Mooring Polyester rope for permanent moorings rope for permanent moorings OFFSHORE Ropes for Deep Water Mooring 0316 OFFSHORE 2 Lankhorst Ropes develops and delivers world record breaking

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www.lankhorstropes.com

Ropesfor Deep Water

Mooring

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Lankhorst Ropes develops and delivers world record breaking products to the o� shore oil & gas industry.

Applications range from Deepwater Mooring to Deepwater deployment. Utilising our proven rope technology we maintain our position as global leaders in the industry.


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COMPANY INFORMATION- LOCATIONS- FACILITIES- KEY PROJECTS

DESIGN- GAMA 98® AND CABRAL 512®- PARTICLE FILTER- SEA-BED INSTALLATION- CUT RESISTANT JACKETS (CRJ)- LENGTH- AXIAL STIFFNESS- FATIGUE LIFE- LENGTH MEASUREMENT- SPLICING & TERMINATION

SHIPMENT REELS AND CRADLES - RIGGING- STORAGE CAPACITY- PACKING AND TRANSPORTATION

CONNECTION SOLUTIONS

TESTING AND JOINT INDUSTRY PROJECTS (JIPS)

PROJECT MANAGEMENT

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Lankhorst Ropes is a WireCo WorldGroup brand. With 4,000 employees worldwide, WireCo WorldGroup is the world’s leader in manufacturing, engineering, and distributing wire rope, synthetic rope, specialized assemblies, wire products and electromechanical cable. With true global reach, WireCo WorldGroup can deliver the right products for your equipment and application no matter where your worksite might be.

With more than 200 years of experience Lankhorst Ropes is an innovative company with fully equipped production sites, and R&D departments, located in Portugal and Brasil, with capabilities to produce a wide range of o� shore ropes.

Lankhorst Ropes trades under the names of Lankhorst Euronete Portugal S.A. (LEP) and Lankhorst Euronete Brasil (LEB).

Lankhorst Ropes continuously strives for improved product performance, customer satisfaction and product innovation. LEP has been certi� ed by Lloyd’s Register Quality Assurance and LEB by Bureau Veritas Certi� cation according to ISO 9001:2008.

This brochure covers Deep Water Tethers for the permanent mooring of o� shore installations.

Locations

The most modern factories in the world dedicated to production of ropes for the o� shore industry:

Portugal

The Lankhorst Ropes site of 6,000 m2 is located in Viana do Castelo, Portugal and became operational in September 2012. It is the most modern factory worldwide dedicated to the production of ropes for the o� shore industry. Positioned near the port of Viana do Castelo, the facility is well suited to produce heavy deepwater mooring ropes. The recent commissioning of a new reel take-up stand brings our capacity to handle single piece weights of up to 250 tonnes gross (rope and reel).

COMPANY INFORMATION


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Brazil

The production facility of Lankhorst Euronete Brasil covers around 12,000m2 in an 18,000m2 property in the industrial site of Queimados in Rio de Janeiro with easy access to the ports of Rio de Janeiro and Sepetiba. The company started production of Deepwater Mooring ropes in 2012. Capacity has been doubled in 2015 with the addition of a complete new production line using state-of-the-art machinery.

Facilities

The factories are dedicated to the design, production and testing of o� shore mooring ropes and specialty products such as deep water installation ropes. Modern production and testing equipment permits all the following activities to be undertaken in-house:

• Conversion (twisting) of � at yarn into rope yarn

• Stranding of rope yarns into strands

• Braiding or twisting of strands into subropes

• Application of soil ingress � lters

• Production of braided jacket material (twisted yarn / cut resistant tape)

• Closing (over braiding) of subropes into mooring ropes

• Length Measurement System (LMS) under tension up to 30 tonnes

• Length marking under tension in 75 m increments

• Axial (anti-twist) line marking

• Full scale proto-type testing

- Break strength testing up to 1,200 tonnes

- Tension-tension fatigue testing

- Sti� ness and elongation testing

- Simulation of installation and “What If” scenarios.

- Cut resistant jacket testing

- Linear density testing

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Key Projects

Lankhorst Ropes have manufactured and supplied over 800,000 metres of deepwater mooring ropes for major projects such as:

GAMA 98®

• Tahiti spar for Technip (Operator: Chevron)

• Thunder Hawk semi-submersible for SBM Atlantia (Operator: Murphy)

• Cascade and Chinook FPSO for APL/BW O� shore (Operator: Petrobras Americas)

• Lucius spar for Technip (Operator: Anadarko)

• Goliat FPSO for Eni Norge 1 and 2 (Operator: Eni Norge)

• Heidelberg spar for Technip (Operator: Anadarko)

• WIDP for Dana Petroleum (Operator: Dana Petroleum)

• Aasta Hansteen spar for HHI-Technip 3 (Operator: Statoil)

• Appomattox semi-submersible for Shell 4 (Operator: Shell USA)

1: Polyester ropes manufactured for the Goliat FPSO set a world record for the highest Minimum Breaking Load (MBL) ropes ever produced and tested.

