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Noble Industry

Noble Industry



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  • 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
  • About UsBastion Technologies, Inc. Oil &Gas and Petrochemical Division, (Bastion OGP) is amechanical and structural engineering firm. We provide engineering analysis,design and drafting, risk and failure modes assessment, and training developmentfor the offshore oil and gas industry.Bastion Technologies, a HUB, was founded in 1998 and employs over 400employees approximately 250 of which are engineers. Bastion is ISO 9001:2008certified.Our corporate office is located in Houston and we have branch offices at six otherlocations 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 corporateoffice in Houston, TX.Bastion has a three year average revenue of approximately $55MM. 2
  • Capabilities/Services
  • Engineering CapabilityStructural and Mechanical Design • Generate Conceptual Design • Fabrication Design • Create Detailed Drawings • Form, Fit, and Function AnalysisStructural Analysis • Stress Analysis/FEA Modeling • Vibration and Fracture Analysis • Dynamic/Non-Linear AnalysisSpecialty Services • FMECA – Risk Assessment • Coupled Loads Analysis • Procedural Development • Training Development 4
  • Engineering CapabilityStructural 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
  • Engineering CapabilityStructural/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
  • Structural Engineering
  • 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
  • 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 9BT #3062
  • BURNER BOOM FOUNDATION MODIFICATIONS and ANALYSISOur client needed a new foundation design for the relocation of the aft burner booms for a deepwater drillship. Bastion was contracted toanalyze both burner boom foundations located on the aft end of the ship. Redesign and analysis was necessary as a result of changes in loadingconditions and new requirements imposed since the completion of the original design. The new loading conditions require that the boom iscapable of moving up and down between 0 degrees (horizontal) and 45 degrees in elevation. The boom will also be required to swing inboardand outboard while at any angle between these two inclinations. Further, the client required that all reinforcements to existing structure mustbe added above the deck to eliminate interference with existing structures below deck; specifically in the vicinity of the dynamic positioningcontrol room. Any additional reinforcement was limited to approximately 350mm in height. The burner boom is designed in accordance withAmerican Bureau of Shipping (ABS) rules and guidelines (ABS Rules for Building and Classing Mobile Offshore Drilling (Ref 4.2), and theguidelines 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 beamTypical Burner Boom during gas flaring von Mises Stress 16.2 KSI 10
  • Structural Evaluation of Drilling Rig Mast With 750,000lb Hook Load RatingBastion was requested to conduct a structural analysis and evaluation of the mast of adrilling 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 structurewith a height of 148ft. The STAAD Pro structural engineering finite element programwas used for the structural analysis. .The table below shows the mast front and side elevations taken from an assemblydrawing. This is the final static load case table. It was created by varying the B750 hookstatic load, the stand percent and the wind speeds. This gave eight major static loadcases. The analysis validated the rated hook load as a function of wind speed chart forthe structure. B750 Mast Static Load Cases B750 Mast front and side elevations 11
  • 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 ModelTypical offshore Jack-Up Vessel around the pedestal manway 12
  • Analysis and Re-rating of ASME B16.5 Flanges for Offshore Metering Skid Chevron-Shamrock ManagementA manufacturing company in Houma, LA was contracted to build metering skids for a major oil company. The fabricator usedASME B16.5 rated flanges as part of the construction. In order to maintain alignment, the fabricator machined the flange facesand 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 wasgenerated in order to achieve the desired performance. The upper and lower torque limits were verified by FEA stress analysisand hand calculations. 16” Flange von-Mises stress on flange face FEA and hand calculations for torque 13
  • Design and Analysis for Installation of Utility Crane Pedestal on Noble Danny Adkins BOP TransporterBastion Technologies was retained by Noble Drilling to provide a design and analysis of a utility crane pedestal. The pedestal is tobe attached to the top of an existing BOP transporter for the Noble Danny Adkins semi-submersible rig. The crane pedestal wasengineered for both strength and buckling. The Bastion Technologies engineering team coordinated the design with the customersengineers 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
  • Rhodia Chemical – Baytown Analysis of Tower/Deck WalkwayBastion Technologies was asked to provide an analysis of the Rhodia Chemical – Baytown Plant, tower deck walkway. Rhodia maintenanceand operations employees expressed concerns that the walkway was not safe for personnel. Specifically, the employees had objection to theamount of flex allowed by the Chemgrate panels spanning the transverse supports of the walkway. Following analysis of the duct andwalkway, it was determined that the panels did in fact allow excessive flex beyond that allowed by OSHA. Also, the transverse supports failedunder the specified load condition per AISC. It was recommended to Rhodia Chemical that the walkway be condemned until modificationscould 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
