1. Bastion Technologies, Inc.
Oil & Gas and Petrochemical Division
Engineering Capabilities
17625 El Camino Real, Suite 330
Houston, Texas 77058
(281) 283-9330
www.BastionOGP.com
2. About Us
Bastion Technologies, Inc. Oil &Gas and Petrochemical Division, (Bastion OGP) is a
mechanical and structural engineering firm. We provide engineering analysis,
design and drafting, risk and failure modes assessment, and training development
for the offshore oil and gas industry.
Bastion Technologies, a HUB, was founded in 1998 and employs over 400
employees approximately 250 of which are engineers. Bastion is ISO 9001:2008
certified.
Our corporate office is located in Houston and we have branch offices at six other
locations across the US including, White Sands NM, Huntsville AL, Washington DC,
Johnson and Kennedy Space Centers and Glen Research Center.
Our Oil & Gas and Petrochemical engineering team works from the corporate
office in Houston, TX.
Bastion has a three year average revenue of approximately $55MM.
2
4. Engineering Capability
Structural and Mechanical Design
• Generate Conceptual Design
• Fabrication Design
• Create Detailed Drawings
• Form, Fit, and Function Analysis
Structural Analysis
• Stress Analysis/FEA Modeling
• Vibration and Fracture Analysis
• Dynamic/Non-Linear Analysis
Specialty Services
• FMECA – Risk Assessment
• Coupled Loads Analysis
• Procedural Development
• Training Development
4
5. Engineering Capability
Structural and Mechanical Design
• Definition of technical performance requirements
• Development of design concepts and preliminary analysis
• Support customer system, component design, and Interface Control Document development
• Certification and QA/QC of mechanical systems and subsystems
• Provide design and checking support to meet engineering goals for system applications
• Provide Preliminary, Detailed, and Critical Design Review Support
5
6. Engineering Capability
Structural/Mechanical Analysis
• Perform classical stress analysis and finite element analysis for structural and
mechanical systems
• Recommendations for design modifications and optimization
• Review of safety documents and identification of critical design issues
• Preparation of computational models for fracture analysis
• Perform structural beam instability, column buckling, beam-column, shear web
buckling, and shell stability analysis
• Perform engineering analysis tasks in the areas of dynamics, controls, and simulations
of dynamic systems
• Develop integrated loads and dynamic analysis for super structures
6
8. Floating Production Semi-Submersible
TRUSS JOINT MODELING AND ANALYSIS
Bastion Technologies, Inc. was contracted to model and analyze three new truss joint configurations for a new semi-submersible deepwater
drill rig. The goal of such an analysis is to use less tubular connections to support the entire deck load thus decreasing weight and facilitating
inspection.
Bastion structural engineers built three different bar to beam element models and ran over 700 load cases per joint in order to determine
the optimal design. All models were built using FEMAP and calculated with NASTRAN solver. All supporting structural analysis was performed
per ABS code requirements. All three designs along with the associated recommendations were delivered to the client for consideration.
Entire Truss Structure Truss Joint FEA Model
8
9. STRENGTH & BUCKLING ASSESSMENT
of FLYING LEAD PALLET DESIGN
Bastion Technologies, Inc. performed a structural analysis on a flying lead pallet used to hold sub sea umbilicals for transportation, storage and installation. The
pallets hold about 1,300 ft. of 3.5” diameter umbilical which is used for control related functions on sub sea installations. The fully wound weight of the structure
is approximately 20,000 lbs. Bastion performed shell and structural strength assessments using NX/NASTRAN software and hand calculations for buckling due to
lifting, transportation and storage of the umbilical. All required analysis adhere to DNV codes and standards.
Umbilical installation vessel
Solidworks 3D Model of empty pallet
NX Nastran / FEMAP Model
with applied 12,000 lb.ft.
winding load case
9
BT #3062
10. BURNER BOOM
FOUNDATION MODIFICATIONS and ANALYSIS
Our client needed a new foundation design for the relocation of the aft burner booms for a deepwater drillship. Bastion was contracted to
analyze both burner boom foundations located on the aft end of the ship. Redesign and analysis was necessary as a result of changes in loading
conditions and new requirements imposed since the completion of the original design. The new loading conditions require that the boom is
capable of moving up and down between 0 degrees (horizontal) and 45 degrees in elevation. The boom will also be required to swing inboard
and outboard while at any angle between these two inclinations. Further, the client required that all reinforcements to existing structure must
be added above the deck to eliminate interference with existing structures below deck; specifically in the vicinity of the dynamic positioning
control room. Any additional reinforcement was limited to approximately 350mm in height. The burner boom is designed in accordance with
American Bureau of Shipping (ABS) rules and guidelines (ABS Rules for Building and Classing Mobile Offshore Drilling (Ref 4.2), and the
guidelines of the American Institute of Steel Construction (AISC), Manual of Steel Construction, Allowable Stress Design (Ref 4.1).
