TECH SPOTLIGHT


TRELLEBORG SEALING SOLUTIONS HELPS DEVELOP REVOLUTIONARY SUBSEA PRODUCT


When faced with the challenge of helping to create a product to boost safety and efficiency for offshore engagement, Trelleborg went above and beyond in developing a complete sealing solution to help its partner “revolutionise” the oil industry.


When the question of whether it would be possible to create a large bore, high pressure hydraulically retractable coupler was first posed, one of the initial challenges that needed to be overcome was finding a seal that was up to the job.


As a leading global supplier of polymer-based critical sealing solutions, Trelleborg Sealing Solutions was the natural choice to help Subsea Technologies Ltd (STL) create an innovative engineered solution to accelerate performance of its dynamic two inch hydraulically Retractable Subsea Coupler.


STL, which specialises in providing reliable and cost effective products to solve complex subsea challenges, required a custom-made seal which would work inside the pioneering product. STL had previously developed small bore retractable couplers, used as sub-components in its unique XR Connector, however, scaling up to a large two inch bore to allow for choke and kill lines passing through the XR Connector, posed a number of major challenges.


The hydraulically retractable couplers assist in creating the XR Connector’s unequalled high-angle release capability which has no maximum riser angle limit. It was designed to deliver radically improved vessel safety, reduce environmental risk and decrease costs by greatly boosting a vessel’s operating window.


In order for the full potential and functionality of the two inch coupler to work, it needed a seal to be developed that would work in harmony with the coupler, the world’s first of that size with a hydraulically retractable element.


During the initial round of testing, STL discovered that the original hydraulic seals were extruding during the high temperature and high pressure phase of the test programme.


As the product development stage was so advanced, STL asked Trelleborg to propose a sealing solution that would address the issue of extrusion of the seal cap, without the need to change any of the existing hardware groove dimensions.


below: STL’s hydraulically Retractable Subsea Coupler is designed to deliver radically improved vessel safety.


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Trelleborg immediately set about overcoming the issue and developed custom versions of its Turcon® Captive Glyd Ring® with XploR™ V9T82 elastomer material and Turcon® Stepseal® 2A CR with PEEK corner reinforcement rings.


Left: Trelleborg set about meeting requirements and developed custom versions of its Turcon Captive Glyd Ring.


The Stepseal® 2A CR is the new standard corner reinforced rod/piston seal for single-acting use and has many advantages, such as its anti-tilt design and that the dimensions of the seal body and CR-Ring which can be modified to facilitate installation.


Andrew Longdon, Technical Manager for Trelleborg Sealing Solutions in the UK, said: “Throughout the process we constantly had to think about the safety issues and challenges that are frequently faced when working with heavy duty engagement of subsea equipment.


“We worked with STL as the team conducted a very lengthy test programme including a full PR-2 temperature and pressure cycling programme along with endurance cycle testing on the products in accordance with the ISO 10423 standard.


“STL also conducted two disconnects with 10,000 psi bore pressure. This was all completed with one set of seals which I think is some achievement.


“We pride ourselves on innovation and relished this opportunity to work with STL in a bid to find a solution and ensure the two inch hydraulically Retractable Subsea Coupler was working to its full capability.”


Not only does the coupler provide new opportunities for remote emergency release system designs for subsea applications, it also enables people to be removed from stab plate engagement functions on the surface. By being hydraulically retractable, it allows the heavy duty engagement of equipment both on surface and subsea to be separated from the comparatively delicate engagement of control system interfaces.


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