10.Large Scale Hazards Testing External

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Safety & Risk Management Services

Large Scale Hazards Testing (Spadeadam)

Germanischer Lloyd – Service/Product Description



Contents

Service Description and Values Generated

Detailed Method Statement

The detailed method statements descibe the typeof work that can be conducted at the test site andthe range of data that can be provided.

Case Studies and Examples

Tests of Low Pressure Vent Panels

Blast and Fire Engineering Project forTopside Structures Phase 2

Corrosion Resistant Lining for Subsea Pipelines

Fracture Propagation Testing ofTransmission Pipeline

Hot Gas Pressure Test of Heat Exchanger

Scavenging of Hydrogen Sulphide fromMulti-phase Flowing Systems

Subsea Intervention Valve Tests forExpro North Sea Ltd.

Test Pressure Safety Valve

New Fire Protective Coating Material

Page 3

Pages 4 - 9

Pages 10 - 19

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Large Scale Hazards Testing

(Spadeadam)Service Title: Safety & Risk Management Services

Lead Practice: GL Safety and Risk (UK)

Germanischer Lloyd – Service/Product Description

2



Service Description

and Values Generated:The Spadeadam Test Site operated by Germanischer Lloyd (GL) is aworld class centre where full scale destructive and non-destructiveexperiments of a hazardous nature can be designed and conductedprofessionally, discreetly and with complete confidentiality.

This unique site carries out research, investigative testing and technicalproject work for the energy sector, as well as specialist work for otherindustries and various Government agencies.

The testing can demonstrate that items are fit for purpose, test newproducts, techniques or processes or provide data to validatecomputer models. Typical projects undertaken involve some or all of

the following features:

Flammable or toxic gases or liquids

High pressures or temperatures

Cryogenic liquids including LNG

High explosives

Large-scale test rigs

Rapid data capture

Risk of loss of containment

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SERVICE DESCRIPTION



GL at Spadeadam

Where would you go to set off a large explosive charge in a controlledenvironment or conduct a gas explosion in an offshore module?Where would you go to purposefully fracture a very large diameterhigh-pressure steel pipeline?

The answer is GL Spadeadam….. where you can carry out large scaletesting in a real world environment to validate design, assessperformance and improve safety and all of this in a secure andconfidential environment.

Introduction

GL operates a remote test site, located in a Cumbrian forest.Spadeadam is a unique facility able to provide a wide rangingexperimental and testing services and was first developed in the1960’s by the Ministry of Defence as part of the Blue Streak Rocketprogramme. Subsequently British Gas took over the site in 1977 toconduct full-scale pipeline fracture tests. Large-scale testing aimed atstudying the full range of oil and gas industry hazards developed, andthe infrastructure and facilities at the site have since increased over aperiod of 30 years.

With the demerger of British Gas and BG Group, the research andtechnology arm of British Gas evolved into GL Ltd which then became

part of the GL Group in 2007. With a strong background of studyinto major hazards associated with the oil and gas industry,Spadeadam now offers extensive testing of products, equipment andprocesses especially relating to energy and process industryoperations, but also for engineering, construction and defence.

The Spadeadam Test Site is operational throughout the year with ateam of scientists and engineers permanently based at the site. Thereare more than fifteen separate test facilities that are maintained andconstantly being developed to simulate most of the hazards that theoil and gas industries could experience. In addition test rigs can bepurpose built for specific test requirements.

