Ocyan and Magma Global announce new CompRiser® partner
BrasFELS shipyard arrives to strengthen the project
Ocyan and Magma Global today signed a new MOU (Memorandun of Understanding) that guarantees the participation of BrasFELS in the CompRiser® solution, a riser tower system that utilises carbon fibre composite pipes. BrasFELS, located in Angra dos Reis, is the Brazilian shipyard of Keppel Offshore & Marine, the global leader in offshore rig design, construction and repair, ship repair and conversion, and specialised shipbuilding.
“The BrasFELS participation in the CompRiser® development is another achievement of this initiative. The shipyard location, its installed manufacturing capacity and reputation in the Brazilian market further reduces the project risk assessment. It’s certainly a partner that aggregates a lot of value”, explains Marcelo Nunes, Ocyan Director – Subsea Services.
Tony Duncan, Executive Vice President at Magma Global, said: “The CompRiser is an effective solution for deepwater and pre-salt environments. It’s a clever design that uses m-pipe in a static application thus streamlining the qualification needs versus dynamic riser designs. Confirming BraFELS as the manufacturing location means we can bring this design project to fruition in the very near future.”
Mr Marlin Khiew, CEO and President, Keppel FELS Brasil, said, “BrasFELS is the most established shipyard in the Latin American region, with a strong track record in the construction, integration, upgrading and repair of a wide range of products. We are proud to collaborate with Ocyan and Magma Global in the development of the innovative CompRiser® solution, which will strengthen the position of BrasFELS as a one-stop provider of solutions for deepwater production platforms.”
CompRiser® is a hybrid riser system created in partnership with Magma Global for use in the deepwater and ultradeep water oil exploration industry. The Thermoplastic Composite Pipe (TCP) used in the CompRiser® will be m-pipe®, manufactured by Magma. TCP provides high corrosion resistance (e.g. CO2 and H2S), of great value to the subsea systems at the pre-salt area, significant weight reduction and the possibility of withstanding high temperature and pressure. Its mechanical flexibility allows the design of a new concept for the lower termination (patent pending) that allows the riser to be connected directly to the flowline – both rigid and flexible.
Its compact and modular manufacturing method allows high local content. Additionally, m-pipe is delivered in reels and does not require welding, simplifying the bundle assembly which can be completed in less than 30 days. The offshore installation takes another 20 days, without the need for special vessels and with minimal exposure to bad weather conditions.
As a decoupled solution, the product uses less than 20% of the load applied by other solutions in the production units. The result of this difference can exceed 9,000 tons per FPSO, conditioned to quantity of project risers. The reduction of weight and load in the FPSOs (floating production storage and offloading) operations is a constant demand of the operators.
Magma wins Energy Institute Award for Innovation
Portsmouth, UK, 27th November 2018: Magma Global, manufacturer of carbon-fibre composite pipe, today announces it has won the Energy Institute’s 2018 Award For Innovation. Magma was up against a variety of renewable energy innovations, including SSE’s Wind Turbine Nitrogen Accumulators and Imperial College’s Next-Generation High-Efficiency Affordable Hybrid Solar Systems, but m-pipe was selected due to its positive impact on the oil and gas industry.
Martin Jones, MD at Magma Global, said: “m-pipe is being seen as a game changer as it delivers cost effective and ecologically improved development of deepwater reserves. It significantly simplifies engineering and in doing so reduces cost and time to first oil. Most importantly it doesn’t corrode or degrade in the oil field and can be lifted and reused at the end of a field’s life.
“We’d like to thank our early supporters who helped pave the way for qualification and market adoption, and our team of engineers who strive to simplify a complicated world. m-pipe is being embraced by a justifiably risk averse industry and we are delighted to be recognised with this award.”
Energy Institute President Malcolm Brinded CBE FREng FEI said: “Beating climate change – whilst extending the tremendous benefits of energy to all populations – calls for innovation and a lot of hard work, by many smart people, all around the world.
