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Engineering Services Department overview

September 2016

Introduce cost-efficient, light-weight & corrosion

resistant solutions to enhance your operations

Our ESD provides expert technical services & design consultancy for FRP composite structures & pipe systems, with a competitive edge. The unique combination of cutting-edge design & advanced manufacturing provides our clients with a “one-stop-shop” solution, maximising safety, efficiency & structural integrity.

Experienced & skilled, our engineers are dedicated to providing sustainable & optimised solutions, solving the most complex of projects in a multimedia environment. The ESD capabilities consistently develop to encompass broader technical services provision across a wide range of materials & applications, as required by clients, with the ability to work directly within clients own design offices (national or international). Our services include:

• Finite Element Analysis (FEA)• Laser surveys: Offshore surveys, 3D laser surveys & dimensional

control• Innovation, R&D, 3D printing & prototyping• NAVISWORKS project review to support BIM• Piping design assistance & verification• Caesar II Piping stress analysis• Structural Engineering (CEng)• CAT II design checks• Computational Fluid Dynamics (CFD)• Global site service, field service & installation teams• Bondstrand® GRE Training & Certification

ENGINEERING SERVICES OVERVIEW

FINITE ELEMENT ANALYSIS (FEA)

Pipex px® Engineering Services Department are able to provide Finite Element Analysis (FEA) on composite & thermoplastic products as part of our comprehensive product design & development service. This behavioural evaluation enables optimisation of designs prior to prototyping.

Projects examples:

� Fixed ‘T’ MARRS® connectors – Design & optimisation of combined top rail & post connector to improve MARRS® fabrication efficiency & reduce overall product cost.

� Sea Water Reverse Osmosis (SWRO) pressure vessels – 290 no. high pressure offshore SWRO vessels for installation on the BP Clair Ridge Platform in the North sea.

� Subsea 7 Hub covers – Laminate design of resin infused impact protection covers for subsea valve assemblies during tow out, meeting strict weight limits to suit ROV operational limits.

� PLA – HUMP® - Stress of the platform level access units was analysed as they will be undergoing consistent high footfall once installed in 4 central London Stations; Farringdon, City Thameslink, St Pancras & Blackfriars.

� Blow Out Preventer (BOP) Access platform – Lightweight, rotating, resin infused access platforms to preserve & maintain BOP, & provide quick & safe access/operation in an emergency.

LASER SURVEYS

Our highly experienced in-house personnel have specialist experience in offshore surveying and are available to mobilise at short notice to survey or repair GRE piping issues and FRP Structures. As experts in GRE Piping Systems with over 20 years experience, our Engineers are highly skilled in the repair of GRE piping and are able to offer efficient solutions within the challenging offshore environment.

The Team are equipped to carry out 3D laser imaging surveys using cutting edge scanning equipment and interpretation software. They are able to produce highly accurate and detailed drawings for structures and piping systems for both onshore and offshore applications. 3D laser scans are especially useful in busy and complex environments as they allow the flexibility to continuously reassess design and measurements without the need to return to the site.

Project examples:

� Texaco Captain F.P.S.O. – 3D laser survey of Ballast tank to optimise the maximum spool size and confirm feasibility of transporting replacement piping spools through the tank access hatchway and bulkhead penetrations to their final location at the base of the tank.

� Bahamas Stenna Drilling - 3D laser survey was conducted on board a Stena DrillMAX Vessel to analyse the existing Copper Nickle (CuNi) pipework that had degraded beyond repair due to seawater corrosion. Visit the Pipex blog page for the full story.

� Network Rail 3D laser for Platform Level Access (PLA) - HUMP - City Thameslink, St Pancras, Blackfriars, Farringdon– 3D laser survey combined with Total Station to provide on grid data for coordination of new FRP platforms with existing platform furniture, signalling, lighting and signage.

� BP Kinneil – 3D laser scan and routing of replacement tank drain GRE pipework.