The team of experienced and skilled engineers at the site provide acomplete service, from planning of experiments to meet customers’objectives, through design and construction of a test facility, to theconduct of tests and capture of data. The Spadeadam team also work closely with industry renowned consultants from within GL and otherorganisations to provide effective solutions.The facilities include:

Three 100m x 100m concrete test pads

Dedicated control room facilities local to each test pad

Jet fire impingement test rigs at both large and mediumscale

Pipeline fracture propagation testing for steel and plasticpipes

Failure initiation of high pressure pipelines and vessels

Large chambers to study confined explosions and test rigsto study vapour cloud explosions

A corrosion test lab incorporating autoclave units

Large scale test rigs for full scale corrosion and inhibitortesting

LNG storage and supply pipework

High pressure gas and liquid storage

Heating and chiller units and heat exchangers to allowtests to be conducted at extreme conditions

Ballistics testing which can accommodate large targetsincluding complete vehicles

Engineering workshop

Offices and stores

A test facility dedicated to polyethylene pipe testing tointernational standards

In addition there is a fully equipped conference facility for audio-visualpresentations, briefings and debriefings, meetings, courses andconferences.

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DETAILED METHOD STATEMENT



Why Test at Large-Scale?

The advanced design and manufacturing techniques now used by theenergy and process industries are the result of many years ofexperience and research. This work has also led to the developmentof effective design codes supported by mathematical models. Thesemodels are routinely used by design engineers of process plant andinstallations, to ensure that structures are fit for purpose and are ableto withstand the loads imposed on them by the environment (such aswind or waves), the process (such as high pressures, extremetemperatures or corrosive fluids) and accidental events (such as fire orexplosion loading).

It is essential that these mathematical models and design codes arevalidated against experimental data. In many situations the physicalprocesses are scale dependent, this is especially the case for fires and

explosions, where the combustion characteristics and theconsequential effects of the event are strongly scale dependent. So,for example, the flame speeds, turbulence and overpressuresgenerated in a laboratory-scale gas cloud explosion are notrepresentative of a large gas cloud engulfing a process plant on anindustrial site. This means that it is important that models arevalidated against experimental data obtained at as close to full-scaleas possible. For this reason, GL through GL has a long history of con-ducting major research projects obtaining large-scale data on the ef-fects of fire and explosions which has been used to improve the risk assessment models used by the oil and gas industry. In this way, thesite has contributed to the improved understanding of majorhazards in the oil and gas industry sector and how this can be usedto ensure the safety of operations.

Similarly, new designs of equipment or novel processes need to betested before implementation and there is no better way of provinga product or process than demonstrating its performance at full-scalein a realistic environment.

Large-Scale Testing at Spadeadam

To conduct a full-scale, potentially hazardous, experiment in a safeand controlled manner, there is a requirement for a large area in aremote location with the necessary infrastructure. This is exactly whatSpadeadam has got. The site extends to about 35 hectares and islocated within a forested area on the south west fringe of the KielderForest. As well as a suitably remote space, the site also benefits froma high pressure natural gas system capable of storing up to 40 tonnes,an engineering workshop, many large and full-scale test facilities andan extensive range of instrumentation and data logging equipmentfor use during tests. The team of experienced and skilled engineersat the site provide a complete service, from planning of experimentsto meet customers objectives, through design and construction of atest facility, to the conduct of tests and capture of data. Data analysisand interpretation can also be provided, backed up by the scientists

at the UK main office in Loughborough, Leicestershire.

Spadeadam specialises in experiments involving some or all of thefollowing features:

Flammable or toxic gases or liquids

High pressures or temperatures

Cryogenic liquids including LNG

High explosives

Large-scale test rigs

Rapid data capture

Risk of loss of containment

The GL Spadeadam Test Site

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Fire Testing

The core work at Spadeadam for many years has been fire andexplosion testing. Fire testing remains a major part of the testingcapabilities of the site. A wide range of scientific instrumentation isavailable to study fires and their effect on structures and thesurroundings. Facilities include high pressure natural gas storage (upto 40 tonnes and at pressures up to 165bar) and a network of aboveand below ground pipework with pressure and flow control systemsto enable a wide range of gas releases to be undertaken undercontrolled conditions.

Liquid hydrocarbons including LNG, LPG and crude oil can be releasedunder pressure to form jet fires either alone or mixed with gases.Alternatively, liquid pools can be formed and Spadeadam hasextensive experience of conducting pool fire experiments involving

LNG, LPG, methanol, condensate, kerosene, diesel, crude oil, etc.

