Page 1

MATTERS Dyneema Max Technology ®

Dyneema ® Max Technology represents a breakthrough in HMPE rope technology, redefining the capability of synthetic ropes in deepwater permanent moorings. Designed specifically for use in deep- and ultra-deep water, Max Technology, Dyneema® converted into incredibly strong ropes, provide unrivalled strength, stiffness and durability. Rigorously

tested, fully accredited and trusted by oil and gas majors around the globe, Dyneema® is the world’s strongest fiber. Now the best just got better - with Dyneema® Max Technology offering assurance in deep water permanent moorings, far beyond the operational life of the installation. Mooring ropes with Dyneema® Max Technology offer benefits across the planning, system design,

logistics, installation, hook-up, and production stages, as they are significantly lighter and smaller than polyester mooring ropes. They guarantee not just maximum strength over a maximum lifetime, but improved handling and safety - leading to a much happier workforce. Far more vessels of opportunity can now be used to transport and install mooring systems in

deep water, thanks to the unique properties of Dyneema® Max Technology and the ropes that use this technology. This is just one way in which customers enjoy a return on their investment, blowing SWR and polyester alternatives out of the water. Dyneema® Max Technology - takes mooring rope capability to a whole new dimension.

Seaway Heavy Lifting: “We’re Ready For Max Technology” Seaway Heavy Lifting (SHL), the world-renowned provider of first class marine transportation and construction services to the offshore oil, gas and renewable energy industry, is already geared up for working with the new Dyneema® Max Technology for mooring ropes. SHL’s heavy lift crane vessels are widely used for installing offshore structures in these sectors sectors. That includes the mooring systems that keep floating structures on station in ever-deeper international waters. The company’s state-of-the-art new DP3 heavy lift crane vessel, ‘Oleg Strashnov’, is dedicated to this buoyant market, with prospects in the Gulf of Mexico, Australia, West Africa and the northern North Sea.

Jan-Peter Breedeveld, Manager of SHL’s Engineering Department, outlines the benefits of this pioneering new rope technology from an installation perspective. “Rope made with Dyneema® Max Technology delivers on all the performance criteria that operators are looking for, despite being a third of the diameter of traditional polyester or SWR. That quality alone means that we can store a much larger volume of rope on board our crane barges and hence make fewer trips to pick up and transport lines. Depending on the number of lines and the remoteness of the location, this will have a significant impact on the speed and cost of installation for the customer, as well as allowing existing equipment to deploy the new lines in deep water”. SHL has developed unique

POLICAB BRAZIL Dr. Fulvio Chimisso, Professor of Mechanical Engineering, and Head of the POLICAB, Tension Analysis Laboratory of the Rio Grande Federal University in Brazil, has been working with Dyneema® products since 2002. His evaluation work is part of a multiyear project sponsored by PETROBRAS, aiming at selecting the best fiber for offshore mooring.

installation methods for deepwater mooring systems - expertise that DSM and its partner companies were keen to leverage in the development of their new fiber and synthetic rope weave. DSM has asked SHL to give a presentation on the issues concerning line installation, and to provide feedback on the potential impact of their new product. Knowledgesharing was key throughout the development of ‘ Dyneema® Max Technology’, contributing to the overcoming of acknowledged installation problems. This, in turn, helped DSM and its partners to optimise both the technical and operational performance of a rope that is now being hailed as ‘the next step’ in deepwater mooring solutions.

Prof. Chimisso has stated that “Dyneema® Max Technology has excellent mechanical performance, and its floatability makes it ideal for offshore work”. In addition, DM20 “exhibits much reduced creep in comparison to SK78”, as a result of “improvements in technology from DSM Dyneema in the past fivesix years”. Background Dr. Fulvio Chimisso Policab – the Tension Analysis Laboratory of Dr. Chimisso the School of Engineering of the Rio Grande Federal University - FURG, has been developing projects for ten years (starting in December 2001) in partnership with and under sponsorship of Petrobras. They have created a laboratory of excellence, as classified by Petrobras, for tension analysis of single and multiple yarns. Thus, Policab achieved credibility and reliability in a short time, taking their work seriously. 1