Stena Drill Max –Cooling Water Line Survey

• 6 floors• 98 scans• 12 days on-board surveying• Scope included survey, design,

fabrication and on-site installation

OFFSHORE LASER SURVEY

Seven Atlantic – Diving support vessel

• 3D laser of metallic piping• Generation of isometric drawings• Seawater cooling was provided for

the Stena Carron, Stena Forth & Stena Drillmax

LASER SURVEYS

3D LASER SURVEY

Automotive – Wildcat Range Rover Custom Bumpers

2) Concept Model

3) Mould Tool

4) Prototype

3D LASER SURVEYS & DIMENSIONAL CONTROL

1) 3D laser survey

5) Custom bumper

Engineering services dept. conducted a 3D laser survey to gather the geometry of the existing Range Rover bumpers, data was then imported to the surface modelling program Autodesk Alias for development of a bespoke bumper.

A set of Fibre Reinforced Polymer (FRP) front and rear prototype bumpers were designed and built in-house using our 5-axis CNC machine, working under 1mm tolerance.

The lightweight prototype bumpers were manufactured using E-glass vinyl ester parts and were sprayed at a 3rd party location.

INNOVATION, RESEARCH & DEVELOPMENT

With the ever-growing advancement of our design, engineering, machining & manufacturing capabilities, we are able to turn complex concepts into a reality.

Pipex px® are committed to solving construction weight, corrosion & access issues with the advanced design & unique manufacturing of FRP composite & thermoplastic pipe systems, chambers, vessels & structures. Our innovative products are custom design &build, and are complimented by our expert in-house engineers to provide sustainable & optimised turn-key solutions.

Our specialist teams focus on developing innovative initiatives requested directly from customers or initiated by Pipex px® people.

Project examples:

� PLA HUMP – a highly engineered modular platform that provides step-free access system for person with limited mobility for the Thameslink High Capacity Infrastructure (HCI) project in central London.

� Range Rover custom bumper – a totally unique resin infused bumper for Wildcat Automotive for a UEFA Euro 2016 marketing campaign

� Dover Footbridge - Seawall replacement footbridge, Dover, South East, UK. 2 No. 14.5m Hybrid pultrusion & resin infusion FRP pedestrian footbridge plus FRP pultruded stairs & landings

Platform Level Access – step-free access

The PLA-Hump® is a specialist FRP composite modular system that was designed for the Thameslink High Capacity Infrastructure Programme (HCI) to aid the successful transport of Personnel with Reduced Mobility (PRM). The PLA-Hump® will facilitate 24 trains per hour by providing unassisted level access at four core London train stations: City Thameslink, Farringdon, Blackfriars and St Pancras.

This highly engineered FRP composite modular design negates the need for the Manual Boarding Ramp (MBR).

Built offsite, lightweight & quick to install, the PLA-HUMP® provides consistent & safe step-free access.

It has been designed to meet: · Fire test & approved to LUL—1085 BS 476 Part 7· BS 6853: 1999 Annex D8.6· BS 6853: 1999 Annex B2· 10kN/m² patch load 300mm² BS EN 1991-1· Design life expectancy of 40+ years· High foot fall—13 million+


Product development:

Microstation General Arrangements

Platform Level Access –step-free access

FRP Base

Stainless Steel Countersunk Fixings

Top Cap

Foam Core

Pedestal Female

(Exploded Module 1A)

Pedestal Male

Farringdon Station St. Pancras Station


Vinyl Ester Prototype

London bridge design & trial


London bridge design & trial


30% Cost & Weight Saving

Platform Level Access –step-free access

Other engineering services provided include:

· Finite Element Analysis (FEA)

· Field Service Engineering

· 3D Laser Surveys

· Structural Engineering

· 3D Modelling Available

· Innovation, Research & Development

· Project Services

· Fabrication

· Installation & Site Capabilities


Using a process called “additive manufacturing” Pipex px® are now able to design and produce a 3 dimensional model of your product solution, providing a number of benefits for your project including;

� Cost effective production of concept models and functional prototypes

� Reduced development time� Rapid detection of possible design improvements� Allows superior understanding of final product prior to

manufacture

3D PRINTING & PROTOTYPING

Using Autodesk Inventor & Microstation design packages, we can provide 3D rendered models of our thermoplastic (PP-H/HDPE) and composite (FRP/GRP/GRE) pipe systems, chambers, vessels and structures, to turn information into insight.Our 3D modelling is not limited to our own product range, we can design whatever you need, in any material of your choice, of which models are easily incorporated into Navisworks/BIM software to help support your design & BIM (Building Information Modelling) requirements.

