McDermott A Ref: R3133-200013. | Quote Ref No Q11359.

| Rev No 0, Priced/ Alternative McDermott Australia PtyLtd | ITT Ref:

R3133-200013. | Quote Ref No Q11359. | Rev No 0, Priced/ Alternative

DRILLING RISER
BUOYANCY SYSTEMS
• Deck weight savings – up to 200t for 10,000ft strings
• Space savings – smaller diameter modules
• Increases rig operating depth and sea state
• Increases rig operating window in high current conditions – smaller OD
reduces drag

Document Reference No: E284 – Rev 1, 22/01/14

1
CONTENTS
1 Drilling Riser Buoyancy Systems ...................................................................................................2
1.1 Benefits ................................................................................................................................2
1.2 Features ...............................................................................................................................2
1.3 Material Grades ...................................................................................................................3
2 Configuration & Specifications .......................................................................................................4
2.1 OD Restrictions ....................................................................................................................4
2.2 Inserts ..................................................................................................................................4
2.3 Riser Configuration & Clearances........................................................................................4
2.4 Module Configurations & Options – Two & Three Part ........................................................5
2.5 Riser flexure .........................................................................................................................6
2.6 Stacking Types & Calculations ............................................................................................6
3 Materials .........................................................................................................................................8
3.1 Syntactic Foam Core ...........................................................................................................8
3.2 Composite Macrospheres ....................................................................................................8
3.3 Monolithic Syntactic Foam Encapsulant ..............................................................................8
3.4 Skin Systems .......................................................................................................................9
3.5 Tooling ...............................................................................................................................10
4 Material Grade Comparisons .......................................................................................................11
4.1 Core Density Comparison ..................................................................................................11
4.2 Uplift & Air Weight Comparison .........................................................................................16
4.2.1 Uplift Guides.......................................................................................................................17
4.3 Total Deck Weight Comparisons .......................................................................................19
4.4 Total String Uplift Comparisons .........................................................................................19
4.5 Module OD Comparison – Ultra-light vs. Standard Foams ...............................................20
5 Depth & Depth Breaks..................................................................................................................21
6 Maintaining String Tolerance .......................................................................................................22
7 Material Testing ............................................................................................................................23
8 Labelling & Marking ......................................................................................................................27
8.1 RFID tracking .....................................................................................................................27
8.2 QR Code ............................................................................................................................27
9 Shipping & Packing ......................................................................................................................28
APPENDIX 1 Tooling Range ................................................................................................................
APPENDIX 2 About Matrix Composites & Engineering .......................................................................

DISCLAIMER - Matrix Composites & Engineering Ltd have a policy of continual improvement so please ensure
you are in possession of the last issue of the Product Information Document for the product(s) you are planning to
use. Although every effort has been made to ensure the accuracy of the information contained herein, Matrix
Composites & Engineering Ltd gives no warranty express or implied that the information is accurate and shall in
no circumstances accept any liability if it is not. The customer must satisfy themselves as to the suitability of any
of Matrix Composites & Engineering’s products for their requirements.

Document Reference No: E284 – Rev 1, 22/01/14 1

1 Drilling Riser Buoyancy Systems
The following Technical Data Document provides an
overview of the key technical and operational features and
benefits of the Matrix Drilling Riser Buoyancy range. A
density and uplift table, calculation guide and a fastener and
tooling catalogue are also included.

Riser buoyancy modules provide partial flotation for marine

riser systems which allows the rig to deploy, operate and
recover the marine riser to the depth capability of the drilling
vessel.

Riser analysis determines the total compensation or

buoyancy required for the string over the water depth of the
rig. The analysis takes into account tensioner capacity, sea
state, mud weights, and low marine riser package (LMRP)
and riser weights. Constraints such as tensioner capacity and
diverter housing inter-diameter (ID) restrictions drive the
configuration and selection process of the material density.

Manufactured from lightweight, composite syntactic foams Image 1 – Drilling riser buoyancy and
with high compressive strength, the modules withstand extreme bare joint protection system
hydrostatic forces exhibited at their varying operating depths.

1.1 Benefits
• Deck weight savings – smaller and lighter modules reduce deck weight by up to 200t for
10,000ft strings

• Space savings – smaller diameter modules

• Increases rig operating depth and sea state

• Increases rig operating window in high current conditions - smaller OD reduces drag

• Supported by a global service and distribution network

1.2 Features
• Wide range of lightweight core materials made from composite syntactic foams

• Available in depth ratings to 12,000ft - depth ratings to 15,000ft in development

• Robust construction – reinforced skin system and part geometry

• API 16F tested

Document Reference No: E284 – Rev 1, 22/01/14 2

1.3 Material Grades
Matrix supplies a range of densities across each depth range to address the specific requirements
of the riser buoyancy system. The material grades are tiered, with the highest performing ‘Premium’
3 3
grade exhibiting greater strength to weight ratios, lower densities and greater uplift per m or ft for
each depth range.

MATERIAL GRADE DENSITY DESCRIPTION

• Next generation of ultra-low density foams

• Designed for minimising the cross sectional area of

Premium Lightest
buoyancy for maximum lift efficiency in constrained
envelopes and minimal drag

• High performance ultra-low density syntactic foams

• Designed to reduce cross sectional areas of buoyancy

Ultra-light Light and improve lift per riser joint

• Reduces tensioner capacity requirements by lowering

the ‘in water riser weight’

• Intermediate grade syntactic foam

Hybrid Low • Lower density than standard foams

• More economical than Premium and Ultra-light grades

• Standard density composite syntactic foam

Standard Standard • Used when there are no concerns with dimensional
constraints, dry weight or operational drag loads.

