BARDOT Ballast Modules provide additional weight on Flexible Pipes/Umbilicals/Cables to ensure the bottom stability (Static) or create the lazy wave shape (Dynamic).
BARDOT Ballast Modules can be made of steel or lead and are composed of 2 or 3 elements fastened together on the line requiring additional weight.
To protect them from corrosion, the steel modules are equipped with sacrificial anodes, the lead modules are inert and do not require protection.
Anti-sliding pads made of qualified polychloroprene ensure immobilization and prevent from slippage of the modules on the lines.
BARDOT Static Ballast Modules are used to provide the additional weight required for the bottom stability of Flexible Pipes/Umbilicals/Cables. Modules are designed to withstand the whole service life of the lines, up to 30 years. Extra weight in water can range from 5kg up to 100kg, with material density from 7 to 11.
Our engineering performs bottom stability analysis to optimize the design and provides fit for purpose solutions.
BARDOT Static Ballast Modules compete directly with concrete mattresses for bottom stability solutions. In-line installation during laying operation allows extreme offshore time reductions.
BARDOT Dynamic Ballast Modules are often used with buoyancy modules to create lazy wave or other shapes for Flexibles Pipes/Umbilicals/Cables.
Our qualified solutions of modules can either be directly clamped on the line or assembled through an internal clamp. Our internal clamps for Ballast Modules have been jointly developed with our buoyancy modules solutions. It is fully qualified for dynamic applications. Modules are designed to withstand the whole service life of the lines, up to 30 years. Extra weight in water can range from 5kg up to 100kg, with material density from 7 to 11.
Specific polymer materials allow our clamp to withstand high temperature of pipes, in case of HP/HT fields.
For Shallow Water areas, BARDOT Group focused on developing stabilization engineering methodology and solutions for Cable to ensure the on-bottom stability on the seabed and at crossing locations.
BARDOT Group developed an advanced engineering methodology to ensure line stability on-bottom and at crossing location.
For on-bottom stability, and in order to reach the relative stability of the line, the below steps are followed:
- Global screening to identify unstable section of exposed line
- For each unstable section a first required spacing will be assessed using DNV RP F109 Generalized approach and accounting for Ballast modules characteristics (additional submerged weight & equivalent hydrodynamic diameter)
- For the most unstable sections, and to reduce the quantity of Ballast modules, as per DNV recommendation, we use our calibrated 3D Finite Element Models with different level of embedment (10, 20 & 30%). The maximum tension and minimum curvature are extracted and checked against line properties or with line manufacturer to ensure suitability
For crossing locations, the use of the DNV generalized method could lead to an underestimate of lateral movements of the line with potential influence on resulting tension build up, fatigue damage and potential underestimate of crossing dimensions. Therefore, the below methodology is followed:
- Analytical Stability Screening of all the crossings. Absolute stability analysis comparing available lateral resistance at crossing with wave and current hydrodynamic loads
- 3D Dynamic Analysis to assess the line cumulated displacement, build-up of tension and resulting curvatures under 3 hour storm event (wave/current RP Combination of 10/100 Years or 100/10 years as per DNV RP F109).
BARDOT Ballast Modules are internationally patented (Patent Ref. FR2015/050053) as its represents an innovation for stability of lines in shallow waters. The design is adapted to each project (route, line characteristics, Meteocean data and other relevant inputs).
The Ballast Modules can be made of steel or lead and are composed of 2 or 3 elements fastened together on the line requiring additional weight.
To protect them from corrosion, the steel modules are painted and equipped with sacrificial anodes, the lead modules are inert and do not require protection.
Anti-sliding pads made of qualified rubber ensure immobilization and prevent any slippage.
The manufacturing, testing and packing are done as close as possible to the final delivery location.
In some areas (crossing, corals barrier, etc.) stabilization and additional protection of the subsea line is required. Our heavy BARDUCT® provides a high level of resistance to abrasion and impact as well as an additional submerged weight (5 to 150+ kg/m) to increase lateral and vertical stability. It is an industry standard fully qualified for 40+ years service life in seawater with no need for periodic maintenance.
The half shells are linked together with a hinge and tightened using standard Anti corrosion alloy banding (Inconel, Super Duplex, or as per project specification). Bands are located in grooves which ensure a smooth passage through the machinery/chute and eliminate the need to measure spacing between straps. The design includes a male/female connection at extremities to ensure a continuous coverage.
