MM Subsea Case Study Pack

CASE STUDY
Subsea
Case Studies
www.miragemachines.com
CASE STUDY
Contents
Subsea Window Machining
Subsea Pipe Cutting
Weld Seam Removal
Platform Leg Crack Termination
Tidal Fin Removal
Seam Weld and Doubler Plate Removal

CIMV Removal & Torque Tool Development
Injection Point in Trace Heated Supply Line
About Mirage Machines
PORTABLE PERFORMANCE
Subsea Window
Machining
Case Study
Requirements
A 26-1/2 conductor required a 1.3 x 0.45m window

machining with 50mm radii 9m from the sea bed for a
mud dump vent clamp to be fitted.
Location: Apache North Sea Forties Delta 115m
water depth.
Solution
Cold cutting was specified due to the 26-1/2
conductor housing 13-3/8 casing and a power line
that could not be damaged during cutting.
Milling rail mounted onto the Gantry system

with large hand wheel for the diver to control
the in feed. The auto stop hydraulic valves
controlled the size of the window and
spindle positioning.
The four corners were pilot drilled and then the 4 off
100mm diameter holes were trepanned at fixed
centres, with hydraulic valves acting as datum point
stops. The gantry system was then used to mill
between the corners to produce the window. The cut
out portion of the conductor was retained by cross
member clamps with drilled and tapped holes in the
conductor.
Drilling and trepanning took 45 minutes per hole,
machining top, bottom and sides through conductor
thickness.
Equipment used
Mirage gantry GM2000 and milling rail MR1500.

Used with a chain pipe clamp.
Outcomes
Machining completed within 2 days.
Operation time kept to a minimum using

hydraulic stops and auto feeds on the main axis.
.
Workshop trial.
Email sales@miragemachines.com
05.02.16
Click to watch the

YouTube video
Subsea Pipe
Cutting
Case Study
Requirements
The MDWS being lowered into the sea.
To remove a 512 metre length of Super

Duplex pipe from the sea bed, at a depth of
50 metres. Pipe specification 12 diameter
with a 1 wall thickness.
Location: Saudi Arabia.
Solution
The Mirage MDWS used with a 3 circuit

hydraulic controller. The diamond wire
travelled at 1200 metres per minute at a
feed rate set at 8mm per minute.
Outcomes
22 cuts made within 72 hours.
Pipe sections around 23m long raised to deck.
With the pipeline removed the customer was

able to construct a new pipeline.
Click to watch the

Diamond Wire Saw
animation on YouTube
The first two pipe sections recovered from the sea bed.
05.02.16
Weld Seam
Removal
Case Study
Requirements
Removal of a longitudinal weld seam to allow fitting
of a Morgrip connector.
Location: Apache North Sea, Forties Delta.
Solution
Workshop trial.
Use of the Mirage MR1500SS milling rail
Workshop trials carried out in advance.
Outcome
Successful machining allowed fitting of the
Morgrip mechanical connector.
Subsea cutting operation.
05.02.16
Platform Leg
Crack Termination
Case Study
Requirements
Cracking discovered in the main caisson around a

vent exhaust duct on the platform leg.
The requirement was to machine an elliptical hole
into a 5m diameter platform leg.
Location: Siri Platform, Denmark.
Solution
Use the Mirage 3 axis gantry milling

machine.
Workshop trials carried out in advance.
Outcome
All machining operations were completed first
time, to customers specification and within
time critical operations window.
.
Workshop trial.
05.02.16
Tidal Fin Removal
Case Study
Requirements
Structural plates required removal from tidal

turbine monopoles.
Diving time severely restricted to 20 minutes due

to tidal direction change and Neap Tide.
Solution
Plates (1.8m x 150mm x 30mm) removed

using a slitting saw. Remaining material
removed using face milling.
Quick release tooling used to allow fast

project completion.
Outcome
All machining operations were completed first
time, to specification and within time critical
operations window.
.
Workshop trials using the Mirage MR2000.
05.02.16
Seam Weld and

Doubler Plate
Removal
Case Study
Requirements
Remove a seam weld from 30 pipeline

over 3m length.
Remove anode doubler plates for
relocation at 90m water depth.
Location: North Sea.
Solution
Cold cutting to prevent cutting into the

parent pipeline.
Use of Mirage gantry MR1000SS with

pipe chain clamping system, fixed feed,
and depth stops.
Workshop trials carried out on a circular

test piece.
Outcomes
05.02.16
Milling of seam: less than 1 hour.
Doubler plate removed in 3 hours.
CIMV Removal
& Torque Tool
Development
Case Study
The resulting torque tool created for
the customer.
Requirements
The clients problem was a subsea tree equipped
with a latch lock removal system on a chemical
injection valve which had a mechanical failure on
the connection rod.
Solution
Mirage developed three innovative contingency
solutions to allow an ROV to remove the valve.
The first solution used a one inch, left-handed, four
flute endmill to attempt to turn the inconel rod to
unlatch the CIMV. This solution was delivered to the
Clients design, but was unable to remove the
damaged valve.
Second solution: Having anticipated that a second
solution might be required, we designed and
engineered a contingency tool, which incorporated an
eight inch lathe chuck, with ROV handles, to deploy
the latch onto the inconel rod, in an attempt to turn
the inconel rod to unlatch the valve. This tool was
successful in removing the valve.
Workshop development of contingency solutions.
Third solution: We designed an additional

