海底管道铺设技术重大突破：Denso推出Viscotaq™海上现场接头涂层系统

Groundbreaking Advances in Offshore Pipelay: Denso’s Viscotaq™ Offshore Field Joint Coating System
海上铺管技术重大突破：Denso公司的Viscotaq™海上现场接头涂层系统

Key performance highlights from the use of the Denso Viscotaq™ Offshore Field Joint Coating System on this project include:
使用Denso Viscotaq™在此项目上，海上现场接头涂层系统的关键性能亮点包括：

  • Achieving a record 1,766 hours free of Lost Time Injury (LTI) during the FJC operation.
    创下1,766小时无损失工时伤害(LTI)的纪录在FJC运营期间达成

  • Averaging 200 to 290 Field Joint Coating (FJC) joints per day for the 304.8mm and the 254mm diameter pipelines respectively with a peak of 305 joints per day.
    日均完成200至290个现场接头涂层(FJC)作业分别针对304.8毫米和254毫米管径的管线最高单日完成305个接头.

  • Production application time of less than 5 minutes per joint.
    生产应用时间少于每个接头5分钟.

  • One of the lowest industry repair rates of 0.28% and 0.07% for the 304.8mm and 254mm diameter pipelines respectively. Averaging 0.19% for the entire campaign versus the KPI of 5%.
    行业最低的维修率之一直径304.8毫米和254毫米管道的维修率分别仅为0.28%与0.07%整体平均维修率0.19%远低于5%的KPI指标

  • Realising further cost savings by eliminating the need for PU infill foam on concrete weight joints.
    进一步实现成本节约通过消除混凝土承重接缝处对聚氨酯填充泡沫的需求。

In June 2024, a Malaysia-based oil and gas exploration and production company embarked on an ambitious offshore pipelay campaign aimed at developing three offshore gas fields in Southeast Asia. Executed by a renowned global Offshore Installation Contractor (OIC), the project entailed the construction of two new sour-rated carbon steel pipelines, including risers and subsea spools. These pipelines included an 18 km run of 254mm (10″) diameter pipe and a 22 km run of 304.8mm (12″) diameter pipe, both designed to operate at a temperature of 109° Celsius.
2024年6月，一家总部位于马来西亚的油气勘探生产公司启动了一项雄心勃勃的海上管道铺设工程，旨在开发东南亚地区的三个海上天然气田。该项目由国际知名海洋安装承包商（OIC）承建，主要内容包括建造两条新的抗酸性碳钢管道系统，涵盖立管与海底管汇。其中一条为直径254毫米（10英寸）、长度18公里的管线，另一条为直径304.8毫米（12英寸）、长度22公里的管线，两条管道均设计在109摄氏度的高温环境下运行。

Project Overview项目概述

For this challenging project, the team selected a state-of-the-art global offshore installation DP3 pipelay barge capable of performing S-lay operations with up to 1,524mm diameter (60”) pipelines. This campaign was the first time the offshore installation contractor used a cold applied field joint coating system, specifically the innovative Viscotaq™ Offshore Field Joint Coating (OFJC) system. For this project, the Viscotaq OFJC system was comprised of four layers: ViscoWrap™ XHT, Viscotaq™ PE Outerwrap, Denso™ Glass Outerwrap, and Denso Rockmesh™.
针对这一具有挑战性的项目，团队选用了全球最先进的DP3级动力定位海上铺管船，该船具备S型铺设能力，可处理直径达1,524毫米（60英寸）的管线。此次作业是该海上安装承包商首次采用现场冷涂覆接缝系统，具体而言是创新的Viscotaq™海上现场接缝涂覆（OFJC）系统。该项目中，Viscotaq OFJC系统由四层组成：ViscoWrap™XHT、Viscotaq™PE外保护层、Denso™玻璃纤维外保护层以及Dento岩石防护网™.

  • ViscoWrap XHT: is comprised of a viscoelastic adhesive compound, reinforced with an HDPE mesh and backed with a PE film. It provides the corrosion protection layer of the Viscotaq OFJC system.
    ViscoWrap XHT该产品由粘弹性复合胶粘剂构成，采用HDPE网格增强并覆以PE薄膜作为背衬，为Viscotaq OFJC系统提供防腐保护层。

  • Viscotaq PE Outerwrap: is comprised of a polyethylene tape coated with an adhesive layer. It provides circumferential compression to the corrosion protection layer of the Viscotaq OFJC system.
    Viscotaq PE外护带由涂覆粘合剂层的聚乙烯胶带构成，可为Viscotaq OFJC系统的防腐层提供环向压紧力。

  • Denso Glass Outerwrap: is comprised of a woven glass fabric, impregnated with a moisture-cured polyurethane resin. It provides mechanical protection to the Viscotaq OFJC system.
    登索玻璃外护套由浸渍湿固化聚氨酯树脂的编织玻璃纤维布构成，为Viscotaq OFJC系统提供机械保护。