“Too often these efforts are behind the scenes and complicated, and so they go unnoticed. That’s what the Energy Institute Awards are for – an opportunity to sing the praises of the very best within our industry – from India to the Highlands, from oil and gas to the most advanced smart tech, from the seabed to our classrooms.
“In so doing we also acknowledge the collective endeavour of all energy professionals around the world whose day-to-day is building the energy system of the future.”
The EI Awards is a competition run by the Energy Institute for those shaping the world’s energy future. The awards celebrate the achievements of the energy industry across the globe, giving recognition to individuals and organisations who take an innovative and responsible approach to solving the industry’s challenges of providing society with clean, sustainable, low cost and dependable energy.
£10.5m funding secured to qualify an insulated all carbon fibre subsea pipe
Equinor joins Magma in UK government backed qualification programme
ONS, Norway and Portsmouth, UK, 29th August 2018: Magma Global, manufacturer of carbon-fibre composite pipe, today announces a joint initiative with Equinor, previously Statoil, to qualify an all-Magma solution for jumpers, initially envisaged for use in Norway. This secures the £10.5m project being supported by Innovate UK and will be a step towards fulfilling Magma’s vision of owning the fluid transfer infrastructure from seabed to surface.
Charles Tavner, COO at Magma Global, said: “There is no doubt in our minds that the future subsea infrastructure will be dominated by carbon-fibre composites. We have seen acceptance of this from large contractors, each developing their own solution using m-pipe, which is a natural adoption path. This initiative will fast forward the delivery of an all-Magma solution, thanks to funding support from Innovate UK and Equinor’s vision and understanding of how they can best use available technologies.”
Derek Allen, Innovation Lead at Innovate UK, said: “We are delighted to have supported this innovative project that will ultimately lead to improved efficiency and cost reduction in the UK energy sector”
Ocyan and Magma Global complete Composite Multi-Bore Hybrid Riser (CMHR) design
Commercial commitment signed in readiness to bid for Brazil’s deep-water fields
OTC, Houston, Texas. 2 May 2018: Ocyan and Magma Global, manufacturer of the world’s most advanced thermoplastic composite pipe (TCP), today announce the completion of a Composite Multi-Bore Hybrid Riser design for ultra-deep fields. The companies have signed a long term commercial agreement and will jointly bid the CMHR for deep water developments in Brazil. The design has been validated by a third-party engineering company and is in discussion and analysis with potential clients.
The CMHR offers multiple benefits which address barriers for operators. Today’s FPSOs are on a constant demand for reduced weight and loads. As a decoupled solution, the CMHR applies less than 20% of the loads applied by other solutions resulting in a weight difference of up to 9.000 tons per FPSO.
The use of TCP brings high resistance to corrosion (for example CO2 and H2S), light weight and the ability to withstand high temperature and pressure. Its flexibility enables the design of a novel lower riser termination assembly concept (patent already in place and under final analysis) which allows for the direct connection between the risers and the flowlines – either flexible or steel – with no design change to the CMHR.
The pipe used in the CMHR will be Magma’s m-pipe which is reeled onto reels and needs no welding which makes fabrication compact, simple and standardised, therefore enabling higher local content. Once all CMHR components are at the selected yard, the CMHR assembly takes just 20 days. To complete installation requires only 20 more days offshore, with no need for a specialized vessel and minimum risk from exposure to weather conditions.
Charles Tavner, COO at Magma Global said: “The design phase of this project with Ocyan has been really exciting as it fully exploits and builds on the capabilities of m-pipe. No other pipe can meet the requirements, as they are either not flexible enough or not able to withstand the requirements for strength and heat resistance. We look forward to seeing this excellent TCP riser solution used in large scale oil production in the very near future.”
Marcelo Nunes, Subsea Director at Ocyan said: “We have worked closely with Magma to design this incredibly simple yet robust riser system. It is a perfect match on the technical side as the CMHR provides a discrete support so that the riser works very much like a spool, in a quasi-static application. Furthermore, the concept takes advantage of the mechanical properties of m-pipe. The final result of the project has superseded our expectations and the complexity of the project has dropped dramatically.”
