Bolt on Technology
FOR YOUR
New Revenue Stream
What We Do
PTC Berlin Dr Sarah Anne Keane, Dave Bacon and Tony Barber
The Safer Plug Company Limited have been developing the next generation of pipeline isolation technology.
This includes:
Reel Safe
Plug Positioner
Pipe Dancer
BOP Stop
Grip Safe
Propulsor
The Safer Plug Company’s eight separate ‘technology applications’ have been patented in the European Union, in Norway and in the United States of America
This intellectual property package will allow a suitable Oil and Gas Services Company to enter the autonomous pipeline isolation market, and it will enable them to secure dominance in that market.
In excess of 300 isolations have been conducted globally, offshore and onshore, in the past 25 years from sizes 12-inch to 48-inch, and up to pressures of two hundred and sixty two bar (3799psi). The market is now educated and the trend is upwards.
Figure 1: Growth in Pipeline Isolation’s since 1998
The Safer Plug Company have developed the industry’s first 6-inch multi-set, autonomous isolation tool, which is known as the Safer Plug. The 6-inch Safer Plug is Type Approved by Lloyds for use in offshore and onshore oil and gas pipelines.
It’s development dramatically increases, the number of pipelines systems and sizes that can now be isolated, and the Safer Plug’s Gateway Manifold design is scalable throughout the entire range of pipeline diameters from 6-inch to 60 inch.
Details of the Safer Plug Company’s 6 inch Type Approval can be viewed at this link:
LR Marine & Offshore Approvals Lloyd’s Register | LR under reference LR23388942TA.
Gateway Manifold
THE GATEWAY MANIFOLD IS THE FIRST ADDITIVE PART - CERTIFIED BY LLOYDS -FOR USE IN OIL & GAS
It’s all titanium composition consists of free form geometry, which enables it to house the more than 50 individual parts it must contain to enable the Gateway to control autonomous isolation plugs, to seal pipelines from 6 inches to 60 inches in diameter, without changing any components, only scaling for larger hydraulic volumes or greater battery energy.
Figure 2 Gateway Manifold Solidworks Design View
Safer Plugs are low voltage 12 - 24 v DC electrical/electronic systems.
Safer Plugs enable double block and monitor High Pressure isolations
Safer Plugs contain triple redundancy (three independent methods of un-setting)
Safer Plugs are all titanium builds (low weight, high strength)
Safer Plug topside communication systems (COM 1 units) are ATEX certified
Safer Plug subsea communications systems (COM 2 units) are ATEX certified
Safer Plug inside pipe isolation system (COM 3 Control pods) are pressure activated to address ATEX
Figure: 3 SPC 6 Inch Type Approved Plug
The 6 inch Safer Plug design has received Type Approval from Lloyds for offshore and onshore pipeline isolation and is the future of safe, systemised, reliable and repeatable, cost effective Autonomous
Pipeline Isolation. Details of the Safer Plug Company’s 6 inch Type Approval can be viewed at this link: LR Marine & Offshore Approvals | Lloyd’s Register | LR under reference LR23388942TA
Figure 4: Gateway Manifold
ELECTROPLUG – THE FUTURE
ELECTROPLUG IS A SINGLE MODULE ALL TITANIUM ISOLATION TOOL WITH AN
EXTREMELY SHORT FOOTPRINT ElectroPlug is fitted out with a completely autonomous, on-board operating system capable of completing the launch, pigging, setting, set, monitoring, un-setting and pigging back to start point launcher, or pigging onwards to end point receiver without operator intervention.
Figure 5: The Electro Plug
ElectroPlug is the worlds first - self drive - self setting isolation plug
ElectroPlug can be operated entirely elf command free
ElectroPlug contains its own on-board 9 axis inertial navigation system
ElectroPlug uses journey mapping against pipeline isometrics and time of flight
ElectroPlug can set in the tan of the end connector of a flexible flowline
ElectroPlug is fitted with twin packer seals on a one unit plug
ElectroPlug has elf compatible double block and monitor capability
ElectroPlug contains triple unset redundancy
Electorpolug is an all electric drive – and is direct energy driven
With ElectroPlug there is no electric to hydraulic energy transfer loss
ElectroPlug was developed for the floating production storage offshore (FPSO vessel market) where there is a requirement to set in the end connector of an FPSO flexible riser
ElectroPlug is suitable for short tan isolation applications, extremely short set locations, nuclear power plants etc
SELF DRIVE CARS, LIKE SELF DRIVE PLUGS – ARE THE FUTURE
REEL SAFE
REEL SAFE IS AN AUTONOMOUS BUCKLE ARRESTING RAPID SETTING TOOL
Reel Safe activates within 2 seconds and seals the pipeline being laid, once an ingress of
water or a change in internal pressure of the pipeline being laid, has been detected.
