Protection solutions category

Bend restrictors prevent over-bending at the interface between flexible flowlines/umbilicals/cables and rigid structures by mechanically locking up. They are normally used in static applications but, unlike bend stiffeners, only provide protection once the pipe has achieved the desired bend radius between the flexible line and rigid structures such as wellhead connections, J-tube exits, rigid pipe crossovers and PLET connections. Accredited by Bureau Veritas to API 17L standards and tailored to meet or exceed customer requirements across the oil & gas, renewable energy and defence industries, Balmoral bend restrictors provide cost effective solutions through optimised design methods, an ongoing development programme and the use of multiple rigid PU grades. They are supplied as two-piece units that are bolted together. Balmoral’s bend restrictor solutions are designed and manufactured in-house using state of the art design software. Key information required for this process includes: Flexible pipe OD Minimum bend radius Service life Length of coverage by angle or length Support structure details Flexible pipe min and max internal temperatures; operation and installation Flexible pipe min and max thermal conductivity value if pipe is heated Min and max installation air temperature Min and max seawater operation temperature Installation and operation shear force Installation and operation bending moment Flexible pipe stiffness if not taken into consideration in the bending moment and shear force loads Balmoral’s vision is to be a solutions provider and, in most cases, provides a bespoke product tailored to meet specific or environmental conditions. It is understood, however, that clients can seek off the shelf options offering the same quality and surety that a bespoke product typically provides. Through an extensive investment and research and development project Balmoral analysed its extensive track record and developed a range of standard bend restrictors to cover a multitude of diameters operating to specific temperatures, loading capacity and MBR. This programme resulted in Balmoral’s standardised bend restrictor range which offers: A rethink of the load transfer mechanism to a ‘Box to Box’ systemy Standard mouldings catering to a wide range of diametersy Improved lead-times on documentation and productsy Tested to capacities with the potential to reduce qualification and expense on individual project testingy Potential cost reduction over bespoke designs subject to performance requirements, specification and quantitiesy API 17L Type Approved design methodology Boltless bend restrictors Balmoral extended its bend restrictor range to include a genuinely boltless restrictor (patent pending). This innovation allows fitting times to be slashed, offering huge savings in offshore installation costs. In line with Balmoral’s acknowledged track record for product improvement, value has been added by taking something away. Some existing products claim to be boltless but, in reality, none of them actually are. Balmoral’s boltless restrictor retains industry-leading performance while offering significantly reduced installation times and costs. balmoral boltless bend restrictors Boltless bend restrictor benefits Rapid installation time creating significant offshore savings Revolutionary boltless interlocking method fully utilising the material’s strength Superior load capacity for long and short term conditions Excellent temperature resistance, specifically important to long term creep performance Significant multiple unit cost efficiency savings Minimises sub-supplier risk Materials and design methodology API 17L 1&2 compliant Features Interlocking male and female mouldings Innovative interlock system (patent pending) removes the need for fasteners Bend restrictor lockout prevents cable/pipe over bending Proprietary design and testing delivers long service life in extreme environments Material fully API 17L 1&2 certified Material is mercury and MbAOC free (REACH compliant) Design specification Typical cable/pipe diameters: 20-450mm Typical bending moments: 2-120kNm Standard minimum bend radius: 1-8m Materials: Balmoral marine polyurethane Design life: 35 years (or specific project requirement) Balmoral offers a variety of options for bend restrictor end fittings, also known as reaction collars, where a robust design is required to provide the smooth transfer of load from the client interface to the end of the restrictor string ensuring protection is maintained at all times. Forged reaction flange Using this method, Balmoral restrictors couple to the structure by means of a flanged (male) end fitting. Forged reaction flanges are manufactured using compliant material as a single body which is machine finished and requires no welding. They are coated with a standard marine grade paint system (NORSOK System 7B) and supplied as split units that are bolted together using B7M bolts. It is not standard practice for Balmoral to supply the bolts used to connect the reaction flange to the end fitting but this can be arranged if required. Forged reaction flange PU reaction collar Using this method, bend restrictors couple to the structure by means of a PU fitting connected to a steel flange located within the groove of the end fitting. Steel flanges are supplied in two halves with a pitch circle diameter (PCD) to match the PU end fitting. All above options can be supplied in Balmoral’s standard welded assembly format. Polyurethane reaction collar PU reaction flange PU reaction flanges are the connecting point between PU bend restrictors and the subsea termination interface and are designed to match clients’ end fittings. The PU reaction flange design is based on the bend restrictor as both components share neck and pin geometry and utilise the same material. Benefits of PU interface options include Part of Balmoral’s API 17L approval Minimising weight above and below the surface Eliminating arduous weld specs and procedures Minimises need for CP systems In-house control from design to delivery Solutions designed to match client interface requirements Balmoral distributed buoyancy modules are fully accredited by Bureau Veritas to API 17L standards. API17L

