Projects

Case Studies

  • TRAC-Tec Tool

    Offshore inspection, cleaning and repair solutions transformed with innovative new approach

    Offshore inspection, cleaning and repair solutions transformed with innovative new approach

    In a collaboration between TRAC Oil & Gas and ToolTec, this project developed a cleaning and inspection tool (Trac-Tec Tool) that can be remotely deployed from the platform, to clean and inspect various sizes and configurations of caissons and conductors in the area immediately above and below sea level, or 'splash zone'.

    Typically, inspections are carried out by divers from a diving support vessels (DSVs) or remotely operated vehicles (ROVs) deployed from the platform or a vessel. This can be challenging due to the sea state and proximity to the jacket structure, not to mention the use of support vessels being expensive. This new technology delivers a solution that removes the need for divers, ROVs and DSVs. Phase one that focussed on the development of the tool, with the second phase proving the concept via field trial.

    Industry Value

    The technology has the potential to reduce inspection costs by 50%, while improving safety, quality and efficiency.

    Typical annual workscopes for an individual platforms splash zone inspection range from £300,000 to £3 million, based on various riser, structural and pipeline schedules, and using ROVs/divers. By using the TracTec Tool, the cost to carry out similar workscopes are in the region of £15,000 - £150,000, providing a 95% cost saving.

    Technology Organisation

    TRAC Oil & Gas

    TRAC Oil & Gas Ltd is a leading global provider of Rope Access Inspection, Repair & Maintenance services for the Oil & Gas and related industries.

    http://www.tracoilandgas.com

    ProjectTRAC-Tec Tool

    Challenge

    Asset Integrity

    Vision

    Fix Today

    Entry TRL

    4

    Field Trial

    Completed

    Technology

    Trac-Tec Tool

    Type

    Develop

    Achieved TRL

    8

    Technology Organisation

    TRAC Oil & Gas

    TRAC Oil & Gas Ltd is a leading global provider of Rope Access Inspection, Repair & Maintenance services for the Oil & Gas and related industries.

    http://www.tracoilandgas.com

    Key Results

    The tool was trialled on four caissons in the North Sea to test and prove functionality.

    The project has also been shortlisted in the Innovation category of the 2019 Press & Journal Energy Voice Gold Awards.

    Speaking of the shortlisting, Business Delivery Manager Jan Stander said: "Working with ToolTec on this specific project, supported by OGTC, has enabled us to pool our respective expertise and has led to a solution which has enormous safety and cost benefits for the oil and gas industry as a whole."

    Lessons Learned

    In addition to cost savings, the system also allows for higher quality inspection data to be obtained, improving the integrity of caissons and conductors. This enables more frequent inspection campaigns and the proactive development of appropriate and cost-effective remediation plans if required.

    • OGTC
    • TRAC Oil & Gas
  • EC-OG - Subsea Power Hub

    Ground-breaking marine turbine system successfully powers remote subsea drill sites

    Ground-breaking marine turbine system successfully powers remote subsea drill sites

    EC-OG's ground-breaking turbine system harnesses energy within ocean currents to produce autonomous electrical power for multiple applications - including subsea wells. The project with the OGTC provided support to complete FEED work for a North Sea field trial, focused on optimising the deployment and de-risking the installation and operational phases. By successfully integrating renewable energy technologies in to the production process, this delivers a low carbon source of power while reducing overall operating cost.

    Industry Value

    The SPH lowers the lifecycle cost of subsea fields, with the potential to deliver £200 million in savings for the UKCS - while at the same time reducing carbon footprint.

    Technology Organisation

    EC-OG (East Coast Oil and Gas Ltd)

    Leaders in Subsea Energy Conversion, Storage and Delivery. From its inception in 2013, EC-OG has built a reputation for excellent customer service through the delivery of professional engineering services. Being at the forefront of subsea technology, the team at EC-OG are currently working on the commercialisation of the innovative Subsea Power Hub.

    http://www.ec-og.com

    ProjectEC-OG - Subsea Power Hub

    Challenge

    Marginal Developments

    Vision

    Fix Today

    Entry TRL

    6

    Field Trial

    No

    Technology

    Subsea Power Hub

    Type

    -

    Achieved TRL

    N/A

    Technology Organisation

    EC-OG (East Coast Oil and Gas Ltd)

    Leaders in Subsea Energy Conversion, Storage and Delivery. From its inception in 2013, EC-OG has built a reputation for excellent customer service through the delivery of professional engineering services. Being at the forefront of subsea technology, the team at EC-OG are currently working on the commercialisation of the innovative Subsea Power Hub.

    http://www.ec-og.com

    Key Results

    During recent workshop trials supported by a North Sea operator, the SPH was used to power a commercial Subsea Control Module (SCM) and local power distribution system. By operating the SCM using lithium ion battery technology, located within EC-OG's proprietary Energy Storage and Intelligent Energy Management System, the test successfully confirmed the Subsea Power Hub's capabilities for operating North Sea wells without a power umbilical from a topside installation.

    Lessons Learned

    Critical to operability, the trial successfully demonstrated the full operating range of SCM functions through both SPH operating modes; battery power and battery charging. All testing was completed at Cohort company SEA's facility in Aberdeen, where in April 2018 a previous integration trial was conducted with SEA's pre-commercial SCM which they modified to work on DC power. The most recent test was conducted on the North Sea Operator's SCM, using an AC power supply from the Subsea Power Hub.