Document Reference No: E284 – Rev 1, 22/01/14 3

2 Configuration & Specifications
2.1 OD Restrictions
Restrictions including rotary table ID, diverter housing ID, spacing of riser racking and operational
limitations such as dressed riser weight and drag issues can limit the maximum diameter of the
module. Matrix has material and configuration solutions to address these issues including different
material densities across depth ratings and module insert systems.

2.2 Inserts
The use of inserts significantly increases the uplift of a module by utilising the space in between the
ancillary lines and the riser. Inserts also reduce the amount of ‘trapped water’ in the space between
the lines and the riser which can reduce riser recovery loads during disconnect and recovery.

Image 3 – Inserts

Image 2 – Ultra-light module running through a

diverter housing

2.3 Riser Configuration & Clearances

Riser buoyancy modules accommodate ancillary lines including kill, choke, booster and hydraulic
lines. The geometry of the module accommodates the riser clamp pockets and MUX clamps.

Document Reference No: E284 – Rev 1, 22/01/14 4

 Image 4 - Riser configuration mock-up

Image 5 – Example: auxiliary line clearance

2.4 Module Configurations & Options – Two & Three Part

Modules are configured in two or three parts as shown in Image 6 and 7 to accommodate line
assemblies, although the use of three part modules may limit stacking heights.

Image 6 - Two part design Image 7 – Three part design

Document Reference No: E284 – Rev 1, 22/01/14 5

2.5 Riser flexure
Risers flex during handling and operation. To accommodate riser flexure, the module is equipped
with fibre reinforced plastic (FRP) flex pads that contact the riser allowing it to flex within the ID of
the module. This reduces the likelihood of the module cracking and breaking.

Image 8 – DRBM cross section displaying flex pad location

2.6 Stacking Types & Calculations

Stacking loads are a critical design input when manufacturing riser buoyancy modules. Stacking
loads take into account stacking height, module and riser lifting point orientation, module geometry
and static and dynamic loads. In some scenarios, dressed risers are stacked up to 12 layers high.

Testing is required to confirm stack heights. At Matrix, the company produces a full-scale mock-up
of the buoyancy assembly and riser pipe, with the module assembly subjected to the predicted
loads and load orientations. Load and deflection data is recorded and analysed and the parts
inspected for any mechanical damage. Image 9 below shows the simulation of cross beam loading.

Image 9 – Scale stack test

Document Reference No: E284 – Rev 1, 22/01/14 6

 Image 10 – Stacked risers Image 11 – Finite stress element analysis

Document Reference No: E284 – Rev 1, 22/01/14 7

3 Materials
The Matrix drilling riser buoyancy module has a vacuum
processed composite syntactic foam core and moulded
outer FRP reinforced skin.

As depicted in Image 12, the black carbon fibre

composite macrospheres are encapsulated by white
monolithic syntactic foam surrounded by an outer FRP
skin.

3.1 Syntactic Foam Core

Syntactic foam consists of the following: Image 12 – Composite syntactic foam core and
moulded outer FRP reinforced skin
• Composite Macrospheres
• Monolithic Syntactic Foam Encapsulant

3.2 Composite Macrospheres

Composite macrospheres are lightweight hollow fillers
that reduce the density of syntactic foam whilst
maintaining the hydrostatic and compressive strength
required by the finished syntactic foam system.

Macrospheres are constructed from a lightweight foam

sphere, typically 10-50mm in diameter with an outer
laminated shell. Depending on the grade, the shell is
constructed from epoxy resin and a functional filler such
as carbon fibre or a reinforcing mineral fibre.

3.3 Monolithic Syntactic Foam

Encapsulant Image 13 – Composite macrospheres

The syntactic foam encapsulant is manufactured in

liquid form and injected into an evacuated macrosphere
filled tool. The liquid syntactic foam encapsulates the
macrospheres and cures to form the finished composite
syntactic foam structure.

Manufactured from a combination of liquid epoxy resin

binders and hollow glass microspheres, the encapsulant
is vacuum processed to form a liquid monolithic
syntactic. When cured the liquid forms a rigid polymer
structure.

Image 14 – Scanning Electron Microscope (SEMS)

image of hollow glass microsphere

Document Reference No: E284 – Rev 1, 22/01/14 8

Hollow Glass Microspheres (HGMS) appear as free flowing white powder to the naked eye. They
3 3
are made from Borosilicate glass and range in density from 100kg/m to over 1000kg/m .

The high compressive strength to weight ratio of HGMS makes them an ideal binder filler for
syntactic foams. Due to their spherical shape, they can also be highly loaded in the resin binder to
minimise the density of the syntactic foam.

3.4 Skin Systems

The outer skin of the buoyancy module is
manufactured from an integrally moulded fibreglass/
aramid composite which produces a lightweight,
tough, rigid outer layer that is abrasion and impact
resistant. The outer skin consists of a double layer of
FRP and a backing layer of aramid mesh. Extra
reinforcement to high impact and strain areas is
applied if required. The skin system can be painted
with a variety of surface treatments including epoxy
resin or polyurethane.

The materials and systems used in Image 15 are

Image 15 – Skin system
‘closed cell’. Should any external damage or puncture
of the skin system ensue, virtually no buoyancy loss
will occur. Alternative systems such as lightweight PU foams with PE shells will experience
significant buoyancy loss if their skin systems rupture. Repair kits are available.

Document Reference No: E284 – Rev 1, 22/01/14 9

SKIN SYSTEM PROPERTIES

Outer Skin E-Glass CSM reinforcement

Secondary
Bi-axial aramid fibre
Reinforcement Layer

Application Process Integrally moulded

Paint System Two pack epoxy, 100% solids

ASTM D4541 pull off strength for coatings.

