afglobal presentation

afglobalcorp.com

Registered office address: Mill Lane, Rainford, St Helens, Merseyside WA11 8LR Registered number: 1138116 VAT No:113 672042 Website: www.weldingunits.com , www.afglobalcorp.com/cstep Email: [email protected]

Introduction to

Prepared By: Giuseppe Rizzo Business Development Manager AFGlobal Connectors & Sealing Technologies Unit B1 Tebay Road, Bromborough, Wirral, UK, CH62 3AB Direct: +44 (0) 151 3433922 Office: +44 (0) 151 343 1810 Mobile: +44 (0) 7950 985761 For enquiries: [email protected]

Copyright: The Copyright of this document and all related documentation is vested in AFGlobal, UK. All rights reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the Copyright owner.

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mailto:[email protected]


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Engineered Solutions






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What We Do… AFGlobal is a modern and innovative business that provides high-profile strategic customers with total value solutions for their forged component, fabrication, sub-assembly and fully integrated system needs.

AFGlobal Corporation is a Privately held, Houston based corporation, with a global footprint across more than 30 facilities in five countries spanning four continents. Our offerings support the Oil and Gas, General Industrial, Aerospace and Power Generation markets.

AFGlobal businesses and plants provide a wide range of forging, ring rolling, heat treating, machining, welding, assembly, fabrication, coating and testing capabilities.






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Basic Forging Advancing Technology Turnkey Solutions

Forged Vessel Connections

Ameriforge

Coffer Flange

Texas Metal Works

Steel Industries Inc.

Taper-Lok®

Advanced Technology Center

SMI Manufacturing

PK Manufacturing

Welding Units, U.K. Cuming Corporation

NRG Manufacturing

AJT Special Flanges

1996 1999 2002 2007 2008 2010 2011 2012 2013 2014

Allpoints

Century Corrosion Prince Industries

Gloenco

M-Tech

Turnkey Drill Riser Facility

VerdErg Connectors






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GROUP

Woodville, TX

Houston, TX (12)

New Iberia, LA (3)

Avon, MA

Greenville, SC

Shunde, China

Detroit, MI (5)

Biddeford, ME

Newport, NH (2)

U.K. (3) Calgary, Canada

Welland, Canada

Macaé, Brazil

34 global facilities │ 2,500 dedicated people │ 4 distinct markets






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AJT Friction Stir Welding Aluminum Drilling Risers M-Tech High-end Machining,

Welding & Assembly

Allpoints Subsea Fabrication,

Drilling Riser Inspection & Repair

NRG Engineered Turnkey Frac, Subsea & Pressure Vessel

Solutions

Alphatech Drilling Riser & Buoyancy Inspection & Repair PK Tubulars & Fabrication

Ameriforge Flange

Products Carbon Steel & Alloy Flanges Prince Finish Machining

Ameriforge Group

Engineered Turnkey Solutions

Shrinkfast Engineered DIY Industrial Product

Century Corrosion Custom Coatings SMI Machining &

Inlay Welding

Coffer Carbon Steel & Alloy Flanges

Special Flanges

Specialized and standard flanges, forgings and rolled

rings

Cuming Flotation

Patented Buoyancy & Insulation

Steel Industries

Forged & Machined Products

Cuming Insulation Thermal Insulation Taper-Lok Patented

Engineered Connections

Dynafab Corp Custom Fabricated Tanks

Texas Metals Stainless Flanges

Flotec Patented

Distributed Buoyancy & Insulation

VerdErg Patented Engineered Connections

Forged Vessel Connections

Long Weld Neck Flanges & Connectors Welding Units Patented

Engineered Connections

Gloenco Finished & Tested Multi-component Assemblies

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Unconventional Oil & Gas Offshore Drilling

Drilling Fluid Handling Substructures

Pressure Vessels

Buoyancy Modules

Taper-Lok Connectors

Subsea Moorings

Drill Riser Assembly

Fluid Flow Nozzle Seamless Rolled-Rings

Turbine Blades/Vanes

Pressure Pumping Units

Power Generation General Industrial Aerospace / Transportation

Offshore drilling segment focuses on the discovery and development of

subsea oil and gas resources, subsea drilling, production, completion, and

infrastructure

Power generation includes coal-fired, gas-turbine, hydroelectric, nuclear and green energy sources such as

wind power

The unconventional oil & gas segment focuses on fracking and

land-based drilling, completion and infrastructure

General industries includes building and construction, drilling and mining, chemical, machinery and many other

