150116BridonIR_Final JW A4
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Global Technology<br />
Leader<br />
Driving the world’s most advanced rope testing<br />
facility. Producing the most technically advanced<br />
products and developing bespoke solutions for<br />
customers exacting needs.<br />
A History of Innovation<br />
With a world wide heritage stretching back over two<br />
centuries, we are a customer focused group investing to<br />
deliver unique solutions.
Customer<br />
decision on<br />
future rope<br />
manageme<br />
nt policy<br />
Current<br />
inspection /<br />
maintenanc<br />
e & changeout<br />
policy<br />
Our<br />
recommende<br />
d advice to<br />
customer<br />
from Bridon<br />
Report<br />
reviewe<br />
d by<br />
Bridon<br />
Application<br />
s<br />
Specialist<br />
Forensic /<br />
Inquest<br />
report<br />
completed<br />
by Bridon<br />
Tech Centre<br />
Fully<br />
worked<br />
sample<br />
&<br />
operating<br />
parameter<br />
s sent to<br />
Bridon<br />
The MORE<br />
Programme Maximum<br />
operating rope efficiency<br />
Expert support to maximise your<br />
working rope life<br />
Bridon Technology<br />
Centre<br />
One of the world’s most advanced<br />
rope testing facilities with over 30<br />
dedicated design, manufacturing &<br />
specialist staff The hub of rope
BRIDON IS EVOLVING<br />
• Bridon has always had a close connection<br />
with our offshore customers, both directly,<br />
and through marine forums<br />
• Following feedback from customers, Bridon<br />
embarked on a “customer facing”<br />
restructuring programme driving the<br />
development of our Bridon Technology<br />
centre which opened in 2013<br />
• This has led to a series of customer<br />
focused product developments aimed at<br />
addressing industry challenges and<br />
significantly lowering our customers<br />
rope operating costs.
BRIDON’S<br />
PHILOSOPHY<br />
International Services<br />
savings, safety<br />
assurance, risk mitigation,<br />
peace of mind<br />
Technology Centre<br />
Application Expertise<br />
• Installation<br />
• Re-lubrication<br />
• Inspection<br />
• Maintenance<br />
• NDE<br />
One of the world’s most<br />
advanced and bespoke<br />
testing facilities<br />
• Forensic Analysis<br />
• Inquest Reports<br />
• Mechanical Testing<br />
• Rope Training<br />
• Applications advice<br />
• Product Selection<br />
• User Guide<br />
An advanced NPD programme driven by a clear customer<br />
focus
BTC FACILITIES AND SERVICES<br />
Multi-layer spooling machines<br />
3 x Rope destruction test machines<br />
2 x Torque/turn machines<br />
Customer<br />
decision on<br />
future rope<br />
managemen<br />
t policy<br />
Current<br />
inspection /<br />
maintenanc<br />
e & changeout<br />
policy<br />
Our<br />
recommended<br />
advice to<br />
customer<br />
from Bridon<br />
Fully<br />
worked<br />
sample<br />
&<br />
operating<br />
parameter<br />
s sent to<br />
Bridon<br />
Report<br />
reviewed<br />
by<br />
Bridon<br />
Application<br />
s Specialist<br />
Forensic /<br />
inquest<br />
report<br />
completed<br />
by Bridon<br />
Tech Centre<br />
4 x Bend fatigue test machines<br />
M O R E<br />
Wire forensic analysis
INTERNATIONAL SERVICES PACKAGE<br />
Selection &<br />
specification<br />
Rope record<br />
management<br />
Storage &<br />
transport<br />
Guidance on<br />
discard &<br />
feedback<br />
Total<br />
Se rvic e<br />
Solutions<br />
Installation<br />
Tensile<br />
testing<br />
Delivering cost effective support to<br />
maximise the operational life of<br />
our customers ropes.<br />
Inspection &<br />
examination<br />
Maintenance
APPLICATION SPECIALISTS<br />
Bridon is one of the only rope manufacturers to<br />
employ application specialists who can deliver<br />