Paint Adhesion Standard
ISO 20340 paints and varnishes - performance requirements for
protective paint systems for offshore and related structures. (Annex
A: durability)
Paint Durability Test
UL 94 - Test for flammability of plastic materials, HBF
Conditions

Flame Spread Index Test

Pass
Conditions

Acceptance Criteria

Paint Adhesion Standard Min-2 MPa (ASTM D4541)

o
Paint Test Conditions Min 24 hours after painting @ 23 C

3.5 Tooling
Matrix draws from experience in the aerospace tooling industry to design and manufacture high
accuracy machined tooling that maintains surface accuracy and part flatness. The tooling process
ensures:

• Improved part accuracy

• Parts are fully interchangeable

• Low level of post finishing – elimination of manual finishing processes

Appendix 1 contains the Tooling Technical Data Sheets.

Document Reference No: E284 – Rev 1, 22/01/14 10

4 Material Grade Comparisons
4.1 Core Density Comparison
Matrix supplies a range of densities for each depth range which address the specific requirements
of the riser buoyancy system. The density grades range from the ‘Premium’ material through to the
‘Standard’ density composite syntactic foam. The higher performing materials exhibit greater
3 3
strength to weight ratios, lower densities and greater uplift per m or ft for each depth range.

Material Grade Density Description

• Next generation of ultra-low density foams

• Designed for minimising the cross sectional area of
Premium LIGHTEST
buoyancy for maximum lift efficiency in constrained
envelopes.

• High performance ultra-low density syntactic foams

• Designed to reduce cross sectional areas of

Ultra-light LIGHT buoyancy and improve lift per riser joint.

• Reduces tensioner capacity requirements by

lowering the ‘in water riser weight’

• Intermediate grade syntactic foam

• Lower density than standard foams

Hybrid LOW
• More economical than the Premium and Ultra-light
grades

• Standard density composite syntactic foam

Standard STANDARD • Used when there are no concerns with dimensional
constraints, dry weight or operational drag loads.

Document Reference No: E284 – Rev 1, 22/01/14 11

Graph 1 and 2 demonstrate the density and uplift differences between each grade of material.

GRAPH 1 – CORE DENSITY COMPARISON OF 8,000FT RATED SYSTEMS

560
540
520
Density (kg/m³)

500
480
460
440
420
400
Premium Ultra-light Hybrid Standard
Series2 458 482 514 547

GRAPH 2 – UPLIFT PER M3 COMPARISON OF 8,000FT RATED SYSTEMS

580
560
540
Uplift per m³

520
500
480
460
440
420
Premium Ultra-light Hybrid Standard
Series4 567 543 511 478

Document Reference No: E284 – Rev 1, 22/01/14 12

CORE DENSITY GUIDE

Core Core
Matrix Depth Depth
Material Grade System Description Density Density
Material (ft) (m) 3 3
kg/m ) (lbs/ft )

STANDARD

999194 Macrosyn 610B 2000 610 346 21.6

Macrosyn 762B - Std
999199 2500 762 357 22.3
Density
999166 Macrosyn 914 CW 3000 914 369 23.0

999104 Macrosyn 914 3000 914 388 24.2

999106 Macrosyn 1219 4000 1219 415 25.9

999108 Macrosyn 1524 5000 1524 452 28.2

999110 Macrosyn 1829 HS 6000 1829 488 30.5

999112 Macrosyn 2134 HS 7000 2134 516 32.2

999113 Macrosyn 2286 HS 7500 2286 526 32.8

999114 Macrosyn 2438 HS 8000 2438 547 34.1

999116 Macrosyn 2743 HS 9000 2743 584 36.5

999117 Macrosyn 3048 HS 10000 3048 593 37.0

999164 Macrosyn 3353 HS 11000 3353 619 38.6

999165 Macrosyn 3658 HS 12000 3658 649 40.5

HYBRID

999167 Macrosyn 1219 CW 4000 1219 396 24.7

999163 Macrosyn 1524 CW 5000 1524 429 26.8

999168 Macrosyn 1829 CW HS 6000 1829 461 28.8

999169 Macrosyn 2134 CW HS 7000 2134 484 30.2

999171 Macrosyn 2438 CW HS 8000 2438 514 32.1

999172 Macrosyn 2743 CW HS 9000 2743 537 33.5

999173 Macrosyn 3048 CW HS 10000 3048 542 33.8

999174 Macrosyn 3353 CW HS 11000 3353 579 36.1

999175 Macrosyn 3658 CW HS 12000 3658 601 37.5

ULTRA-LIGHT

999122 Macrosyn 610B 2000 610 324 20.2

999132 Macrosyn 762 CF 2500 762 351 21.9

999133 Macrosyn 914 CF 3000 914 351 21.9

Document Reference No: E284 – Rev 1, 22/01/14 13

 Core Core
Matrix Depth Depth
Material Grade System Description Density Density
Material (ft) (m) 3 3
kg/m ) (lbs/ft )