Standard Fire Tests

In addition to tests designed specifically to meet customers particularrequirements, Spadeadam offers several standard fire tests fordifferent industries:

An indoor facility is available to test passive fire protectivesystems on pipes, plates or structures in accordance withthe ISO 22899-1. This facility is fully accredited by LloydsRegister to BS 7501 (EN45001).

A purpose built test rig for the fire resistance testing ofvehicle fuel tanks. The tests are conducted in accordancewith the ECE standards E/ECE324 and E/ECE/TRANS/505(Prevention of Fire Risks (Passenger Cars).

Natural Gas cylinders used in motor vehicles can be testeduntil they vent or fail catastrophically using a standardpool fire test.

Fire Test of PFP covered Valve

Fire Response, Protection and Mitigation

The control and mitigation of fires is studied using water sprinklersystems. Spadeadam has a test rig with a roof measuring 20m by20m incorporating an area water deluge system capable of deliveringup to 16,000 litres/min. The roof can be positioned from 2 to 8mabove a concrete floor upon which pressurised jet fires or pool firescan be conducted and studied under the influence of water deluge.Vessel specific deluge systems designed to protect individual vesselsfrom fire can be constructed and tested using different fire sources.

Several studies have been undertaken using this test facility, providinga large body of data which has improved the understanding of theperformance of water deluge systems under different operatingconditions and fire scenarios.

The effect of fire on materials, equipment or structures to suitcustomers particular needs is also investigated. A typical exampleincludes the response of an LPG storage vessel to fire attack, whichcan result in a BLEVE (Boiling Liquid Expanding Vapour Explosion) ifthe vessel fails catastrophically.

Protecting equipment from fires is also achieved using Passive FireProtective (PFP) materials, sometimes applied as coating, or byconstructing protective barriers. Fire testing of PFP is routinely

undertaken. Another example is testing the ability of dividing wallsbetween large transformers to provide protection from an oil firearound an adjacent transformer.

During fire experiments, data on the event are obtained usingradiometers, heat flux calorimeters, thermocouples and infra-redimaging systems.

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Gas Explosion Testing

With over 30 years experience in studying gas cloud explosions,GL are world leaders in the field. Gas cloud explosions can be studiedwithin confined or partially confined geometries or within congestedregions of pipework and vessels, typical of process sites. In somecases, a full-scale representation of a process site geometry has beenconstructed. Due to the cost of such constructions, GL developed avalidated scaling technique which allowed explosionexperiments to be conducted at a slightly reduced scale (perhaps u to1/5th of the size). Although still at a large-scale, considerable savingscan be made and full-scale behaviour can be simulated by oxygenenrichment of the gas mixture.

Offshore Module

The offshore module test rig is typical of the kind of large facility thatSpadeadam can develop to meet clients’ specific requirements. Therig provided a flexible facility for studying both gas accumulation andexplosions in a geometry representative of a full-scale offshoremodule. This rig was 28m long, 12m wide and 8m high and capableof withstanding explosion loadings equivalent to a uniform staticpressure of up to 3.5bar. Features of this flexible rig included:

4m by 4m wall and roof panels enabling the perimeterconfinement to be varied

A deluge system which could be configured to berepresentative of those installed offshore enabling

explosion suppression by water deluge to be studied.

A high pressure gas supply enabling dynamic releases ofup to 20kg/s and 50 bar to be produced for both gasbuild up and explosion studies.

Internal pipework and vessels which were added orremoved to provide different levels of congestion

Instrumentation to measure gas concentration, explosionoverpressure and flame velocities

This offshore module test rig was originally constructed to carry out

a major Joint Industry Project, initiated following the North Sea PiperAlpha disaster, aimed at obtaining full-scale data on the explosionhazards faced by offshore operators. Over 80 experiments wereconducted in this test rig and the data provided a major step forwardin the understanding of explosion hazards. One important findingwas the major reduction in overpressure that can be accrued fromthe activation of water deluge prior to gas ignition. Experimentsconducted in this test rig were some of the largest gas explosionsstudies ever performed and were featured on the BBC televisionprogramme Tomorrow’s World.