  • Deltatek Global - Articulock phase 2

    ArticuLock drillpipe technology increases operating envelope and reduces waiting on weather time

    ArticuLock drillpipe technology increases operating envelope and reduces waiting on weather time

    The OGTC funded a project with Deepwater Oil Tools to develop, test and certify ArticuLock - a special articulated joint within the drillpip running string. This is used when deploying subsea equipment through the drilling rig during well construction. The technology enables drilling operations in rough weather conditions, reducing waiting on weather time, which is a multi-million pound issue annually to the drilling industry.

    Industry Value

    Approximately 25% of subsea wells could benefit from this technology, increasing the operating weather window by up to 35% - resulting in multi-million pound savings.

    Technology Organisation

    Deltatek Global

    Deltatek Global was established in response to growing industry demand for efficiently implemented, intelligent, cost saving and risk reducing products to the Oil & Gas Drilling industry.

    http://www.deltatekglobal.com

    ProjectDeltatek Global - Articulock phase 2

    Challenge

    Wells

    Vision

    Fix Today

    Entry TRL

    6

    Field Trial

    Completed

    Technology

    Articulock

    Type

    Develop

    Achieved TRL

    8

    Technology Organisation

    Deltatek Global

    Deltatek Global was established in response to growing industry demand for efficiently implemented, intelligent, cost saving and risk reducing products to the Oil & Gas Drilling industry.

    http://www.deltatekglobal.com

    Key Results

    Deltatek's ArticuLock® technology provides open-water, riser, casing or landing string articulation, even in extreme storm conditions to:
    - Expand the weather window for deployment of sub-sea trees, flow-bases, EDP/LRPs, casing strings etc by >400%
    - Eliminate low cycle fatigue (remove stiffness) associated with hang-off or suspending loads during riserless or open-water operations
    - Provide a contingency to allow subsea deployment or intervention operations to continue even in high significant wave height, sea-swell or loop current conditions
    - Reduce waiting on weather time

    The project has field trialed the ArticuLock tool concept in an operational environment, proving the ability of the tool to interface with racking equipment and rig floor hardware, as well as executing long term degradation testing of the ArticuLock, by use of substantial hanging mass (65MT) to represent actual subsea hardware being installed beneath the tool, and allowing the ArticuLock to demonstrate its functional performance in the intended load condition

    Lessons Learned

    Following the long term degradation testing of the ArticuLock tool it has been learnt that over 70 days of constant use tool life exists before seal integrity begins to degrade

    • Deltatek Global
    • OGTC
  • 3-SCI Ltd - C-Beaver Phase 1- Technical, Economic, Legal, Operational and Scheduling ('TELOS') study

    Accelerated corrosion technology trial optimises steel removal post-decommissioning

    Accelerated corrosion technology trial optimises steel removal post-decommissioning

    3-SCI Ltd conducted a 'TELOS' (Technical, Economic, Legal, Operational and Scheduling) feasibility study.

    Completed over a 14-week period, it explored a new method of removing subsea metallic structures via an accelerated corrosion technique, which can cut or fully dissolve steel. This would have both cost and environmental benefits compared to traditional methods, where steel is either left subsea or returned to shore.

    This technology has the potential to increase the rate at which steel is currently eliminated, enabling a reduction in time and cost efficiency.

    Industry Value

    The removal, long-term surveillance and potential intervention associated with steel structures remaining subsea post-decommissioning is a significant cost to industry.

    Workshop data suggest that C-Beaver tools could dissolve steel at the rate of ~100 Kg per MW-hr (approximately 10 watts eliminating 1 gram of steel per hour).

    For example:
    Applying 10 kwatt to 100 feet of 38lb/foot steel tubular using the C-Beaver method could reduce it to its corrosion product within two months.

    A 6 MWatt capacity offshore wind turbine (assumed creating average power at approximately 25% of capacity, could help eliminate steel at the rate of approximately 1000 tons per year.

    Technology Organisation

    3-SCI Ltd

    3-Sci Ltd is run by a team of technical specialists who have experienced in research, product and business development in the engineering, physical and materials sciences. They offer various products in the industrial asset monitoring sector, including our Wi-Corr, wireless remote corrosion monitoring system.

    http://www.3-sci.com

    Project3-SCI Ltd - C-Beaver Phase 1- Technical, Economic, Legal, Operational and Scheduling ('TELOS') study

    Challenge

    Decommissioning

    Vision

    Transform Tomorrow

    Entry TRL

    4

    Field Trial

    No

    Technology

    Electrical tool to disolve steel by accelerated corrosion & cuts through small lengths of subsea pipeline study

    Type

    Adapt

    Achieved TRL

    4

    Technology Organisation

    3-SCI Ltd

    3-Sci Ltd is run by a team of technical specialists who have experienced in research, product and business development in the engineering, physical and materials sciences. They offer various products in the industrial asset monitoring sector, including our Wi-Corr, wireless remote corrosion monitoring system.

    http://www.3-sci.com

    Key Results

    Phase 1 was completed in 2018, which consisted of a feasibility study and labratory trials to prove the technology.