  • Mechanical Engineering
  • LMRP Alignment Analysis December 2009Bastion Technologies, Inc. was contracted by a leading deepwater drilling company to model and analyze the motion of a LMRP assemblyfor representative wellhead tilt. In performing the analysis Bastion engineers considered three different tilt scenarios, a 1 and 2 degree tiltabout 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 chokeor kill slabs due to alignment error, calculate alignment error with tolerance effects using current pin design and analyze expected damageto 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 becontrolled 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 anew straight pin design was recommended. The new straight alignment pin design resulted in an error of less than 0.077 degrees vs. 0.3degrees when the spherical pins were used. The resultant forces at the stabs reduce the stress from a value above the Brinelling stress to avalue of 37 KSI. Collet Connector at 2 deg. Misalignment von Mises Stress on Choke Side Stab New Alignment Pin Design 17
  • Design and Analysis for Turret Locking System for Noble DiscovererThe Noble Discoverer drill ship sustained minor damage after amooring line failed in a storm while on station at the Ruru Well off theSouth Taranaki Coast, New Zealand. Noble Drilling hired BastionTechnologies to assist with the design and analysis of a modifiedturret locking and rotation system (LRS). The final design of the LRSincorporated a guide shoe, (2) double pin locks (shown below) and (4)hydraulic cylinders as part of a redundant system. The design wassubmitted to Noble Drilling an has been installed on Discoverer whichis 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
  • Crane Design, 500T Offshore CraneBastion Technologies was retained to provide structural engineering for the mast and boom of a 500 Tonoffshore crane. This is pedestal crane to be installed on a jack-up work platform. The projectscope presented numerous design challenges which were systematically solved withina condensed work schedule. Minimization of weight was of particular interestto the customer. Versus initial estimates, Bastion engineers were able toreduce gross weight by 24% while maintaining 96% of the desireddesign rating.The 500 ton crane is expected to be load tested andCommissioned 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
  • OIL STATES INDUSTRIES, INC. / BOP TRANSPORTER SYSTEM; DESIGN and ANALYSISBastion Technologies, Inc. recently supported the design and analysis of a new blow-out preventer stack transporterdesign to be implemented on three semi-submersible vessels for use in deepwater Gulf of Mexico offshore drilling. Thissystem 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 thedesign 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, gearbox 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
  • Structural Engineering Modifications for Transocean Celtic Sea FIELD ENGINEERINGBastion was retained by Transocean to provide field engineering services for the GSF Celtic Sea Semi-submersible rig. The Celtic Seawas towed from Brazil to Cape Town, South Africa for extensive modifications. When the rig arrived Bastion engineers joined theTransocean team on site for approximately 4 months. Engineering design and analysis was provided on dozens of equipmentsystems throughout the vessel. Of chief concern to Transocean were the ROV platform reinforcements, new cement unitfoundations, BOP support mods, cuttings dryer supports, and the I/WOCS foundations. The rig modifications were complete in latesummer of 2011 and the rig was towed to its assigned drilling location off the coast of Angola where it will be operating under a 3years lease to Esso (ExxonMobil). Railings and deployment structure for life boat cradle and launcher GSF Celtic Sea under tow BOP stack support modifications 21
  • Risk AssessmentProcedural & Safety Training Development Deep Water Dropped Objects
  • 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 customerLift plan for Mad Dog topside 23
  • Safety and Procedural Development and Training ATLANTIS SS2 CHANGE-OUTBastion 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 Octoberassistance 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 4/12procedures 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 12:00PMproject 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-Inexpedited. 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 Beginsengineering 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 10:00AMtask. 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 6/22presented 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 7/8installation 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 daysBastion also provided interactive operations procedures that were Allowances 7/8 12:00PM 8/6 12:00PM 29d 7/8 8/6used 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
  • Deep Water Dropped Objects AnalysisBastion technologies was retained to conduct a study of the excursiondistribution of objects dropped in deep water. A total of 7 differentgeometries were included in the study. Objects included a manifold, jumper,mudmat, spreader bar and a special case with a coupled spreader bar andjumper. The trajectories for the objects were calculated using a proprietarycoupled loads analytical tool developed in the aerospace industry and usedto derive debris dispersion patterns for exploding objects at altitude. Theanalysis resulted in the affirmation of the high probability of largeexcursions of some object geometries. Bastion recommended a modificationto the procedures for raising and lowering objects to the sea floor and amitigation for the design of the spreader bar. 25