MaxTechnology Matters is a publication by DSM Dyneema April 2012

Interactive demo at OTC Lankhorst shows the new technology at their booth

DSM Dyneema & Lankhorst Ropes Collaboration Oil and gas developments are moving into ever deeper and more challenging offshore environments, and the demand has never been greater for enhanced mooring systems that satisfy the technical parameters of extreme operating conditions. Over ten years ago, DSM Dyneema and Lankhorst Ropes teamed up to and since then develop technically advanced ropes. As DSM Dyneema’s Segment Manager Offshore, Jorn Boesten explains, it is a logical partnership. “Put simply, DSM develops groundbreaking fibers that Lankhorst Ropes translates into ultra-strong synthetic ropes. Together, we have been able to demonstrate the proof points of HMPE mooring ropes on deepwater Mobile Offshore Drilling Units (MODUs). Our next step was to develop a rope capable of enhanced performance in permanent deepwater and ultra-deepwater moorings”. DSM Dyneema set to developing a new grade of fiber that had the strength and flexibility required. Lankhorst then translated those properties into possibly the strongest deepwater synthetic rope construction in the world - ‘Gama 98® incorporating Dyneema® Max Technology’. As Jorn Boesten points out, the new rope is not only stronger than polyester and steel alternatives, but lighter and easier to install. “This will allow many more vessels of opportunity to install mooring systems far quicker and safer than ever before. The new rope also offers more freedom at the riser design stage of production facilities, as well as a host of other operational benefits”, he adds. During development, both DSM Dyneema and Lankhorst used their individual testing facilities to evaluate the tensile strength,

fatigue and breaking strength of both the fibers and rope constructions. Lankhorst Euronete Ropes’ Sales Director Chris Johnson explains the rationale: “Lankhorst used their 1,200 tonne capacity fatigue and tensile strength-testing equipment and DSM gathered their own performance data on a smaller scale. Sharing the results from these tests enabled the development of the new rope to be much quicker and more robust”. Convincing the offshore industry of the viability of synthetic fibers for deepwater permanent mooring has been achieved through further cooperation. Chris Johnson explains the joint approach here. “Teams of representatives from both companies are speaking directly to potential customers, presenting a comprehensive case for the new product. This begins at the molecular level, with DSM Dyneema providing evidence of the unique fiber properties, which are key to the operational performance of the end product”. Over the next 18 months to 2 years, DSM and Lankhorst Ropes will carry out joint presentations directly to oil and gas industry leaders around the world, both at customer facilities and at conferences. They will demonstrate the proven capabilities and clear advantages of Gama 98® with Dyneema® Max Technology. The first of these presentations will take place at OTC in Houston Chris Johnson this coming April/May, where the product will be officially launched.


Dyneema -based Mooring Ropes A Sound Return on Investment

Dyneema® Max Technology Technical Paper Abstract

Once thought to be an expensive alternative to traditional steel wire and conventional polyester-based synthetic ropes, ropes made with Dyneema® are becoming widely accepted across the offshore industry as the optimum solution for MODU and permanent deepwater moorings. ConocoPhillips, Shell and Petrobras are now working with systems based on the ‘ultra high strength at low weight’ fiber, the durability and longevity of which is delivering performance and user benefits that impact positively on operating cost.

M.P. Vlasbom and J. Boesten of DSM Dyneema, together with S. Leite of Lankhorst Ropes, and P.Davies of IFREMER, will be delivering a technical paper at OTC that considers the development and performance capabilities of High Modulus Polyethylene (HMPE) fiber for Permanent Deepwater Offshore Moorings.