Installation of our solutions is safe, fast and very robust.
Here below are a few inputs for your analysis:
- Installation time of Ballast modules: Laying rate + 45 seconds per ballasts
- Installation time of 10 linear meter of Heavy BARDUCT®: 6 minutes.
Our solutions are cost effective compared to other solutions, mainly because installation time and mobilization costs are saved.
BARDOT Crossings have been developed to ensure a safe support of the new line to be laid over an existing line.
They can be used in any crossing area of flexible or rigid lines, in shallow or deep waters, for short-term or long-term use.
Pipeline Crossings are usually required to ensure a minimum gap between the existing line and a new one. BARDOT Crossing Supports, made of HDPE pipes and filled with ballasted elements, safely provide this required gap. BARDOT Crossing Supports can range up to OD 2500mm and can withstand crossing pipes up to 42’’ OD steel with concrete coating.
BARDOT Crossings are made of thick HDPE pipes, extruded out of high grade HDPE raw material. Length, thickness and OD can be adjusted to fit the specifications. BARDOT team of engineers runs FEA to ensure BARDOT Crossings are designed to withstand the installation loads and the weight of the pipes for its entire lifetime.
Our Crossings are made of non-corrosive materials and therefore do not require any protection nor intervention over their lifetime.
BARDOT Crossing Supports provide extreme reduction of installation time offshore. The limited number of elements to install creates huge time savings during laying operations, compared to the use of concrete mattresses.
Per Anker Hassel, project manager with DNV GL – Oil & Gas, said: “Thermoplastic composite pipes are a new, robust lightweight pipe alternative that will impact field layout, and installation methods, and ultimately reduce the cost level.”
Thermoplastic composite pipes offer advantages across all stages of the lifecycle of a pipeline or riser:
1. Design: easy-to-tailor strength and good fatigue capacity, sufficient for the deepest waters and resilience to fluids and elevated temperatures
2. Manufacture: cost-effective continuous spoolable lengths and fully bonded, and the same thermoplastic material can be used for the liner, composite layers and outer coating
3. Installation and decommissioning: cost-effective; lightweight and spoolable
4. Operation: no metal corrosion, high thermal and pressure tolerance and minimal flow resistance.
DNVGL-RP-F119 Thermoplastic composite pipes (TCP) was developed through a DNV GL-led joint industry project involving 18 companies covering the whole supply chain; from polymer producers, via TCP manufacturers, to oil companies as the end users.
Espen Cramer, global service director with DNV GL – Oil & Gas, said: “As the recommended practice describes the requirements for flexible TCP for offshore applications, it builds trust and confidence in the safe and reliable use of these pipelines.
“This opens up new, cost-efficient, innovative offshore pipeline solutions, which are of vital importance for reducing overall costs in the industry.”
TCP have a variety of application areas offshore, including: flowlines, risers, jumpers, choke and kill lines, expansion spools, access lines, and chemical injection lines, as well as commissioning and intervention lines.
DNV GL says the RP targets operators, contractors, suppliers, and others seeking acceptance for using TCP in offshore operations, and is intended for:
• Suppliers of TCP for offshore operations and suppliers of raw materials for such pipes that are seeking market access for their products
• Operators and contractors seeking acceptance for using TCP in offshore operations
• Suppliers and recipients of TCP which need a common technical basis for contractual reference.
In the present context, the world is pursuing the development of renewable energies. One promising solution is marine renewable energy. In this field, Ocean Thermal Energy Conversion (OTEC) has the opportunity of becoming an essential contributor in using the temperature gradient between warm sea surface and cold deep sea water to run a heat engine and/or air conditioning (SWAC). Actually, those technologies are only at their beginning and there is room for major improvements thus major advantages can be highlighted compared to existing solutions.
Bardot Group is a renowned world Polymer specialist for subsea solutions. Our new concepts based on polymer materials allow significant cost reductions and efficient solutions for OTEC & SWAC technologies.
Bardot Group experience relies on a solid knowledge of the HDPE (High Density Polyethylene) material, based upon 10 years of subsea projects and in house laboratory material qualification.
Bardot Group has also developed and delivered its own Water Intake Riser (WIR) for cold water pumping for production process.