999135 Macrosyn 1067 CF 3500 1067 378 23.6

999136 Macrosyn 1219 CF 4000 1219 378 23.6

999137 Macrosyn 1524 CF 5000 1524 406 25.3

999138 Macrosyn 1829 CF HS 6000 1829 428 26.7

999139 Macrosyn 2134 CF HS 7000 2134 449 28.0

999140 Macrosyn 2286 CF HS 7500 2286 461 28.8

999160 Macrosyn 2438 CF HS 8000 2438 482 30.1

999142 Macrosyn 2743 CF HS 9000 2743 496 31.0

999146 Macrosyn 3048 CF HS 10000 3048 509 31.8

999144 Macrosyn 3353 CF HS 11000 3353 528 33.0

999145 Macrosyn 3658 CF HS 12000 3658 554 34.6

999195 Macrosyn 3962 CF 13000 3962 573 35.8

999196 Macrosyn 4267 CF 14000 4267 591 36.9

PREMIUM

999147 Macrosyn 3353 CF HS X 11000 3353 523 32.6

999148 Macrosyn 3658 CF HS X 12000 3658 532 33.2

999197 Macrosyn 3962 CF XLD 13000 3962 550 34.3

999198 Macrosyn 4267 CF XLD 14000 4267 569 35.5

RD-8000-
Featherlite 8000 8000 2438 458 28.6
FL
RD-
Featherlite 10000 10000 3048 485 30.3
10000-FL

Note: Core densities do not take into account fasteners or skin systems

Document Reference No: E284 – Rev 1, 22/01/14 14

 GRAPH 3 - CORE DENSITY & UPLIFT CHART - STANDARD

1200
Sum of Core Density & Uplift

1000
800
(kg/m3)

600
400
200
0
2000 2500 3000 4000 5000 6000 7000 7500 8000 9000 10000 11000 12000
Standard
System Depth (ft)

GRAPH 4 – CORE DENSITY & UPLIFT CHART - HYBRID

1200
Sum of Core Density & Uplift

1000
800
(kg/m3)

600
400
200
0
3000 4000 5000 6000 7000 8000 9000 10000 11000 12000
MacroSyn H
System Depth (ft)

GRAPH 5 – CORE DENSITY & UPLIFT CHART - ULTRA-LIGHT

1200
Sum of Core Denstiy and Uplift

1000

800

600
(kg/m3)

400

200

0
2000

2500

3000

3500

4000

5000

6000

7000

7500

8000

9000

10000

11000

12000

13000

14000

Ultralight
System Depth (ft)

Document Reference No: E284 – Rev 1, 22/01/14 15

 4.2 Uplift & Air Weight Comparison
Graph 6 shows how the use of lower density materials can significantly increase overall string
buoyancy whilst maintaining OD. In this example, the uplift difference between a Standard grade
buoyancy string and a Premium grade string is approximately 185MT, or over 400,000lbs.
GRAPH 6 - 54’’ MODULE * 10,000FT STRING COMPARATIVE UPLIFT CHART

1.8

1.6

1.4
(metric tonnes - 000's)

1.2

0.8

0.6

0.4

0.2

0
Standard Hybrid Ultralight Premium
10000 246189 274967 293279 307175
8000 272350 290663 308976 314255
6000 305902 321599 339912 339912
4000 348381 358845 369310 369310
2000 310763 317588 327626 337664

As portrayed in Graph 7, deck weight savings are significant, with a decrease in string weight whilst
maintaining OD.
GRAPH 7 – 54’’ MODULE * 10,000’ STRING COMPARATIVE WEIGHT CHART

1.6
Air Weight (metric tonnes - 000's)

1.4
1.2
1
0.8
0.6
0.4
0.2
0
Standard Hybrid Ultralight Premium
10000 361900 333080 314820 300960
8000 335720 317460 299200 293920
6000 302280 286440 268180 268180
4000 259820 249260 238700 238700
2000 186840 180000 169920 159840

Document Reference No: E284 – Rev 1, 22/01/14 16

4.2.1 Uplift Guides

4.2.1.1 Seawater Buoyancy

Seawater Buoyancy (Bsw) = Density Sea Water (δsw) x Volume Part (V) – Dry Weight (WD)

Imperial Metric
3 3 3 3
Bsw (lb) = 64 (lb/ft ) x V (ft ) – WD (lb) Bsw (kg) = 1025 (kg/m ) x V (m ) – WD (kg)

E.g. Module Dry Weight = 1200 lb E.g. Module Dry Weight = 545 kg
3 3
Module Volume = 45 ft Module Volume = 1.274 m

Bsw = 64 x 45 – 1200 = 1680lb Bsw = 1025 x 1.274 – 545 = 761kg

Alternatively, if Module Density (δM) is known Alternatively, if Module Density (δM) is known
3 3 3 3
Bsw (LB) = (64 – δM) (lb/ft ) x V (ft ) Bsw (kg) = (1025 – δM) (kg/m ) x V (m )
3 3
Module Density = 26.67 lb/ft Module Density = 427.8 kg/m

Bsw = (64 - 26.67) x 45 = 1680lb Bsw = (1025 - 427.8) x 1.274 = 761kg

4.2.1.2 Module Volume Estimate

Module Element Volume (V) = Gross Volume (VG) – Excluded Volume (VE)

Imperial Metric

L (OD2 − ID2 ) L (OD2 − ID2 )

VG = VG =
4400 2.5466

VE VE
= Vol of Mux Grooves, Clamp Recesses, Pockets Etc = Vol of Mux Grooves, Clamp Recesses, Pockets Etc

E.g. Module Length (L) = 204” E.g. Module Length (L) = 5.182m

Module ID = 21.75” Module ID = 0.553m

Module OD = 54” Module OD = 1.372m

3 3
VE = 12 ft VE = 0.3398 m

204 (542 − 21.752 ) 5.182 (1.3722 − 0.5532 )

VG = VG =
4400 2.5466

V = 101.3ft3 V = 2.868 m3

NOTE - There are typically two elements per module assembly.