expert advice.<br />
These services include:<br />
•Advice on rope selection, installation and<br />
maintenance<br />
• Recommendations on increasing rope operating life<br />
• Rope life management support<br />
Rope Training<br />
BlueBook App<br />
• Rope training workshops<br />
• User manuals User and Manual installation and guides Installation Guides
OFFSHORE MARKET CHALLENGES<br />
Bridon has always had a close connection with customers, both directly,<br />
and through marine forums. Actively listening to customer feedback the<br />
following challenges were identified.<br />
• Accelerated corrosion (especially in warmer climates)<br />
• Operation in Arctic conditions<br />
• Ineffective re-lubrication methods<br />
• Effects of pressure in deeper waters<br />
• Legislation on environmental lubricant obligations (VGP 2013)<br />
• High cost of wire rope integrity management<br />
• Market perception shift on rope from commodity to capex item<br />
• Market requirement for cost savings through increasing rope
Development<br />
s
SUMMARY OF TECHNOLOGY DEVELOPMENTS<br />
Based on customer feedback, Bridon defined a series of key<br />
developments required to address these industry challenges<br />
Customer Requirement Bridon Development Product Technology<br />
Increased corrosion protection<br />
(especially in warmer climates)<br />
Environmental VGP compliance<br />
Lowering cost of in-service maintenance<br />
Ropes operating effectively in ultra<br />
deep water<br />
Operational flexibility in challenging<br />
environments<br />
Bridon NXG, Brilube<br />
20, ECO & Extreme<br />
Brilube<br />
ECO<br />
Bridon NXG, Brilube 20 &<br />
Extreme<br />
Bridon NXG, Brilube<br />
Extreme<br />
Bridon NXG, Brilube<br />
Extreme & Bristar Polar<br />
Bridon NXG, Brilube<br />
20, Extreme, ECO<br />
NXG core protection and enhanced<br />
corrosion resistance from new lubricants<br />
Fully VGP compliant service lubricants with<br />
no loss in performance<br />
NXG technology and new lubricants give longer<br />
protection between maintenance cycles<br />
Bridon NXG and Brilube Extreme combine to<br />
give pressure resistant performance and<br />
longer operating life to 4,000m depth<br />
Increased operating temperature range gives<br />
more flexibility in hot and cold environments<br />
including AHCS<br />
All of the above developments give extended<br />
rope operating life<br />
Enhanced operating rope life
CORROSION PROTECTION<br />
BARRIERS<br />
1 2<br />
LUBRICATION<br />
(Blocking<br />
Compound)<br />
POLYMER CORE<br />
(Blocking<br />
Compound)<br />
WIRE<br />
COATING<br />
(Zinc)<br />
EXTENDED<br />
ROPE LIFE<br />
3<br />
3<br />
NXG Polymer Core<br />
Sealed, plastic core keeps the<br />
rope lubricant inside and<br />
seawater and abrasive<br />
particles outside.<br />
2 2<br />
3<br />
1<br />
More accurate and durable<br />
placement of the strands<br />
resulting in even load distribution<br />
Brilube Extreme<br />
Enhanced fatigue life performance<br />
New rope lubricant with extreme<br />
pressure resistant additives,<br />
enhanced wash<br />
off resistance and improved<br />
corrosion protection additives<br />
1
IR ROPE TECHNOLOGY<br />
Delivering cutting edge polymer technology. World class developments<br />
working in collaboration with customers to achieve more from your<br />
ropes NXG Feature NXG Benefit Additional Benefits<br />
Enhanced corrosion protection<br />
Increased fatigue life<br />
Low friction polymer technology<br />
Core protection<br />
Wider operating temperature<br />
High pressure resistance<br />
Longer rope operating life<br />
More operating flexibility in<br />
challenging environments such as<br />
arctic and tropical waters<br />
Use in ultra deep waters<br />