2 : First polyester ropes manufactured with cut resistant jacket with Dyneema® � bre.

3: Polyester ropes manufactured for the Aasta Hansteen spar incorporated the � rst double layer cut resistant jacket with Dyneema® � bre.

4: 2 ropes per reel with gross weight of 130 tonnes.

CABRAL 512®

• P58 for Petrobras (Operator: Petrobras)


• FPSO Cidade de Maricá for SBM (Operator: Petrobras)

• FPSO Cidade de Saquarema for SBM (Operator: Petrobras)

• FPSO Cidade de Itaguaí for SOFEC/MODEC (Operator: Petrobras)


• FPSO Pioneiro de Libra for Odebrecht/Teekay (Operator: Petrobras)

• Atlanta for Teekay Petrojarl (Operator: Petrobras)

• FPSO Cidade de Caraguatatuba for SOFEC/MODEC (Operator: Petrobras)

For a more detailed project reference list please contact [email protected]


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Lankhorst Ropes have two rope constructions within their product portfolio for Deepwater Mooring applications.

GAMA 98®GAMA 98® polyester ropes are made from high e� ciency subrope cores laid parallel within an outer braided jacket. Each subrope is monitored during rope manufacture to ensure all subropes have equal tension and length. Typically, GAMA 98® ropes include 7 to 18 subropes, each subrope being of a long lay length 12 x 1 construction, which gives a 100% torque free rope.

CABRAL 512® The design of this mooring rope is similar to GAMA 98 but uses parallel laid yarns to construct the strands of the subrope cores which are also laid parallel within an outer braided jacket. Again, each subrope is of a long lay length 12 x 1 construction, which gives a 100% torque free rope.

DNV Approval of Manufacturer Certi� cates

DESIGN

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Table of rope properties of GAMA 98® and CABRAL 512® Particle Filter

Filter elements are included between jacket and load bearing subropes. They are e� ective in � ltering out particles greater than � ve microns whilst allowing free � ooding of the rope. Seabed particles such as sand or clay in some conditions can cause damage to the subrope yarns when cyclically loaded. The � lter acts as a barrier to stop these particles from entering the ropes core.

Sea-bed Installation

Filter systems can be provided to allow for ropes to be pre-installed on the seabed prior to vessel hook-up. In addition to our standard � lter, Lankhorst has developed new � lter technology that permits limited dynamic cycling during rope installation. In locations where the sea state can be challenging, the rope could see movement at the touch down point with the sea bed. At this point, it is possible for particles to be forced into the rope. Our � lter technology stops this from occurring and has been approved on a previous project by DNV.

[TF]

4505006007008009001,0001,1001,2001,2501,3001,4001,5001,6001,7001,8001,9002,0002,1002,2002,3002,4002,500

* Mass in Air is measured with the rope under a tension of 1% MBL

[mm]

118124135145155168177185193205209216223230237243251256261266273277284

Kg/m

10.011.013.415.718.119.422.024.126.527.728.831.033.235.638.040.142.945.247.149.452.454.256.9

Kg/m

2.62.83.54.04.75.05.76.26.87.17.48.08.59.29.8

10.311.011.612.112.713.513.914.6

[TF]

4,4134,9035,8846,8657,8458,8269,807

10,78711,76812,25812,74913,72914,71015,69116,67117,65218,63319,61320,59421,57522,55523,53624,517

MBF Diameter Mass in Air* Mass in Water*


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Cut Resistant Jacket (CRJ)

Polyester mooring rope systems operating in some o� shore locations can be at risk from damage through contact with � sh trawling wire ropes. Lankhorst Ropes have developed cut resistant jackets using Dyneema® � bre especially for two systems in Norwegian waters.

The number of polyester mooring systems are rapidly increasing and there is always a risk of failure due to external damage. Cut resistant jackets will gradually become more common. Lankhorst Ropes can now o� er a proven cut resistant jacket for � bre ropes. Lankhorst Ropes is committed to develop jacket designs to maintain the best performance at an acceptable price level to the market, and we will introduce a range of jackets with di� erent performance levels to suit di� erent applications and locations.