Document Reference No: E284 – Rev 1, 22/01/14 17

4.2.1.3 Riser Weight in Sea Water

Riser Weight in Sea Water (RSW) = Riser Dry Weight (RDW) × 0.87

Imperial Metric

E.g. Riser Dry Weight (90ft) = 39,930 lb E.g. Riser Dry Weight (90ft) = 18,150 kg

RSW = 39,930 × 0.87 = 34,739 lb RSW = 18,150 × 0.87 = 15,791kg

4.2.1.4 Buoyancy Compensation (%)

Buoyancy Provided
Buoyancy Compensation % (BC) = 𝑥 = (100%)
Riser Weight in Sea Water

Imperial Metric

E.g. 5 module assemblies @ 6809lbs on a riser E.g. 5 module assemblies @ 3,095 kg on a riser
weighing 39,930lb in air weighing 18,150 kg in air

5 ( 6,809) 5 (3,095)
BC = (100%) BC = (100%)
39,930 (0.87) 18,150 (0.87)

BC = 98% BC = 98%

4.2.1.5 Conversions

Imperial Metric

Density: 1pcf (lb/ft3) 16.02kg/m3

Volume: 1cf (ft3) 0.0283m3

Mass: 1lb 0.454kg

Length: 1ft 0.3048m

Length: 1inch 25.4mm

Document Reference No: E284 – Rev 1, 22/01/14 18

 4.3 Total Deck Weight Comparisons
GRAPH 8 – TOTAL DECK WEIGHT COMPARISONS

1.5

1.45

1.4
(metric tonnes - 000's)

1.35

1.3

1.25

1.2

1.15
Standard Hybrid Ultralight Premium

4.4 Total String Uplift Comparisons

GRAPH 9 – TOTAL STRING UPLIFT COMPARISONS

1.7

1.65
(metric tonnes - 000's)

1.6

1.55

1.5

1.45

1.4

1.35
Standard Hybrid Ultralight Premium

Document Reference No: E284 – Rev 1, 22/01/14 19

4.5 Module OD Comparison – Ultra-light vs. Standard Foams
The diagram below illustrates the reduction in OD when using lower density material. Premium
ultra-light material reduces buoyancy OD by 4” inches and dressed riser weight by 4,884kg
(10,745lbs) per joint (based on a 75’ inch joint dressed with 10,000ft rated modules). Overall, uplift
is the same for all geometries.

Image 16 – Comparison of cross sections for equivalent uplifts at 10,000’ SW

Document Reference No: E284 – Rev 1, 22/01/14 20

5 Depth & Depth Breaks
The deeper the design depth of the foam system, the higher the compressive forces it must
withstand, therefore the higher the density of the syntactic core material. In order to maximise
string uplift, buoyancy modules are supplied in depth rating breaks. Lighter materials are used at
shallower depths to increase the uplift of the riser string.

Riser buoyancy modules are used at any position along the string from the surface to the module’s
maximum design depth. All modules are marked and have colour-coding bands to represent their
depth ratings as displayed in the table below.

COLOUR DEPTH RATING (ft) DEPTH RATING (m)

White 0-500 0-152

Pink 501-1000 153-305

Green 1001-2000 306-610

Blue 2001-3000 611-914

Yellow 3001-4000 915-1,219

Orange 4001-5000 1,220-1,524

Black 5001-6000 1,525-1,829

Red 6001-7000 1,830-2,134

Purple 7001-8000 2,135-2,438

Brown 8001-9000 2,439-2,743

Grey 9001-10,000 2,744-3,048

Cyan 10,001-11,000 3,049-3,353

Tan 11,001-12,000 3,354-3,658

N/A 12,001-15,000 In development

Document Reference No: E284 – Rev 1, 22/01/14 21

 6 Maintaining String Tolerance
Riser buoyancy strings typically contain up to 1,000 module halves. Part and string tolerance need
to be monitored during the production process to ensure that cumulative part tolerances fall within
the required API ± 2% string design tolerance as well as the individual part tolerance requirement
of ± 5%.

Matrix’s part weight inspection processes are controlled at two critical stages of the production
process:

• Macro Fill stage

• Liquid Syntactic Injection stage

These key processing points are monitored and controlled using an automated SCADA-based
system to ensure that part and string tolerances are maintained as portrayed in Graph 10.

GRAPH 10 – STRING TOLERANCES

1460
Calculated
1440 Buoyancy
1420
Average Buoyancy (kg)

Target buoyancy
1400

1380 String Min

1360
String max
1340

1320
Module Max
1300
100
105
Count
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95

Buoyancy Element

Document Reference No: E284 – Rev 1, 22/01/14 22

7 Material Testing
All Matrix core materials are tested in accordance to the requirements of API 16F Section 13
Edition 1.

Materials qualification testing is carried out in test chambers capable of testing modules with
diameters of up to 62” to a simulated water depth of 16,850ft. (5,135m).The chambers are fully
instrumented and capable of recording pressure, buoyancy loss and temperature changes over
time.

Buoyancy loss data is extrapolated over a 12-month period to ensure compliance with the
acceptance criteria.

Image 17 – Hydrostatic pressure testing facility Image 18 –

Hydrostatic pressure testing facility

Document Reference No: E284 – Rev 1, 22/01/14 23

SYSTEM TEST CONDITIONS (96 HOUR TYPICAL TEST REGIME)

API-16F

Liquid Composition Water, corrosion inhibitor and glycol blend

Temperature Temperature controlled: 4deg – ambient

Pressure Equivalent to system design water depth

Pressure Cycle 6 cycles, min. 10 minute dwell

Exposure Time 96 hours at full depth pressure + cycling

3
Density Testing 1030 kg/m

Crush Testing <1.25 × hydrostatic depth pressure

Acceptance Criteria

Buoyancy Loss >5%

Maximum elastic loss >1.5%

Hardness >80 shore D

Visual Inspection All parts should be free of structural damage. Localised skin
imperfections should not exceed 0.5% of the part’s surface area.