Combined with the<br />
unique MORE programme<br />
these benefits enable<br />
customers to achieve<br />
MORE from their ropes,<br />
ultimately delivering<br />
operating cost savings<br />
M O R E
LUBRICATION DEVELOPMENTS<br />
Lubricant<br />
Lubricants applied in manufacture<br />
Lubricants<br />
applied<br />
in service<br />
Brilube 20 Brilube ECO Brilube Extreme Brilube ECO<br />
Features<br />
Benefits<br />
Enhanced corrosion<br />
resistance<br />
High performance<br />
crane rope lubricant<br />
supplied as standard<br />
Outperforms industry<br />
benchmarks in lab testing<br />
✔<br />
EcoLabel Certified<br />
lubricant with no loss<br />
of performance<br />
Fully complies with<br />
2013 VGP legislation<br />
✔<br />
Pressure resistant, tacky<br />
lubricant designed primarily<br />
for use in ultra deep waters<br />
Maintains performance up to<br />
4000m water depth. Significantly<br />
increased fling off and wash off<br />
resistance combined with<br />
enhanced corrosion protection<br />
and wider temperature operating<br />
range. ✔<br />
EcoLabel<br />
Certified<br />
lubricant with no<br />
loss of<br />
performance<br />
Fully complies<br />
with 2013 VGP<br />
legislation<br />
✔<br />
Increased wash<br />
off<br />
resistance<br />
VGP compliance<br />
✔<br />
✗<br />
✔<br />
✔<br />
✔<br />
✗<br />
✔<br />
✔<br />
Increased fatigue<br />
life<br />
✔<br />
✔<br />
✔<br />
✔<br />
Increased rope<br />
operating life<br />
✔<br />
✔<br />
✔<br />
✔
HYBRID ROPES - LONGER STRONGER LIGHTER<br />
Steel and fibre combination rope where the fibre is an integral load bearing<br />
member As strong and robust as steel but lighter with superior bending<br />
properties.<br />
Benefits<br />
• Can be deployed on<br />
existing vessels and<br />
winch systems<br />
• Performs like steel<br />
Steel Fibre Hybrid<br />
MBL Benchmark Matched Matched<br />
Weight<br />
Benchmark<br />
Up to 80%<br />
lighter<br />
15%-40% lighter<br />
• Existing equipment can<br />
carry increased payload<br />
• Existing equipment can<br />
travel to greater depths<br />
Fatigue Benchmark +100% +85%<br />
Robustness Benchmark Very low Matched<br />
Multi layer<br />
spooling<br />
• Enhanced fatigue<br />
Field performance Trial<br />
• Six strand Triangular Hybrid currently in a field test in the deepest gold mine in South<br />
Africa<br />
Temperature<br />
performance<br />
Benchmark Low Matched<br />
Benchmark<br />
HMPE - Lower<br />
Aramid - Matched<br />
• Bridon’s Hybrid rope is installed on an electrically coupled Blair multi-rope (BMR) man<br />
material hoist at a gold mine in South Africa. It was the first hoist to operate to a depth of<br />
3,150m in a single wind with an end-load of 23 mt.<br />
• Further opportunities being discussed with key partners<br />
Matched
The Bridon MORE Programme<br />
Customer<br />
decision on<br />
future rope<br />
management<br />
policy<br />
Current<br />
inspection /<br />
maintenanc<br />
e &<br />
change-out<br />
policy<br />
Developed for:<br />
• Crane Ropes<br />
Our<br />
recommended<br />
advice to<br />
customer<br />
from Bridon<br />
Fully<br />
worked sample<br />
& operating<br />
parameters<br />
sent to Bridon<br />
• Drilling Lines<br />
• Marine Riser<br />
Tensioners<br />
• Anchor Lines<br />
Report<br />
reviewed<br />
by Bridon<br />
Applications<br />
Specialist<br />
Forensic /<br />
Inquest<br />
report<br />
completed by<br />
Bridon Tech<br />
Centre<br />
Bridon can only provide observations on the condition of the rope and relevant<br />
historic comparisons. The final decision on rope changeout policy shall always be<br />
the responsibility of the customer and Bridon will provide no warranty or<br />
assurances that the rope is suitable for continued use.
