Release Systems and Devices
Issue No: 1
Issue Date: 15-Feb-19
Author: MPV
Introduction
This document is intended to provide an overview of Avalon Engineering
Solutions Ltd’s (AESL) capability with regards to releasable fixing devices and
systems. It is might be useful to provide some background to the development of
release systems.
AESL is a Project Engineering company. It specializes in providing turnkey
solutions to a range of engineering problems. It services the Marine, Offshore,
Defence and Aerospace industries.
ASEL has a partnership with a Digital Control Systems Company and can
therefore provide complete turnkey electromechanical solutions. ASEL has
provided services that range from the design of products
through release systems for marine moorings to test rigs
systems for rocket motor test beds.
ASEL has developed a range of high reliability release
systems capable of controlled release of loads up to 1400
tonnes. These systems are based on individual proven
release devices and fasteners. Actuation can be
mechanical, hydraulic, electrical, hydrostatic or pyrotechnic.
A range of releasable fasteners has been developed over the years. These have
been the result of customers finding themselves in engineering difficulties where
a release device or system was the most cost effective extraction route. These
devices and systems have not been marketed. AESL is a reactive organisation
responding to customers’ needs and requirements.
Opportunities arise from word of mouth within the engineering community.
Applications range from individual release fasteners to
subsea structure failure protection systems. The release
fastener principles are novel and have been protected by
patent.
AESL has designed a range of Pyromechanisms for release
and ejection applications. These include Ejector Bolts,
Protractors and Retractors, Pyro Initiated Hydraulic and cold
gas actuator systems and Cable Cutters.
A novel plug in 5 Tonne lift point has been developed for subsea diver single
handed connection of lift cables. The lift point is essentially a socket and probe
arrangement.
Mooring Release Systems
Tandem mooring
AESL has developed extremely reliable release systems for the emergency
release of FPSO Tandem Moorings. These are based on release fastener
devices. The FPSO Tandem Mooring Release utilises a M52
Release Bolt in a calliper link assembly.
The system has been used in anger at least 3 times by two
FSPOs. It is suspect that there have been more incidents,
however, as is the case with many offshore incidents, it is
difficult to retrieve full details.
In one such instance, the out of control shuttle tanker had
become parallel to the FPSO. The mooring hawser had started
to collapse one of the helideck supports before the decision to
release was taken. The release was successful and prevented
prolonged tethering to the FPSO which would have certainly
resulted in further significant damage.
The premise utilises a calliper which captures a standard 85
Tonne shackle and is held closed by the release bolt. The calliper geometry is
arranged so that 13% of the tensile load applied to the link appears in the bolt.
This allows the link to release reliably at tensile loads above the yield point of the
shackles. Indeed, the link will release at a load of 425 Tonnes.
The system consists of a release link, a hydraulic control unit and an electrically
operated control station. The system is essentially self-contained requiring only
an electrical input of 240V ac or 24Vdc. An accumulator contained in the
hydraulic control unit provides the hydraulic pressure. A specially designed zero
leakage electro mechanical valve controls the bolt release.
These units have a long service life and are deployed on FSPOs around the west
coast of Africa. There are currently two customers using this equipment namely
Fred Olsen, and BW Offshore. These systems are seen to be fundamental to
safe operation of the FPSO during transfer. Indeed, transfer without the mooring
release system is prohibited. AESL recommend that the equipment is maintained
and recommissioned every 3 years.
Main FPSO mooring
A main mooring release system was developed and deployed on the FPSO
Ikdam. This was an extreme device as again the customer had not considered
the issue of releasing the FPSO from her main mooring in an emergency. This
device can release at a load of 1400 tonnes. The release
element is a pair of M125 release nuts. The nuts are
interesting as they are automatically closed and tensioned.
The system went from concept to delivery in 8 weeks
preserving her sailing date.
Load sensing was also included in the package for
autonomous emergency release.
Mooring Release Control Systems
The Mooring Release Control System was designed and developed to meet the
safety critical requirements of emergency release of moorings. However, it has
been used in modified form for other applications.
The control system consists of an electro hydraulic cabinet and an electrical
control panel. Problems of operation in Zoned areas have been overcome by
placing the control cabinet and panel in safe areas (below
deck and in a safe area observation post).
Release Devices
Release Studs / Bolts & Nuts
ASEL has developed a range of reusable high reliability releasable screw
fastener devices. Because of their inherent reliability in both fastener and release
mode they have found use in many safety critical applications. They have also
found applications on submersibles and subsea structures.
Both bolt/stud and nut formats are provided. Load carrying capability range from
60kN to 3500kN. All of the release device designs are specific to their function.