Benefits you get from our 3D Product Models:� Compatible with Navisworks/BIM software� Total clarity on the end product which will be delivered

to you� De-risks the possibility of errors/site clashes – saves

time & money on your project� Improves project efficiency� One 3D Model uploaded to online Databases so you

have access at all times� Intelligent structure detail at your fingertips (weight,

colour, material & cost)

NAVISWORKS PROJECT REVIEW TO SUPPORT BIM

CADWorx

CADWorx Plant Professional includes the most complete range of tools for efficient, faster and easy creation of fully intelligent 3D plant models

• Efficient Plant Modelling• Structural Steel and Equipment Modelling• Ducting and Cable Trays Modelling• Automatic Isometric • Collision Checking• Production Walkthrough Capabilities• Bi-directional Links CAESAR II Stress Analysis

3D MODELLING

CADWorx Piping Overview

3D MODELLING

In addition to general arrangements for pipework coordination and routing design, our engineers produce fabrication and installation isometrics, spool details and support design utilising CadWORX plant design software together with complete Bondstrand® GRE product libraries.

Projects examples:

� BP Clair Ridge GRE pipe systems – 2.1km of BONDSTRAND® GRE verification of clients design was supplied to ISO14692 and manufacturers recommendations.

� BP KBR Shah Deniz II – Material take off (MTO) of BONDSTRAND® components, specification preparation & general technical product support was provided direct from the KBR client offices. Stress analysis verification of client supplied reports was also carried out at Plymouth HQ to the UKOOA piping code.

� BP Scottish Water Grangemouth – Effluent tie-in to Scottish Water. Overlay of client routing with BONDSTRAND® 2416C piping producing general arrangements, erection and fabrication isometrics, support details and stress analysis to ISO14692.

� BP Sullom Voe – FEED design of new 16” GRE buried fire main to include identifying all required materials, confirmation of routing, stress analysis incorporating transient loads, road crossings, PED assessment and custom designed valve chambers for tie-ins.

� Ferrybridge Carbon Capture – Piping design of 32” GRE vent line supported on lattice towers at spans up to 23m. Supporting designed to accommodate large thermal movements while keeping axial loads transferred to the towers to a minimum.

PIPING DESIGN, ASSISTANCE & VERIFICATION

The reason?

The challenge?Design, Test, Qualify, Manufacture and Supply a specialized Filament Wound GRE SWRO Pressure containment Vessels, in accordance with BS-EN 13923, following Class I PED.

* 76 bar operating pressure,

* 4X safety factor.

* Requirement for 290+ units in extremely tight delivery period.

BP’s initial supply of vessels plagued by a number of issues.

* Unacceptable leakage issues at sealed side port nozzles location.

* Internal surface defects major cause for concern.

* Side port penetration poorly fabricated and out of tolerance.

PIPING DESIGN, ASSISTANCE & VERIFICATION

BP SWRO Pressure Vessels

DESIGN, PROTOTYPING & INITIAL TESTING

Design

* Structural calculations for carcass according

ISO 14692 as a harmonized standard.

* Test jigs built to carry out.

preliminary Evaluation & Testing.

of side port gasket material.

Prototyping

* Assisted by NOV FGS Malaysia & Singapore during trials

phase.

* Prototype vessel carcass subsequently burst test to

confirm structural calculation.

* Prototype vessel structure and manufacturing layup

confirmed for production.



Fabrication Process

* Assisted with Design and building of 2X 4 Axis CNC pipe mills to achieve geometric tolerances of

0.2mm.

* Specified manufacturing process flow and integrated new quality control equipment and methods.

* Developed ITP and quality plan, approved by BP.

* Identified scope for product improvement in areas where redundancies were noted.

DESIGN VERIFICATION

Qualification & Certification of design motivated using 3D FEA analysis of side port locations

* FEA analysis completed on side port locations to verify structural capacity of

machined areas.

* Analysis considered 3D nature of model using 2D material properties set around a

circular axis.