Sideshell (simple supports) Girder simply supported
Helideck Struts (simple supports)
FEA model showing constraints for forward
strut anchor beam substructure
Frame 55 Bulkhead
(assumed simple supports)
Frame 56
Centerline Frame (simple supports + x axis rotational to approximate symmetry)
Von Mises Stress on Deck Plate
Forward strut anchor beam
Typical Burner Boom during gas flaring von Mises Stress 16.2 KSI
10
11. Structural Evaluation of Drilling Rig Mast
With 750,000lb Hook Load Rating
Bastion was requested to conduct a structural analysis and evaluation of the mast of a
drilling rig with a rated hook load of 750,000 pounds. The rig is a 1500 horsepower
“slingshot” type land rig with an unguyed mast. The mast is an open truss type structure
with a height of 148ft. The STAAD Pro structural engineering finite element program
was used for the structural analysis. .
The table below shows the mast front and side elevations taken from an assembly
drawing. This is the final static load case table. It was created by varying the B750 hook
static load, the stand percent and the wind speeds. This gave eight major static load
cases. The analysis validated the rated hook load as a function of wind speed chart for
the structure.
B750 Mast Static Load Cases
B750 Mast front and side elevations
11
12. Strength and Buckling Analysis of
Offshore Crane Pedestals
Bastion Technologies, Inc. was contracted to analyze the structural integrity of a relocated crane pedestal and its immediate supporting structures
on the starboard side of Jack Up Vessel “Thule Energy Hull 051”. The crane is a Type C pedestal mounted rotating crane per the American Bureau
of Shipping (ABS). A FEMAP model was created for both the crane pedestal cylindrical thick-wall column and three supporting deck panels with
plate elements. The stress results were solved using MSC/NASTRAN solver. Additionally, a hand calculation and verification was provided to prove
the subject structure has adequate buckling resistance strength according to ABS, AISC, and API codes. A report was written to show the designs
specified in the reference drawings are structurally sound with respect to strength and buckling resistance when both the dead weight load and
maximum operational loads are simultaneously applied at the top of the crane pedestal. The complete stress report addresses the strength and
buckling assessments for this pedestal and its immediate supporting structure. The report was used to verify standards compliance of the crane
pedestal design. The final report was submitted to ABS.
Pedestal and supporting structure
FEA of Major Principle stresses located
FEA Math Model
Typical offshore Jack-Up Vessel around the pedestal manway
12
13. Analysis and Re-rating of ASME B16.5
Flanges for Offshore Metering Skid
Chevron-Shamrock Management
A manufacturing company in Houma, LA was contracted to build metering skids for a major oil company. The fabricator used
ASME B16.5 rated flanges as part of the construction. In order to maintain alignment, the fabricator machined the flange faces
and consequently nullified the ASME rating. The fabricator asked Bastion Technologies to provide an analysis of the 12” and 16”
sizes of the 150# flange in order to validate the performance per ASME B16.5. The 12” flange passed without condition,
however the 16” would not pass the leak test under the torque conditions specified per B6. A special bolt torque procedure was
generated in order to achieve the desired performance. The upper and lower torque limits were verified by FEA stress analysis
and hand calculations.
16” Flange von-Mises stress on flange face
FEA and hand calculations for torque
13
14. Design and Analysis for Installation of
Utility Crane Pedestal on Noble Danny
Adkins BOP Transporter
Bastion Technologies was retained by Noble Drilling to provide a design and analysis of a utility crane pedestal. The pedestal is to
be attached to the top of an existing BOP transporter for the Noble Danny Adkins semi-submersible rig. The crane pedestal was
engineered for both strength and buckling. The Bastion Technologies engineering team coordinated the design with the customers
engineers in an iterative process which produced a cost effective design ahead of schedule.
Top of transporter frame with
pedestal attached
Fabrication drawings for
utility crane pedestal
14
15. Rhodia Chemical – Baytown
Analysis of Tower/Deck Walkway
Bastion Technologies was asked to provide an analysis of the Rhodia Chemical – Baytown Plant, tower deck walkway. Rhodia maintenance
and operations employees expressed concerns that the walkway was not safe for personnel. Specifically, the employees had objection to the
amount of flex allowed by the Chemgrate panels spanning the transverse supports of the walkway. Following analysis of the duct and
walkway, it was determined that the panels did in fact allow excessive flex beyond that allowed by OSHA. Also, the transverse supports failed
under the specified load condition per AISC. It was recommended to Rhodia Chemical that the walkway be condemned until modifications
could be made to the design.