heavy industries. Ameriforge has been serving this segment for over

100 years

Provides forged and machined components to the Aerospace and

Transportation market segments. The market includes heavy-truck, off-

highway, rail, shipbuilding, aerospace (commercial, military and space) and

defense industries

Products and Key End Markets In

dust

ry

Ove

rvie

w

Prod

uct O

fferin

gs

Appl

icat

ions

Production Riser Buoyancy Turbine Combustor

Combustor

Power Transmission Sub-Assemblies For Heavy

Equipment Locomotive Brake Drum

Drum

Flanges

Land-based Drilling Rigs

Jet Engine Brake Disk

Subsea Drilling Casing Protector Turbine Main Hub & Strut

Synthetic Diamond Growth Chambers

Drilling Masts

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Engineered Products division Primary product lines & services: Main activities in Upstream Oil & Gas include:

– Engineering activities – Connectors and Sealing Technologies

- Diver-Assist Installation - Taper-Lok® Sealing Technology - Bolted Subsea Topside Flange Connections & Fittings, amongst them ASME/ANSI RF & RTJ

Weld Neck, Swivel & blinds flange connectors, API 6A (RTJ WN and Blinds) & API 17D ( Swivel Type) flange connectors and NORSOK L005 ( WN & Blinds) design compact connectors.

- Diverless Installation - Mechanical Clamp Connections (Retlock® Clamp) – On shore/ offshore support

AFGlobal’s Connectors & Sealing Technologies business unit provides clients systems to support an entire project, from one source - from diver-assisted bolted connections and topside flanges and fittings to advanced deepwater diverless connection solutions. We also further support our diverse customer base by providing Field Services support and aftermarket care.






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Diver Assisted Product line Today’s Design Approach

ASME VIII Div 2, Section 5.2.2. Linear elastic stress analysis. Stress slices taken of Membrane & Membrane + Linearised Bending Stress.

ASME VIII Div 2, Sections 5.2.3 – 5.3.3. Global & Local failure analysis

ASME VIII Div 2, Sections 5.2.3 – 5.3.3. Global & Local failure analysis






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FLANGE TYPES ASME / API RTJ FLANGE

NORSOK L-005 FLANGE

±2.0° Typical

TAPER-LOK






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ASME / API 6A (R type) RTJ Flange connectors.

ASME B16.5 : NORMAL

GASKET YIELD & WIDE SPREAD YIELDING OF GROOVE DUE TO CHANNELING OF LOAD






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API 6A + API 17D (BX type) flange connectors.

API 6A BX : GASKET YIELD AND RADIALLY DEFORMED TO FIT THE GROOVE, LOCALISED YIELDING OF GROOVE LIMITED BY FACE TO FACE MEETING






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NORSOK L005 (WN & Blind) design compact connectors.






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The Taper-Lok® Connection

Male Female Seal

SPHERICAL MALE NOSE MAKES THE ‘BALL’

SPHERICAL SEAL RING FACE MAKES THE ‘SOCKET’

TAPER-LOK PROVIDES EVENLY DISTRIBUTED CONTACT STRESS DUE TO LARGE AREA SEAL UP TO 20 TIMES THE SEALING SURFACE OF AN ANSI / RTJ OR LENSE SEAL






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Metal to Metal

Converging Angles

*Load Energized*

*Pressure Energizing*

Wide Area Seal

Elastic Condition

Same Gasket Material

Self Aligning

Visual Seal

Field Repairable

Withstands High External Loads

The Taper-Lok® Connection






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•DESIGNS TO SUIT ASME B16.5 PRESSURE CLASSES UP TO 2500lb

•DESIGNS TO SUIT API PRESSURE CLASSES UP TO 20,000psi

•WELD END TO WELD END CONSTRUCTION

•OPTIONAL WELD END TO ANSI/API RTJ CONSTRUCTION

•STANDARD ±10° ANGULAR MISALIGNMENT, MORE COMPACT DESIGN FOR REDUCED ANGLE

•EXTERNAL TEST PORT FACILITY

•RETAINED SEAL RING FOR EASY INSTALLATION

•CRA SEAL FACES FOR LONG TERM USEABILITY

±10° MISALIGNMENT BALL FLANGE






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20” ANSI 900# Flange Assembly 20” TAPER-LOK 900# Flange Assembly

VS

427mm

856mm 686mm

495mm

Taper-Lok® v. ANSI Size & Weight






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0

200

400

600

800

1000

1200

1400

1600

1800

2000

3 4 5 6 7 8 9 10 11 12

Wei

ght (

kg)

NPS (in)

ANSI vs. Taper-Lok Weights

Taper-lok ASME

2500 # Flange Comparison






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•The tapering of the seal face gives a mechanical advantage, achieving high contact forces with low bolt loads. •The bolt preload required is only 25ksi compared to 75 – 90 ksi for other types of compact or HP flange. •Large Gasket Area makes the leak path very long. Not as sensitive to field mishandling, scratches or ingress of sand or grit. •Self Aligning due to conical surfaces – very important for large sizes and subsea applications. •There are no RTJ type stress concentrations.