Reel Safe is an all titanium, light weight, high strength, electro hydraulic traction tool, which sets rapidly to maintain pipeline integrity, and prevent pipeline buckles propagating.
Reel Safe is fully autonomous and can travel inside the length of a reeled pipeline string using it’s own power system
Reel Safe does not require any pigging fluid to get from start to finish of a pipeline string.
Reel Safe communicates through the pipeline wall, using ELF through pipe communications.
Reel Safe reduces the requirement for higher top tension - because it rapidly isolates the dry riser pipe above any laid pipe or touchdown buckle
Reel Safe reduces the requirement for higher top tension, because it can travel within the riser pipe and keep the riser pipe dry, in the event of sag bend buckle.
Reel Safe can provide gauged confirmation of a pipelines installed integrity, without flooding, based on dry pipeline waiver (thereby eliminating dewatering and vacuum drying costs)
Reel Safe eliminates the requirement for installation of external buckle arrestors as it removes the flooded riser concern thereby saving fabrication cost, vessel buckle arrestor installation interruption time and reduces pipelay duration and risk
PLUG POSITIONER
Plug Positioner is an all titanium enabling tool, and Plug Positioner eliminates the requirement to use
water or any other pigging fluid to move your tool to its destination inside a gas or oil pipeline.
Plug Positioner is an electro hydraulic traction tool
Plug Positioner will move any load horizontally into and along a pipeline, from its launcher, and position it precisely
Plug Positioner enables gas pipelines to be serviced, without using fluid.
Plug Positioner is fully autonomous (no umbilicals) and is controlled from outside the pipeline using elf through pipe wall communications
Plug Positioner has triple unset redundancy
Plug Positioner has full extraction redundancy
Plug Positioner eliminates the need to pig a tool to a precise location inside a pipeline using any pigging fluid
Plug Positioner is ‘fluid freedom’
Plug Positioner ensures that the operator continues to export dry gas, following maintenance
PIPE DANCER
PIPE DANCER IS THE WORLD’S FIRST TRACTION TOOL FOR MOVING 1,000KG LOADS
UP AND DOWN INSIDE A PIPELINE RISER AND AROUND PIPELINE BENDS, WITHOUT
CAUSING HARM TO THE PIPE WALL.
Pipe Dancer is an all titianium, high strength, low weight enabler, which can traverse both horizontal and vertical bends in pipelines without the use of pigging fluid.
Pipe Dancer can move any tool, (once coupled) from launcher barrel, through the pipeline geometry, to sea bed, and back again, without the use of fluid or gas pressure pigging medium.
Pipe Dancer is an electro hydraulic traction system which enables un piggable pipeline branches, to be entered and navigated without the requirement for a propelling fluid
Pipe Dancer is fully autonomous, and is controlled through the pipeline wall using elf through pipe wall communications.
Pipe Dancer has triple redundancy across both traction systems
BOP STOP
BLOW OUT PREVENTERS ARE LOCATED AT THE SEABED, AND SIT ON TOP OF THE
WELL HEAD CASING AND BOP STOP CAN SEAL IN MINOR LEAKAGE CASES AND
MINIMISE ENVIRONMENTAL POLLUTION
The marine riser is the hollow pipe which guides the drill string from the drilling rig or drill-ship, through the Blow Out Preventer, on into the seabed casing and down into the well.
A loss of well control event can be catastrophic if the Blow Out Preventer fails as this allows hydrocarbons to escape up the marine riser.
BOP STOP is an autonomous marine robot that is suitable for positioning a pipeline isolation plug in a vertical pipe such as a marine riser, resulting in sealing of the marine riser.
BOP STOP is a system which pulls an isolation plug, down into a cut marine riser in order to seal the marine riser, thereby isolating the well.
BOP STOP provides a technical solution which removes the requirement for a Top Hat heavy lift crane vessel or a
DP collection tanker to remain stationed on the surface.
