Weld overlay cladding specialist Arc Energy Resources has successfully completed a contract for supply of two riser joints for Aquaterra Energy, the provider of world-class and award-winning offshore solutions.
The components are part of two low pressure risers for an oil platform. The finished risers were destined for a set of twenty wells being drilled in the North Sea off the coast of Norway. It is a brand new development for a low pressure section of pipes to deal with any drill fluids and shallow gas that they may encounter while drilling the first top-hole section of a well.
Commenting for Arc Energy Resources, director Andrew Robinson says: “This project played well to our core strengths, a full supply contract for which we secured the material for both components (a flange and pipe for each), applied the weld overlay cladding, welded the flanges to the pipes, organised the pressure testing, completed radiographic testing requirements and arranged final coating of both items all within a very tight delivery schedule.”
The project is a DNV class rig, designed to the DNV0SE101 code and was signed off by Det Norske Veritas as suitably manufactured and designed for the task. Aquaterra Energy Project Engineer Matt Hugo comments: “DNV is one of the oil & gas industry’s largest verification bodies, which confirms calculations that pipe wall thickness and flanges are sufficient for the pressure. For this project they also undertook a review of the overall design of this section of pipe.”
The component acts as a conduit for drilling fluids and equipment during the top hole section and ensures that in the event of gas passing up through the well it can be contained and routed to the rig diverter where it can be vented to atmosphere.
The risers need to have a sealing ring groove in the end of the flange, which is inlaid with an extremely hard, corrosion resistant Inconel 625 alloy.
As Aquaterra Energy has previously used Arc Energy Resources for specialist welding requirements, it approached the company again with a view to provide full supply of materials, carry out all required welding, inlaying of the flange, testing and coating.
Arc Energy Resources sourced the machined flanges and clad with Inconel 625, before completing the welding requirements for the project using Submerged Arc Welding – a process that provides a high quality finish.
Once welded, the parts were pressure tested. Domed end caps were welded onto the straight pipe lengths and then both joints were sealed together through adjoining flange faces to form a complete vessel. For the first stage of pressure testing, the riser was filled with water to a test pressure of 750psi, which provided a safe 500psi working pressure. After being held at this pressure for 5 minutes it was pressured down and pumped back up, then held for a further 15 minutes before being drained-down. When the pressure test was complete, radiographic testing was carried out to confirm that the welds hadn’t cracked or been damaged. The end caps were removed with pipe free ends being finish machined as required. The parts were then sent to be coated.
Says Matt Hugo: “We were at Arc Energy Resources’ site when the testing was carried out and were very impressed with the way they conducted the demanding procedures, whilst maintaining their high levels of health & safety.”
The final checks for the unit were carried out by a team that included an inspector from Aquaterra Energy’s customer and their own inspector accompanied by an inspector from DNV. Following the riser’s final check the unit was ready for use. It was delivered offshore and installed in position on-time where it has since operated very successfully.
Summing up, Matt Hugo says: “This project was quite a straightforward concept. But, as with many straightforward concepts, there is potential for things to go wrong. Fortunately, Arc Energy Resources’ knowledge and experience ensured that nothing did, and they kept us up-to-date every step of the way and the whole project went very smoothly. Arc Energy Resources did a sterling job, delivered an excellent project, with exceptional performance throughout the manufacture of the unit. They did everything we have asked of them.”
Eastington-based Arc Energy Resources – one of the UK's leading specialists in weld overlay cladding and quality assured fabrication services – will once again be supporting this year's Stroud Festival of Manufacturing & Engineering and hopes to encourage pupils from the county's local schools and colleges to choose a career in engineering.
Director Rosemary Robinson is proud of the skilled engineers the company has assembled, a team that is qualified to internationally recognised standards and specifications, and capable of delivering quality products from enquiry to delivery and the service beyond.
Explaining the company's approach to people management, Rosemary says that if Arc Energy Resources is to maintain its standards and plan for the future, it is essential to continue to recruit and train skilled staff. "Recruiting and training has proved a major challenge recently. A decade ago there was a pool of skilled staff who moved between companies, many of them having served apprenticeships in large organisations." says Rosemary. "Today this resource no longer exists. Manufacturing became unfashionable with government and education and was allowed to decline. Fewer apprenticeships were served, fewer students entered engineering and, as experienced engineers retired there were fewer, new engineers trained to replace them."
