THE FLOATATION PROFESSIONALSprofloat.com/wp-content/uploads/2020/09/Brochure...THE FLOATATION PROFESSIONALS. OUR COMPANY ProFloat are experts in the maintenance of Drill Riser Buoyancy,

THE FLOATATION PROFESSIONALS

OUR COMPANY

ProFloat are experts in the maintenance of Drill Riser Buoyancy, offering industry-leading repairs, modifications and condition assessments worldwide. Since establishment we have attended to the maintenance of thousands of Buoyancy Modules for various drilling contractors in Africa, Europe, Asia and Australia. ProFloat is also expanding our operational capability in 2020 to include strategic geographic targets in North & South America as well as Central America & the Caribbean.

Our repairs are not only world-class but present significant long-term value relative to their cost, by ensuring that buoyancy equipment achieves its intended life span. We carry out repairs in the field at any location required by the Drilling Contractor, and we do so at any time throughout the life cycle of the buoyancy and often coincides with 5 year and 10 year riser recertification windows.

“BEST IN CLASS” BUOYANCY REPAIRS

EXTREMELY SHORT PROJECT TIMES

LOW CRITICAL MASS FOR MOBILIZATION

HIGHLY FLEXIBLE, IN AND OUT SERVICE

AVOID DROPPED OBJECT RISKS

AVOID QUARANTINING RISER JOINTS

MAXIMIZE BUOYANCY LIFESPAN

ALIGN WITH THE CBM ETHOS

OUR TEAM

ProFloat is led by enthusiastic and dynamic professionals with key skill sets representing a number of fields, each chosen for their ability to add

value to the Company and our Customers.

KEANE HARVEYManaging Director

PHILIP LOUWProject Engineer

TODD GRAHNVice President of Sales -

North & South America

MARLON OKKERS Production Manager

JEROME LOUWQuality Assurance

Manager

JONATHAN CRUISEFinancial Director

ADAM VAN DER WALTDesign Engineer

GARTH TOOTHBusiness Development

Manager - EMEA

NATHAN PHILLANDERProduction Supervisor

SIVUYILE KLAASCoatings Manager

BUOYANCY REPAIR Drill Riser Buoyancy is costly equipment intended to last 20 years. Potential down time or quarantine of impaired riser joints can result, if this equipment is not properly maintained in fit-for-service condition.

Buoyancy is unfit for service if it is cracked, broken in multiple pieces, missing major sections, contains deteriorated buoyancy material or has suffered water ingress.

ProFloat has developed a “best-in-class” repair methodology over 10 years of service in the industry. We have over 35 technicians trained extensively in all categories of repair. Combining this with specialized products and materials intended for rigorous offshore use, we provide a repair quality which is second to none. Following is an overview of the repair process:

Transverse Crack Repair

Channel Alignment For Main Tube & Aux Line Housing

Painting & Marking

Longitudinal Crack Repair

Shaping & Fairing of Critical Dimensions

QC & Weighing

Buildup of Major Sections

Lamination & Skin Restoration

Reporting & Data Packs

RISER DRESSING & BUOYANCY SWAP-OUT

ProFloat often conducts services in field locations where our Customers have little or no personnel and support.

In these situations, we provide a turn-key solution by undressing riser joints, repairing buoyancy and then redressing riser joints to be ready for load-out and return to the rig.

We also carry out buoyancy swap-out, which entails making up the desired number of joints of the desired depth rating, providing a Disposition Report regarding damage observed and providing a reliable basis for reactivation-related costs.

STRAP & VIV RETROFIT, CHANNEL

MODIFICATIONS & MUX WINDOW INSTALLATIONS

Buoyancy frequently requires other remedial work in order to improve performance, safety or usability.

This can include modification of the main channels in order to fit a different riser configuration, installation of MUX clamp windows or retrofitting of retention strap & tensioner recesses or VIV-suppression improvements.

ProFloat offers seamless engineering and implementation of bespoke modifications through onsite installation and ProFloat proprietary modification techniques.