FEA model of duct and
transverse supports Recommended grating support system for deck structure
Resultant deflection of cantilever walkway supports
15
17. LMRP Alignment Analysis December 2009
Bastion Technologies, Inc. was contracted by a leading deepwater drilling company to model and analyze the motion of a LMRP assembly
for representative wellhead tilt. In performing the analysis Bastion engineers considered three different tilt scenarios, a 1 and 2 degree tilt
about the cone pin axis and also a 2 degree tilt perpendicular to the cone pin axis. The goal was to analyze expected damage to the choke
or kill slabs due to alignment error, calculate alignment error with tolerance effects using current pin design and analyze expected damage
to cone pins and cone pin slot during engagement. ProE 3D was used in conjunction with NASTRAN 601 to perform the analysis.
Bastion engineers determined the spherical pin design produced a constant alignment error which forced motion of the LMRP to be
controlled by one set of spherical pins and the cone pin. This condition caused damaging wear to the cone pin and cone pin slot. Further,
the misalignment at engagement of the choke/kill side stabs resulted in damage to the lands and likely leakage.
It was determined that the defect was in the design of the spherical alignment pins. Removal of the spherical pins and replacement with a
new straight pin design was recommended. The new straight alignment pin design resulted in an error of less than 0.077 degrees vs. 0.3
degrees when the spherical pins were used. The resultant forces at the stabs reduce the stress from a value above the Brinelling stress to a
value of 37 KSI.
Collet Connector at 2 deg. Misalignment von Mises Stress on Choke Side Stab New Alignment Pin Design
17
18. Design and Analysis for Turret Locking
System for Noble Discoverer
The Noble Discoverer drill ship sustained minor damage after a
mooring line failed in a storm while on station at the Ruru Well off the
South Taranaki Coast, New Zealand. Noble Drilling hired Bastion
Technologies to assist with the design and analysis of a modified
turret locking and rotation system (LRS). The final design of the LRS
incorporated a guide shoe, (2) double pin locks (shown below) and (4)
hydraulic cylinders as part of a redundant system. The design was
submitted to Noble Drilling an has been installed on Discoverer which
is now on its way to Alaska.
Exploded view of
revised ring rail
guide shoe
Noble Discoverer deepwater drill ship
FEA of #2 Locking Pin
18
19. Crane Design, 500T Offshore Crane
Bastion Technologies was retained to provide structural engineering for the mast and boom of a 500 Ton
offshore crane. This is pedestal crane to be installed on a jack-up work platform. The project
scope presented numerous design challenges which were systematically solved within
a condensed work schedule. Minimization of weight was of particular interest
to the customer. Versus initial estimates, Bastion engineers were able to
reduce gross weight by 24% while maintaining 96% of the desired
design rating.
The 500 ton crane is expected to be load tested and
Commissioned in early 2012.
Von Mises stress
General
results for mast
Arrangement 500
(total height - 54
Ton offshore
feet)
crane.
Details of auxiliary
boom assembly
19
20. OIL STATES INDUSTRIES, INC. /
BOP TRANSPORTER SYSTEM;
DESIGN and ANALYSIS
Bastion Technologies, Inc. recently supported the design and analysis of a new blow-out preventer stack transporter
design to be implemented on three semi-submersible vessels for use in deepwater Gulf of Mexico offshore drilling. This
system enables the operator to lift up riser assemblies or to position the blow out preventor during drilling operations.
Our scope of work utilized both Solidworks for design and ANSYS software for analysis. The work entailed supporting the
design of the transporter structure, which stands over 50 feet tall and is capable of lifting a 400 ton BOP stack frame.
Other aspects of the project included engineering consultation on the design of the bridge system/riser hang-off, gear
box installations and dynamic loading for variable frequency AC motor drives.
Transporter
Traverse drive system
LMRP Lift Off and Cart Assembly
Bridge design with tractor and traverse drive system
All images are provided courtesy of Oil States Industries, Inc.