    Phase 2 was recently approved and, through field trials, will demonstrate that accerelated corrosion can eliminate, cut or drastically reduce the mass of subsea structures. 

    Lessons Learned

    1. Validation of the accelerated corrosion technique on a larger scales (e.g. using large water tanks) is required.

    2. Additional studies are required to confirm the precise approaches for provision of power.

    3. The approaches to effectively eliminate the various coatings and electrically-isolating barriers on steels needs to be defined.

    4. Design and early prototyping work should commence for the production of a large scale accelerated corrosion tool prototype for sea trials.

    5. Assuming a positive outcome of recommendation 1, and no early 'blockers' being identified through recommendations 2 and 3, an Environmental Impact Assessment (EIA) should be conducted. This should focus on the possibility of discharging the accelerated corrosion products directly into sea. The outcome of this EIA may influence the nature of prototyping work and the scope of application of accelerated corrosion.

    • OGTC
    • 3-SCI Ltd
  • Ardent - Jacket buoyancy recovery

    Ardent delivers innnovative buoyancy concept as an alternative to heavy lift vessels

    Ardent delivers innnovative buoyancy concept as an alternative to heavy lift vessels

    Ardent has designed a new external buoyancy system to recover offshore jackets, as an alternative to more costly heavy lift vessels (HVL) - potentially reducing cost by 35%. Optimising the low draught featured within the design, the Ardent system allows delivery and offload at any suitable quayside facility without recourse to dredging and intermediate barge transfer.

    This follows the ground-breaking parbuckling and refloating of the shipwreaked Costa Concordia cruise liner undertaken off the coast of Italy, by Ardent. The lessons learnt from that operation were fundamental in this design work.

    Industry Value

    This step-change in approach provides flexibility, is safe and easy to deploy and ultimately saves up to 35% in cost vs HLV methods - worth up to £460 million to the UKCS. This new technology also has the potential to create new jobs for the industry, opening up UK yards for large/heavy jackets.

    Technology Organisation

    Ardent Maritime UK Ltd

    Ardent was created to offer a more comprehensive solution to the maritime industry. We will achieve this by diversifying our services from traditional salvage to a full range of emergency management services, project related work, offshore decommissioning and underwater services.

    http://www.ardentglobal.com

    ProjectArdent - Jacket buoyancy recovery

    Challenge

    Decommissioning

    Vision

    Transform Tomorrow

    Entry TRL

    2

    Field Trial

    No

    Technology

    Jacket retrieval

    Type

    Develop

    Achieved TRL

    5

    Technology Organisation

    Ardent Maritime UK Ltd

    Ardent was created to offer a more comprehensive solution to the maritime industry. We will achieve this by diversifying our services from traditional salvage to a full range of emergency management services, project related work, offshore decommissioning and underwater services.

    http://www.ardentglobal.com

    Key Results

    This provided a viable alternative method of jacket removal, without lifting, using an external buoyance caisson (EBC) for float and tow. This technique can be used for jackets between 5,000-10,000 tonnes in water drafts 8m or less.

    Lessons Learned

    The front end engineering process required a diverse group of engineers, which resulted in a more complex start-up. However through strong collaboration and team work, this was resolved - acknolwedged through a nomination at Decom North Sea's 2019 industry Collaboration Award.

    • Ardent Maritime UK Ltd
    • OGTC
  • Infinity  - Actuator Safety Gauntlet

    Safer, low cost replacement for valve actuators realises 90% savings, adding >£300million to the UKCS

    Safer, low cost replacement for valve actuators realises 90% savings, adding >£300million to the UKCS

    Infinity has developed a product that could diffuse "ticking time bombs" on platforms, saving UK operators more than £320million.

    Actutors are automated devices used to open and close valves - they contain huge amounts of potential energy. If they break, the powerful springs inside them can eject components at high velocity which undoubtably can cause fatal injuries and damage equipement.

    The Failforce Actuator Safety Gauntlet is akin to a bullet proof bag, that can be fitter over actuators which have fallen into poor condition offshore, thus making them safe.

    The actuator gauntlet is made of layers of Kelvar, inside a water-tight, UV-resistant bag. It is intended for single use, but the material could be recycled (depending on the level of damage cause by an actuator blowout).

    Industry Value

    There are approximately 600 actuators on board each offshore installation, with 261 operational assets in the UKCS - this is potentially more than 156,500 actuators in the UKCS alone.
    The estimated total cost to replace all actuators would be in excess of £1.4 billion. Even if only 25% of all actuators needed to be replaced, that would cost £368 million. The cost of installing the Failforce Actuator Safety Gauntlet to those 25% would cost £39 million - a saving of approximately £329 million across the UKCS.
    90% cheaper than replacement, with a potential to add >£300million to the UKCS.

