See How Toray Uses VARTM Technology To Repair Deep-Sea Oil and Gas Production Equipment That has been in Service in Harsh Offshore Environments for Many Years

 

There are many Composite Molding Processes – spraying, winding, molding, injection, pultrusion, RTM, LFT, vacuum induction, autoclave, ATL/AFP, 3D printing, etc. Today, let’s follow the leader of the carbon fiber industry – Toray, and learn about Toray’s use of vacuum assisted resin transfer molding (VARTM) technology to repair deep-sea oil and gas production equipment, and constantly keep up with the times, improve the process, and develop a CFRP repair technology based on surface corrosion repair technology and suitable for pitting corrosion. If you want to know more about the development of advanced composite molding processes and equipment, welcome to our annual event on December 20th. I believe you will definitely not regret it.

MODEC and Toray Industries, Ltd. announced on December 18 that they have jointly developed a carbon fiber reinforced plastic (CFRP) repair technology for the repair of floating production, storage and offloading units (FPSO) and floating storage and offloading units (FSO).

MODEC, a general contractor specializing in engineering, construction, operation and maintenance services for offshore oil and gas vessels, will use this carbon fiber reinforced plastic (CFRP) repair technology for pitting repairs in its FPSO and FSO repair services from 2024.

The American Bureau of Shipping (ABS), which provides classification services for marine and offshore assets, has approved this technology for repairing areas up to 300 mm in diameter damaged by pitting.

FPSO and FSO maintenance work is carried out without interrupting oil and gas production. Therefore, it is crucial to develop a repair technology that facilitates efficient deployment of materials and equipment offshore and does not involve high-temperature operations. These factors prompted MODEC and Toray to jointly develop the Vacuum Assisted Resin Transfer Molding (VaRTM) process for CFRP repair in 2020, as shown in Figure 1. ABS approved the application of CFRP to steel to restore its mechanical strength.

The repair technology jointly developed by the two companies uses a special carbon fiber fabric with high strength and high elastic modulus. Compared with the traditional repair method using steel, it is easier to carry materials and equipment, requires fewer people and equipment, and has a shorter construction period. In addition, since no firefighting work is involved, the impact of the repair work on oil and gas production is expected to be minimized.

 

 

(Figure 1. Schematic Diagram of a new Offshore Repair Method Suitable for Repairing Large areas of Corrosion)

 

(Figure 2. CFRP Base Plate Repair)

 

While this process is well suited for repairing large areas of corrosion, it is less suitable for repairing pitting corrosion. In this case, the new CFRP patch technology is a more direct and effective solution.

It only requires bonding prefabricated CFRP patch flat plates to the pitting corrosion, which reduces labor by half and shortens delivery time (referring to on-site time compared to the VARTM process, excluding delivery time for material procurement).

The technology does not require vacuum pumps and other equipment, simplifying the process of transporting reinforcement materials and construction tools on board. In addition, since no hot work is required, the technology ensures minimal disruption to oil and gas production.

Together with Toray, MODEC will meet the various corrosion repair needs of FPSO and FSO operators by providing in-situ VARTM technology for large-area repairs and CFRP patching technology for local repairs. The two companies will continue to develop repair technologies for these vessels to meet market needs in a timely manner while addressing environmental and other social issues and contributing to sustainable economic development.