Magma at MCE Deepwater Development, Milan, 9-11th April
Join as for a drink at the icebreaker reception at 18:30 in the main exhibition hall then come and hear our Chief Operating Officer, Charles Tavner, present a paper at 14:45 on Tueday 10th April in Le Baron A.
Charles will present a case study detailing the cost, delivery, deployment and performance benefits of two 2.5in m-pipe® gas lift jumpers, linked to an ENI floating production system in a water depth of 850m in the Mediterranean.
He will cover m-pipe® materials, the manufacturing process and production automation systems and the transport and delivery methods. He will examine the commercial and product performance reasons ENI selected m-pipe® over flexible and hose alternatives, and the main factors behind a rapid and low risk deployment via a standard offshore supply vessel.
Charles will also include a cost analysis of m-pipe® versus comparative flexible hose which shows that, for a given specification, m-pipe® has the lowest fully deployed pipe and end fitting cost in the current market.
Download the MCEDD 2018 brochure here.
Portsmouth, UK, 23rd March 2018: Magma Global, manufacturer of the world’s most advanced thermoplastic composite subsea pipe (TCP), today announces that it has been selected by TechnipFMC to collaborate on the development of the core element of its hybrid flexible pipe solution. It will be used notably to address the challenges of the Libra field in the Santos basin pre-salt area in Brazil and other major deepwater projects. To secure its hybrid product TechnipFMC has also taken a minority share in Magma Global.
Brazil’s Libra field, operated by Libra Oil & Gas BV, is a deep-water pre-salt environment and considered to be one of the most challenging projects for the industry. The new hybrid flexible pipe incorporating Magma’s m-pipe® will deliver robust risers and flowlines with increased performance while offering significant overall reductions in the product installed cost. This will be achieved by combining the chemical resistance and fatigue performance of Magma’s high-end carbon fibre PEEK TCP with the stability and strength of flexible steel armour.
Martin Jones, Magma Global CEO, said: “We are delighted to be working with TechnipFMC and believe that their vision for a hybrid flexible product provides a logical step for the increased adoption of TCP in full field developments, paving the way towards Magma’s long-term vision of an all-composite subsea infrastructure. Ultimately we will deliver that by continuing to offer the unique benefits of Magma’s m-pipe® to a wide range of industry players and applications.
Barry Glickman, President of Engineering, Manufacturing & Supply Chain at TechnipFMC, stated: “I am very pleased that we have reached this agreement with Magma, which will further enhance TechnipFMC’s Subsea 2.0 product platform. The lighter, higher performance, and more cost-effective HFP solution, will enable TechnipFMC to strengthen its leadership position in the flexible pipe business and address the new challenges of offshore deepwater fields”.
Piping in a new way to lighten the load
Extract from Upstream published 26 January 2018 – by Russell McCulley.
A lighter, corrosion-resistant alternative to metal pipe is building a track record in the oilfield as its proponents eye the ultimate prize, a deep-water riser made entirely of composite materials
The past couple of years have witnessed a flurry of activity for the manufacturers of bonded thermoplastic composite pipe (TCP), a product that its makers say addresses many cost and safety concerns of operators.
The technology has recently been deployed in several oilfield applications following a decade of development and trials. UK-based Magma Global, which manufactures a high-end, bonded carbon composite product branded m-pipe, had a banner year, seeing its TCP light well intervention system deployed in the ultra-deepwater US Gulf of Mexico.
Magma delivered several high-sour gas TCP jumpers to Eni for use in the Adriatic Sea, supplied a number of high-sour hydrocarbon risers for onshore application in the Middle East and, early this year, announced a contract with Tullow Oil for two 2.5-kilometre, six-inch spoolable carbon composite flowlines at its Tweneboa, Enyenra and Ntomme (TEN) project off Ghana.
The company has been “building operational experience” in different applications, says Magma chief operating officer Charles Tavner, noting that m-pipe® was the first TCP product to receive third-party verification under a DNV GL recommended practice issued in 2015.
