Dubai
2016
A leading piping contractor entrusted Chase Resource, Tube-Mac’s ASEAN distributor, with the estimation, supply and site supervision for the hydraulic piping installation on GMS Evolution, a Self-Propelled Self-Elevating DP2 Jackup Barge.
GMS Evolution is equipped with DP2 positioning capabilities, accommodation for approximately 150 personnel, multiple cranes including a 200-tonne capacity crane, a retractable cantilever and a workover unit.
The project involved the implementation of non-welded hydraulic and high-pressure piping systems for the Main HPU Distribution System and Cantilever Ring Line System, along with hydraulic connections to major drilling and pipe-handling equipment.
The major equipment served included the Top Drive System, Travelling Assembly, Main Rider Winch, Iron Roughneck, Pipe Handling System and Hydraulic Cathead.
Chase Resource was responsible for the estimation, supply and site supervision of non-welded hydraulic and high-pressure piping systems for the GMS Evolution jack-up barge.
The scope covered approximately 1,100 metres of piping, incorporating line sizes ranging from 12 mm to 97 mm OD and system pressures of up to 5,000 psi.
The scope included:
Main HPU Distribution System comprising 80 × 10 mm and 97 × 12 mm piping operating at pressures up to 5,000 psi, using the Tube-Mac® Retain Ring Flange System.
Cantilever Ring Line System comprising 50 × 5 mm, 60 × 4 mm and 60 × 5 mm piping operating at 3,000 psi, using the Tube-Mac® 37° Flare Flange System.
Hydraulic equipment connection lines in sizes ranging from 12 mm to 38 mm, with operating pressures up to 5,000 psi, using Pyplok® non-welded fittings.
Development of the piping Bill of Materials (BOM) based on available P&IDs, equipment connections and routing information.
Supply of Tube-Mac® non-welded piping components, fittings and associated materials required for the systems.
Site technical supervision for pipe fabrication, installation, pressure testing, flushing and commissioning.
Technical coordination with the customer's engineering, installation and QC teams to ensure the piping systems were installed in accordance with the approved routing and Tube-Mac® installation procedures.
Based on preliminary information provided by the end user, including P&IDs, tentative routing plans and equipment end connections, Chase Resource developed the required Bill of Materials (BOM) for the piping systems.
Routing was refined through coordination between the customer’s design team and Chase Resource’s field personnel to achieve accurate installation, practical routing and a clean aesthetic finish.
Following finalisation of the routing plan and client approval, pipe spool fabrication was carried out at a workshop arranged near the vessel.
The site team, consisting of 1–2 lead technicians, worked alongside the customer’s installation team to fabricate the required pipe spools.
Particular attention was given to protecting the tubing and pipework from contamination caused by dirt, moisture, rust and other environmental factors. Each fabricated spool was inspected and certified by the yard QC team before installation.
QC-inspected pipe spools were installed in accordance with the approved piping layout and Tube-Mac Installation Standards and Procedures.
The installation was closely supervised by Chase Resource and Tube-Mac technicians, ensuring that the non-welded piping systems were installed in accordance with the applicable procedures.
Tube-Mac Pyplok® End Flange Adapters were used for connecting small-bore piping to valve manifold blocks, while Retain Ring and 37° Flare Flange Systems were utilised for the higher-pressure piping connections.
Wherever practical, tube bending was incorporated into the routing to reduce the number of fittings, potential leak paths and overall installation cost.
Pipe supports were installed in accordance with the design requirements. Following completion of pipe erection, all piping joints were torqued to the specified values prior to pressure testing.
Following installation, the hydraulic piping systems were pressure tested at 1.5 times the system working pressure using hydraulic oil. The pressure testing was witnessed and completed successfully.
The piping systems were subsequently flushed to achieve the required cleanliness level.
The non-welded Tube-Mac® piping system facilitated the flushing process and enabled the required cleanliness standard to be achieved efficiently.
After successful completion of flushing, the temporary flushing loops were dismantled and the piping was reconnected to the respective equipment ports.
All reassembled joints were re-torqued to the specified values before the equipment was operated.
The systems were successfully commissioned and handed over, with the customer acknowledging completion of the work through signed project reports.
The GMS Evolution project demonstrates the application of Tube-Mac® non-welded piping technology across high-pressure hydraulic systems on a complex offshore jack-up vessel.
With approximately 1,100 metres of hydraulic piping installed across multiple systems and pressure ratings of up to 5,000 psi, the project incorporated Tube-Mac® technologies including Pyplok®, Retain Ring Flanges and 37° Flare Flanges to deliver a practical, clean and efficient piping installation.
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