Further Concept Development

* Original side port nozzle assembly could be improved.

* Redesign removed redundant clip components.

* Formed flange integrated into nozzle design.

* Nozzle alterations allow for less material to machined from vessel wall, increasing structural capacity.

Our engineers have a long and wide experience in providing static analysis in low pressure systems in thermoplastic, thermosetting (GRE) and metallic piping for suspended, buried, marine, industrial and offshore applications.In combination with CAESAR II, the most widely used pipe flexibility and stress analysis software, we carry out detailed piping stress analysis, evaluating and confirming structural and operational integrity of process piping systems to ensure compliance in accordance with international piping codes and standards ISO14692, B31.3, UKOOA, BS7159, API610 and AWWA.

Structural Integrity:Design adequacy for the pressure of the carrying fluid. Failure against various loading in the life cycle. Limiting stresses below code allowable.

Operational Integrity:Limiting nozzle loads of the connected equipment within allowable values.Avoiding leakage at joints. Limiting sagging & displacement within allowable values.

Optimal Design:Avoiding excessive flexibility and also high loads on supporting structures. Aim towards an optimal design for both piping and structure.

Project examples:

� ADMA-OPCO Zakum fine filter skid – stress code compliance to ISO14692 for suspended BONDSTRAND® 7000M up to 14” diameter including support design, equipment nozzle checks and surge loads from hydraulic analysis.

� BP Sullom Voe Terminal fire main – Stress code compliance to ISO14692 for new buried 24” BONDSTRAND® 2416C main with valve chambers and tie-ins to existing including surge loads from hydraulic analysis; road crossings to AWWA M45.

Direct link between CADWorx

and CAESAR II.

BP Grangemouth – replacement 8” oily water line from 36 diameter tank. 3D Laser Scanned > Overlayed with CADWorx > Output to Caesar II.

CAESAR II PIPING STRESS ANALYSIS

STRUCTURAL ENGINEERING

Pipex px® Engineers can produce structural calculations to determine the effects of loads on physical structures. This process determines the suitability of material performance to required specifications and relevant design codes.Fibre Reinforced Polymer (FRP) is an anisotropic material that requires specialist experience in evaluating the suitability and capability of structures. Pipex px® Engineers are experts in this field.

Pipex px® has extensive experience in structural engineering across many industries with particular experience in Transport, Offshore, Water and Waste Water and Oil & Gas.

Project examples:

� Crane access phenolic walkways - Pipex px® have designed the first ever fully phenolic walkway system in the UK. The bespoke FRP (Fibre Reinforced Polymer) phenolic crane access walkway is to be fabricated in sections and assembled on site in summer 2013. All materials are to be supplied in accordance with BS EN ISO 14122.

Phase 1: Concept and detailed design of FRP phenolic walkways, handrails and ladders in conjunction with the client

Phase 2: Selection and design of FRP phenolic profiles and materials in conjunction with Services

Phase 3: Structural testing and fire testing of materials in conjunction with the client

� BP Clair Ridge HVAC structure – phenolic FRP, 4 structures supplied to form an access platform with incorporated MARRS® OFFSHORE handrails.

Foam Monitor Access Platform - Fpso Hummingbird

DESCRIPTION

A bespoke FRP Foam Monitor Access platform to replace the severely corroded, original steel platform. Designed and manufactured in-house from EXTREN® profiles and MARRS® OFFSHORE handrail

• Handrails – 0.74 kN/m Horizontal Load or 1.0 kN Point Load

• Ladders – 1.5kN rung load (Point Load)

• Platform Grating – 5 kN/m² or 4.5 kNPoint Load

• Wave Load (Green Sea) = 1 bar

= 100kN/m²

LOADING


� Original Corroded Steel Platform

� New FRP Replacement

Foam Monitor Access Platform - Fpso Hummingbird


CAT II DESIGN CHECKS

Pipex px® Engineering Services Department has the capacity & structure to facilitate CAT II Structural Design Check process requirements as requested by the client.This detailed process is required for the construction of all structures within the public domain and requires 3 stages of design approval;Approval in Principle (Form 1)Approved for Construction (Form 2)Design Check (Form 3)

Our Engineers have the experience/expertise to be accepted by Network Rail Project Engineer (PE) to perform design and CAT II Structural Design Checks in the role of Contractors Responsible Engineers (CRE’s) & Checkers.