COLLABORATIVE DEVELOPMENT<br />
FEA modelling<br />
Green energy<br />
mooring system<br />
Property<br />
stability<br />
Sheave loss<br />
testing<br />
Friction hoist<br />
testing<br />
Condition<br />
monitoring<br />
Full fibre low<br />
rotation CBOS<br />
Hoist rope<br />
Modelling dual<br />
fall cabling<br />
Rotation<br />
performance
Drilling<br />
Lines
DRILLING LINES SUMMARY<br />
Key Performance<br />
Requirement<br />
• Increased uptime through confident<br />
extension of ton mile goals<br />
• Resistance to crushing on drum<br />
• Larger surface contact area with sheaves<br />
• Maintaining diameter stability<br />
• Resistance to wear and abrasion
DRILLING LINES<br />
IR Available<br />
Enhancements<br />
• Dyform Bristar NXG with friction reducing polymer<br />
technology<br />
• Dyform Bristar Polar arctic grade polymer technology<br />
Current Best Performing<br />
• Dyform Bristar 6 x 26 or 6 x 31 with unique fluted polymer<br />
core<br />
Industry Standard - API9A<br />
• Conventional IWRC 6 x 19 or 6 x 26<br />
constructions
HOW CAN YOU BENEFIT FROM THESE PRODUCT<br />
UPGRADES<br />
Cutting edge polymer technology from Bridon to help you get more from<br />
your ropes<br />
Improvement Benefit Additional Benefits<br />
Increased fatigue<br />
resistance<br />
Increased diameter<br />
stability<br />
Reduced fling<br />
off<br />
Longer rope operating<br />
life<br />
More operational<br />
flexibility<br />
Combined with the<br />
unique MORE programme<br />
these benefits enable<br />
customers to achieve<br />
MORE from their ropes,<br />
ultimately delivering<br />
M<br />
operating<br />
O<br />
cost<br />
R<br />
savings<br />
E
CASE STUDY<br />
EXAMPLE<br />
Leading Drilling Contracto
SUMMARY<br />
The<br />
Problem<br />
Customer<br />
failing to<br />
benefit<br />
from<br />
existing<br />
ropes<br />
being used<br />
on drilling<br />
rig<br />
Current<br />
Situation<br />
Customer<br />
unaware of<br />
potential<br />
Ton-Mile<br />
performance<br />
of Bristar<br />
Drilling Lines<br />
and value add<br />
Bridon<br />
services<br />
The<br />
Solution<br />
Partnering<br />
with Bridon<br />
to fully<br />
understand<br />
rope<br />
condition at<br />
current<br />
Ton-Mile<br />
goal to<br />
safely &<br />
confidently<br />
increase<br />
ton-mile<br />
targets.<br />
Resul<br />
t<br />
Using inquest<br />
reports customer<br />
has increased<br />
Ton-Mile goal<br />
to 46 ton-mile/ft<br />
(8000 ton-miles<br />
between slip<br />
&cut) after just 1<br />
report. An<br />
increase of<br />
over 8%<br />
equivalent to<br />
savings of<br />
$171,000 p.a.
EXISTING SET UP<br />
• 2” 6X31<br />
Drilling Line x 15,000 ft<br />
• NOV SSGD-5750 active heave<br />
compensated drawworks<br />
• Current Ton-Mile target<br />
- Automated ton-mile recorder<br />
- 42.5 Ton-Miles/ft reference point<br />
- 7,360 Ton-Miles with cut length of 174<br />
ft
THE PROCESS<br />
Current<br />
operating<br />
parameters<br />
(Start point –<br />
42.5 tonmile/ft)<br />
Fully worked<br />
sample<br />
removed at<br />
Bridon<br />
first slip & cut<br />
recommendation<br />
and returned to<br />
for extended life<br />
BTC<br />
utilising Bridon<br />
Bristar drilling<br />
lines supported by<br />
MORE program.<br />
Strip down<br />
analysis complete<br />
& report issued<br />
to customer with<br />
recommendatio<br />
ns<br />
Extended<br />
interval<br />
between slip &<br />
Customer cut operation by<br />
confident to >500 ton-miles<br />
increase Tonmile<br />
goal to<br />
46 ton-mile/ft<br />
Increase of Tonmile/ft<br />
goal of<br />
8%<br />
following first<br />
report<br />
8% increase in ton-mile goal equates to ~$171k per annum on 1<br />
rope
THE<br />
NUMBERS<br />
4 x<br />
$42,750 =<br />
estimated<br />
saving of $171k<br />
per annum<br />
This 8%<br />
improvement<br />
($171k) is<br />
from the first<br />
report<br />
analysis<br />
Increase<br />
d Ton-<br />
Miles<br />
means 4 less<br />
slip & cuts per<br />
annum<br />
A potential<br />
of >25% gain<br />
when a full<br />
cycle report<br />
analysis is<br />
complete<br />
This would<br />
equate to ~<br />
$513<br />
k<br />
Savings (or a free<br />
day)<br />
Increase<br />
from 7,500 to<br />
8,000<br />
Ton-Miles<br />
Rig day<br />