Nowadays our design is based on a mix of structural and hydrodynamic analysis. In the past of the industry, studies remained focused in modelling the pipe/riser behaviour under waves and current mainly for steel structure.
The use of HDPE pipes for SWAC and OTEC now brings new challenges that leads to develop specific material behaviour programs.
The aim of this paper is to present, in the first part, our testing program on HDPE mechanical properties. As a second part the paper will present the innovative Bardot concept for pumping cold water for Offshore systems and its applications to OTEC and SWAC.
For HDPE Pipes, specific material tests have been developed to assess the following mechanical properties:
* Abrasion tests to demonstrate the possible friction between two riser intakes or with the seabed.
* Ageing process in seawater to model the variation of mechanical behaviour
* Tensile uniaxial fatigue
* Flexure fatigue
A full-scale test program is also scheduled to define:
* Full-scale impact tests in case of interference with another material
* Axial stiffness test
* Hoop stress tests
In 2015, Bardot has developed a HDPE Water Intake Riser for the Total/Saipem Kaombo FPSO project (built in Singapore). The aim of the WIR is to use cold water for the FPSO process and to reduce the use of heat exchanger.
Thanks to using HDPE Riser, the loads applied on the hull and during the installation of the system are significantly reduced compared to steel Riser. Intensive hydrodynamic FEA on the global HDPE structure have been carried out. These FEA analysis showed that the HDPE light weight and low stiffness allows to decrease stress, moment reaction and impact in the line. Furthermore, our test campaign have also qualified the HDPE concept in fatigue using our SN Curve for HDPE.
Bardot is now exploring deep WIR for process cooling solutions.
Indeed today, HDPE material appears like a competitive solution also for OTEC.
The main challenge in OTEC system is pumping water into deep water.
Based on our experience and bringing our test campaign solutions, Bardot Group is developing innovative concepts for OTEC and SWAC system. Our knowledge gained on WIR is applied onto more important flow rates and deeper water depth for OTEC. HDPE riser also presents all necessary characteristics (low weight to reduce tension in top structure, good capacity in flexure...).
At last, Bardot is applying its technology also to SWAC system including pipeline stabilisation system but also anti friction devices.
As a conclusion, the HDPE technology for designing, building and installing a deep water and large diameter riser for water pumping is a key element in the success of OTEC, SWAC and WIR.
The proper material definition but also tests are key milestones in the development of this technology. Association of polymer specialist, hydrodynamic and use of HDPE can move OTEC/SWAC from research to industrial and competitive solutions.
In order to improve the process efficiency, WIR designed by BARDOT GROUP are able to pump water as deep as 1000m and sustain the potential mechanical stresses created by currents, vibration and WIR structure’s weight.
BARDOT Group developed an innovative and efficient solution of Deep Water WIR, combining:
* High Density Polyethylene (HDPE) pipes
* Rubber Hoses
* Riser seats
* Polyurethane tapers
High Ratio of Local Content
Thanks to various manufacturing sites worldwide, BARDOT Group is able to produce WIR solutions close to where it is requested, and helps you optimize your local content and project logistic.
Our expertise in composite manufacturing allows us to reach custom-made solution and flawless product quality, to deliver timely the best product to our clients.
BARDOT Group’s WIR are designed to be modular and lightweight to ease handling and improve installation steps. Thanks to smart & modular design, installation is adapted to the vessel’s constraints.
A custom-made Installation Procedure is provided for each project of WIR to ensure the proper assembly of your equipment.
Our engineers are also available for training and on-site monitoring of the installation, providing maximum support to our clients.
WIR are designed to fit your requirements of water depth, temperature, flow rate, and to accommodate the hydrodynamics stresses of your operation environment.
Materials have been selected for their good behaviour over time. Our design conservatively considers end-of-life properties, and guarantees that no maintenance will be necessary.
The low weight of our WIR decreases the overall weight of the equipment, and allows the pumping at greater depth with less impact on Hull.
The modular design of our WIR allows a quick on-board installation, through the vessel’s hull or aside hull with optimized installation facilities.
Modular strapping systems
Our wide range of strapping systems provides adapted solutions to fit with your environmental loads and project life.
Compliance to standards
Designed with respect of international offshore standards, especially API17-L1 and API17-L2.