Length

There is increasing pressure to reduce cost, risk and hook-up time during the mooring line installation phase of deepwater � oating production systems. Longer rope lengths mean reduced number of segments and connecting hardware in a mooring line. Lankhorst Ropes’ equipment can in theory manufacture ropes of in� nite length. Recent project trends demand two rope segments per reel thus reducing the quantity of shipment packages and associated o� shore handling times. Lankhorst Ropes’ recent investment in a new reel take-up stand brings our capacity to handle package weights of up to 250 tonnes gross (rope and reel).

Maximum length is a function of the maximum reel weight and the linear weight of the rope which is dictated by the required breaking load.

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Fatigue Life

The fatigue life of polyester rope is typically quoted as being approximately 80 decades superior to steel wire rope. The fatigue life curve of polyester rope was established during the Durability of Polyester JIP as shown in the graph. It can be seen that the rope gets stronger during the initial life phase, as the individual yarns straighten out the molecular chains under constant cyclic loading before losing strength and returning to initial Minimal Breaking Load after approximately 30% of the fatigue life.

Axial Sti� ness

Sti� ness is normally divided into two de� nitions, static sti� ness and dynamic sti� ness. Static sti� ness is used to determine the extension of the rope from � rst order motions and calculate the o� set of the vessel. Dynamic sti� ness is used to calculate the peak loads in the mooring lines during second order motions of the vessel.

GAMA 98® is the sti� est rope construction currently available in the market for deepwater mooring applications, requiring less constructional extension due to bedding in and lower overall elastic extension resulting in smaller platform o� sets and the option to utilise lower pre-tensioning during installation.

In order to maximise the e� ciency of the mooring system, Lankhorst recommends performing a sti� ness test at an early stage. This sti� ness test should incorporate static and dynamic loading scenarios and is performed on a subrope. Lankhorst can o� er this service to our clients, please ask for further details.


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Splicing and Terminations

The GAMA 98® and CABRAL 512® rope constructions are suitable for hand spliced terminations. The eye splice is engineered for high e� ciency strength realisation. To achieve this, each subrope is allocated a pre-set position around the eye so that the load is shared equally by all the subropes. Subropes are colour coded for identi� cation purposes so they have the same position throughout the rope, within each eye and are spliced to themselves. The eyes and splice area are protected with polyurethane. Digital photos at key stages of each splice are taken for quality control checks as well as recording the individual splicer’s and team leader’s name. These records form part of the � nal documentation pack.

Lankhorst provide a wide range of connection solutions for integration of mooring line components including:

• Polyester to polyester• Polyester to chain• Polyester to steel wire

We work closely with third party suppliers of mooring jewellery to ensure good interface connections.

Length Measurement

Ropes for deep water tethers are manufactured under a machine tension of approximately one tonne back tension. LEP have installed a unique Length Measuring System (LMS) for length measurement under a controlled tension. The rope is pre-tensioned to 1% Minimum Breaking Load (maximum 30 tonnes) for length measurement in 75m increments. Proto-type testing typically starts from the same reference tension of 1% Minimum Breaking Load. Length accuracy is achieved with a laser gun and mirror which is calibrated to 75m ±3mm. The rope is marked at each 75m increment and the marks, numbered sequentially (1=75m; 2=150m; etc.), are recorded by digital camera, thus minimizing the risk of human error. Feedback from the � rst permanent mooring project to bene� t from this system has demonstrated the method’s accuracy.

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Lankhorst Ropes supply deepwater tethers spooled onto shipping reels/cradles that are designed to meet project speci� c requirements.

Reels and shipping cradles are typically designed to DNV Rules for Planning and Execution of Marine Operations and/or Noble Denton General Guidelines for Marine Transportations, as well as to customer and installation contractor speci� c requirements. Ropes can be spooled directly onto shipment reels from the production line with a back-tension of 5Tf on all rope layers. This will eliminate the rope burying into the rope layers beneath, which can happen with lower spooling tensions.

Lankhorst Ropes recommend that an installation contractor is consulted to ensure that interface issues between reels/cradles and installation equipment/vessels/transportation barges are addressed at an early stage in the project.

Typical reels/cradles are shown at the right.

SHIPMENT REELS AND CRADLES

Rigging

Certi� ed lifting slings and spreader beams are also provided. Each reel can be pre-rigged with slings. Wire rope slings are terminated with Flemish eyes and steel ferrules. A typical arrangement is shown below.