20
21. Structural Engineering Modifications for
Transocean Celtic Sea
FIELD ENGINEERING
Bastion was retained by Transocean to provide field engineering services for the GSF Celtic Sea Semi-submersible rig. The Celtic Sea
was towed from Brazil to Cape Town, South Africa for extensive modifications. When the rig arrived Bastion engineers joined the
Transocean team on site for approximately 4 months. Engineering design and analysis was provided on dozens of equipment
systems throughout the vessel. Of chief concern to Transocean were the ROV platform reinforcements, new cement unit
foundations, BOP support mods, cuttings dryer supports, and the I/WOCS foundations. The rig modifications were complete in late
summer of 2011 and the rig was towed to its assigned drilling location off the coast of Angola where it will be operating under a 3
years lease to Esso (ExxonMobil).
Railings and deployment structure for
life boat cradle and launcher
GSF Celtic Sea under tow
BOP stack support modifications
21
23. Vessel Verification Practice
Failure Modes Effects and Criticality
Analysis (FMECA)
Bastion Technologies was awarded a two year contract to provide consulting engineering, statistical analysis, risk
assessment and FMEA/FMECA for a major oil company in Houston. Bastion obtained significant FMECA experience as
an aerospace engineering contractor to NASA and the US Department of Defense since 1998. The services provided by
Bastion are part of the qualified procurement process. Our effort provides an additional level confidence that the
vessel selected is the correct vessel for the task, and the vessel/equipment on-board is fit for service. If deficiencies
are discovered, Bastion will make recommendations either to use an alternate vessel/operator/procedure or will
provide procedural or physical recommendation hat will mitigate the risk and/or consequences. The customer calls
this process the Vessel Verification Practice.
Fault Tree Analysis for S7000
S7000 Criticality Matrix (8x8) per customer
Lift plan for Mad Dog topside
23
24. Safety and Procedural
Development and Training
ATLANTIS SS2 CHANGE-OUT
Bastion Technologies was asked by a major oil company to provide
8/23/2011
Page 1 of 1
BP Confidential
Field / Activity Start End Days 2012
Date Date March April May June July August September October
assistance with development of safety, equipment and installation South Atlantis Production
Shutin
4/1
12:00AM
4/1
12:00AM
0d 4/1 Partial Field Shut-In
4/1 4/12
procedures training for a large production field refurbishment. This
De-Oil South End of Field 12d
12:00AM 12:00PM
North Atlantis Production 4/12 4/12
0d 4/12
Shutin 12:00PM 12:00PM
project was in very deep water and the schedule was highly All Production Down
4/12
12:00PM
4/12
12:00PM
0d 4/12 Full Field Shut-In
expedited. Coordination was required with dozens of other De-Oil North End of Field
Field De-Oiled
4/12
12:00PM
4/27
7/26
6:00PM
4/27
15d 4/12 4/27
0d 4/27 De-Construction Begins
engineering and services contractors to successfully complete the
De-construction Begins 10:00AM 10:00AM
4/27 5/24
De-Construction Activities 27d 4/27 5/24
10:00AM 10:00AM
task. The training systems developed by Bastion, a total of five, were Construction Activities
Install and Test
5/7
12:00PM
6/22
12:00PM
46d 5/7
Construction Begins
6/22
presented to several hundred management, engineering and
6/22 6/26
Internal System Test 4d 6/22 6/26
12:00PM 12:00PM
6/26 8/12
Dewatering Activities 12d 6/26 7/8
installation professionals throughout the 8 month operation.
12:00PM 2:00PM SS2 Change-Out Durations:
- Deterministic = 99 days (no allowances)
7/8 7/8
Oil Production Starts
12:00PM 12:00PM
0d Field Start-Up 7/8 - P50 Duration = 138 days
Bastion also provided interactive operations procedures that were Allowances
7/8
12:00PM
8/6
12:00PM
29d 7/8 8/6
used by the “company men” to direct the activities of the project.
8/6 8/16
Contingency 10d 8/6 8/16
12:00PM 12:00PM
Field Shut-In Allowances/Contingency Milestone
Schedule for
refurbishment of
production field
Manifold and Close proximity
pigging loop SIMOPS
installation procedure
24
25. Deep Water Dropped Objects
Analysis
Bastion technologies was retained to conduct a study of the excursion
distribution of objects dropped in deep water. A total of 7 different
geometries were included in the study. Objects included a manifold, jumper,
mudmat, spreader bar and a special case with a coupled spreader bar and
jumper. The trajectories for the objects were calculated using a proprietary
coupled loads analytical tool developed in the aerospace industry and used
to derive debris dispersion patterns for exploding objects at altitude. The
analysis resulted in the affirmation of the high probability of large
excursions of some object geometries. Bastion recommended a modification
to the procedures for raising and lowering objects to the sea floor and a
mitigation for the design of the spreader bar.
25