Document Reference No: E284 – Rev 1, 22/01/14 24

MODULE HYDROSTATIC PERFORMANCE REPORT TYPE CERTIFICATION TEST

Document Reference No: E284 – Rev 1, 22/01/14 25

MODULE HYDROSTATIC PERFORMANCE REPORT TYPE CERTIFICATION TEST,
WEIGHT GAIN DATA PLOT

Document Reference No: E284 – Rev 1, 22/01/14 26

8 Labelling & Marking
Each module is identified by the information
contained on the nameplate, including:

Serial No

Depth Rating

Project Name

Riser Identification No

Manufacturer’s Name

8.1 RFID tracking

Image 19- labelling on buoyancy modules
Each element includes an RFID chip embedded into the module as part of the manufacturing
process.

8.2 QR Code
The label has a QR code, which contains relevant information about the product and project. QR
codes may be scanned and read by mobile hand held devices.

Document Reference No: E284 – Rev 1, 22/01/14 27

9 Shipping & Packing
In most cases, riser buoyancy modules are shipped in standard, high cube or open top 40’ shipping
containers. Modules can be top loaded or skid-mounted and are typically shipped from the Port of
Fremantle, Western Australia to a range of global destinations.

Image 20 – Example: buoyancy module packing configuration

Document Reference No: E284 – Rev 1, 22/01/14 28

APPENDICES

Document Reference No: E284 – Rev 1, 22/01/14

 APPENDIX 1
TOOLING RANGE

Document Reference No: E284 – Rev 1, 22/01/14

 MATRIX Catalogue

Riser Buoyancy
Tool No. 760396

Imperial
Property SI Unit
Unit

Dim. A 56.00 1422.40

Dim. B 157.70 4005.58

Dim. C 21.00 533.40

Stacking
Flat 0
Orientation 0

Attachment Method Straps

Tool No. 760352

Imperial
Property SI Unit
Unit
Dim. A 55.00 1397.00

Dim. B 164.00 4005.58

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 0

Attachment Method Straps

matrixengineered.com
 MATRIX Catalogue

Riser Buoyancy
Tool No. 760735
Imperial
Property SI Unit
Unit
Dim. A 47.00 1193.80

Dim. B 150.00 3810.00

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 45

Attachment Method Studs

Tool No. 760737

Imperial
Property SI Unit
Unit
Dim. A 47.00 1193.80

Dim. B 180.00 4572.00

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 45

Attachment Method Studs

matrixengineered.com
 MATRIX Catalogue

Riser Buoyancy
Tool No. 760723
Imperial
Property SI Unit
Unit
Dim. A 54.50 1384.30

Dim. B 204.00 5181.60

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 45

Attachment Method Studs

Tool No. 762672

Imperial
Property SI Unit
Unit
Dim. A 36.00 914.40

Dim. B 180.00 4572.00

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 0

Attachment Method Straps

matrixengineered.com
 MATRIX Catalogue

Riser Buoyancy
Tool No. 760688
Imperial
Property SI Unit
Unit
Dim. A 45.00 1143.00

Dim. B 180.00 4572.00

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 0

Attachment Method Straps

Tool No. 760647

Imperial
Property SI Unit
Unit
Dim. A 55.50 1409.70

Dim. B 163.00 4140.20

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 0

Attachment Method Straps

matrixengineered.com
 MATRIX Catalogue

Riser Buoyancy
Tool No. 760780
Imperial
Property SI Unit
Unit
Dim. A 58.00 1473.20

Dim. B 167.00 4241.80

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 45

Attachment Method EK Style

Tool No. 760711

Imperial
Property SI Unit
Unit
Dim. A 54.00 1371.60

Dim. B 165.00 4191.00

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 45

Attachment Method Studs

matrixengineered.com
 MATRIX Catalogue

Riser Buoyancy
Tool No. 760244
Imperial
Property SI Unit
Unit
Dim. A 54.00 1371.60

Dim. B 204.00 5181.60

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 45

Attachment Method Studs

Tool No. 760552

Imperial
Property SI Unit
Unit
Dim. A 54.00 1371.60

Dim. B 203 - 206 5232.40

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 45

Attachment Method Straps

matrixengineered.com
 MATRIX Catalogue

Riser Buoyancy
Tool No. 760679
Imperial
Property SI Unit
Unit
Dim. A 54.50 1384.30

Dim. B 204.00 5181.60

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 45

Attachment Method Studs

Tool No. 760401

Imperial
Property SI Unit
Unit
Dim. A 54.00 1371.60

Dim. B 206.60 5247.64

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 0

Attachment Method Straps

matrixengineered.com
 MATRIX Catalogue

Riser Buoyancy
Tool No. 760491
Imperial
Property SI Unit
Unit
Dim. A 56.00 1422.40

Dim. B 207.00 5257.80

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 0

Attachment Method Straps

Tool No. 760349

Imperial
Property SI Unit
Unit
Dim. A 41.00 1041.40

Dim. B 180.00 4572.00

Dim. C 12.00 304.80

Stacking
Flat 0
Orientation 0

Attachment Method Straps

matrixengineered.com
 MATRIX Catalogue

Riser Buoyancy
Tool No. 760679-MO1
Imperial
Property SI Unit
Unit
Dim. A 54.50 1384.30

