Vulcan: Synthetic ETOP

Danielle Stenvers
ITOSF – Houston – February 22, 2011
Synthetic Emergency Tow Off Pendants

• Current Systems
• Technology Development
> Fiber
> Coating
> Testing
• Strength and Weight Specifications
Synthetic ETOP Development

• Current Systems
• Technology Development
> Fiber
> Coating
> Testing
• Strength and Weight Specifications
Why Synthetic ETOP?

• Numerous injuries to workers deploying pendants:

> Strain injuries
> Pinching and impact injuries
> Repetitive stress injuries due to repeated handling
• OCIMF and ISGOTT requirements for synthetics:
> “Adequate fire resistance”
> “Similar functionality to wire”
> Requirements are not defined with respect to HEAT or
FLAME performance (for synthetics or wires)
Synthetic ETOP: Targets

• Reduce weight by half or more

• Heat Performance:
> Equal strength as wire after 30 min at 20% load at 300ºC
• Flame Performance:
> Equal strength as wire after 10-sec exposure to 600°C flame
Synthetic ETOP Development

• Current Systems
• Technology Development
> Fiber
> Coating
> Testing
• Strength and Weight Specifications
Fiber Selection: Aramids

• Properties of Technora Fibers:

> High strength at elevated temperatures
> Good heat cycling properties
> Good abrasion properties
> Good chemical resistance
> Not effected by hydrolysis
> Low Limiting Oxygen Index (LOI ) = good flame retardant

• Other Desired Properties:

> Good performance when exposed to open flame
• No specific requirement by OCIMF
• Multiple fibers were tested for exposure to open flame
FR Enhancement: Coating

• FR Coating
> Water based latex
> High solids
> High flexibility, exceeds 20% elongation at –24°C
> No solvent, low VOC (Volatile Organic Compounds)
> Flame retardant
> Heat resistance and thermal barrier

• Provides protection allowing the rope to withstand direct

flames considerably longer
> Delayed rope failure from 12 min to 65 min
(small diameter ropes in open flame exposure)
Fiber Selection: Further Enhanced

Exposure to 750°C flame:

How long before the rope fails?

FR Coated Dyneema (30 sec) FR Coated Technora (65 min)

Effect of Heat on Different Fiber Types

Exposure to 750°C flame:

How long before the rope fails?

Fiber Type Uncoated FR Coated

Technora 12 min 65 min

Polyester <1 min 1.75 min

Nylon <1 min 1.5 min

Dyneema <1 min <1 min

Testing performed on ½” dia ropes

Synthetic ETOP Development

• Current Systems
• Technology Development
> Fiber
> Coating
> Testing
• Strength and Weight Specifications
Testing Standards

Samson-Developed Test Method:

• Heat Test:
> 300°C oven temperature
> 30-min exposure while loaded to 20% of break strength
> Break while still at 300°C
• Flame Test:
> 600°C Flame
> 10-sec exposure
> Break at room temperature
Specialized Equipment: Heat Testing

 300°C oven temperature

 30-minute exposure while loaded to 20% of break strength
 Break while still at 300°C
Heat Testing: Wire vs. Vulcan

Retained Strength: 30 min, 20%Load, 300°C

100%
90%
80%
% of New Rope Strength

70%
60%
50%
40%
30%
20%
10%
0%
WIRE Vulcan

1" dia ropes

Heat Testing: Effect of Diameter

Retained Strength: 30 min, 20%Load, 300°C

100%

90%

80%
% of New Rope Strength

70%

60%

50%

40%

30%

20%

10%

0%
1 1 1/2 2 2 1/2
Dia (in)
Specialized Equipment: Flame Testing

 600°C flame temperature

 10-second exposure
 Break (at room temperature)
Flame Testing: No Strength Loss
Retained Strength after 30 sec Flame (600°C)

100%

95%

90%

85%
% of New Rope Strength

80%

75%

70%

65%

60%

55%

50%
Wire Vulcan

1" dia ropes

Synthetic ETOP Development

• Current Systems
• Technology Development
> Fiber
> Coating
> Testing
• Strength and Weight Specifications
Vulcan: Specifications

New Rope Strength

Vessel Size MBS Wire Dia Vulcan Dia Weight
(DWT) Requirement Savings over
Wire
<20,000 30 MT 7/8” 1” 80%
20-100,000 55 MT 1-1/4” 1-5/16” 70%
100-300,000 100 MT 1-5/8” 1-7/8” 70%
300,000+ 120 MT 1-3/4” 2-1/8” 70%

Heated Rope Strength

Vessel Size MBS Wire Dia Vulcan Dia Weight
(DWT) Requirement Savings over
Wire
<20,000 30 MT 7/8” 1-1/4” 57%
20-100,000 55 MT 1-1/4” 1-11/16” 63%
100-300,000 100 MT 1-5/8” 2-1/8” 65%
300,000+ 120 MT 1-3/4” 2-1/2” 65%

*Actual Wire Rope strength loss at temperature: 5-10%

Conclusions

• Synthetic ETOP:
> Requires larger size to achieve same strength as wire
> Larger diameter is only 1/3 the wire weight
> Heat damage is delayed through protective FR coatings and
insulating covers
• Heat Performance: 300°C – 30 min – 20% Load
> Wire: 5–10% strength loss
> Synthetic: 20–45% strength loss
• Flame Performance: 600°C – 10 sec
> Wire: 0 strength loss
> Synthetic: 0 strength loss
Product Currently In-Use

• Conoco Philips
• OSG Polar Tankers
• Algoma Tankers
Patented Technology

High-Temperature Resistant Rope Systems and Methods

• US 7,168,231 January 2007

• US 7,437,869 October 2008
• US 7,743,596 June 2010
Questions?