    Technology Organisation

    Infinity

    Infinity is a group of independent company's operating within the Engineering, Offshore and Logistics sectors. Over the years we have built a reputation for delivering high quality, cost effective solutions to our clients.

    https://www.infinityoilgas.com

    ProjectInfinity - Actuator Safety Gauntlet

    Challenge

    Asset Integrity

    Vision

    Fix Today

    Entry TRL

    2

    Field Trial

    No

    Technology

    Fail Force

    Type

    Develop

    Achieved TRL

    8

    Technology Organisation

    Infinity

    Infinity is a group of independent company's operating within the Engineering, Offshore and Logistics sectors. Over the years we have built a reputation for delivering high quality, cost effective solutions to our clients.

    https://www.infinityoilgas.com

    Key Results

    The Actuator Safety Gauntlet (ASG) is a non‐metallic solution which would mitigate the risk of the actuator return spring being released. The Fail-Force Actuator Safety Gauntlet aims to eliminate the risk to personnel and infrastructure of such a failure, while providing a safe decommissioning device.

    Lessons Learned

    Feedback from OGTC operator members was valuable to produce a product that would be accepted in the industry.

  • Global Design Innovation - Non-Intrusive Tank Inspection - defect assessment software study

    Digital twin technology revolutionises asset inspection, saving >£2 million per platform per year

    Digital twin technology revolutionises asset inspection, saving >£2 million per platform per year

    At present, the industry cannot visualise data across the full asset integrity lifecycle, current digital worker technology relies on traditional methods. Relating digital data to a physical plant location is a manual and subjective activity, which leads to lost time, high costs, potential errors and inconsistencies.

    Global Design Innovation (GDi) has developed the latest later scanning and photogrammetry technology, which has the potential to transform the entire asset integrity management process.

    The development of a revolutionary handheld later scanner which will rapidly obtain accurate inspection data, automatically detect and categorise defects, and generate virtual inspection reports will enable engineers to manipulate and manage information.

    Industry Value

    This technology improves safety, integrity and asset value, saving more than £2 million per platform, per year - £500 million annually on the UKCS.

    Technology Organisation

    Global Design Innovation Limited

    GDi provides fit for purpose repair orders, engineering support and design solutions across the energy sector. GDI deliver tailored engineering solutions and provide clients a cost effective means of safely and efficiently maintaining assets by utilising latest technology to streamline workflows and increase uptime.

    https://www.globaldi.co.uk/

    ProjectGlobal Design Innovation - Non-Intrusive Tank Inspection - defect assessment software study

    Challenge

    Asset Integrity

    Vision

    Fix Today

    Entry TRL

    2

    Field Trial

    No

    Technology

    Non-Intrusive Tank Inspection - defect assessment software study

    Type

    Adapt

    Achieved TRL

    3

    Technology Organisation

    Global Design Innovation Limited

    GDi provides fit for purpose repair orders, engineering support and design solutions across the energy sector. GDI deliver tailored engineering solutions and provide clients a cost effective means of safely and efficiently maintaining assets by utilising latest technology to streamline workflows and increase uptime.

    https://www.globaldi.co.uk/

    Key Results

    GDI's digital twin solution eliminates the need for traditional reporting, improving the efficiency of inspection, repair and maintenance work. It allows the operator to visualise the overall health of an asset in order to make critical decisions more effectively and efficiently.

    Lessons Learned

    The trial was used to develop the proof of concept, which was fully proven.

    • OGTC
    • Global Design Innovation Limited
  • Cortez Subsea - Mechanical Connector - Study

    Mechanically connected subsea pipelay system improves integrity and saves 25-45% compared to traditional methods

    Mechanically connected subsea pipelay system improves integrity and saves 25-45% compared to traditional methods

    Welded subsea pipeline systems are used in most developments. Industry needs more time and cost-effective alternatives to improve economics and unlock reserves.

    The Cortez Subsea patented Modular Pipelay System (MPS™) enables Zap-Lok™ and other mechanically connected pipe to be laid from a standard DP2 vessel. This flexible pipelay is adjustable in both width and length, and has no heat affected zones, avoiding the need for welding. The GMC Intelligently Connected Pipe (ICP™) is designed for deep water and ultra deep water (including pre/post-salt projects).

    The ICP™ offers faster make-up due to pre-manufactured components being transported to the field as completed pipe joints. Integrity is also increased using high-strength, fatigue and corrosion-resistant connections.

    Industry Value

    With faster make-up and improved integrity, this technology has the potential to reduce overall costs by between 25-45%.

    Technology Organisation

    Cortez Subsea Limited

    Focused on Advancing Technology and Maximising Value, Cortez Subsea is an enabler of subsea pipeline and inspection solutions for the oil & gas industry.

    https://www.cortezsubsea.com/

    ProjectCortez Subsea - Mechanical Connector - Study

    Challenge

    Marginal Developments

    Vision

    Fix Today

    Entry TRL

    1

    Field Trial

    No

    Technology

    Mechanical Connector Study

    Type

    -

    Achieved TRL

    N/A

    Technology Organisation

    Cortez Subsea Limited

    Focused on Advancing Technology and Maximising Value, Cortez Subsea is an enabler of subsea pipeline and inspection solutions for the oil & gas industry.

    https://www.cortezsubsea.com/

    Key Results

    The Cortez Subsea Modular Pipelay system is cheaper than traditional methods and can be used in both deep water and ultra deep water and can be laid from a standard DP2 vessel.

    Lessons Learned

    With no spool base, there is the potential for reuse and further industry efficiency savings.