BOP STOP offers an alternative solution to isolate the flow of gas or hydrocarbons from a leaking marine riser, and provides a valve method to introduce mud and cement downhole, to regain control of the reservoir, without relief well drilling.
GRIP SAFE
SAFER PLUGS HAVE TWIN MODULES, WHICH CONTAIN RADIAL SETS OF GRIPS
(WEDGES) TO SECURELY LOCK THEM IN PLACE AND CONFIGURE THEIR TWIN
PACKERS TO ENSURE AN EFFECTIVE PIPELINE SEAL.
During the setting cycle of a Safer Plug the grips experience loads from the actuation flange which forces them up the bowl and outwards.
The grips then engage and hold against the pipeline wall while the internal hydraulic cylinder pulls the flange inward (shortening the overall length of the tool), to SET.
The loading from the downstream Delta pressure further intensifies the SET
The grip teeth are raked backwards and are designed for a perfect ‘bowl size’ matching, when at the top of the cone when engaging the pipe wall.
The sharp teeth bite into the carbon steel pipe wall, to a defined depth which is calculated, designed and managed to not exceed the carbon steel pipe’s corrosion allowance.
TCP and polymer lined pipe is becoming a preferred alternative carrier in oil and gas operations.
In TCP or polymer lined pipe, this biting action of the grip teeth, can damage the TCP or polymer liner and induce failure of the composite or polymer.
The sharp teeth of existing grips or wedges in conventional isolation plugs are not suitable for isolation of TCP or polymer lined pipe.
The new and unique geometry of The Safer Plug Company’s 3D printed ‘Grip Safe titanium locks’ allows for controlled and managed deformation of the pipe’s internal polymer surface, ensuring effective engagement without exceeding the elastic limit of the material.
The application of Hoop stress, von Mises stress, Hooke’s Law and Saint-Venant’s Principle collectively contributes to this new design of gripping mechanism that ensures controlled deformation, even stress distribution, and effective engagement without causing harm to the polymer lining of the pipeline.
GRIP SAFE affirms that a TCP, RTP or any polymer lined pipe wall will not be cut, scored or otherwise impaired, during autonomous pipeline isolation activities.
PROPULSOR
PROPULSOR IS AN ENCLOSED ROTOR SYSTEM LOCATED AT THE FRONT
END OR AT THE REAR END OF A SAFER PLUG TO ENABLE BOTH PUSHING
OR PULLING BY PROPULSION OF THE SAFER PLUG INSIDE A FLUID
PIPELINE, TO ITS AUTONOMOUS ISOLATION LOCATION.
Propulsor when coupled within an autonomous Safer Plug train, along with the Plug Positioner tool, is designed to enable the Operator to maintain a predetermined pressure level (typically 30 bar) over a designated section of reel laid pipeline, to prevent wrinkling or liner buckling of such mechanically lined pipes when moving unpressurised sections over curved surfaces. (known as reverse reeled unpressurised bending cycles)
Propulsor can be coupled to various pipeline tools should they meet the weight and required Navier Stokes ratio for turbulent flow.
Propulsor can negotiate and move coupled tools through certain dead headed fluid spurs and through non piggable fluid pipelines
CONCLUSION
Bread and butter plugging for removal and replacement of leaking or corroding valves, risers, launchers or receivers, isolation joints or adding new pipeline infrastructure under pressure.
Plus Provision of EPRS (Emergency Pipeline Repair Systems)
Are the current core earners
Additional opportunities enabled by the Safer Plug Company’s patented new technology include:
Elimination of wrinkling of the liners of Mechanically Lined Pipes (the CRA liner) using it’s Magic Plug ™ system.
Flexibles isolation for flexible riser removal or their replacement within pressurised piping systems as found on FPSOs
Autonomous inspection or plugging of previously ‘non piggable’ pipelines.
All of these will further augment ‘the traditional autonomous isolation earners’ and while providing an edge - can add additional revenue streams.
The questions to you are two………………..
The market is in excess of 50m USD annually, with only 2 existing companies one American and one Japanese owned. Today’s Geopolitics suggests it’s time for a third player European, Chinese, Brazilian, Indian or other to enter this autonomous isolation market.
If you require further technical, IP or commercial information then contact
ciaran.early@thesaferplugcompany.com or dave.bacon@thesaferplugcompany.com