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Storage Capacity

Secure outside storage areas for � nished product are available to clients at both our Portugal (LEP) and Brasil (LEB) facilities. At LEP there is 4000m2 with further storage available at the nearby port of Viana do Castelo. At LEB there is 1,200m2 with an additional 42,000m2 at our transport carrier partner located 1.5km from our factory in the same industrial park.

Packing and Transportation

Ropes on reels are protected from the environment with specially � tted tarpaulins, which if required can be of � re resistant material.

Transportation of oversize reels to the port of shipment is carried out by low-load transport specialists.

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It is now widely recognised within the industry and classi� cation societies that the � bre tether is part of a mooring line system and cannot be certi� ed in isolation. Thus the soft eye termination has to be tested with the connector that will join the soft eye of the rope to the next segment of the mooring line, whether this is a chain, wire, anchor or some other component.

Details of this connector, in particular the size and shape of the rope eye bearing surface have to be fully recorded. Substituting a di� erent type and shape of end termination will render the rope certi� cation invalid.

The choice of connector solution will often be driven by the installation methodology and the handling issues arising from the deployment scenario. The type of connector used for over boarding the stern roller of an AHV will probably be di� erent from a connector used for installation via a crane barge. Pre-tensioning methodology may also impact on connector design.

Regardless of installation issues, all connectors have the same basic requirements:

• To be lightweight

• To be small and compact

• To meet the design strength and fatigue life

• To be rope friendly and maximise splice e� ciency

Lankhorst Ropes can supply a range of connection solutions to meet the industry needs in the form of thimble rolls, H-links, pear links and Y-links. In addition, our sister company Lankhorst Mouldings can also design and manufacture any buoyancy that the mooring system may require. We recommend that you consult Lankhorst Ropes for advice on termination or buoyancy options to suit your mooring system at an early stage of engineering design.

CONNECTION SOLUTIONS

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Lankhorst ropes have participated in the following JIPs and have been instrumental in helping to shape the industry and the rules governing the deployment of � bre ropes in deepwater mooring applications:

• Engineers Design Guide

• Durability of Polyester Ropes

• Durability of Polyester Extension

• Damage Assessment Guidelines

• Design Practice Guidelines

• Insert JIP

• Safe Service Life (Arelis)

• FPS Mooring Integrity

• OCIMF 2000 Hawser Guidelines

• API RP 2SM Revision

• RPSEA JIP

• Arctic Mooring JIP

In addition to the JIPs listed, we also participate in privately sponsored research projects and other JIP’s speci� cally related to other Fibre Rope Mooring applications, Chain and Mooring Jewellery.

Lankhorst Ropes has a wealth of test data from these JIPs, and in-house testing, as well as from numerous test programmes undertaken at DNV Bergen laboratories and FURG-POLICAB in Brasil.

Lankhorst Ropes has invested in a 1,200 tonnes Minimum Breaking Load x 25m long test machine to enhance the service provided to our clients by enabling:

• Quicker response time to certify products.

• Faster R&D development programmes.

• Client speci� c testing programmes.

• Simulation of installation and “What If” scenarios.

• Reduce data errors with longer test samples.

The test machine is fully automated for cyclic testing as well as break load testing and is calibrated to class 1 level.

All Deepwater Mooring (DWM) projects follow the established framework of the Association of Project Management Body of Knowledge which de� nes the key principals for project management. During the bid phase, a Lankhorst Ropes project team is assigned which is made up of representatives from the key disciplines required for the contract. The project team is led by a specialist DWM Project Manager. The project team is responsible for the successful delivery of the contract. Key to the management of any project is the Project Management Plan (PMP) and, since every project is unique, Lankhorst Ropes tailors the PMP in accordance with each projects requirement. The PMP is considered as the governing document for the execution of the project and de� nes how the project is undertaken, monitored and controlled. This process driven methodology to the management of projects ensures consistency, not only throughout the project, but across all Lankhorst Ropes’ DWM projects.

TESTING AND JOINT INDUSTRY PROJECTS (JIPS)

PROJECT MANAGEMENT


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LANKHORST ROPES OFFSHORE

LANKHORST EURONETE PORTUGAL, SARua da Cer� l (Cap. Gramaxo)4475-468 Nogueira da MaiaPortugal

Tel: +351 229 619 200

LANKHORST EURONETE BRASILRua Minas Gerais 1920 Distrito Industrial de QueimadosCEP 26.373-280 – QueimadosRio de JaneiroBrasil

Tel: +55 21 2663 1100

Email: [email protected]

Documents

Mooring Polyester rope for permanent moorings rope for permanent moorings OFFSHORE Ropes for Deep Water Mooring 0316 OFFSHORE 2 Lankhorst Ropes develops and delivers world record breaking