    • Cortez Subsea Limited
    • OGTC
  • Interwell - Thermite Plug

    Award winning collaboration accelerates development of thermite wellbore barrier for P&A, avoiding the use of traditional cement techniques

    Award winning collaboration accelerates development of thermite wellbore barrier for P&A, avoiding the use of traditional cement techniques

    The OGTC is supporting Interwell's development of a new wellbore barrier for the plug and abandonment of a well. The thermite plug is designed to create a high temperature chemical reaction in the wellbore. It creates a molten metal plug that melts the adjacent casing strings and, on solidification, fuses to the rock. This creates a metallic barrier in the wellbore and is an alternative to conventional cement.

    Industry Value

    This has the potential to substantially reduce the cost of plug and abandonment, saving approximately 10-14 days per well. This equates to £200,000 - £400,000 per well, per day, or £3.6 million per well overall.

    By applying this approach to just 10% of the projected 1,400 wells to be abandoned over the next 10 years, could save the UKCS around £0.5 billion.

    Technology Organisation

    Interwell

    Interwell, established in Norway in 1992, has become an international service company providing technologies from wellbore construction right through plug & abandonment.

    http://www.interwell.com/

    ProjectInterwell - Thermite Plug

    Challenge

    Wells

    Vision

    Maximise Recovery

    Entry TRL

    7

    Field Trial

    Completed

    Technology

    Thermite Plug

    Type

    Develop

    Achieved TRL

    8

    Technology Organisation

    Interwell

    Interwell, established in Norway in 1992, has become an international service company providing technologies from wellbore construction right through plug & abandonment.

    http://www.interwell.com/

    Key Results

    During recent field trials, the thermite plug was deployed and successfully set across a salt formation in a UK land well with no harm to people, the environment or equipment. Further trials will enable the technology to develop and mature.

    Lessons Learned

    Offshore deployments continue and barrier verification methods are being developed.

    A key driver in developing this technology was establishing a Thermite Collaboration Forum. This cross-industry partnership was established by The OGTC and Spirit Energy, making it possible to accelerate development and qualification of the technology. The OGTC and Spirit Energy were recognised for their "Excellence in Collaboration" at the Decom North Sea 2019 Awards, which recognised the outstanding teamwork in delivering a transformational approach for developing decommissioning technology.

    https://www.theogtc.com/newsroom/news/2019/ogtc-and-spirit-energy-celebrate-excellence-in-collaboration-at-decom-north-sea-awards/

  • AquaTerra Group Ltd - Conductor/Caisson/Riser Stabilising System

    Aquaterra develop efficient stabilising system, achieving 80% savings over traditional methods

    Aquaterra develop efficient stabilising system, achieving 80% savings over traditional methods

    Lateral wave movements cause impact on caissons, risers and conductors, and their supporting steelwork. This causes fatigue and fretting damage, which is both costly and dangerous.

    Existing shim-type solutions can be costly and, in some cases, unreliable, require replacement after a short period of time. The OGTC supported Aquaterra to develop new technology aimed at stabilising offshore caissons, risers and conductors, to reduce movement, increase guide stability and moderate vibrations - in the long-term extending their operational life.

    The initial phase of the project developed and tested a urethane-based two component polyurethane system (including installation tests on a conductor restraint mock-up) that doesn't require specialist equipment to install and cure at low temperatures.

    Industry Value

    A typical shim programme costs approximately £50,000 per conductor. Using this system would result in 80% cost savings, due to the materials used, ease of installation and efficient preparation and deployment.

    Technology Organisation

    AquaTerra Group Ltd

    AquaTerra is a leading industry specialist for difficult access operations and potentially hazardous environments.

    http://www.aquaterra.co.uk

    ProjectAquaTerra Group Ltd - Conductor/Caisson/Riser Stabilising System

    Challenge

    Asset Integrity

    Vision

    Fix Today

    Entry TRL

    3

    Field Trial

    No

    Technology

    Conductor/Caisson/Riser Stabilising System

    Type

    Develop

    Achieved TRL

    7

    Technology Organisation

    AquaTerra Group Ltd

    AquaTerra is a leading industry specialist for difficult access operations and potentially hazardous environments.

    http://www.aquaterra.co.uk

    Key Results

    The project was successful in identifying a suitable urethane material that is predicted to withstand the environmental loads, easy to install using mechanical aids (a mould) and does not require specialist storage, handling, or application equipment. A significant added advantage of using the material and installation methodology is that a pre-job site survey is not normally required.

    Lessons Learned

    The second phase of the project will undertake field trials with two operators.

    • AquaTerra Group Ltd
    • OGTC
  • Sonomatic - Non-Intrusive Vessel Inspection

    Sonomatic study - alternative non-intrusive inspection method could save up to £242 million per year

    Sonomatic study - alternative non-intrusive inspection method could save up to £242 million per year

    Process vessel inspection is a major cause of production downtime and incurs significant cost to industry. The OGTC collaborated with Total to support the field trial of three non-intrusive inspection (NII) technologies as an alternative inspection method.

    Total identified two process pressure vessels on its Elgin Franklin platform that were scheduled for traditional intrusive inspection. However in advance of this, they agreed to a NII field trial being carried out while the vessels were online and operational, allowing the results of both approaches to be compared and verified.