Since last year, Gloucestershire Engineering Training has begun to offer welding and fabrication apprenticeships in Gloucester, which, thanks to its accessibility, they have been very happy to take advantage of by sponsoring their latest apprentice, Tyron Cleaver who has started his first year there.
A recent success for Arc Energy Resources is Charlie Fryer who, at just 14, enjoyed a week's work experience with the company in 2005. Encouraged by the 'experience', Charlie applied for and was accepted for an apprenticeship at Arc Energy Resources on leaving school. And in July 2013, having undergone extensive on- and off-site training and an often intensive course at Gloucester College, Charlie completed his apprenticeship and is now employed by the company as a Project Engineer. And the story doesn't end there because Charlie, now 23, has completed an HND in Mechanical Engineering and is now working towards a degree. Lee Crosbee (22) and Kieran Kellett (24) have continued with their apprenticeships in Fabrication and Welding.
Summarising, Rosemary Robinson explains that the skills and experience the Arc Energy Resources team brings to the company is invaluable in ensuring that it remains the partner of choice for the supply of weld overlay cladding and complex weld fabrications.
If you're considering a career in engineering, Arc Energy Resources will be exhibiting at the Stroud Festival of Manufacturing & Engineering on 24th November at Stroud Leisure Centre and will be on hand to offer advice.
Advanced Insulation (www.aisplc.com)
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AL-KO Kober (www.al-ko-co.uk)
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Arc Energy Resources (www.arcenergy.co.uk)
Arc Energy Resources is one of the UK’s leading specialists in weld overlay cladding and fabrication for the oil & gas industry. The company’s expertise provides protection against corrosion and wear for a variety of process and pipeline equipment for use in any hostile environment.
The company recently made a major investment in two new Rotating Head welding machines costing £500,000. This has increased productivity and extended the size and scope of work it can handle, which now includes complicated component geometries for the full or partial cladding and fabrication of a huge range of component sizes weighing up to 15 tonnes. The company’s in-house designed cladding workstations feature state-of-the-art control systems developed to suit its customer’s specialised engineering requirements, and can clad bores up to four metres diameter and areas of restricted access within bores as small as 20mm diameter. Arc Energy also offers in-house test weld, heat treatment, PMI and NDT facilities.
Industry certifications include ISO 9001:2008 quality management, ISO 3834-2 fusion welding of metallic materials, and the internationally renowned ASME U and R Stamps, as well as ISO 14001:2004 environment management, Investors in People and OHSAS 18001:2007 Health & Safety management system.
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We are ISO 9001 accredited and constantly strive to achieve continuous improvements in the overall quality of our products and service.
Exmac Automation has has established a reputation for supplying high quality, robust systems at competitive prices.
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Fulton Limited (www.fulton.co.uk)
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Q8Oils (www.Q8Oils.co.uk / @Q8OilsUK)
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Q8Oils has a unique and innovative approach producing some of the world´s finest quality lubricants. Manufactured in its state of the art plant at Leeds, West Yorkshire, Q8Oils represent the very best and latest in lubricant technology. With over 1000 grades of finished lubricants, base oils, process oils, extracts and waxes.
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TLV Euro Engineering (www.tlv.co.uk)
TLV Euro Engineering UK is part of TLV, an internationally-established designer, manufacturer and provider of steam traps, condensate recovery pumps, pressure reducing valves and other specialist steam solutions. The company plays a leading role in the promotion of efficient energy systems and increased environmental conservation on a worldwide scale through its products and consulting and engineering services.
Rockatek (www.rockatek.com)
Cheltenham-based Rockatek Ltd is an engineering consultancy that offers design, analysis and physical testing services that set it apart from others. Its directors have over 40 years’ experience in complex engineering product optimisation and development; and its engineers specialise in engineering solutions for harsh environments and value improving reliability and performance.
Verco (www.ver.co.uk)
Founded in 1965, Verco quickly built a reputation for supplying quality refrigerated glass door and open chill cabinets to supermarkets, convenience and forecourt stores. Verco is now a leading supplier of retail refrigeration and the largest UK manufacturer of glass door cabinets.