Stud / Bolts
First developed in 1994 as a replacement for defence related explosive
bolts.
The release is achieved by displacing a cone from the centre of the
fixed portion of the stud / bolt. In the unreleased condition the cone
holds 6 threaded fingers against the wall of a threaded hole. The
tensile load in the stud is transferred across the separation plain by the
engagement of the threaded fingers in the female thread. Displacing
the cone allows the fingers to contract disengaging the thread and
releasing the load.
Two configurations of stud / bolt have been developed. The release
bolt and the ejector bolt. The ejector bolt contains a stiff spring element
that exerts an axial load on the released section of the fastener. On
release this load positively drives the ends of the released fastener
apart, guaranteeing separation.
Studs have been most popular format, however, bolts with special
heads that allow easy integration with existing interface designs have
been provided in large numbers.
The primary method of actuation is by application of hydraulic pressure
to the internal operating piston. The volume of oil required to effect release is very
small, 2.5cc for the M24 stud. This allows multiple stud/bolts to be released
simultaneously.
AESL has a fully developed small volume accumulator based safety interlocked
electrically initiated release system specifically designed for offshore use.
Actuation methods employed
• Hydraulic
• Electrical by a pyrotechnical charge
• Electrical by motorised actuator
• Hydrostatic pressure
• Cold gas (nitrogen, carbon dioxide)
• Mechanical
Applications
Release bolts have been used for many years for emergency
release in the marine, civil and defence industries in the
following examples:
• Release of recovery section practice subsea ground mine
• French emergency flood water divergence systems.
• Oil riser pipes and umbilical’s from FPSO vessels. Gola
Nor used M24 Release Studs as per the illustration in
‘Stud / Bolts’ Section. Some of the existing Grayloc
connectors had the bolts replaced with M24 Release
Studs.
• Release of structures and payloads subsea. Both
routinely or in emergency situations.
• Pipeline float out End Plate rapid removal.
• Launch of Jackets and Hyperbaric Lifeboats
• Fuel Tanks jettisoning in offshore platform emergencies.
• Simulations of loss of structural integrity in heavy goods vehicle
suspension failure testing.
• Film special effects.
• Ships Weapons systems containers. The M20 release bolt was chosen to
retain the doors on a ship born air flight weapon container in preference to
explosive bolts. The advantages over explosive devices were that they
could be reset after operation. The ability for reset allowed training and
routine maintenance to be conducted without explosive hazards.
• Rig emergency evacuation gondola release system.
• Emergency release of cutters from a trenching ROV.
• Emergency access to life rafts on S Class Submarines.
• Rig abandonment temporary support structure release.
• Routine changing of gate valves and choke plates in petro-chemical pipe
lines.
• Release of payloads in drop testing.
Release Nuts
Designed in 2003 to support a French rocket motor
development programme. The release nuts replaced
explosively fragmented nuts that were considered to
hazardous for the application. The application utilised 24 x
M45 nuts released simultaneously by a propellant driven water
pressurisation system. The nuts allowed a 50Tonne plate to be discarded in
10ms.
Release nuts have an advantage over bolt / studs in their ability to carry loads. A
release nut will carry the same load as a conventional nut. The size of a release
nut is slightly bigger than its conventional counterpart.
Release operation is achieved by introducing
pressure into a cavity in the containment sleeve
causing it to displace axially. This axial displacement
allows the male thread to push the nut inserts out of
engagement causing the load to be released.
A range of nut sizes has been produced from M10 to
M125.
Nuts have been developed that will auto engage and
tension by application of pressure to the appropriate
port.
Actuation methods employed
• Hydraulic
• Electrical by a pyrotechnical charge
• Hydrostatic pressure
• Cold gas (nitrogen, co2)
Applications
Release nuts have been used for many years for emergency and routine release
in the marine, defence, civil engineering and aerospace industries. Examples
below:
• Securing space vehicle escape hatch.
• Gearbox case securing in inaccessible location (hydraulically engaged and
tensioned).
• Rocket motor test stand sequential cover release.
• Fighting vehicle emergency tow hook release.
• Emergency release of submarine towed array.
• Remotely operated flange couplings (automatic engagement and
disengagement).
• Flow line separation couplings.
• Separating rigid marine riser in the event of an unintended drive away.
• Breakaway Couplings.
Miscellaneous Release Devices
The above release devices have been incorporated into the design of a number
of systems for varied applications. These include:
• Re-installable Semi Sub Anchor System.
• Spread Mooring release System.
• Rig Abandonment Systems.
• Drop Test release Systems.