This work is provided as a stand-alone service or as a part of on-going repairs. The output is a product which is more suited to the needs of our customers.

SUPPLY OF AUXILIARY EQUIPMENT

ProFloat sources, supplies and manufactures a range of auxiliary

equipment required for the effective operation of Drill Riser Buoyancy.

This includes:

Straps and Tensioning systems for Drill Riser Buoyancy,

Buoyancy Stacking Shims and Riser Guards

ExoFloatTM Buoyancy Shields

ExoFloatTM Buoyancy End Caps

VIV Fairings

BENEFITS:

� Avoid utilising damaged buoyancy which presents a risk of harm to people and equipment

� Avoid relegation of riser joints with damaged fitments

� Rig Subsea Personnel will report detected defects at any time

� Drill Riser Buoyancy Modules are a 20 year investment. For buoyancy to reach this life span requires prompt attention to damage

� Avoid minor damage (such as damaged leading edges) leading to material deterioration and water ingress

BUOYANCY CONDITION BASED MAINTENANCE

ProFloat provides condition-based maintenance of buoyancy through our first of its kind FloatCon™ CBM.

FloatCon™ provides assessments, tracking and repair which align with existing riser CBMs.

FloatCon™ operates on a fixed price subscription model delivering extreme value for tracking and repair.

The program includes visits carried out at least once annually during Between Well Maintenance or at another suitable time.

Visits are followed by Detailed Condition Assessment Reports, proposed repair schedules, guidance to subsea personnel and engagement with shore-based asset management.

Our Engineers engage at set monthly or quarterly intervals throughout the year with Rig Subsea Engineers. Cracked or crumbling elements are scheduled for immediate repair on the rig or at a local shore base and there is a very low critical mass for mobilisation.

READINESS REPORTING

We have developed a specialized reporting & disposition process that gives our customers key insights into the depth readiness of their riser string.

Tailored to suit stacked rigs or rigs awaiting contract, our Readiness Reporting is designed to highlight the true condition of the buoyancy on any rig, detailing the number of elements requiring repair in order to fulfil contractual depth obligations, form the basis of on-going maintenance cost forecasting and facilitate buoyancy storage and rotation programs.

Since introducing this service, we have been invited to numerous rigs in locations around the world to provide this cost effective and insightful report.

READINESS REPORT

Drilling Contractor

Drill Riser Buoyancy Modules

OEM : XYZ Corporation

READINESS REPORT Doc. No. PRO-QA-072

Rev. No. 000

Uncontrolled if Printed Date Printed : 2018-08-27 Page 3 of 18

i. Introduction ProFloat are experts in the lifecycle management of drill riser buoyancy. This entails industry-leading repairs, modifications, handling (dressing, undressing, swop-out) and condition assessments, all of which are provided worldwide by means of facility and field services. ProFloat have been engaged by the Drilling Contractor to prepare this Readiness Report in respect of the drill riser buoyancy on 108 buoyant riser joints belonging to the Rig. The inspection was carried out on 14 August 2018 in Tenerife. Due to the extremely good accessibility to every tier of the riser bay, we were able to carry out a more in-depth inspection than originally expected. That said, there were still elements in the interior of the stack and centre of the riser joints which we were not able to inspect at all. In summary, we found 65 elements requiring repair, of which 32 elements are categorised as Majors and 33 as Mediums. Due to the nature of the mediums (being delamination), we highly recommend that these be repaired in order to avoid them degrading further. Additional comments on this point are set out further below. We estimate that there are a further 10 to 15 elements on the interior of the riser bay that would likely require repair. ii. Purpose With reference to the buoyant riser joints in the Riser Bay of the Rig, the purpose of this Readiness Report is threefold: - Provide an indication of the number of buoyancy elements requiring repair;

- Provide comments on kinds of damage observed, the possible cause of the damage and associated recommendations;

- Provide commentary on the readiness for contractual depth obligations;

- Provide a basis for a detailed budgetary quotation to assist in readiness planning.