rate:<br />
$513,000<br />
Calculated<br />
cost per slip &<br />
cut: $42,750<br />
(day rate)<br />
Estimated slip<br />
and cut time:<br />
2 hours
SUMMARY COMMENTS<br />
Through partnering with Bridon customers have<br />
been to reduce downtime costs<br />
Bridon has achieved this through the knowledge and<br />
experience of our Application Specialists and technology<br />
centre to produce condition assessments and offer expert<br />
advice<br />
This is an ongoing process and through collaboration<br />
Bridon can help maximise Ton-Mile goal<br />
M O R E
Marine Riser<br />
Tensioners
MARINE RISER TENSIONER SUMMARY<br />
Key Performance<br />
Requirement<br />
Key Performance<br />
Requirement<br />
• Increased uptime through<br />
improved Ton-Cycle targets<br />
• High bend fatigue resistance<br />
• Corrosion resistance<br />
• High operating temperature<br />
range
MARINE RISER TENSIONERS<br />
IR available<br />
enhancements<br />
• Dyform Bristar NXG with friction reducing polymer<br />
technology<br />
• Dyform Bristar Polar arctic grade polymer technology<br />
Current best performing<br />
• Dyform Bristar 6 or 8 x 36 class and 6 or 8 x 37<br />
class with unique fluted polymer core<br />
Industry standard - API9A<br />
• Conventional 6 or 8 x 36 class and 6 or 8 x<br />
37 class
SUMMARY OF TEST DATA<br />
Significant improvement in bend fatigue performance over<br />
benchmark ropes<br />
7.5 x improvement in laboratory tests<br />
Number of cycles to<br />
failure<br />
Cycles<br />
to<br />
failure<br />
100<br />
%<br />
Cycles<br />
to failure<br />
490%<br />
Cycles<br />
to<br />
failure<br />
750%<br />
Tested under<br />
laboratory<br />
conditions FOS<br />
5:1<br />
D:d 20:1<br />
Rope<br />
Constructio<br />
n<br />
Benchmark<br />
6 x 36 IWRC<br />
Rope<br />
Constructio<br />
n<br />
DYF 8 x 36 PI<br />
Rope<br />
Constructio<br />
n<br />
Bristar 8 NXG
HOW CAN YOU BENEFIT FROM THESE PRODUCT<br />
UPGRADES<br />
Improvement Benefit Additional Benefits<br />
Improved bend fatigue<br />
performance<br />
Improved corrosion<br />
resistance<br />
Wider operating temperature<br />
range<br />
Longer rope operating<br />
life<br />
More operational<br />
flexibility in arctic and<br />
tropical waters<br />
Combined with the<br />
unique MORE programme<br />
these benefits enable<br />
customers to achieve<br />
MORE from their ropes,<br />
ultimately delivering<br />
M operating O cost R savings E
Offshore Crane<br />
Ropes
OFFSHORE CRANE ROPE SUMMARY<br />
Key performance requirement<br />
Key Performance<br />
Requirement<br />
• Resistance to crushing<br />
• Resistance to cross over<br />
damage<br />
• High corrosion resistance<br />
• High bend fatigue resistance<br />
• Lower maintenance requirement<br />
• Increased resistance to<br />
demands of ultra deep water<br />
activities
OFFSHORE CRANE ROPES<br />
IR available<br />
enhancements<br />
• Dyform Bristar NXG with friction reducing polymer<br />
technology<br />
• Hydra 34LR NXG with friction reducing polymer<br />
technology Current best performing<br />
• Dyform Bristar 6 or 8 and 34LR /PI multistrand (Max for Boom<br />
Hoist)<br />
Industry standard - API9A<br />
• Conventional 34LR /PI and 6 or 8 strand constructions<br />
All of the above are available with Brilube Extreme for deep water<br />
operations
HOW CAN YOU BENEFIT FROM THESE PRODUCT<br />
UPGRADES<br />
Improvement Benefit Additional Benefits<br />
Improved corrosion<br />
resistance<br />
Improved fatigue<br />
resistance<br />
Improved operating<br />
design<br />
Longer rope operating<br />
life<br />
Lower<br />
maintenance<br />
requirement<br />
Combined with the<br />
unique MORE programme<br />
these benefits enable<br />
customers to achieve<br />
MORE from their ropes,<br />
ultimately delivering<br />
M operating O cost R savings E
SUMMARY OF TEST DATA<br />
Significant improvement in bend fatigue performance over<br />
benchmark ropes<br />
Number of cycles to<br />
failure<br />
Stranded rope test<br />
tesults<br />
Cycles<br />
to<br />
failure 100<br />
%<br />
Cycles<br />
to failure<br />
490<br />
%<br />
Cycles<br />
to<br />
failure<br />
750<br />
%<br />
Number of cycles to<br />
failure<br />
Low rotation rope test<br />
results<br />
Cycles<br />
to<br />