®

Ten years ago, when DSM Dyneema first entered the market, manufacturers and users shied away from the comparatively high cost of its products, but as their long-term value became clearer,

and users reported a return on initial CAPEX through savings elsewhere, perceptions changed. The Dyneema® fiber is now acknowledged to be a very sound investment. Brazilian oil giant Petrobras certainly thinks so. It specified DSM Dyneema’s ultra strong, lightweight SK78 fibers for one of its new semi-submersible MODUs. SK78 is the only HMPE fiber approved by Bureau Veritas and ABS for MODU moorings. Jorn Boesten, DSM Offshore Segment Manager believes: “Petrobras chose Dyneema® over polyester for a number of reasons, including the speed of mooring, savings on equipment costs and lowering of operating costs. With ropes made with Dyneema® taking up half the space of polyester, fewer supply

DSM Dyneema reveals its brand new technology for permanent deepwater mooring at OTC in Houston. A huge step in the latest developments in HMPE technology. The development of this new technology was done together with Lankhorst Ropes - the high performance rope manufacturer and developer.

OTC represents the perfect showcase opportunity to launch pioneering new products like this onto the international stage. Over 70,000 industry experts from all around the world are expected to attend this well-know exhibition and conference in Houston and this will be their first ever chance to

trips are needed - a significant factor when you consider the remoteness of the Petrobras fields and the high day rates of supply ships”.

Cost savings from using these ropes arise in other, less obvious ways; for example, they need no oil or grease, unlike other synthetic ropes and SWR. Working with ropes with Dyneema® therefore, eliminates the need for expensive, environmentally-unfriendly grease and the manpower needed to manage its application. In many cases, the period needed to pay back the initial investment for these advanced ropes is surprisingly short. This is especially true when factoring in the absence of costs relating to injury-related incidents, maintenance, repair and replacement - typically associated with SWR and other, less durable synthetic lines. The extent of opportunities for seeing a return on investment is so much higher with ropes that are made with Dyneema®.

Ropes made with Dyneema® are popular in drill rig mooring systems. With rigs often being moved every 3-6 months, the speed of relocation is a critical project cost factor. Ropes made with Dyneema® enable rig moves to be 40% quicker and hookup twice as fast as with polyester. The reduced width of ropes with Dyneema® translates into commercial benefits too. Smaller, less expensive anchor handling vessels can be used and fewer trips to shore are required. Over time, this can amount to considerable OPEX savings, which comfortably offset the higher CAPEX cost.

DSM and Lankhorst together at OTC in Houston

NI 432 DTO R01E

Issuing body

Creep prediction

Rope creep testing

Guidance notes on offshore mooring fiber rope

API-RP-2SM

Bureau Veritas (7)

Det Norske Veritas (8), (9)

American Bureau of Shipping (10)

American Petroleum Institute (11)

International Organization for Standardization (12)

Long-term creep of the rope based on fiber creep data.

Creep failure resistance to be specified by rope manufacturer. Yarn manufacturer to test to yarn creep failure.

Creep analysis to estimate the total creep strain during the design service life. Creep rupture analysis to estimate the creep rupture life.Creep model based on fiber creep data.

Creep analysis based on mean and maximum design loads. Creep failure analysis based on rope test data.

Estimate of creep rate and allowable creep elongations, in operating conditions on most critical area of the rope. Based on model of fiber creep properties.

Number of discrete design conditions to calculated annual creep strain and predict total strain for design service life.

Several tension intervals to calculate annual cumulative creep rupture damage.

Verification test for rope creep rate in at least one load and one temperature. Test continued till for at least 24 hours a constant creep rate with time is reached. Subropes allowed for parallel rope constructions.

The creep data are collected at two tensions. The percent creep at 3 min., 30 min., 300 min. and 3000 min. may be extrapolated on a semi-log basis (creep on normal scale vs. time on log scale) to longer times.

Calibrate long-term rope creep rates on prototype rope with fiber data and creep model. Subropes allowed for parallel rope constructions.

To be determined on case-by-case basis, if applicable Number of test specimens to be tested on creep.

Creep monitoring in use

Most critical section (usually top part or top section).through adequate marking.

Length measurements to assess creep progression.

Creep discard criterion

95% of initial rope strength or 10% of installed rope length.

Total creep strain limited to 10% of total length of HMPE rope. Creep failure safety Factor of safety over factor of 3 for mobile the design service life moorings and 5- 8 for against creep rupture: long-term moorings. 5 (creep is monitored) or 10 (creep is not monitored).