Explosion Chamber

The Explosion Chamber is 4.5m x 4.5m in cross-section and 9m long.With a adjustable vent opening in the front face and different levelsof pipework congestion inside, this chamber can be used to providean overpressure pulse with a peak of up to 4bar and a duration from50msec to over 300msec.

With this level of flexibility, the chamber is well suited for testing theperformance of blast resistant equipment and structures such asdoors, fire walls, panels, tubular members and Passive Fire Protection,etc. Test samples can be mounted in the back face of the chamber, ormounted across the vent opening. Tests are often undertaken onbehalf of manufacturers who wish to demonstrate that their productsare fit for purpose.

The chamber is also ideal for studying mitigation systems, such aswater deluge.

High Explosive Testing

With qualified explosives engineers, Spadeadam has expertise in theuse of high explosives and their effects. The site has a capability tocarry out tests with a net explosive quantity (NEQ) of up to 400kgTNT equivalent. Typical explosive tests include:

Use of shaped charges to cut through steel (eg. to initiatecatastrophic failures on pressurized pipes/vessels)

Testing of blast resistant materials to contact charges orat set distances (including the 'Range Test' of windows,doors and shutters to the draft European Standard)

Novel explosive devices or techniques or applications

A complete service can be offered including all civil and mechanicalworks required to build or support structures under test and extensiveinstrumentation and data logging equipment to measure and recordthe effect of explosives on structures, such as pressure transducers,displacement transducers and accelerometers.

Gas Explosion in Offshore Module

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Corrosion and Material Testing

Natural gas and oil reservoirs sometimes produce gas and oilcontaining components that are corrosive or toxic, for example,Hydrogen Sulphide or Carbon Dioxide. These substances can have anadverse effect on the steel and, for example, result in pipeline failurefrom corrosion. Spadeadam can perform intensive and long termtesting of the corrosion resistance of materials subjected to sour andcorrosive environments often at elevated pressure and temperature.Other materials, used for lining pipes or gaskets etc, such as polymers,can also be tested for their resistance to swelling or blistering whensubjected to pressure and temperature cycling in the presence ofprocess fluids.

Tests can be conducted to determine the effect of corrosion inhibitorsor the performance of novel materials under operating conditions.

Testing different materials under specific corrosive conditions allowsthe selection of the most suitable material.

To undertake these tests, Spadeadam has 5 autoclaves varying in sizefrom 5 to 15 litres and a full scale facility allows pipeline sections upto 30m long to be tested within a large containment vessel. Tests canbe static or dynamic as well as at elevated temperature and pressure.

Gas Accumulation and Ignition Risk

For reasons of weather protection, compliance with planningregulations or noise reduction, it is sometimes necessary on gasprocessing sites to house plant within enclosures, leading to the

potential for gas accumulation and an explosion risk. Experimentaltests can help to provide information to understand the gasaccumulation process and the effectiveness of different ventilationregimes (forced or natural).

The release of volatile flammable liquids, such as LNG, LPG, etc underpressure may form dispersing dense gas clouds. The resulting gascloud may occur at ground level and as such may not disperse asreadily as a lighter than air release, such as natural gas. Experimentscan provide information on the dispersion of the gas cloud underdifferent conditions.

In order to assess the risks to personnel it is important to study anypotential ignition sources to determine if they could cause ignition of

a flammable gas air mixture. Spadeadam has facilities to test items ofequipment that may be present in a hazardous area to determine ifthey can act as an ignition source. The items of equipment can betested under normal operation or under “failed condition” of theequipment, such as a short circuit. Typical examples have includedmobile phones, pagers, and gas detection equipment.