failure 100<br />
%<br />
Cycles<br />
to<br />
failure<br />
185<br />
%<br />
Rope<br />
Constructi<br />
on<br />
Benchmark<br />
6 x 36 IWRC<br />
Rope<br />
Constructi<br />
on<br />
DYF 8 x 36 PI<br />
Rope<br />
Constructi<br />
on<br />
Bristar 8<br />
Cycles to full failure tested under laboratory conditions FOS 5:1<br />
D:d 20:1<br />
Rope<br />
Constructi<br />
on<br />
Benchma<br />
rk DYF<br />
34LR<br />
Rope<br />
Constructi<br />
on<br />
iR 34LR<br />
Hydra NXG
CASE STUDY<br />
EXAMPLE<br />
Leading Subsea Construction<br />
Contractor
SUMMARY<br />
The Problem Current Situation The Solution Resul<br />
t<br />
Customer<br />
experiencing<br />
premature<br />
rope failures<br />
through<br />
accelerated<br />
corrosion in<br />
ultra deep<br />
waters<br />
Customer<br />
looking for<br />
reasons why<br />
ropes are<br />
failing early in<br />
ultra deep<br />
water<br />
operations,<br />
and a solution<br />
to stop<br />
premature<br />
failure while<br />
maintaining<br />
specified<br />
operating<br />
parameters<br />
Partnering<br />
with Bridon<br />
to fully<br />
understand<br />
reasons for<br />
rope failure<br />
and<br />
collaborative<br />
development<br />
on a new<br />
deep water<br />
rope,<br />
including a<br />
new lubricant<br />
New NXG<br />
Extreme<br />
range of ultra<br />
deep water<br />
ropes<br />
eliminated<br />
the cause of<br />
accelerated<br />
corrosion and<br />
extended the<br />
rope life to<br />
customer<br />
expectations<br />
(5-6 years)
DEEP SEA OPERATIONS<br />
Operating depths are becoming increasing deeper offshore and<br />
this poses new challenges previously unseen in the industry.<br />
Arctic Temperature Profile<br />
Tropical Temperature Profile<br />
Pressure<br />
• Pressure increases linearly with water<br />
depth: 300 bars (4409 psi) of pressure at<br />
a 3000m (10,000ft) water depth<br />
• The effect of pressure is more significant<br />
than temperature on the performance of<br />
rope lubricants<br />
• Viscosity of lubricants increases with<br />
pressure (from Barus equation)<br />
• Lubricant is expelled out when rope when<br />
it is retracted back on to the drum. This<br />
can happen at water depth from 1500m<br />
(5000 ft)
EXISTING CHALLENGES<br />
Lubrication loss causes:<br />
• Premature rope failure<br />
• Accelerated corrosion<br />
• Deck safety concerns<br />
• Environmental impact<br />
• Increased operating costs
PRESSURE RE-LUBRICATION TRIALS<br />
Lost lubricant CANNOT be replaced in multi-strand ropes<br />
54mm as supplied<br />
Brilube 70 with Viper<br />
applicator<br />
Total Bio adhesive<br />
with viper applicator<br />
Outer<br />
Improved corrosion<br />
resistance<br />
Longer rope operating<br />
life<br />
Core<br />
Inner
PROTOTYPE OF NEXT GENERATION MULTI-STRAND<br />
ROPE<br />
Sample Ropes – EN12385 class 35 (W) X K19<br />
• Benchmark rope: 63mm (2.48”) standard<br />
lube in all stranding and closing operations<br />
• Development rope: 63mm (2.48”) enhanced<br />
lubricant Brilube Extremein stranding and<br />
plastic impregnated core and NXG polymer<br />
blended
HYPERBARIC TESTING OF ROPES - EXAMINATION<br />
• NXG polymer used for plastic impregnation intact<br />
• No evidence of water trapped inside the PI core<br />
• No evidence of grease loss or weight gain in outer<br />
strands
Testing and Field Trial<br />
Lab Testing<br />
BREAK LOAD TEST<br />
Field Trial Inspection<br />
•Actual breaking load = 378.8t<br />
•Design MBL = 358t<br />
•Design parameters remain unaltered<br />
• Safety factor : 5<br />
• D/d ratio : 20:1<br />
• Speed : 13 cycles / min<br />
• Discard criteria :<br />
3 wire breaks<br />
Control rope 100%<br />
Hydra NXG 198%
1 st YEAR FORESNSIC INSPECTION CONDUCTED AT BTC<br />
Condition Assessment<br />
63mm 34LR Rope<br />
• Rope returned appeared well lubricated along<br />
the entire length with no visible signs of<br />
corrosion<br />
• No evidence of mechanical damage or wire<br />
breaks on the rope surface.<br />
Plasticated Core<br />
• No major loss in zinc coat weight when<br />
compared to a sample of the original<br />
manufacture specification<br />
M O R E<br />
• Plastic impregnated layer appeared to be in a<br />
good condition with no visible signs of damage<br />
or splitting.