Safety & Performance.






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ROV operated diverless mechanical clamp multibore connectors for pipeline, flowline, umbilical, rigid and flexible spools, riser towers and riser bases, based on Retlock® connector.

Retlock Clamp

RTC Riser Tower Connector

RTC Riser Base Connector Installation

DMaC PLR Installation

Diverless Connections






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First diverless connections installed in the West of Shetland Basin (1996).

Over 1,600 Retlock Connectors installed.

Blue-chip clients list.

Connection deployment systems based on patented Retlock Clamp Connector and proven guidance and alignment technology blocks.

Various installation and orientation scenarios can be catered for with connections at any angle

required.

Retlock Connector qualified for various pressures up to 1035 bar, sizes up to 20” diameter and water depths up to 3,000 metres.

Innovative development and qualification of

Riser Tower and Base connectors HP/HT Connectors

Large-Bore Connectors Integral insulated connector solutions

Pipeline repair solutions

Fast track delivery (6 months) of connector and tooling system for extension or step out well tied back to existing production facility for early production.

FTC Pullhead

DMaC Pullhead

RTC Pullhead

DMaC Porch







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• Compact & Light Weight

• Broad/Robust Metal-to-Metal Sealing Surface

• Manufacture using International Best Practice Materials

• Fallible Clamp Components Retrievable without Removing Jumper

• Continual Leak Monitoring System, and annulus port for pressure testing

• Versatility for Bore Configurations & Deployment Systems

Retlock Shaft

Inboard Hub

Outboard Hub

Clamp Top Half

Sealplate Assembly including Gasket







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Connection System

DMaC (Diverless Maintained

Cluster)

FTC (Flowline Type Conn)

DVC (Diverless Vertical Conn)

RTC (Riser Type Conn)

FTP (Fly-to-Place Conn)

Orientation Horizontal Horizontal Vertical Oblique Horizontal

Guidance System

• Drag-to-Place system • Run-to Place system • Run-to-Place system • Run-to-Place system • Drag-to-Place system

• Fly-to-Place system

Attributes

• Flexible jumper connection

• Suited to application in areas with harsh environmental conditions

• Ability to wet park jumpers for later installation

• Ability to connect / disconnect PLRs

• Versatile low cost system for connection of: - Rigid and flexible

pipelines - Rigid flexible jumpers - Umbilicals - PLRs

• Stab and Hinge over and lay away

• Guidelines or Guidelineless

• Rigid jumper connection

• Allows wet parking of rigid jumper without final connection

• Guidelineless • Small footprint • Saves costs as crane

vessel is not required for full installation

• Orientation flexibility • Potential synergy

between Riser Tower and Riser Base connections

• Subsea winching or direct pull-in of Riser

• Guidelines or Guidelineless

• Low cost • Fully adaptable to

different vendors couplers

• Umbilical snag protection

• Can be configured for chemical injection, instrumentation, flow meters, DP cells.

Applications

• Manifold – XT • Manifold – FLET • Flexible Riser – FLET • PLR – Manifold or PLET

• Manifold – XT • Manifold – Pipeline • Manifold – PLR • XT – Pipeline • Riser Base - Pipeline

• Manifold – XT • Manifold – Pipeline • XT – Pipeline • Riser Base - Pipeline

• FPSO flexible Riser – Riser Tower (URA)

• Riser Tower Base (LRA) – FLET (pipeline)

• Flexible Riser – FPSO – Offshore loading vessel

• Flying leads instruments

• ROV replaceable instrumentation

Bore Sizes 2 –10 inch 2- 24 inch -

Water Depth 70 m - 2,500 m 70 m - 2,500 m 1,000 m - 2,500 m 70 m - 2,500 m 70 m - 2,500 m


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1.Any angle Subsea Diverless Connector 2.Compact and lightweight design minimising size of subsea structure 3.Integrated Insulation systems with no separate insulation tooling. 4.Retlock Shear Pin and Clamp in two halves allow release of hubs and connected pipes in case of emergency. 5.Standard Connector building blocks reduce engineering and testing requirements and minimises spare parts and tooling requirements and facilitates shorter lead times and standard installation protocol. 6.Multibore Connections Possible in Single Pullhead. 7.Customised deployment reduce installation time and suitable for flexible and rigid pipelines.