  • Denso Rockmesh: is comprised of an extruded polymer mesh. It provides sacrificial, additional mechanical protection to the Viscotaq OFJC system during pipeline construction.
    Denso Rockmesh：由挤压聚合物网构成。在管道施工期间，它为Viscotaq OFJC系统提供额外的机械保护作用。

Rigorous Testing严格测试

The start of this successful campaign began in early 2023 with an extensive third-party testing phase. This testing was to confirm that the Viscotaq™ OFJC system met the requirements of the international standard ISO 21809-3; ultimately, it was deemed that the Viscotaq OFJC system successfully met all requirements of the standard, at a maximum service temperature of 115° Celsius. The Denso Glass Outerwrap also demonstrated outstanding abrasion resistance and excellent impact resistance.
这场成功推广的开端始于2023年初，当时进行了广泛的第三方测试阶段。该测试旨在确认Viscotaq™ OFJC系统符合国际标准ISO 21809-3的要求；最终认定Viscotaq OFJC系统在最高115摄氏度的使用温度下，成功满足了该标准的所有要求。Denso玻璃外缠带还表现出卓越的耐磨性和出色的抗冲击性。

Training and Product Qualification Tests (PQT) were conducted at one of the OIC’s facilities in Kuantan, Malaysia. This demanding phase required a short total cycle time including the time allowed for the Denso Glass Outerwrap to cure to a minimum of Shore D 40. The PQT phase concluded successfully, with the OIC’s applicators demonstrating their ability to apply the entire system in under 4 minutes with the Denso Glass Outerwrap achieving an average Shore D 45 hardness after a cure time of 5 minutes. The product application was so user-friendly that after just 2 hours of training, the OIC’s applicators were able to start applying the Viscotaq OFJC system independently.
培训和产品资质测试(PQT)在OIC位于马来西亚关丹的一处设施中进行。这一严苛阶段要求总周期时间较短，包括允许Denso Glass Outerwrap固化至最低肖氏D硬度40的时间。PQT阶段圆满结束，OIC施工人员展示了在4分钟内完成整套系统施工的能力，且Denso Glass Outerwrap在5分钟固化时间后平均达到肖氏D硬度45。该产品应用极其便捷，OIC施工人员仅经过2小时培训后，就能独立开始施工Viscotaq OFJC系统。

In addition to the PQT, the OIC required Roller Box Testing to be completed. The Viscotaq OFJC system was subjected to a 10-tonne load roller/stinger simulation. This testing was completed during the Pre-Production Test (PPT) stages at the OIC’s yard. The Viscotaq OFJC system met all requirements of the Roller Box and PPT.
除PQT测试外，OIC还要求完成滚筒箱测试。Viscotaq OFJC系统承受了10吨负载的滚筒/刺杆模拟测试。此项测试在OIC场地的预生产测试(PPT)阶段完成。Viscotaq OFJC系统全面满足滚筒箱测试及PPT的所有要求。

Seamless Project Execution and Project Completion
无缝项目执行与项目完成

The project was awarded to Winn & Coales (Denso) Ltd in collaboration with Pluperfect Technology, Denso’s local Malaysian partner, at the end of 2023. Denso promptly manufactured approximately 7,000 precut ViscoWrap XHT sheets (the inner layer of the Viscotaq OFJC system) – along with the other system components – within three weeks.
该项目于2023年底授予Winn & Coales (Denso) Ltd公司与其马来西亚当地合作伙伴Pluperfect Technology共同完成。Denso在短短三周内迅速生产了约7,000张预切割ViscoWrap XHT板材（Viscotaq OFJC系统的内层）以及其他系统组件。

By June 2024, the installation team had completed the entire FJC work onboard the OIC’s pipelay vessel, finishing three days ahead of schedule and realising savings of over one million USD. A summary of all key performance highlights achieved through the use of the Viscotaq OFJC system can be found at the beginning of this article.
截至2024年6月，安装团队已完成OIC铺管船上全部的FJC工作，比原计划提前三天完成，实现节省超100万美元。通过使用Viscotaq OFJC系统实现的所有关键性能亮点总结可在本文开头查看。

Conclusion结论

This project has highlighted the advantages of the Denso Viscotaq OFJC system. This choice of system has demonstrated to both the client and the OIC that a cold-applied FJC system can be safe, efficient, robust, and effective while significantly reducing specialist equipment and manpower.
该项目凸显了Denso Viscotaq OFJC系统的优势。该系统的选择向客户和OIC证明，冷施工FJC系统可以安全、高效、可靠且有效，同时显著减少专用设备和人力需求。

If you would like to find out more information on the Viscotaq OFJC System:
如果您想了解更多关于Viscotaq OFJC系统的信息：

  • Send us an email with your request to mail@denso.net;
    将您的需求通过电子邮件发送至mail@denso.net;

  • Send us a message via the contact form on our Contact page by clicking here;
    通过点击此处，在我们的联系页面填写联系表单给我们发送消息这里;

  • Find out more about our application training sessions here;
    了解更多关于我们的应用程序培训课程信息这里;

  • Or contact your local representative for further details.
    或联系当地代表获取更多详情。


< BACK
PRINT