    Three technology providers - Sonomatic, Eddyfi and MISTRAS - were selected to conduct the field trials, and deployed a range of ultrasonic corrosion mapping and time of flight diffraction solutions.

    Each company was given the brief to develop a Non-Intrusive Inspection plan using industry standard DNV Recommended Practice G103. The aim of this was to meet the requirements of a full intrusive inspection w

    Industry Value

    Overall, the value of non-intrusive inspections (NII) to the industry has been calculated to be in the region of £242 million per annum. This project helps leverage this cost saving by providing an attractive technology which further enables the adoption of NII.

    Technology Organisation

    Sonomatic Ltd

    Sonomatic is a worldwide organisation whose expertise in ultrasonic inspection design, development and application, dates back more than 30 years to our roots in the nuclear sector. Today the company has widened its focus and provides proven yet pioneering services to customers in defence and power generation, but our largest client base is in the challenging oil and gas industry, both upstream and downstream.

    http://www.sonomatic.com

    ProjectSonomatic - Non-Intrusive Vessel Inspection

    Challenge

    Asset Integrity

    Vision

    Maximise Recovery

    Entry TRL

    9

    Field Trial

    Completed

    Technology

    Non-Intrusive Vessel Inspection

    Type

    Adopt

    Achieved TRL

    9

    Technology Organisation

    Sonomatic Ltd

    Sonomatic is a worldwide organisation whose expertise in ultrasonic inspection design, development and application, dates back more than 30 years to our roots in the nuclear sector. Today the company has widened its focus and provides proven yet pioneering services to customers in defence and power generation, but our largest client base is in the challenging oil and gas industry, both upstream and downstream.

    http://www.sonomatic.com

    Key Results

    Sonomatic used a combination of their:
    - TOFD (time-of-flight diffraction) screening and corrosion mapping of shell
    - Newly developed End Dome Robotic Inspection System (EDRIS): a robotic technology used to ultrasonically inspect pressure vessel bottom dome ends, and does not require man entry to the confined space at the vessels support skirt
    - TOFD weld scanning
    - Nozzle corrosion mapping

    Their assessment concluded both vessels were fit for continued service and NII was deemed a suitable replacement for intrusive inspection. Time constraints limited inspection of some nozzles which prevented overall frequency assessment.

    This alternative inspection technique was proven to reduce risk associated with confined entry, while optimising production efficiency - reducing the need for shut downs.

    Lessons Learned

    The OGTC and Total were commended by industry for their collaboration and won the Maximising Economic Recovery (MER) UK 2017 Award for their work on the trials.

    Next steps: in line with the UKCS MER strategy, The OGTC and ABB then carried out a landscaping study to establish the use of NII technology across the UKCS and the potential wider application.

    • OGTC
    • Sonomatic Ltd
  • Mistras Group Ltd - Non-Intrusive Vessel Inspection

    MISTRAS study - alternative non-intrusive inspection method could save up to £242 million per year

    MISTRAS study - alternative non-intrusive inspection method could save up to £242 million per year

    Process vessel inspection is a major cause of production downtime and incurs significant cost to industry. The OGTC collaborated with Total to support the field trial of three non-intrusive inspection (NII) technologies as an alternative inspection method.

    Total identified two process pressure vessels on its Elgin Franklin platform that were scheduled for traditional intrusive inspection. However in advance of this, they agreed to a NII field trial being carried out while the vessels were online and operational, allowing the results of both approaches to be compared and verified.

    Three technology providers - MISTRAS, Eddyfi and Sonomatic - were selected to conduct the field trials, and deployed a range of ultrasonic corrosion mapping and time of flight diffraction solutions.

    Each company was given the brief to develop a Non-Intrusive Inspection plan using industry standard DNV Recommended Practice G103. The aim of this was to meet the requirements of a full intrusive inspection wi

    Industry Value

    Overall, the value of non-intrusive inspections (NII) to the industry has been calculated to be in the region of £242 million per annum. This project helps leverage this cost saving by providing an attractive technology which further enables the adoption of NII.

    Technology Organisation

    Mistras Group Ltd

    Mistras Group is one of the world's largest suppliers of Integrity and Inspection services. The company specialises in providing innovative asset integrity solutions for all projects using enhanced services that include asset monitoring, engineering services, advanced and conventional NDT.

    http://www.mistrasgroup.co.uk/

    ProjectMistras Group Ltd - Non-Intrusive Vessel Inspection

    Challenge

    Asset Integrity

    Vision

    Maximise Recovery

    Entry TRL

    8

    Field Trial

    Completed

    Technology

    Non-Intrusive Vessel Inspection

    Type

    Adopt

    Achieved TRL

    8

    Technology Organisation

    Mistras Group Ltd

    Mistras Group is one of the world's largest suppliers of Integrity and Inspection services. The company specialises in providing innovative asset integrity solutions for all projects using enhanced services that include asset monitoring, engineering services, advanced and conventional NDT.

    http://www.mistrasgroup.co.uk/

    Key Results

    Mistras used a combination of their:
    - Automated LSI robotic scanner system
    - Phased array scanning
    - Manual scanning of nozzles

    Their assessment was both vessels were fit for continued service with next recommended inspection date of October 2027 (10 year interval).

    This alternative inspection technique was proven to reduce risk associated with confined entry, while optimising production efficiency - reducing the need for shut downs.

