Crude Oil Lines Defy Harsh Operating Conditions

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February 2011 Dunlop Oil & Marine has landed a key order from the Sakhalin Energy Investment Company. The order is for two complete hose systems for the transportation of crude oil in winter from a tower loading station to a buoy which serves to moor, discharge, and fill tankers. Each system consists of 6 individual hoses linked together to make up a total length of 67 meters.

SEIC operates the tower loading station for the production of crude oil off the coast of Russia's Sakhalin Island, employing two different hose systems – one in summer and the other in winter. When the sea is frozen over and floating hoses cannot be used, the oil flows through a hanging aerial line construction. Dunlop Oil & Marine supplied the first hoses for both systems already in 2007. "Customers know that they can depend on our products," says managing director Kam Zandiyeh.

Last year SEIC was forced to reduce the weight of the winter system on the loading station in order to operate within the safe limits of the loading station. To achieve this, the customer turned once again to Dunlop Oil & Marine, which offered a hose with a diameter of about 0.5 meters that satisfied the requirements for this application. The new lines weigh roughly 15% less than the original ones. The hose that is used features all the unique selling points of the latest DEEPFLO product group while also profiting from a special rubber compound that is suitable for application temperatures down to -30°C.

To ensure that the hose was suitable for this application, it was first subjected to meticulous testing, which showed that the hose can withstand a pressure 5 times that of the actual operating pressure. Dynamic tests have confirmed flexibility at the lowest specified temperature conditions and fatigue tests have confirmed that the hose will meet the specified service life.

DEEPFLO was developed to satisfy the stringent requirements of the 17K standard of the American Petrol Institute (API). All materials were tested thoroughly with regards to ageing and fatigue resistance to guarantee a service life of 25 years. The result is a hose that can fulfill the most demanding requirements. The smooth inner liner reduces not only the pressure loss in the line but can also minimize transport costs as well as the costs for the power supply. The biggest savings effect, however, comes from the conveying capacity, which makes it possible to keep the number of lines used to a minimum.

The patented hose coupling is both lightweight and compact, and reduces connecting times and costs substantially. The coupling flanges are wear-free and the triple seal remains tight for the entire product life. The compact flanges can be connected easily, eliminating the welding process, which is as expensive as it is time consuming.

The hybrid reinforcement, which is also patented, enables large diameters together with low weight, whereby the line must remain ultra-strong and flexible. This was a decisive chararacteristic when it came to landing the first order for the sophisticated application under the harsh environmental conditions that prevail on Sakhalin, where some of Russia's largest petroleum and natural gas reserves are found.

Plans are to deliver the hoses already in April. "A very tight time frame for us,“ Zandiyeh explains. This allowed SEIC, however, to complete the replacement program in time.

Crude Oil Lines Defy Harsh Operating Conditions

 

Crude Oil Lines Defy Harsh Operating Conditions

 

Crude Oil Lines Defy Harsh Operating Conditions

 

Crude Oil Lines Defy Harsh Operating Conditions

 

Crude Oil Lines Defy Harsh Operating Conditions