“It’s the same product every time,” Tavner says. “What we’ve done is put that same qualified product into high sour gas applications, high sour hydrocarbon applications, water injection applications and high-temperature lines.”
Bonded composite pipe resembles steel pipe in that it has a single solid wall, but unlike steel it is lightweight and mostly impervious to corrosion from seawater, hydrogen sulphide (H2S), carbon dioxide (CO2) and many harsh chemicals used in oil and gas production.
While much more expensive than steel, its advocates say it can cut costs considerably in installation and over the life of a field and offer a durable alternative to steel flexible pipe in many applications.
The TEN flowline, for example, will save Tullow 65% in installation costs immediately, Magma says, because the 100-tonne pipe and deployment package can be mounted on a small offshore construction vessel rather than a large lay ship, which would be required for an equivalent steel flexible pipe package weighing 500 tonnes.
“That’s very exciting for us. It’s a validation of what we’ve been saying for a long time, that the light weight allows you to use much smaller installation vessels. It’s great to see a customer proactively identify that and come to us and put together a package that takes advantage of it,” Tavner says.
The aerospace and automobile manufacturing industries have used thermoplastic composite materials in non-load bearing applications. Offshore has been an early proving ground for TCP use in load-bearing applications, but a conservative oil industry has been slow to embrace the technology.
Magma has formed important alliances to help push the technology along. Subsea 7 and BP have worked with Magma to qualify m-pipe for increasingly demanding subsea applications, and last year Magma reached an agreement with Odebrecht Oil & Gas (now renamed Ocyan) to supply its product for use in composite multi-bore hybrid risers in high-CO2 pre-salt projects off Brazil.
Charles Tavner said: “That’s why the m-pipe® intervention downline is exciting, because it’s effectively a small riser system. It’s only three inches inner diameter but it’s a dynamic system. By deploying it, we underpinned what the testing shows – that the product is effective in dynamic scenarios.”
A TCP riser could deliver significant savings, he says, because it would require fewer buoyancy modules and allow shorter flowlines by rendering lazy-wave systems unnecessary. Installation costs would also be much less, he adds.
“It’s always been about riser systems, because that’s really where the biggest cost benefits are.”
The corrosion-induced failure of two steel flexible gas re-injection risers last year at Petrobras’ pre-salt Lula field has lent some urgency to the quest, highlighting the potential life of field benefits of TCP. Magma reports a significant increase in interest in TCP and in the number of actual projects in the works.
Tavner says: “What has surprised me over the past few years is how there will be periods when you don’t see huge amounts of progress, and then you’ll see a number of operators move quite quickly. We seem to be in that period at the moment.”
Tullow Oil subsidiary, Tullow Ghana Limited, has awarded a 2.5km flowline to Magma Global for its TEN project in Ghana.
The 6 inch spoolable carbon composite m-pipe® will be deployed from a 10m diameter reel with a 20-ton tensioner, and the total weight of pipe and deployment package is under 100 tons. As a result the flowline can be deployed from the Tullow infield MPCV, currently in-country on long term charter.
Magma Global COO Charles Tavner said, “We are delighted to be able to help Tullow reduce the cost for this infill work. At 1,800m this is another deepwater deployment in a production application for Magma m-pipe®, in what has already been a busy year for us.”
At the Westin Hotel, Houston USA, Magma Global held a market update event for forty senior oil and gas executives, project managers and subsea engineers.
Attending were representatives from BSEE, Shell, Cobalt, BHP, TechnipFMC, JDR, EnPro, Chevron, Exmar, McDermott, OneSubsea, 2H, Intec, Oceanflow, BP, MWCC and Marubeni, as well as other local oil and gas operators and contractors.
The briefing focused on 2017 key milestones for Magma’s m-pipe. This included the fact that m-pipe is currently the only Thermoplastic Composite Pipe product qualified to DNVGL-RP-F119, as verified by DNVGL.
m-pipe uptake was shown to have been rapid since DNVGL product qualification, mainly due to the confidence the oil and gas industry has in the product’s ability to solve production and tieback project challenges with existing steel and non-bonded flexible components, such as deployment weight, corrosion, fatigue and flow rate.