Bend stiffeners are used to support flexible pipe, umbilicals and cables when connected to rigid structures or a floating production system where there is a requirement to control the minimum bend radius of the pipe. They are usually attached at either the topside or seabed connection. Balmoral bend stiffeners are fully accredited by Bureau Veritas to API 17L standards and, using specifically formulated polyurethane materials, are designed to suit engineered operational parameters including fluid temperature variance, project specific flowline, umbilical or cable stiffness and minimum bend radius (MBR) requirements. In dynamic applications bend stiffeners require to have sufficient fatigue resistance to control the in-service bend radii and sustain the cyclic loads to the end of the specified life whereas in static applications they protect against gross over-bending. Stiffeners are typically conically shaped polyurethane mouldings with a cylindrical bore that slips over the pipe, umbilical or cable. Balmoral uses the proprietary package ‘Orcabend’, an industry standard for many years, to generate a profile for the active conical section of the stiffener. Information that is critical to bend stiffener design includes: Tension and angle data from the riser analysis Temperature Interface detail Riser end-fitting profile Diameter and stiffness Minimum bend radius Riser analysis fatigue data Balmoral’s FEA package is used to verify the Orcabend design and analyse the end-fitting structure and can also provide thermal analysis if required. Balmoral bend stiffeners are comprehensively flex-fatigue tested and Type Approved by Bureau Veritas. A combination of Orcabend and FEA technologies allows split stiffeners to be designed for retro fitting. Balmoral has invested heavily in the technology and infrastructure to produce what are thought to be the largest bend stiffeners available to the industry. The market-leading facility allows the company to produce one-piece stiffeners exceeding 15m in length. A key aspect of the Balmoral bend stiffener/restrictor development program was to negate the significant health and safety issues associated in traditional elastomer stiffener supply. The material systems used in Balmoral products meet the increasing demand for minimum hazard at all stages of manufacture and use. Balmoral does not use carcinogenic aromatic amine cross-linkers and uses only ‘stripped’ prepolymers, ie, materials that are essentially free of volatile and toxic toluene diisocyanate (TDI). Additionally, Balmoral bend stiffeners comply with Norwegian Product Regulation 2.3 which bans the use of toxic mercury catalysts. Dynamic bend stiffeners Dynamic bend stiffeners provide localised stiffening for umbilicals and flowlines in demanding applications. They are designed to protect the MBR inflicted by flexing while under axial loads and also to prevent fatigue failure. The end steelwork on dynamic stiffeners is custom-designed and fully encapsulated to connect with the matching project hardware. API 17L Type Approved Tailored to optimise performance for bend protection and fatigue resistance for the desired service life and environmental conditions accounting for fluid temps, environment, client-specific riser, flowline or umbilical stiffness and MBR requirements Prevents overbending and adds localised stiffness Steel and alloy 625 integrated steelworks tailored to match client end fittings and specifications FBE or nickel based coatings for corrosion protection Several flex fatigue tests performed Multiple grades of PU enables Balmoral to provide the most cost-effective solution to meet performance requirements Black or yellow pigmentation Extensive track record 10m3 one-shot pumping capacity means all product sizes are readily accommodated Balmoral’s unique manufacturing capability means that stiffeners of virtually any size can be produced. Intermediate bend stiffener Intermediate bend stiffeners Typically used for mid-line connection where dynamic loads are at a minimum. They are usually a simplified dynamic bend stiffener with a metallic interface measuring between 0.5-2m in length. Static bend stiffener Static bend stiffeners Balmoral static stiffeners provide overbend protection during installation and overboarding procedures. They support and control the MBR on flexible pipe and cable at the end fitting and mid-line joints. A standardised Orcabend design and modular tooling means that static stiffeners can be offered on a very quick turnaround. Split bend stiffener Split bend stiffeners These Orcabend-designed products are generally produced for retrofitting to umbilicals, cables and flowlines already in service and are analysed in all orientations to ensure performance meets project requirements. Split stiffeners can be used on a number of end fittings and are usually strapped or bolted in place. Bend stiffener interface structure A smooth transition is required between the rigid flange and the flexible cone of the stiffener. Balmoral’s design achieves this by creating both rigidly bonded and un-bonded areas that provide deflection and minimum stress in these localised areas. Balmoral SolGuard® UV protection coating The vast majority of offshore elastomer products are used subsea where UV degradation is not an issue. However, a limited number of moulded products are deployed above the surface and by far the most critical in terms of performance and consequences of failure are bend stiffeners. To overcome this issue, Balmoral developed its unique SolGuard UV protection system which effectively creates an overcoat layer preventing UV penetration to the stiffener. Balmoral bend stiffeners are fully accredited by Bureau Veritas to API 17L standards. API17L

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