    Lessons Learned

    The OGTC and Total were commended by industry for their collaboration and won the Maximising Economic Recovery (MER) UK 2017 Award for their work on the trials.

    Next steps: in line with the UKCS MER strategy, The OGTC and ABB then carried out a landscaping study to establish the use of NII technology across the UKCS and the potential wider application.

    • OGTC
    • Mistras Group Ltd
  • Eddyfi - Non-Intrusive Vessel Inspection

    Eddyfi study - alternative non-intrusive inspection method could save up to £242 million per year

    Eddyfi study - alternative non-intrusive inspection method could save up to £242 million per year

    Process vessel inspection is a major cause of production downtime and incurs significant cost to industry. The OGTC collaborated with Total to support the field trial of three non-intrusive inspection (NII) technologies as an alternative inspection method. Total identified two process pressure vessels on its Elgin Franklin platform that were scheduled for traditional intrusive inspection. However in advance of this, they agreed to a NII field trial being carried out while the vessels were online and operational, allowing the results of both approaches to be compared and verified. Three technology providers were selected to conduct the field trials, and deployed a range of ultrasonic corrosion mapping and time of flight diffraction solutions. Each company was given the brief to develop a Non-Intrusive Inspection plan using industry standard DNV Recommended Practice G103. The aim of this was to meet the requirements of a full intrusive inspection without vessel entry.

    Industry Value

    Overall, the value of non-intrusive inspections (NII) to the industry has been calculated to be in the region of £242 million per annum. This project helps leverage this cost saving by providing an attractive technology which further enables the adoption of NII.

    Technology Organisation

    Eddyfi

    Eddyfi was established with the goal of pursuing and developing eddy current array (ECA) technology to its full potential.

    https://www.eddyfi.com/

    ProjectEddyfi - Non-Intrusive Vessel Inspection

    Challenge

    Asset Integrity

    Vision

    Maximise Recovery

    Entry TRL

    6

    Field Trial

    Completed

    Technology

    Non-Intrusive Vessel Inspection

    Type

    Adopt

    Achieved TRL

    8

    Technology Organisation

    Eddyfi

    Eddyfi was established with the goal of pursuing and developing eddy current array (ECA) technology to its full potential.

    https://www.eddyfi.com/

    Key Results

    Eddyfi in conjunction with their sub-contractor (CAN) used their:
    - Phased array corrosion mapping
    - TOFD (time-of-flight diffraction) weld scanning
    - Manual ultrasonic inspection
    - PEC inspection through PFP on vessel skirt base

    Their assessment concluded there was some degradation noted on both vessels and defect detection was at least as good as an intrusive inspection.

    This alternative inspection technique was proven to reduce risk associated with confined entry, while optimising production efficiency - reducing the need for shut downs.

    Lessons Learned

    The OGTC and Total were commended by industry for their collaboration and won the Maximising Economic Recovery (MER) UK 2017 Award for their work on the trials.

    Next steps: in line with the UKCS MER strategy, The OGTC and ABB then carried out a landscaping study to establish the use of NII technology across the UKCS and the potential wider application.

    • OGTC
    • Eddyfi
  • Tendeka - PulseEight - Onshore PulseEight trial

    Wireless communication technology between surface and downhole can save up to £4m per year

    Wireless communication technology between surface and downhole can save up to £4m per year

    The OGTC supported Tendeka to undertake a field trial of their PulseEight technology, onshore in a gas storage well.

    PulseEight is a wireless, intelligent completion technology, capable of bi-directional communication between the surface and downhole. It uses a unique pressure pulse telemetry suitable for multi-phase fluid environments, to allow wireless communication between the wellhead and downhole. Because this eliminates control lines, it is easy to install and therefore a cost-effective solution.

    Industry Value

    Using this technology allows operators to extend the life of existing assets, as well as developing new fields more effectively, reducing the need for intrusive well intervention work.

    It reduces the need for at least one wireline intervention per year on a well. For every 25 wells the system is deployed on, the industry would save around £4 million per annum.

    Technology Organisation

    Tendeka

    Advanced Completions and Production Optimisation for our Clients' Reservoirs From simple to complex well designs, Tendeka's extensive track record to overcome production challenges in the most demanding operating environments ensures measurable results for our clients.

    http://www.tendeka.com

    ProjectTendeka - PulseEight - Onshore PulseEight trial

    Challenge

    Wells

    Vision

    Maximise Recovery

    Entry TRL

    5

    Field Trial

    Completed

    Technology

    PulseEight - wireless telemetry

    Type

    Adapt

    Achieved TRL

    6

    Technology Organisation

    Tendeka

    Advanced Completions and Production Optimisation for our Clients' Reservoirs From simple to complex well designs, Tendeka's extensive track record to overcome production challenges in the most demanding operating environments ensures measurable results for our clients.

    http://www.tendeka.com

    Key Results

    Various options were undertaken to test the downhole device and prove the surface decoding system. The two week trial was a success, proving the capability to communicate downhole data to surface, and the functionality of controlling remotely.

    Lessons Learned

    The PulseEight was capable of robust, bi-directional communication between the surface and downhole. Additional offshore field trials will therefore be conducted to further develop and prove the technology.