WHAT THE CUSTOMER GAINED<br />
What this meant to the Customer<br />
Utilising the NXG polymer<br />
technology the core of the rope is<br />
now protected from ingress of<br />
seawater and abrasive particles<br />
Longer rope life in deep &<br />
ultra deep water<br />
applications<br />
The NXG technology increases<br />
rope life through the reduction of<br />
inter strand fretting and locking<br />
in the lubricant within the core<br />
More confidence in rope<br />
life management cycles<br />
Brilube Extreme provides<br />
enhanced wash off and fling off<br />
resistance, increased operating<br />
temperature range, and pressure<br />
resistant properties providing all<br />
round protection to the rope in<br />
deep waters<br />
Increased rope operating<br />
life, lower cost of<br />
maintenance, lower rope<br />
operating costs
DEMONSTRATION PROJECTS<br />
NEXT GENERATION MULTI-STRAND ROPES<br />
The following ropes have been manufactured and supplied by<br />
Bridon:<br />
• 34mm x 2500m 34LR low rotation rope<br />
• 48mm x 2800m 34LR low rotation rope<br />
• 63mm x 800m Hydra low rotation rope<br />
• 109mm x 3200m Hydra low rotation rope<br />
• 92mm 6-strand high performance Bristar NXG Anchor<br />
Lines<br />
• 103mm DF6X52 BRISTAR NXG EXTREME<br />
• 76mm DF6X47 BRISTAR NXG EXTREME<br />
• 30mm DF34LR NXG EXTREME<br />
• 38mm DF34LR NXG EXTREME<br />
• 64mm DF34LR NXG EXTREME<br />
• 34mm DF34LR NXG EXTREME<br />
• 96mm x 3000m Hydra low rotation rope
Anchor<br />
Lines
ANCHOR LINES SUMMARY<br />
Key Performance<br />
performance requirement<br />
Requirement<br />
• Limited opportunity for<br />
maintenance:<br />
• Increased resistance to corrosion<br />
• Prevention of particle ingress<br />
• Complex winch arrangement<br />
• Extended fatigue performance<br />
• Increased line length & deeper<br />
operations<br />
• High strength to weight ratio
ANCHOR LINES<br />
IR available<br />
enhancements<br />
• Bristar NXG sealed, enhanced polymer core<br />
with Extreme high performance subsea<br />
lubricant<br />
Current best performing<br />
• Bridon Diamond<br />
Blue<br />
• Bridon DB2K<br />
Industry standard - API9A<br />
• Conventional 6 x 36 IWRC<br />
constructions
CORROSION PROTECTION<br />
BARRIERS<br />
1 2<br />
LUBRICATION<br />
(Blocking<br />
Compound)<br />
POLYMER CORE<br />
(Blocking<br />
Compound)<br />
WIRE<br />
COATING<br />
(Zinc)<br />
EXTENDED<br />
ROPE LIFE<br />
3<br />
3<br />
NXG Polymer Core<br />
Sealed, plastic core keeps the<br />
rope lubricant inside and<br />
seawater and abrasive<br />
particles outside.<br />
2 2<br />
3<br />
1<br />
More accurate and durable<br />
placement of the strands<br />
resulting in even load distribution<br />
Brilube Extreme<br />
Enhanced fatigue life performance<br />
New rope lubricant with extreme<br />
pressure resistant additives,<br />
enhanced wash<br />
off resistance and improved<br />
corrosion protection additives<br />
ANCHOR LINES<br />
1
HOW CAN YOU BENEFIT FROM THESE PRODUCT<br />
UPGRADES<br />
Improvement Benefit Additional Benefits<br />
Improved corrosion<br />
resistance<br />
Improved fatigue<br />
resistance<br />
Improved operating<br />
design<br />
Longer rope operating<br />
life<br />
Lower maintenance<br />
requirement<br />
Combined with the<br />
unique MORE programme<br />
these benefits enable<br />
customers to achieve<br />
MORE from their ropes,<br />
ultimately delivering<br />