Magma showed m-pipe uptake has been influenced by its development of dynamic open-water applications for hydrocarbon, gas and water injection and, in particular, for high temperature, high pressure and sour service jumper spools, flowlines and downlines. Magma demonstrated that clients have been positively influenced by an ability to develop complete subsea systems and solutions such as the Magma IDP system, currently on rental for a deepwater job in the Gulf of Mexico.
Magma also covered some of the new awards recently received for specialist subsea and onshore deployments, such as composite umbilical components and large diameter composite riser tower solutions, as well as temporary applications such as small diameter flying leads to eliminate flexible hose vacuum collapse risks.
At the networking session afterwards, there were discussions around the recent Magma projects, m-pipe qualification program, and the qualification process for larger diameter production service and dynamic riser systems, which is nearing completion.
Feedback from the event showed that attendees were impressed with the m-pipe product and end fitting test program that resulted in DNVGL product qualification in August 2017.
There was also pleasant surprise expressed at the rapid growth of client take-up of m-pipe for subsea applications, and especially the large project type range and number of subsea deployments throughout 2017 and in progress for 2018.
In Stavanger, Norway, Magma Global presented to a group of Norwegian operators and contractors. The TechDay gave an overview of Magma m-pipe® capabilities for subsea applications ranging from jumpers and flowlines through to downlines, commissioning lines and return lines.
The morning presentation was viewed by senior project and operations managers from operators and contractors including Statoil, Island Offshore, Knutsen, Ocean Installer, Oceaneering, Subsea7, TechnipFMC and Wood Group.
Charles Tavner, Magma COO, gave an introduction to the current challenges facing operations on the Norwegian Continental shelf and m-pipe manufacturing capabilities, designed to capitalise on increased demand for m-pipe® in a range of diameters from a growing number of clients around the globe. He also covered the latest research that showed how the oil and gas industry is increasingly viewing composite pipe as a solution to reducing Capex costs, deployment costs and overall risks for subsea projects.
MCE 2017 Amsterdam audience survey results:
- 85% said composite pipe is a promising way to achieve deep water project cost reduction
- 88% thought reducing riser weight through composites will become an increasing feature offshore
- 97% agreed the use of composites would simplify subsea jumper spools and reduce installation time and cost
Ramin Moslemian from DNVGL also presented an overview of the DNVGL-RP-F119 qualification standard that has been purposely developed for composite pipe, due to the limitations of other standards like API15S that does not cover subsea use. Magma’s m-pipe® is the first composite pipe product in the world to be qualified to DNVGL-RP-F119, as verified independently by DNVGL.
David Charlesworth went into detail about the m-pipe qualification program both for smaller diameter downlines and the larger diameter pipe of 6in and 8in required for jumpers and flowlines. Charles also covered the commercial, design, transport and deployment benefits of m-pipe, with examples from operators that have assessed TCP compared to non-bonded flexible pipe and steel pipe for a range of larger diameter production applications such as jumper spools and flowlines.
Asaf Hisherik reviewed the benefits of m-pipe® to reduce costs versus existing hose products, and showed case studies and examples of recent projects where m-pipe® has delivered benefits with low weight and high fatigue strength, combined with advantages for deep water applications and sour service conditions.
The TechDay finished off with a lunch and networking session to discuss some of the major challenges facing the NCS and North Sea and how Magma and m-pipe could benefit future subsea production applications and projects.