Rev. No. 000


1.2 Damage Report for Buoyancy Elements

019

B1 = DL


Rev. No. 000


iii. Categories of Damage and Repair

Throughout this document, reference will be made to Minor, Medium and Major damaged elements and the various forms of damage. The below table indicates the criteria to be met for an element to fall into each of the damaged types:

Minor

Element exhibits any or all of the following: 1 - 25% skin damage, small defects (defects less than 10mm deep with no macrospheres exposed), minor edge damage and requires painting with depth-rating colour bands and markings as per API 16F.

Elements categorized as Minors do not require repair to be operational

Medium

Element exhibits any or all of the following: 25 - 50% skin damage, medium defects (defects up to 2,000ml in volume with macro-spheres exposed), medium edge damage / moderate delamination and requires painting with depth-rating colour bands and markings as per API 16F.

Elements categorized as Mediums require repair to remain operational.

Major

Element exhibits any or all of the following: 50 to 100% skin damage, major defects (defects greater than 2,000ml in volume, requiring macro-spheres and liquid fill), major edge damage / major delamination and require painting with depth-rating colour bands and markings as per API 16F.

Elements categorized as Majors require repair to become operational.

The below table provides overview of the kinds of damage which place an element in the different categories of repair. Further information is set out in the accompanying Inspection Procedure:

Medium Delamination (MEDL)

Skin peeling off of the element across a span of 10 to 25% of the surface of the element, exposing the internal syntactic material to direct water and potential ingress. Distinct from paint peeling which has no practical impact on the use of the element. Elements with Medium Delamination should be repaired to remain operational.

Major Delamination (MADL)

Skin peeling off of the element across a span of 25 to 100% of the surface of the element, exposing the internal syntactic material to direct water and potential ingress. Distinct from paint peeling which has no practical impact on the use of the element. Distinct from Medium Delamination due the extent thereof an immediate risk of falling objects and degradation of internal syntactic material. Elements with Major Delamination must be repaired to remain operational.

Longitudinal Fracture (LF)

A fracture that runs horizontal to the element lying flat. Early stages of Longitudinal Fractures. Elements with Longitudinal Fractures require repair to become operational.

Transverse Fracture (TF)

A fracture that is evident across the length of the element when positioned horizontally Elements with Transverse Fractures require repair to become operational.

Bonds (B) When the element is split into 2 or more pieces. Longitudinal Bond or a Transverse bond. Elements with Bonds require repair to become operational.


Rev. No. 000



029

A2 = TF A4 = DL

064

A1 = TF A2 = DL A3 = DL

A4 = TF X 2 B1 = DL B3 = DL

B4 = LF & TF


Rev. No. 000


iv. Traceability and Handling of Joints Traceability of the riser on the Rig must be commended. All riser joints are properly marked, and easily read and distinguishable with regards to serial numbers, riser numbers and depth ratings. It is immediately apparent that the equipment is maintained very deliberately and that the joints are very well looked after. The handling of the joints must be also be commended. It is evident that extreme care is taken when running the joints, on account that there is minimal handling related damage. It appears however that riser joints stored in the upper 30 to 50% of the Riser Bay are being run considerably more than the ones lower down. This is revealed due to the lack of usage marks on the lower 50% of the riser and the lack of fouling / paint discolouration. This may be taken as an Observation on account that it might lead to overuse of certain riser joints, with a potentially negative impact. As you are no doubt aware this can lead to unnecessary wear and tear on the pins, which in turn can lead to increased findings at the next riser inspection window. We found that access within the Riser Storage Bay itself was excellent due to the multiple levels, good lighting and clean / dry environment. However, an aspect which was noticed and pointed out to the Senior Subsea, is that excessive weight is bearing down on the lower 1 or 2 rows of riser. We discovered approximately 7 buoyancy elements at the bottom of the Riser Bay which were cracked longitudinally, and this was due solely to the weight bearing on them. For this reason, we recommend considering the installation of a brace half way up the Riser Bay, to ensure that the load of the risers is transferred to the heavy-duty Riser Bay framework. Alternatively, a chocking system which ensures that the load is shared at the flanges. More detailed recommendations on this topic can be provided if required, including drawings of the proposed brace or chocking. v. Outcome of Inspection Below is an Inspection Report for each riser joint assessed. We draw your attention to the following important considerations and general notes: - There were 12 riser joints at the top of the Riser Bay. These could be inspected very thoroughly, and we

discovered the majority of the damaged elements on these riser joints;