Pipeline Fracture Resistance Testing

Pipeline failures are rare events and most often are caused by thirdparty interference, such as mechanical diggers accidentally hitting apipeline. It is necessary to design and construct pipelines so that evenif such an incident occurred, the failure is limited. If the design is poor,or the material is not specified correctly, then there is a risk that asmall fracture in a pipeline can propagate resulting in a long sectionof pipeline failing. Effectively, the pipeline ‘unzips’. To prevent such anevent, materials used for pipelines must be capable of arresting apropagating fracture to localise the incident and to minimise the lossof the pipeline asset. Both plastic and steel pipeline materials aretested for their fracture resistance at Spadeadam.

Plastic pipe materials up to 700mm diameter can be tested atfull-scale in a facility incorporating a chilled trench. Tests can be

conducted in accordance with Transco standard PL2 or appropriateNational Standards or the draft European Standard prEN1555.

Steel pipeline material is tested in a high pressure facility capable ofoperating with chilled or heated hydrocarbon gas mixtures. Extensiveinstrumentation allows for measurement of crack growth and gasdecompression during the experiments that are initiated using shapedexplosive charges. A recent major project has studied high strength(X100) steels for which the design codes have not yet been validated.The results of such tests are also used to demonstrate to regulatoryauthorities that new pipelines can be operated safely.

Fracture Propagation Test at Spadeadam

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Component and Process Performance Testing

Manufacturers and users of equipment in, for example, the process,energy or utility industries have a requirement to evaluate theperformance of important components or items of equipment,particularly safety critical items. GL has the facilities andexpertise to simulate both operational and extreme conditions for aspecific system or item of equipment, in order to test and validateperformance. Process equipment or techniques can also be tested atSpadeadam so that items of equipment or novel processes can beproved during the design stage or prior to implementation.

Long duration tests or tests in extreme conditions can show that acomponent is capable of operating outside its normal operationalconditions which provides confidence and a factor of safety duringnormal operation. Typical test conditions could include:

Pressurisation with flammable or inert gases orhydrostatically

Flowing conditions involving process fluids

Elevated or below ambient temperatures

Extreme shock loading (eg. from sudden pressurereduction)

Fire or blast Loading

A typical example of component testing is the assessment of sub-sea

check valves in their ability to isolate flow. These valves are fitted to theexport lines from offshore installations. The valve is held open by theflow of gas away from the installation. However, if accident causes thepipeline to fail close to the installation, the gas escape could cause theflow in the pipeline to reverse and flow back towards the platformand so cause a major gas release. The reversal of the flow in thepipeline causes the check valve to close. This event itself may besudden and subject the moving parts of the valve to highaccelerations and so it is important to prove that the valve is capableof surviving the closure event and remain intact. Spadeadam hastested full-size valves on behalf of manufacturers prior to installationof the valves offshore. These tests simulate a worst-case event wherethe failure is close to the valve resulting in a sudden depressurisationevent and high differential pressures across the valve.

In another project, a novel approach to removing hydrogen sulphidefrom multi-phase process streams has been investigated using a 60mlong 75mm diameter pipeline loop made from stainless steel. Theloop incorporates a holding vessel, a recirculation pump and a heatingsystem enabling the performance of the chemical reactions to beassessed under controlled conditions representative of the expectedapplication. Liquids such as oil and water can be added to the looptogether with hydrocarbon and other gases commonly foundoffshore.

Instrumented Check Valve

Summary

From its heritage within British Gas, and the BG Group, GL at theSpadeadam test site has developed into a world leader inlarge-scale testing services aimed at:

Validating Design

Assessing Performance

Improving Safety

Specialising in experiments involving potentially hazardous gases andliquids, or where the experiment itself poses a significant hazard,makes the Spadeadam Test Site one of a kind. So, whether you wantto test an item of process plant, subject a structure to a gas explosion,or pressurise a component to failure, Spadeadam has the ability todo it in a safe and controlled manner.