Dim. B 204.00 5181.60

Dim. C 18.00 457.20

Stacking
Flat 0
Orientation 45

Attachment Method Studs

matrixengineered.com
               
                                              
Techn
nical Da
ata She
eet
 

 
Matrix/
M / AIMS Low Drag
D Bu
uoyant Fairing Syste
em 
 

Property
P Drag Coe
efficient V
VIV Supp Effficiency

Parallel
P Fin 0.5 to 0.6 > 95%
%

Tapered
T Fin 0.4 to 0.5 > 95%
%
 
Property
P Imperial Unit
U (lbs) SI Unit (kg)

Weight
W in airr (per shroud) 416.0
00 188.6
69

Weight
W in wa
ater (per shrroud) 40.0
00 18.14
4

*L
Low drag buoyantt fairing system is copyrighted to Ad
dvanced Industriall & Marine, Inc (AIIMS)
Disclaimer:
D Perform
mance data is for information purposes only. Matrix aaccepts no warrannty or implied warranty express from
m third party relian
nce on data supplie
ed.
N for specification purposes.
Not

mattrixengine
eered.com 
 
                  
                                                
MATRIX Technical Data Sheet
 

 
EK Style Fastener Strap and U-Bolt 
 

Part No. 810456

810456
Part No. 531586

Imperial
Property SI Unit Dim. C 
Unit
 
Dim. A 3.35 85.00 Dim. A 

Dim. B 23.62 600.00

Dim. C 1.97 50.00

Dim. D _____ _____ Dim. B

531586 

Dim. D

This drawing and the information contained therein are the sole property of Matrix Composites and Engineering Ltd. Any reproduction of this drawing without
the written permission of Matrix Composites and Engineering Ltd is prohibited.

matrixengineered.com 
 
                  
                                                
MATRIX Technical Data Sheet
 

 
Strap and Double Bolt Tensioner 
 

Part no. 810456

Imperial
Property SI Unit
Unit

Dim. A 5.31 135.00

Dim. D
  Dim. C
Dim. B
3.35 85.00
(Closed) Dim. B
Dim. C
6.59 167.50
(Open)

Dim. D 9.25 235.00 Dim. A 

To suit 10T Kevlar strap, max width 58 mm

This drawing and the information contained therein are the sole property of Matrix Composites and Engineering Ltd. Any reproduction of this drawing without
the written permission of Matrix Composites and Engineering Ltd is prohibited.

matrixengineered.com 
 
                  
                                                
MATRIX Technical Data Sheet

 
Through Bolt Tensioner 
 

Part No. 810410 810374 810244

Imperial Imperial Imperial

Property SI Unit SI Unit SI Unit
Unit Unit Unit

Dim. A 3.35 85.00 3.35 85.00 3.35 85.00

 

Dim. B 23.62 600.00 26.38 670.00 28.74 730.00

Dim. C 0.75 19.05 0.75 19.05 0.75 19.05

  Dim. C
 

  Dim. A

 
Dim. B
 

This drawing and the information contained therein are the sole property of Matrix Composites and Engineering Ltd. Any reproduction of this drawing without
the written permission of Matrix Composites and Engineering Ltd is prohibited.

matrixengineered.com 
 
 APPENDIX 2
ABOUT MATRIX COMPOSITES &
ENGINEERING

Document Reference No: E284 – Rev 1, 22/01/14

About Matrix Composites & Engineering
Matrix Composites & Engineering (‘Matrix’) provide solutions consisting of engineered products
and integrated services to the global oil and gas industry. Matrix is a leading developer of syntactic
foam products using its core competencies in syntactic foam, composites materials and polymer
material technology.
Matrix is a public company listed on the Australian Stock Exchange (ASX) with operations dating
back to 1980.

Matrix has over 15 years’ experience manufacturing and

Global leader in the manufacture and
refining its subsea buoyancy systems, which are stronger,
supply of subsea buoyancy systems
lighter and last longer.

With a focus on materials technology, Matrix manufactures

Leading developer of syntactic foam
superior performing products, which are stronger, lighter and
technology
longer lasting.

2
Its new 20,000m , AU$80 million facility allows Matrix to
World’s largest, most technically
generate greater quantities of premium quality, cost effective
advanced composites syntactic plant
products within shorter timeframes.

With a global service and distribution network spanning five

Global network close to clients’
continents, Matrix is close by to provide clients’ with local
operations
service and support.

With the world’s largest deepwater simulation chamber

World’s largest deepwater simulation
(7500PSI) for its pressure class, Matrix can qualify and test
chamber (hydrostatic pressure testing
buoyancy systems up to 62 inches in diameter to a service
facility)
depth of 16,850 ft. (5,135m).

Matrix holds the IP rights for many of its products. It invests

heavily in research and development (R&D) which allows it to
Own Intellectual Property (IP)
continue producing superior products that remain ahead of
industry trends and client demands.

• 2013 WA Industry & Export Awards: ‘C.Y. O’Connor Award

for Excellence in Engineering & Technology
• 2012 JEC ASIA Composites Innovation Awards: 'Building/
Infrastructures'
• 2012/2011 Subsea Energy Australia Awards: 'Global
Recognition by industry/ business Exports'
community • 2012 Australian Gas Innovation Awards: 'Commercial'
• Forbes - 'Asia's 200 Best Under a Billion'
• 2011/2010 WA Industry & Export Awards: 'Large
Advanced Manufacturer'
• 2010 Australian Export Award: ‘Large Advanced
Manufacturer’

Document Reference No: E284 – Rev 1, 22/01/14

Integrated Solutions
Matrix is a global leader in its field. It has achieved this through continuing innovation in materials
technology which ensures its suite of products remains ahead of industry trends and client
demands.