    Malcolm Banks, Wells Solution Centre Manager at the OGTC said: "It's great to see it being deployed in a live North Sea well. If it proves successful, it could pave the way for wider adoption of technology that has the potential to change the way we manage wells. This will improve productivity and save the industry millions of pounds."

    • OGTC
    • Tendeka
  • Chevron - Permasense Erosion Sensors

    Innovative wall thickness monitoring system can save industry >85% over traditional methods

    Innovative wall thickness monitoring system can save industry >85% over traditional methods

    A field trial of the Permasense (now Emerson Rosemount) wireless wall thickness measurement system was undertaken on the Chevron Alba Northern Platform. The technology consists of a non-intrusive, wireless sensor which provides continuous measurement of pipework wall thickness, with metal loss detection, for managing asset integrity. Each sensor can route the data it collects back to the gateway and has a battery life of up to nine years, which minimises maintenance requirements.

    The trial focussed on the water injection system and consisted of eight ET210 sensors installed on a number of key bends (at the 6 o'clock position) and at straight sections of pipework, recording over a period of six months.

    Industry Value

    The Permasense wireless wall thickness monitoring system has the potential to save the industry >85% over traditional wall thickness measuring methods. The overall cost saving per annum for one single monitoring location would be in the region of £3,500, with an annual cost saving to the UKCS of £1 million.

    Sensors can be fitted on insulated and uninsulated equipment. When insulated, the sensors are fitted underneath insulation, which has the potential to significantly reduce costs: insulation does not require to be stripped and reapplied every time an inspection is required; plus the sensors are low power with up to nine years battery life, minimising maintenance throughout operations.

    Technology Organisation

    Chevron

    Chevron works to meet the world's growing demand for energy by exploring for oil and natural gas; refining and marketing gasoline; producing chemicals and more.

    https://www.chevron.com/

    ProjectChevron - Permasense Erosion Sensors

    Challenge

    Asset Integrity

    Vision

    Transform Tomorrow

    Entry TRL

    8

    Field Trial

    Completed

    Technology

    Permasense Erosion Sensors

    Type

    Develop

    Achieved TRL

    9

    Technology Organisation

    Chevron

    Chevron works to meet the world's growing demand for energy by exploring for oil and natural gas; refining and marketing gasoline; producing chemicals and more.

    https://www.chevron.com/

    Key Results

    The sensors recorded good quality ultrasonic waveforms, giving stable and reliable thickness trends for the duration of the six month trial.

    Information provided from the real-time monitoring system could be advantageous for chemical treatment programmes to establish sweet spots, problematic areas, reducing overall chemical dosage rates. This not only saves money, it also has the potential to reduce environmental impact.

    Lessons Learned

    The trial was successful and the lessons learnt, along with the capabilities of the technology, could be used to optimise the chemical dosing and non-intrusive inspection programmes for aging plants.

    • Chevron
    • OGTC
  • OilField Innovation - Tubing Compaction

    Rigless compaction technology for well plug and abandonment could save £4m per well

    Rigless compaction technology for well plug and abandonment could save £4m per well

    The OGTC supported Oilfield Innovations' onshore trial for enabling new rigless well plug and abandonment technology.

    Traditionally, abandonment of oil and gas wells is an expensive process using a rig to pull the tubing (reversing the installation process), which then provides unobstructed casing space for cementation opportunities.

    New technology developed by Oilfield Innovation removes a window of approximately 100ft of completion tubing (from above the production packer) to allow access to the production casing for logging and barrier placement, without the need to bring in a rig to recover the entire completion string. Using a piston/hydraulic force to compact the tubing, the piston can also clean casing surfaces during compaction to provide an unobstructed casing space suitable for cement bond logging and placement of a cement plug.

    Industry Value

    Rigless abandonment offers savings of up to £4 million per well - based on 10% of the 1,400 UKCS wells. This could save the UKCS £50 million per year.

    Technology Organisation

    Oilfield Innovations Limited

    Oilfield Innovations Limited is a leader in developing new technology for the Oil and Gas Industry.

    https://www.oilfieldinnovations.com

    ProjectOilField Innovation - Tubing Compaction

    Challenge

    Wells

    Vision

    Fix Today

    Entry TRL

    3

    Field Trial

    No

    Technology

    Tubing Compaction

    Type

    Adapt

    Achieved TRL

    4

    Technology Organisation

    Oilfield Innovations Limited

    Oilfield Innovations Limited is a leader in developing new technology for the Oil and Gas Industry.

    https://www.oilfieldinnovations.com

    Key Results

    Twelve simulation trials were successfully carried out. Half of the trials demonstrated exceeded 47% compaction of 4½" 13Cr L80 12.6-ppf tubing and 5½ inch 13CrL80 17.0-ppf tubing inside of 9⅝ inch 53.5-ppf casing.

    The capability could become an enabler for rigless well plugging and abandonment.

    Not only does the technique reduce risk with minimum personnel and equipment mobilisation, it also reduces pollution by leaving existing barriers and pollutants in place in the well.

    Footage of the trial is available to watch.

    Lessons Learned

    The trials also provided data for a subsequent project by the Oil & Gas Innovation Centre (OGIC) and The University of Glasgow, to mathematically predict tubing compaction results using existing well information.