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a. Tests of Low Pressure Vent Panels

Date: 2001Customer: Mech-Tool Engineering LimitedSavings: Validation testing of new product

Issue:

Mech-Tool Engineering Limited had developed a bid to provide a lowpressure venting system for use in a building containing high pressuresteam piping. The approval process required experiments to validatethe operation of a low pressure venting.

Methodology & Results:

A test rig was designed to conduct the experiments. The test rigprovided a facility to instantaneously release a fixed volume of highpressure nitrogen up to 60 bar into a fixed volume chamber with thevent attached to one end on specially designed fixings.

Measurements included the variation of pressure in the chamberthroughout the venting cycle and the response time of the vent panel,particularly the time to achieve full venting. The vent panels weredesigned to open at a pressure of 5 millibar which occurred just afew milliseconds after the high pressure discharge into the chamber

was triggered.

A series of experiments were completed in a 2 day period and thepreliminary data was analysed in the evening and provided toMech-Tool electronically the following morning.

Benefits:

The acceptance of the product was entirely dependent on successfulvalidation testing and GL’s purpose built test rig enabled this.

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CASE STUDIES



b. Blast and Fire Engineering Project forTopside Structures Phase 2

Date: 1998Customer: Group of North Sea Operators from the UK and

Norway and the HSESavings: Improved accuracy of models used in risk assessment

Issue:

Following the Piper Alpha disaster, a Joint Industry Project (JIP) wasinitiated to ascertain the level of understanding of fire and explosionhazards of offshore operations. Phase 2 was designed to obtain fireand explosion data at a realistic scale.


A test rig was designed and constructed by GL to represent atfull-scale, an offshore module. Inside the test rig, steel obstaclesrepresenting vessel and pipework typically found on offshoreinstallations were placed at floor level and also on a mezzanine deck.

The test rig was instrumented with over 90 ionisation probes todetermine the flame arrival time as the explosion flame progressedthrough the test rig, and 25 pressure transducers were positionedthroughout the test rig and a further 10 positioned outside the testrig to measure the explosion overpressures produced during the

experiments.

Savings:

The customers were provided with good quality full-scale data onoverpressures following gas explosions in an offshore module. Theresults showed that most mathematical models of gas explosionsunder-predicted the hazard and consequently the data was essentialfor improving the accuracy of models now used as part of the risk assessment process by North Sea operators.

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CASE STUDIES



c. Corrosion Resistant Lining for Subsea Pipelines

Date: 2003Customer: COREL Joint Industry ProjectSavings: Validation of linings

Issue:

Identify and prove the concept of an effective internal anti-corrosionlining for hydrocarbon pipelines. Collapse of liners duringdepressurisation or normal operational fluctuations in pressure, is themajor technical hurdle in preventing the progression of this

technology.


Phase 1 identified the technology concepts which have the potentialto lead to a reliable system of subsea venting (or a lining system whichdoes not need venting).

Phase 2 assessed the performance of two proposed solutions in staticconditions. The results from this work were sufficiently encouragingto support a programme to establish that these concepts would work under representative full-scale conditions with product flow. Thepressure in the flow loop was fluctuated in a controlled manner to

simulate such conditions in a real pipeline. In addition, a number ofblowdowns were undertaken to establish how robust the liner designswere at preventing collapse.

Savings:

The project proved the concept of an effective internal anti-corrosionlining for hydrocarbon pipelines. Lining of subsea pipelines has asignificant cost benefit, allowing low cost carbon steel pipelinematerial to be used in place of stainless steel, for example.

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CASE STUDIES



d. Fracture Propagation Testing of Transmission Pipeline

Date: 1998Customer: Alliance Pipeline of CanadaSavings: Validation of pipeline codes

Issue:

In order to obtain approval to build a pipeline with gas compositionand operating pressure outside the validated range for design codes,full-scale tests were required to prove the fracture resistance of thesteels to be used for the pipeline at the appropriate operating

conditions.