Matrix provides an integrated solution through its two divisions; Matrix Composites & Engineering
(MCE) and Matrix Offshore Services & Engineering (MOSE). Matrix designs, tests, manufacturers,
distributes and services a range of engineered products used in the global oil and gas industry
including:

• Drilling Products
• Upstream SURF Ancillary Equipment

• Well Construction Products

• Cryogenic Insulation Systems

MOSE is the specialist equipment services and heaving engineering division of the wider Matrix
group. MOSE provides a range of capabilities and services to the oil and gas, and mineral
resources industries including:

• Fabrication

• Machining

• Maintenance

• Equipment rental

• Offshore services and engineering

Document Reference No: E284 – Rev 1, 22/01/14

Materials Technology
Matrix uses advanced materials and technologies derived from the aerospace and defence
industries to manufacture a range of high performing products. Materials include:

• Syntactic foam

• Composites

• Thermoplastics
• Cryogenic Foams

Operating within a highly dynamic industry, Matrix invests heavily in R&D to continually advance its
product range and capture new opportunities. To protect the IP surrounding new products and to
retain a competitive advantage, Matrix registers many of its products under international patents.

Occupational Health, Safety & Environment (OHSE)

OHSE is central to Matrix’s business and is reflected in two of the Company’s core values; people
and safety. Matrix’s most important assets are its employees, contractors, clients and
suppliers. As such, their health and safety is the Company’s greatest responsibility. The Matrix
team is fully aligned with the corporate expectation and commitment to superior OHSE
performance which is paramount to the Company’s growth, sustainability and on-going success.
Matrix’s products and services reflect this commitment and raise the benchmark for safety,
reliability and technical performance.

Safety at Matrix is the collective responsibility of all employees. The Company has Safety, Health
and Environment (SHE) committees and representatives who champion safety. All Matrix
employees receive training which gives them the skills to ensure their own safety and that of their
colleagues.

Matrix currently operates OHS systems drafted against AS 4801, and along with MOSE, is seeking
accreditation against OHSAS18001 (OHS). The Henderson plant operates under a license issued
by the Department of Environment and Conservation, with ISO 14001 (Environmental Management
System) accreditation sought. These are essential compliance and performance standards that
demonstrate the Company’s engagement in the process of continuous OHSE improvement.

Matrix maintains a Lost Time Injury Frequency Rate (LTIFR) of 3.1 (as of 31/12/13). The
Henderson facility is two years’ LTI free. These results demonstrate the commitment by Matrix
employees to continuously improve in the field of OHSE, whilst maintaining an ability to rapidly
respond to client demands.

Quality Assurance
The Matrix quality management system is founded on a culture of continuous improvement and is
based around the Company’s ISO 9001-2008 accreditation. Matrix operates under the
requirements of API Q1/API 16F for its buoyancy products and ISO 13628-16 (API 17J) for its
SURF ancillary products. MOSE operates under the requirements of API Q1 without restrictions
(Registration No. Q1-1645), ISO 9001 and TS 29001. It is also in the process of working towards
accreditation to API 16A, 6A Monogram status, AS 4801 and OHSAS 18001.

Document Reference No: E284 – Rev 1, 22/01/14

Matrix has an integrated quality management system comprising quality and OHSE. Systems are
continuously improved to ensure its products and services remain ahead of industry trends and
client demands.

Testing
Matrix performs a range of in-house testing including:

• Hydrostatic testing

• Mechanical testing

• Materials testing

• Displacement testing

Global Network
Matrix services its client base through a global network of sales offices, service facilities,
warehouses and agents. Matrix is located close by to many of the world’s major oil and gas
producing regions which means its team of specialists is never far from clients’ operations.

Document Reference No: E284 – Rev 1, 22/01/14

CONTACT
AUSTRALIA AUSTRALIA
Matrix Composites & Engineering Matrix Offshore Services & Engineering (MOSE)
150 Quill Way, Henderson 185 Camboon Road, Malaga
WA, Australia 6166 WA, Australia 6090
T: +61 8 9412 1200 T: +61 8 9249 3300
E: matrix@matrixengineered.com E: mose@matrixengineered.com

BRAZIL (Agent) INDIA (Agent)

Oil States do Brasil Ltda Offtech International
O2 Corporate & Offices, Ed. Evolutio 212, New India Estate
III, Bloco 2, Sala 105, 33, Mahal Industrial Area (off Mahakali Caves
A. Paisagista Jose Silva de Azevedo Road), Andheri (East)
Neto, No. 200, Mumbai, India
Barra da Tijuca, T: +91 22 26879301
RJ, Brasil, CEP: 22775-056 E: india@matrixengineered.com
T: 55-21 3503 2400
E: brasil@matrixengineered.com

KOREA (Agent) MALAYSIA (Agent)

Neptune Energy Delcom OilField Services
th
4 Fl., Gwangan Bldg, #173-20 #2 Jalan Bangsar Utama 9,
Gwangan 2-Dong, Suyeong gu Bangsar 59000 Kuala Lumpur, Malaysia
Busan, Korea 613-804 T: 603-22957788
T: +82 51 245 2221 E: malaysia@matrixengineered.com
E: korea@matrixengineered.com

UK USA
Unit 12, Linnet Court, Cawledge Business Park, 4541 Brittmoore Road,
Hawfinch Road, Alnwick, Houston, Texas USA 77041
England, UK NE66 2GD T: +1 713 461 0552
T: +44 (0) 7585 113471 E: us@matrixengineered.com
E: uk@matrixengineered.com

For further information

To find out more about Matrix Composites & Engineering, or to follow us on LinkedIn, Facebook
and YouTube, scan the QR codes below with your mobile or other hand held device.

Website

matrixengineered.com