contingency tool, which was a hydraulically operated
chucking system. This solution was not deployed, as
the valve was removed with solution two.
Outcomes
05.02.16
The clients problem was resolved.
All three tooling solutions were provided in 10 days.
Client requested we design a tool to prevent the

problem from occurring in the future.
Injection Point in
Trace Heated
Supply Line
Case Study
Requirements
To machine an injection point within a

heavy wall Super Duplex pipe.
No swarf ingress or tool dwelling.
One chance on offshore application.
Location: Islay Project, North Sea.
Solution
Mirage provided a complete

machine/offshore service package.
A process was identified to series

trepan the external of the supply line.
Extensive workshop testing carried out

in advance.
Machine used: HT50 Portable Drill
Outcomes
Client testimonial:
Images above: Test pieces in the workshop.
05.02.16
Did a great job offshore and everyone

was very pleased
About Mirage Machines

Mirage portable machine tools optimise the performance of on-site
assets by achieving operational excellence, maximising uptime and
improving productivity.
Our proprietary technology drives the development of the most reliable,
durable, efficient and precise portable machine tools on the market, that
are capable of delivering the most exacting standards of tolerance with the
highest quality output.
Our portfolio of portable machine tools are suitable for a diverse range of
on-site machining applications. Mirage have been granted ISO 9001:2008
certification for our design and manufacturing systems
and we are able to provide full CE certification for our products.
Industries
Mirage manufacture a range of portable machines for a wide variety of
applications and industries including:
Oil & Gas
Mining & Construction
Wind Power
Subsea
Decommissioning
Utilities
Ship Build & Repair
Nuclear
Petrochemical
Power Generation
Our products are supported by industry experts who work closely with our
customers to optimise performance for industry specific applications.
With extensive experience within service companies, our teams understand
the dynamics of a wide range of industries and have the capability to
deliver turn-key solutions that both meet specific requirements and address
complex challenges.
Contact Us
UK
Mirage Machines
8-10 Enterprise Way
Jubilee Parkway
Stores Road
Derby DE21 4BB
Houston
Mirage Subsea Inc.
8615 Jackrabbit Rd
Houston
TX 77095
United States
T: +44 (0) 1332 291767

F: +44 (0) 1332 370356
E: sales@miragemachines.com
Tel: +1-281-859-1234
E: sales@miragesubsea.com
Perth
Singapore
Mirage Machines
15/4 Wharton Road
Kewdale
WA 6105
Mirage Machines
107 Tuas South Avenue 8
Offshore Marine Centre 637036
Singapore
Tel: +61 0 452 48 1964

sales@miragemachines.com
Tel: +65 9855 0117

sales@miragemachines.com

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CASE STUDY

Seam Weld and Doubler Plate Removal

A 26-1/2 conductor required a 1.3 x 0.45m window

Milling rail mounted onto the Gantry system

Mirage gantry GM2000 and milling rail MR1500.

Machining completed within 2 days.

Operation time kept to a minimum using

Click to watch the

The MDWS being lowered into the sea.

To remove a 512 metre length of Super

Location: Saudi Arabia.

The Mirage MDWS used with a 3 circuit

22 cuts made within 72 hours.

Pipe sections around 23m long raised to deck.

With the pipeline removed the customer was

Click to watch the

Use of the Mirage MR1500SS milling rail

Workshop trials carried out in advance.

Subsea cutting operation.

Cracking discovered in the main caisson around a

Use the Mirage 3 axis gantry milling

Workshop trials carried out in advance.

Tidal Fin Removal

Structural plates required removal from tidal

Diving time severely restricted to 20 minutes due

Plates (1.8m x 150mm x 30mm) removed

Quick release tooling used to allow fast

Workshop trials using the Mirage MR2000.

Seam Weld and

Remove a seam weld from 30 pipeline

Cold cutting to prevent cutting into the

Use of Mirage gantry MR1000SS with

Workshop trials carried out on a circular

Milling of seam: less than 1 hour.

Doubler plate removed in 3 hours.

Workshop development of contingency solutions.

Third solution: We designed an additional

The clients problem was resolved.

All three tooling solutions were provided in 10 days.

Client requested we design a tool to prevent the

To machine an injection point within a

No swarf ingress or tool dwelling.

One chance on offshore application.

Location: Islay Project, North Sea.

Mirage provided a complete

A process was identified to series

Extensive workshop testing carried out

Images above: Test pieces in the workshop.

Did a great job offshore and everyone

About Mirage Machines

Oil & Gas

Mining & Construction

Ship Build & Repair

T: +44 (0) 1332 291767

Tel: +61 0 452 48 1964

Tel: +65 9855 0117

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