GL constructed a test facility at the Spadeadam Test Site involving a370m long, 36” diameter transmission pipeline. The tests involvedpressurising the pipeline to 120 bar with a rich gas mixture at 24 oC(within tight tolerances). A propagating fracture was then initiatedusing a shaped explosive charge positioned on the centre of the testpipe.

The pipe material under test was instrumented with over 90 timingwires to measure crack growth during the experiment, and 20

pressure transducers were deployed to measure the gasdecompression as the pipeline failed.

Savings:

The customer obtained quality full-scale data which was used tovalidate the pipeline design codes for the operating conditions of theplanned pipeline.

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CASE STUDIES



e. Hot Gas Pressure Test of Heat Exchanger

Date: 2000Customer: North Sea OperatorSavings: Validation of heat exchanger

Issue:

The operator wished to use a novel compact and light-weight heatexchanger made from titanium on an offshore platform. However,difficulties during the design and manufacturing process had raisedquestions about the integrity of the heat exchanger when operated at

elevated pressure and temperature for prolonged periods.


GL designed and built a test facility to enable continuoustesting of the heat exchanger for up to 15 days. This facility includeda 12” diameter pipeline loop providing a heated gas stream to thetitanium heat exchanger. This loop incorporated another heatexchanger driven by an oil-fired boiler to heat the natural gas in thepressurised loop and axial fans to circulate the gas. Remotelyactuated valves enabled the titanium heat exchanger to be isolatedduring periods of pressure cycling.

The SCADA based control system was developed by GL toenable the facility to operate safely 24 hours per day withoutpersonnel present. Automated controls were used to ensure thefacility was maintained within the required pressure and temperaturelimits. Alarm conditions, based on monitoring pressures andtemperatures at key points within the facility, ensured that the testfacility would be automatically shut-down to a safe ‘stand-by’ modein the event of a fault condition.

Benefits:

The heat exchanger was tested at realistic operating conditions interms of pressure and temperature and was found to maintain its

integrity. This allowed the operator to install and use the heatexchanger on an offshore platform with confidence that it would notfail.

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CASE STUDIES



f. Scavenging of Hydrogen Sulphide fromMulti-phase Flowing Systems

Date: 2001Customer: Amerada HessSavings: Detailed understanding of the process

Issue:

Amerada Hess wished to develop a gas field containing a highconcentration of hydrogen sulphide (up to 1.8%) using a novelapproach to H2S removal. To prove that the process would work Amerada wished to undertake trials at a large-scale under

representative conditions.


A test facility was constructed using 3” diameter stainless steelpipework. For experiments on gas mixtures, the pipework wasattached to a high-pressure storage vessel which was filled with amixture of natural gas, carbon dioxide and hydrogen sulphide andheated to 60oC. During the experiments, a scavenging chemical wasinjected and then measurements of the hydrogen sulphideconcentration were made at selected locations along the pipework using Draeger tubes. The test facility was reconfigured to allowsimilar tests to be carried out on multiphase fluids.

Savings:

The customer has obtained valuable data at large-scale which hasprovided a detailed understanding of the chemical scavengingprocess. This will enable Amerada to decide if this technique can beadopted on the gas field and to determine the optimum levels ofscavenger injection.

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CASE STUDIES



g. Subsea Intervention Valve Tests for Expro North Sea Ltd.

Date: 2001 and 2006Customer: Expro North Sea Ltd.Savings: Verification of performance of valve

Issue:

Expro North Sea Ltd requested GL to test the performance of theirsubsea intervention valve in accordance with API 14A. With gaspressures up to 173bar and flow rates up to 32kg/s, the tests weredesigned to demonstrate that the valve could reduce the gas flow

rate to less than 5% within 5 seconds of the hydraulic control linedepressuring to zero.