- There were 108 buoyant Riser Joints in the Riser Bay, which are stacked one below the other in columns. Total stacked in each column is 9, and each column is divided according to their specific depth rating. We were able to inspect the outer 4 elements for each of these riser joints (those on the pin and the box end) but not the inner 4 elements of the joints below the top row;

- We estimate approximately 10 - 15 additional elements for repair on the interior stack that could not be visually

inspected;

- Based on the elements identified for repair, being 65 plus the additional quantity estimated 15, the total for repair is 80, which is a repair ratio of about 20%;

- There are approximately 50 other elements requiring minor repair – the repair of which is optional and not

highly recommended, except for the potential benefit of exposing and addressing damage which is likely to become major, such as elements showing early signs of delamination;

- We did not find any elements to be incapable of repair;


Rev. No. 000



073

A1 = LF B1 = TF


Rev. No. 000


- Certain of the damage we have identified will appear to be nothing but cracking in the skin of the element, whereas we have identified it as an actual fracture in the element. The reason for this is that the element material is quite brittle, and a fracture on the exterior normally signifies a crack on the interior (similar to concrete). This has proven to be correct numerous times and where we have insufficient external indication of a fracture, we conduct auditory testing (knocking) along the length of the element to identify hollowness;

- Our inspection and repair experience has allowed us to carry out inspections with a typical 97 to 100%

accuracy rate, ensuring that all likely damaged elements are identified at the outset of the project and minimal unplanned repairs become necessary;

- At the time of repairs, any elements which have been identified for repair, but which appear to be in good

condition, will be patched up and returned at no charge.

vi. Special Commentary on Delamination

We observed extensive delamination on the elements. This is extremely concerning for the longevity of the buoyancy elements which are supposed to last for 20 years. This is however something that we see very often with XYZ buoyancy. In fact, our inspection procedure for delamination specifically captures XYZ buoyancy as the example (see excerpt below). In our experience, delamination is followed by extensive material degradation. Due to the tendency for these elements to delaminate and thereafter degrade, we highly recommend that all delamination be attended to, to ensure that we replace the delaminating skin with a new skin and ensure proper adhesion thereof to avoid future delamination recurring, while providing an improved protection layer on the exterior of the elements.


Rev. No. 000


vii. Summary of Findings

Riser No.

A1 A2 A3 A4 B1 B2 B3 B4 NOTES DL TF LF VS

1 DL & TF DL DL DL TF RISER BAY TOP 4 2

2 DL 1

4 DL 1

6 LF 1

7 DL 1

10 TF DL DL DL RISER BAY TOP 3 1

11 DL DL 2

13 DL 1

14 DL 1

16 DL 1

19 DL RISER BAY TOP 1

29 TF DL RISER BAY TOP 1 1

54 LF 1

64 TF DL DL TF X 2 DL DL LF & TF RISER BAY TOP 4 4 1

65 DL 1

67 LF 1

70 LF 1

71 LF LF 2

72 DL LF LF 1 2

73 LF TF RISER BAY TOP 1 1

76 DL & VS 1 1

80 LF 1

81 LF 1

85 DL 1

89 LF LF 2

90 LF 1

91 TF TF X 2 DL DL & TF DL LF RISER BAY TOP 3 5

92 DL 1

93 DL 1

94 DL 1

98 LF 1

99 LF 1

100 DL DL RISER BAY TOP 2

102 DL 1

103 DL 1


126 VS 1


132 LF 1

TOTAL MEDIUMS 33 SUB-TOTALS 37 14 18 2 TOTAL MAJORS 32


Rev. No. 000


Below are the findings of our inspection:

1. Buoyancy Disposition Report Serial # Not visible

1.1 Buoyancy Element Location


Riser No. Photographs of Element Damage

001

A1 = DL & TF A3 = DL A4 = DL B1 = DL B4 = TF


Rev. No. 000



010

A1 = TF A3 = DL A4 = DL B1 = DL


Rev. No. 000


viii. Overview of Repair Processes

Structural

Structural repairs depend on the type of damage categorized, namely: Longitudinal Fracture, Transverse Fracture or Longitudinal Bonding or Transverse Bonding required. Refer to Structural Repair Procedure (PRO-QA-014) or (PRO-QA-039) depending on whether it is a ProFloat or an OEM type of repair.