8. Wet park facility. 9. Wide installation weather window: Up to

5m sea swell accommodated for DMaC. 10. Wide mis-alignment permissible reduces

installation risks & minimises time spent. 11. Modular tooling skid provides security of

risk of dropped objects, reduces vessel space occupied, operator skill levels required, installation cost & time.

12. In-house Design, Engineering, FEA & Fatigue Analysis; Mechanical, Hydro & Gas Test.

13. Field Services Team dedicated to support installation & ongoing life of field work.

14. Integrated supply chain: 6 month connector lead times possible for agreed materials.

Benefits

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HP/HT Connection Advantage

Conclusions:

• 15 & 20 ksi Connectors are Feasible with Retlock Hubs/Clamps

• HUB & CLAMP SIZE INCREASES ARE MINOR

• Guidance & Alignment Sizes are Unaffected

• 1.0 m Pitch Porch Spacing Remains Feasible 20 ksi Size Envelope

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DMaC System: Flexibles & Umbilicals Installed: Wet Park & Drag-to-Place Applications: Flexibles/Umbilicals Manifolds, SSIVs, FTAs, Trees Size Range: 2-inch to 18-inch Assets in Place: • > 650 DMaC Installed WOS • > 250 new DMaC for Q204 • 6 Tooling Sets Owned • Ops by McDermott, Subsea7 & Technip

A drag to place connection system tailored to operate in extreme environmental conditions. The DMaC provides flexible, interruptible installation with jumper, tree and manifold separately deployed in any sequence. Connection of first and second end can be months apart. Positioning of the jumper requires minimal connection to the surface.

DMaC Pull-in Tool an associated ROV

DMaC Pullhead DMaC Porch

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RTC System: Riser Type Connector

Riser Top Connections

Riser Base Connections

Free Standing Risers Flexible Catenary Risers

The RTC is a pull-in or land & hinge-over connection system able to provide Upper Riser Assembly (URA) and Lower Riser Assembly (LRA) synergies

Hebron Midline Clump Weight

Block 31 Flexible Riser Connector

Neptune FLNG Riser Base Connector

Neptune FLNG Riser Base Connector

Experience Record 81 Flexible Catenary Riser Connections Installed for BP Foinaven & Schiehallion (West of Shetlands, UK) 2 Riser Base Connections Installed for Suez Energy’s Neptune FLNG Import

Terminal (Offshore Boston, USA) 10 Riser Tower Connections Delivered for BP Block 31 (Angola) 32 Riser Tower Connections Planned Backlog for BP Block 31 (Angola) 24 Riser Tower Connections Award for Total Block 32 (Angola) 4 Riser Base & Midline Clump Weight Connections Award for ExxonMobil Hebron (Canada)

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• Fully adaptable to different vendors couplers / connectors • Retlock bolt allows for emergency override • Current maximum configuration 11off Hydraulic + 4 off electrical • Umbilical snag protection • Can easily be configured as chemical injection crossover plates or to

carry retrievable instrumentation packs or flow meter DP Cells.

FTP Umbilical Deployment Basket FTP Fly-to-Place Control Module

FTP System: Fly-to-Place Connections

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Tooling Rental or Purchase

Modular System built around available WROV (Millennium ROV APL Neptune)

Retlock Torque Tool

Cleaning Tool

Seal Plate Change Out Tool

DMaC ROV Tooling Skid (BP Quad 204)

Integrated Tooling Skid (BP Angola Block 31)

Manipulator Deployed Tools

ROV Tooling Operation Services We work Offshore with the installation Contractor, providing the size of team required to support Offshore operations. Offshore site supervision during installation ensures all equipment is operating properly and quickly attended to, minimising installation time.