Safety factor

Meet DSM

illustrating the

DNV-OS-E303 DNV-OS-E301

Method

To the left is a table

see and experience the incredible performance statistics of the latest Dyneema® fiber technology which will be shown as a live demo at the Lankhorst booth.

Norms and guidelines Guideline

HMPE fibers have, to date, been successfully deployed on semipermanent MODU mooring systems. However, DSM and Lankhorst Ropes are jointly introducing a brand new rope incorporating previously unseen HMPE fibers with enhanced dynamic properties. Entitled ‘Dyneema® Max Technology’, this revolutionary new fiber offers the ultra-deepwater oil and gas industry the first opportunity to use synthetic ropes with HMPE in permanent offshore mooring systems. Laboratory tests demonstrate that ropes made with ‘Dyneema® Max

Technology’ retain the property characteristics of HMPE, even under long-term high tensions in loop currents. Critical behavioral qualities - high static strength and stiffness, high modulus, yarnon-yarn abrasion tolerance and exceptional creep resistance enable a smaller, lighter rope to deliver improved performance, handling, safety and production system design benefits. The technical paper considers, in detail, the creep properties of HMPE rope and how DSM has introduced systematic improvements to tackle the problem from the molecular level up. Rigorous laboratory and field tests are outlined in detail alongside predictive modeling based on sub-rope tests. The conclusion is that ‘Dyneema® Max Technology’ fibers enable HMPE mooring ropes to satisfy all industry guidelines and standards for permanent deepwater offshore mooring.

ISO/PDTS 14909

application of norms and guidelines to the analysis of creep in fibers, yarns

Calibrate long-term rope creep rates on full scale rope over 7 days at max.55% BS and max.25°C. Subropes allowed for parallel rope constructions.

and ropes.

Offshore Northern Seas (ONS) Stavanger, Norway 28 - 31 August 2012

Presentations by DSM

Rio Oil & Gas 2012 Rio de Janeiro, Brazil 17 - 20 September 2012 Offshore South East Asia (OSEA) Marina Bay Sands, Singapore 27 - 30 November 2012

Mr Jorn Boesten will be delivering a presentation at this years OTC in Houston as part of the official launch of Dyneema® Max Technology. After the exhibition and conference in Houston, we will be travelling around the world to ensure that potential end-users have an opportunity to see and hear about the many benefits that this new technology offers. You can see the presentation and speak to DSM in person at any of the following conferences and trade shows. Cordage Institute: Annual Conference - 9th-11th May, Florida USA Oceans: 21st-24th May, Yeosu, Republic of Korea Rio Oil & Gas: 17th-20th September, Rio de Janeiro, Brazil

Optional (of influence on the safety factor).

DSM Dyneema attends several international trade exhibitions and conferences. You are most welcome to meet us at any of the following events:

Contact details Marcelo Herszenhaut

marcelo.herszenhaut@dsm.com +1 7044604970

Marc Eijssen

marc.eijssen@dsm.com +31 6 51017250

Jorn Boesten

jorn.boesten@dsm.com +31 6 20447284

Colophon

The Max Technology newsletter is a publication of DSM Dyneema intended for broad distribution. The purpose of this newsletter is to provide interested parties information about the products and activities of DSM worldwide. Nothing can be copied or used without any written confirmation from the Marketing Department of DSM. The contents have been compiled for information purposes only, no rights may be derived from the actual contents. Dyneema® is a trademark of DSM. Use of this trademark is prohibited unless strictly authorized. www.dyneema.com

Editors

DSM Dyneema Brandmarion

Photographs

DSM Dyneema Seaway Heavy Lifting

Factor of safety for creep failure is10 times the service life of the rope.

Design

Brandingworkz

Printing

Brandmarion

Jorn Boesten 2

Dyneema® Max Technology - Newspaper issue #2  
Dyneema® Max Technology - Newspaper issue #2  

Newspaper about the introduction of the Dyneema® Max Technology,

Advertisement