Shaping

The use of repair material to repair small, medium and large defects by filling voids and shaping the element. Refer to Shaping Department Repair Procedure (PRO-QA-015) or (PRO-QA-038) depending on whether it is a ProFloat or an OEM type of repair.

Fairing

Reshaping and aligning the inside and outer diameter of the element. Refer to Fairing Department Repair Procedure (PRO-QA-016).

Laminating

Repairing Transverse and Longitudinal Bonds, Transverse and Longitudinal Fractures, Medium Defects and Large Defects, applying fiberglass & fiberglass consolidation on the elements. Refer to Laminating Department Repair Procedure (PRO-QA-018) or (PRO-QA-035) depending on whether it is a ProFloat or OEM type repair.

Painting

Preparing the inside and outer diameter of the element. Paint Coating, Signage and Stencilling the inside and outer diameter of the element. Refer to Paint Coating Department Procedure (PRO-QA-022).


Rev. No. 000


ix. Conclusion

- There are very few inspected riser joints which do not require any buoyancy repair;

- We estimate that up to an additional 15 elements that were not capable of being inspected, will require repair;

- The majority of damaged elements fall into the upper joints in the riser bay. This is to be expected on the basis

that these joints are run the most frequently and are run every well;

- We have made recommendations regarding the repair of the Medium and Major damaged elements;

- Often, the repair of elements categorised as Mediums can be avoided but in the present case, to avoid inevitable degradation of the elements, we recommend these repairs;

- Aside from having carried out full-scale repairs for the Drilling Contractor previously, we are also the only

company to have carried out any repairs (of significance) in the Canary Islands;

- We have carried out projects in both Gran Canaria and Tenerife and are an authorised vendor in Tenerife;

- We are in a position to quote on the repair of these buoyancy elements alone, or in the context of general riser recertification work if any is forecast.

We thank you for the opportunity to visit the Drilling Contractor and look forward to supporting her.

x. Approved and Issued By

Philip Louw ProFloat Project Engineer

Inspector / Customer (as applicable)

Date: 27 August 2018 Date:

South AfricaNamibiaAngola

Ghana

Senegal

Mauritania

Canary Islands

SpainEgypt & Cyprus

India

Singapore

Malaysia

Indonesia

Japan

Australia

ProFloat is capable of delivering our industry-leading buoyancy support services at a multitude of locations worldwide

Texas

Offices

Work locations

Head Office: 32 Section Street, Paarden Eiland, Cape Town

South Africa, 7405.

USA Address: 2002 Louetta Oak Ct. Spring Texas.

USA, 77388.

Postal: Postnet Suite 61, Private Bag X10,

Cape Town, South Africa, 7506.

Phone: +27 21 556 1631

Email: [email protected]

Website: www.profloat.com

Reg Nr: 2012/195682/07

K E A N E H A R V E Y

M A N A G I N G D I R E C T O R

Phone: +27 82 884 8506Email: [email protected]

P H I L I P L O U W

P R O J E C T E N G I N E E R


G A R T H T O O T H

B U S I N E S S D E V E L O P M E N T MANAGER - EMEA


T O D D G R A H N

V I C E P R E S I D E N T OF S A L E S - NORTH & SOUTH AMERICA


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THE FLOATATION PROFESSIONALSprofloat.com/wp-content/uploads/2020/09/Brochure...THE FLOATATION PROFESSIONALS. OUR COMPANY ProFloat are experts in the maintenance of Drill Riser Buoyancy,