This specialised capability ensures that each structural design is reviewed and verified in detail by the Pipex px® Checker (Independent of the originating design team) and a check certificate is issued on completion.

CAT II Design Checks Projects Portfolio:

FRP composite location cabinet access platforms - CAT II design check process was carried out for Network Rail’s requirement for access platforms at one of their sites in the West Midlands. 36 No. structures were designed in various sizes up to CAT II Structural Design, complete with handrails, safety gates and access ladders or steps. These access platforms were installed in close proximity to overhead power lines -our advanced FRP composite material is the ideal solution due to its non-conductive properties.

Pipex px® Engineering Services Department (ESD) use CFD to optimise complex design systems for a diverse range of fields in a multimedia environment.

In collaboration with the UK’s leading Science & Engineering Universities, CFD allows our Engineers to conduct the latest design processes to have a major impact on reducing development costs and improving manufacturing design cycles, to benefit the project for the long-term. This advanced design process enables our Engineers to provide you with the best possible construction solution, whether it be a pipe system, chamber, vessel, structure or bespoke fabrication.

Project example:

Met Office Weather Station Balloon Shelter – Due to an environmentally harsh location in the Shetland Islands, a steel balloon shelter had on-going and costly maintenance problems. As a result of this, a more robust & maintenance free structure was required. Our ESD used CFD to produce an improved FRP composite design with rotating mechanics, lighting, low maintenance folding doors & Zone 1 ATEX compliance. This provided an aerodynamic solution that was lightweight, corrosion resistant and has a 60+ year design life.

COMPUTATIONAL FLUID DYNAMICS (CFD)

The Pipex px® highly experienced Field Service Engineers are available at short notice to support customers globally, in the installation assistance and verification of Pipex px® products including;

• Specialist thermoplastic welding• GRE/GRV over wrapping, adhesive and mechanical jointing• Client team support, training and certification• Preventative & corrective action reports• Fault investigation & repair• Electrical continuity tests to ISO 14692 standard• Field personnel training of specialist tooling, jointing, installation methods and

material handling.• Unconditional commitment to HSE and quality (LRQA 9001, 14001, 18001)• Commissioning of equipment• Problem solving

Project examples:

BP Shah Deniz II – Our engineers were appointed onsite to provide training to the local workforce at Baku and to oversee HDPE butt and electro fusion jointing/welding operations, Bondstrand® GRE taper jointing & general install of 8.8km of HDPE pipe systems up to 900mm in diameter and 11km of Bondstrand® GRE up to 16” over a 24 month duration.

Royal Navy Type 45 Destroyers – Field service site support and product training was provided for a range of GRE pipe systems; ballast, cooling water, bilge, fuel, drains, sewage, sounding/venting tubes, exhaust. BAE Surface Ships quoted,“Pipex px® contributed proven expertise and experience to the Type 45 Programme and worked closely with the BAE team to deliver key pipework milestones. I’m sure that the results achieved on the Type 45 programme will stand Pipex px® in good stead to deliver on the Queen Elizabeth Class Aircraft Carrier Programme.”

GLOBAL SITE SERVICE, FIELD SERVICE & INSTALLATION TEAMS

BONDSTRAND GRE TRAINING & CERTIFICATION

Pipex px® are the NOV certification body for recognised bonding qualifications. They coordinate international training events through a team of competent trainers. Qualifications are awarded through classroom based tuition, practical assessments, adherence to procedures and workmanship.

Qualifications are awarded upon the validation of products produced by the trainee that withstand stringent hydro-static testing process.

pipexpx.com

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For Case histories/ Technical Documents etc. please visit our website: www.pipexpx.com

To access & view related Pipex px® videos for inclusion on presentations or for distribution to clients please visit our YouTube page; https://www.youtube.com/user/Pipexpx

For accurate recording and distribution general email enquiries should be sent to: [email protected]

• Bill Murphy – VP Sales and Marketing, FGS | Pipex

px [email protected]