Some of the key points that delegates commented on positively about m-pipe during the TechDay included:
- m-pipe product qualification and deployment track record
- Capex reduction by using m-pipe versus equivalent steel or non-bonded flexible pipe
- m-pipe MBR and ease of reeled deployment from smaller and existing vessels
TechDay online questionnaire results
Magma contacted the subsea professional delegates after the TechDay event to understand their views on m-pipe®. The anonymous online survey results were positive:
- 90% said m-pipe® product qualification to DNVGL-RP-F119 is a key factor in future purchase decisions
- 69% believe m-pipe® reduces cost and risk for jumpers & flowlines vs. steel and non-bonded flexibles
- 77% believe m-pipe® has both cost and risk benefits compared to flexible hoses
- 76% see m-pipe® as an enabler for deep water, HPHT and corrosive condition applications
- 73% said they were considering Magma m-pipe® for future subsea projects
Further Magma TechDays and update briefings are planned around the world in 2017 and 2018.
For more details – contact Magma Global
OE European Editor Elaine Maslin reviews m-pipe® developments in global markets – as published in Offshore Engineer September 2017
Magma Global has signed an agreement with Odebrecht Oil & Gas to supply m‐pipe for the CMHR (Composite Multi-Bore Hybrid Riser) solution for future deployment in deepwater pre-salt projects in Brazil.
Magma’s patented m-pipe technology was chosen because it will enable the operator to significantly reduce the scale, complexity and cost of the subsea architecture needed for these challenging deep-water developments, specifically around high CO2 levels, coupled with demanding fatigue performance requirements.
The agreement takes Magma’s m-pipe another step forward, after progressing from use in downlines, to hydrocarbon jumpers, including high sour-gas content jumpers in deep water, offshore Italy, for Eni, and sour service jumpers for use in the Middle East. Magma also recently became the first firm to complete qualification of composite pipe to DNVGL-RP-F119, which will also cover their use offshore deepwater Brazil.
An ongoing project with BP and Subsea 7 is also qualifying the pipe for larger diameter use in more demanding situations, with use for water injection due to be qualified by the end of this year and then hydrocarbon service during the middle of next year.
Charles Tavner, Magma COO, said: “All the qualification done with the BP Subsea 7 program means we are effectively ready to go. Clearly, everyone is working towards risers. Oil operators recognize there’s a big win when it comes to deepwater risers and for the first time we can now see the steps towards big volumes in these projects.
“What is attractive is the combination of light weight, lack of corrosion, resistance to CO2 and being able to build much lower cost riser towers, and not need the buoyancy and or have some of the manufacturing challenges associated with traditional riser towers.” Traditional riser towers need buoyancy and assembly and tow out has to be done carefully to minimize fatigue.
For Odebrecht, Magma will make 6-8in riser towers for up to 10,000 psi service. They will be manufactured in one piece through Magma’s additive manufacturing process. Using m-pipe will also mean the upper and lower riser parts will also be able to be simplified, says Tavner.
Magma’s m-pipe has been used for water injection since 2012. Statoil has used the product for high-temperature (150 deg c) hydrocarbon service since 2015. The product is now in use for high sour gas in deepwater for Eni offshore Italy and in the Middle East.
Magma m-pipe is the first TCP product to complete qualification to DNVGL-RP-F119 with third party verification provided by DNV GL.
Magma Global is pleased to announce the completion of the first DNV GL qualification of a Thermoplastic Composite Pipe (TCP) product under DNVGL-RP-F119. Third party verification has been provided by DNV GL. The qualification covers m-pipe for dynamic surface to seabed applications.
Ramin Moslemian, Project Manager, DNV GL, said:
“The DNVGL-RP-F119 Thermoplastic Composite Pipe was developed in conjunction with oil and gas operators and contractors to specifically meet the needs for cost-efficient and reliable solutions.”
“There is a great potential for TCPs to deliver lightweight, non-corrosive pipeline solutions, and qualification according to DNVGL-RP-F119 provides a robust assessment of the operational integrity of TCPs, especially under challenging deep water environments.”
David Charlesworth Head of Engineering for Magma said:
“We have worked very hard to achieve this qualification for m-pipe and are delighted to have secured DNV GL’s third party verification. This qualification involved extensive materials testing, design process development and verification along with considerable full scale testing.”
“This qualification forms the foundation for further qualification scopes which are already underway, covering larger diameter, long term production applications. My personal thanks goes to the DNV GL team who have worked closely with us to expedite this qualification”