M operating O cost R savings E
CASE STUDY EXAMPLE<br />
Anchor<br />
Lines
CASE STUDIES AND FIGURES<br />
• In Western Australia a rig drifted away following an anchor<br />
line breakage due to premature corrosion<br />
• Cost involved in lost rig day rates<br />
alone:<br />
• Recovery cost:<br />
Repairs cost:<br />
• All above covered by liability insurance<br />
~US$13millio<br />
n<br />
~>US$5millio<br />
n<br />
~>US$3millio<br />
n<br />
• What is not covered, is the resultant reduction of<br />
~US$187m in contract revenue backlog through<br />
reduction of contract by 1 year and ~45 days lost rig<br />
uptime
THE CHALLENGES FOR BRIDON<br />
• To maintain breaking load over time against the effects of<br />
loss of metallic area through corrosion<br />
• To provide an anchor line solution which delivers<br />
increased protection both externally and at the core<br />
(where most anchor line failures occur)<br />
• To provide anchor lines which could survive the full<br />
change-out term with as little maintenance as possible<br />
• Collaborating with customers to provide ongoing forensic<br />
analysis to become best in class for anchor line<br />
reliability and safety
ROPE LIFE MANAGEMENT<br />
Rope life management programme<br />
to be implemented on cut off<br />
samples received, comprising of:<br />
• Annual residual MBL<br />
• Annual forensic testing<br />
• Visual inspection<br />
• Lubricant effectiveness analysis<br />
M O R E
WHAT THE CUSTOMER GAINED<br />
What this meant to the Customer<br />
Utilising the Bristar technology the<br />
core of the rope is now protected<br />
from ingress of seawater and<br />
abrasive particles<br />
Longer anchor line rope<br />
life in high temperature,<br />
high corrosion<br />
environments<br />
The NXG technology increases<br />
rope life through the reduction of<br />
inter strand fretting and locking<br />
in the lubricant within the core<br />
More confidence in rope<br />
life management cycles<br />
in high corrosion<br />
environments<br />
Brilube Extreme provides<br />
enhanced wash off resistance in<br />
the splash zone delivering<br />
increased protection against<br />
corrosion whilst being able to<br />
operate at a wider temperature<br />
range<br />
Increased safety and<br />
Lower risk of costly<br />
claims through damage<br />
caused by anchor line<br />
breaks<br />
M O R E
BRIDON OFFERS<br />
M O R E
Appendix 1 - TON-MILES<br />
General<br />
Definition<br />
A unit of<br />
freight<br />
transportatio<br />
n equivalent<br />
to<br />
a ton of<br />
freight<br />
moved one<br />
mile<br />
What is<br />
drilling<br />
Ton-Mile<br />
The work of<br />
the drilling<br />
line that is<br />
commonly<br />
measured as<br />
the<br />
cumulative<br />
of the load<br />
lifted in tons<br />
and the<br />
distance<br />
lifted or<br />
lowered in<br />
miles<br />
Slip and<br />
Cut<br />
When the<br />
predetermin<br />
ed Ton-Mile<br />
limit is<br />
reached,<br />
drilling<br />
contractors<br />
will perform<br />
slip and cut<br />
to prevent<br />
further<br />
fatigue<br />
Resul<br />
t<br />
Ton-Mile is<br />
an<br />
important<br />
figure that<br />
must be<br />
recorded<br />
correctly;<br />
however, it is<br />
important to<br />
visually<br />
inspect the<br />
drilling line to<br />
see if there is<br />
any worn out<br />
wire
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