GL connected the Expro valve to the Spadeadam nitrogen gasreservoir system to provide the required gas flow rates for the 4 testsplanned. The appropriate instrumentation and logging systems weredeployed and ready to test. Unfortunately though, not everythingwent smoothly, and some technical problems were experienced withthe valve configuration. However, the dedicated staff at Spadeadammade every effort to help Expro overcome the technical problems inorder to complete the series of tests.

Savings:

The performance of the subsea intervention value was verified. Thisallowed Expro North Sea to sell their valve which is a safety criticalpart of the subsea valve string.

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CASE STUDIES



h. Test Pressure Safety Valve

Date: 2002Customer: North Sea OperatorSavings: Verification of operation of safety

valve EMBED PBrush

Issue:

GL was commissioned to test the operation of a balanced bellowssafety valve at realistic release conditions including full design flowusing the unique facilities at Spadeadam.


A test rig was constructed complete with a new section of pipework specially fabricated for this project and instrumentation had beeninstalled. The instrumentation was used to measure the performanceof the valve, including measuring the valve lift. To ensure that rapidvariations in the valve operation were measured, the data was loggedat a rate of 900Hz.

Over a two day period, a test programme was conducted to quantifythe operation of the valve both with the maximum design flow ratethrough the valve and in flow conditions where the valve “chattered”.Representatives from both the client and the HSE were in attendance

at the time of testing.

Savings:

The operation of the safety valve was quantified giving information tothe operator about its duty, lifetime and potential modes of failure.

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CASE STUDIES



i. New Fire Protective Coating Material

Date: 2006Customer: Alderley MaterialsSavings: Validation of use of the new material

Issue:

Alderley Materials Ltd wanted to test a new passive fire protectivecoating material and commissioned GL to undertake the testing atthe Spadeadam Test Site.


Alderley Materials worked with GL on the specification of the jet firetest required for coating and decided to test the coating to thestandard test described in HSE document OTI 95 634. AlderleyMaterials supplied a steelwork sample with the coating applied to theSpadeadam Test Site.

GL installed thermocouples to the rear of the specimen and set upthe test arrangement as detailed in the standard for this jet fire test.The set up and tests were witnessed by an independent assessor.

The jet fire test was run for a period in excess of 2 hours without the

temperature of the steelwork increasing by 350o

C from the initialtemperature.

Savings:

The use of the new fire protective coating was validated and receiveda certificate of approval from an independent assessor. This allowsthe manufacturer access to larger markets.

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CASE STUDIES



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CASE STUDIES



Germanischer Lloyd does not warrant or assume any kind of liability for theup-to-date nature, accuracy, completeness or quality of the information provided.Liability claims against Germanischer Lloyd arising out of or in connection withmaterial or non-material loss or damage caused by the use or non-use of information

provided, including the use of incorrect or incomplete information, are excludedunless such loss or damage is caused by the proven wilful misconduct or grosslynegligent conduct of Germanischer Lloyd.All offers are subject to alteration and are non-binding. Germanischer Lloyd expresslyreserves the right without notice to change, supplement or delete parts of the pagesor the entire offer or to stop the publication temporarily or definitively.

Germanischer Lloyd

Industrial Services GmbH

Oil and Gas

Steinhöft 9

20459 Hamburg, Germany

Phone +49 40 36149-7700

Fax +49 40 36149-1781

[email protected]

www.gl-group.com/glis

Safety & Risk Management Services

Safety Case and Compliance Consultancy

Hazard Identification Studies (HAZID)

Hazard Operability Studies (HAZOP)

SIL Studies (Safety Integrity Level)

Consequence Evaluation (Fire, Release,Explosion, Dispersion), Including CFD

EER Analysis (Escape, Evacuation,Rescue) (GL-Aeneas)

Quantitative Risk Analysis (QRA)

Decision Support (Risk Based Layout Studies)

Performance Standards

Large Scale Hazards Testing (Spadeadam)

Incident Investigation

Documents

10.Large Scale Hazards Testing External