide.