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Tooling Components

• Pit Tool

• Interface Skid

• Pit Tool deployment basket

• Work basket

• Workshop container

• Spares container

• Half Height Container

• Control Laptop

• Single port and quad port Hot stabs

• FTP Skids

• FTP Single and Dual Drive Tools

• Retlock Torque Tool Analysers

• FTP Torque tool analysers

• Cleaning Tools

• Change-out Tools

• Debris Cover

• Reinsertion tool

• Associated spares kits

DMaC Tooling Skid and Basket

DMaC ROV Tooling Skid and associated tooling

DMaC PLR Installation

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Registered office address: Mill Lane, Rainford, St Helens, Merseyside WA11 8LR Registered number: 1138116 VAT No:113 672042 Website: www.weldingunits.com , www.afglobalcorp.com/cstep Email: Email: [email protected]

Statement of Problem An existing installed Tree-to-Manifold flowline connection offshore Nigeria was found to have a broken Gooseneck due to overstress during pipelay. The break was between the Manifold Vertical Collet Connector and the flexible flowline with the result that the flowline was laying on the sea floor in 1,440m water depth.

Pipeline Repair Case Study

Flexible Jumper at Installation Failed Gooseneck Jumper on Seabed

Offshore Deployment First Time Right AFGlobal and MPL successfully completed the first of multiple gooseneck repairs required in 2011 at over 1,400m water depth.






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Assembly & Test Facility

Increase Hydro Testing Pressure:

API 6A High Pressure Gas Testing:

Mechanical Testing:

15,000psi

10,00psi (690 bar (g))

to API 17D with ≤ 10,000psi internal working pressure

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Assembly & Test Facility

WP 1035bar

Test 1552bar

Ext 300bar

2hr 3min 15min

200 cycles

2hr 3min 15min

1hr

Gas (N)

15min External

200OC

All Thermal Cycle Tests at WP (1035bar) except where noted otherwise

-46OC

Ambient

1hr

5% Pressure (52 bar)

15min External

15min 15min 15min

API 6A PR2G Rig

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Combined Load test Facility (API 17D)

Internal Pressure • 414bar (6,000psi) Bending Load • TBC (335,766Nm) Torsion Load • TBC (60,896Nm)

Bending Load

Internal Working Pressure

Torsion Load

Torque Mechanism

Bending Actuator

Retlock Clamp Assembly

Base Frame

Outboard Hub

Mounting Frame

FTC or Porch Inboard Hub & Interface Plate

afglobalcorp.com

Registered office address: Mill Lane, Rainford, St Helens, Merseyside WA11 8LR Registered number: 1138116 VAT No:113 672042 Website: www.weldingunits.com , www.afglobalcorp.com/cstep Email: Email: [email protected]

Certifications






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Taper-Lok® Recent Projects Saipem UK: Det Norske Ivar Aasen PDQ project- Supply of

16” Taper-Lok® Flanges Statoil Johan Sverdrup, Supply of 14”, 16”, 18” and 20”

Taper-Lok® Flanges Saipem Croatia: ICOEEP, Supply of 48” Taper-Lok® Flanges Saipem UK: Statoil- Taper-Lok® Flanges for Test Structure –

Brutus Statoil/ Total- Mariner project, supply of 12” Taper-Lok®

Flanges BP- Clair-Ridge Project- supply of various sizes of Taper-Lok®

Flanges for subsea & topside. UOP- supply of Taper-Lok® Flanges






afglobalcorp.com Registered office address: Mill Lane, Rainford, St Helens, Merseyside WA11 8LR Registered number: 1138116 VAT No:113 672042 Website: www.weldingunits.com , www.afglobalcorp.com/cstep Email: [email protected]

Recent Diverless Projects Client / Project Project Scope

BP Quad 204

West of Shetland Basin

- Supply of Drag-to-Place DMaC Connection Systems and jumper tie-ins - Development and supply of upgraded ROV Tooling Package

Chevron Mafumeira Sul

Angola

- Supply of side-by-side Run-to-Place Horizontal Connection Systems (FTC) combined for different connection sizes [8” and 16”]

- Supply of 1 Tooling suite with dedicated control system

Chevron Rosebank Development

West of Shetland Basin

- FEED to incorporate supply of 80 DMaC Connection Systems for flexible flowline and jumper tie-ins (including insulated connectors).

- Development and supply of ROV Tooling

ExxonMobil Hebron Offshore Loading System

New Foundland

- Supply of 6 RTC Connection Systems [20”) for Offshore Loading System

Total Kaombo Upper Riser Assembly

Angola

- Supply of Upper Riser Tower Connection Systems (4”, 10”, 12”, 14”) for flexible riser tie-ins (including insulated connectors) from FPSO to Upper Riser Tower Assembly

Nexen Blackbird Central North Sea

- Supply of 2 FTP connection systems - Rental of Modular ROV Tooling Package






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THANK YOU




