11-2014 Maximator Oil and Gas en
11-2014 Maximator Oil and Gas en
Contents : Page :
Maximum safety for oil and gas production 2 – 3
Valves, Fittings and Tubing up to 10,500 bar 4 – 5
High pressure units and components for fluids 6 – 7
High pressure units and components for gas 8 – 9
Supply systems for mechanical seals 10 – 11
High pressure workshop testing equipment 12 – 13
Standard surface control panels 14 – 15
Customised surface control panels 16 – 17
Topside equipment for sub-sea applications 18 – 19
Service and testing 20 – 21
Contact 22 – 23
nt
o
Gl
pment
nd develo
P r o du
rch a
c t io n
s ea
, re
ce s
r vi
Se
Engin
eering and programming
In every phase, your projects profit from our • Engineering and programming:
We can fall back on more than 70 engineers, technicians, PC and PLC
specific engineering expertise - from the
programmers to realize well thought-through efficient solutions with
quotation phase, to the delivery – including intelligent safety concepts.
engineering phase. • Production:
Mechanical processing, electrics and mechatronics - whatever the
• Project management: discipline, our team of more than 140 specialists offers first rate
Our workflows achieve prompt results due to efficient and organized support for the construction of optimized and reliable systems.
work processes. • Global service:
• Services, research and development: We support you around the world with our services that include
To ensure everything matches your project, we carry out tests and commissioning, maintenance, on-site installations or repairs. More
modifications in line with your guidelines for your products and than 50 employees at 20 international sites are on hand to help you.
systems, be they standard or customized developments, flexibly
on our own high-pressure testing systems in our service centers.
2|3
How is the rigging of oil and
gas production plants made a
surefire thing?
Reliable and high-quality components made of Components from the manufacturer – for all requirements
As a system manufacturer of testing and production systems for high
high-strength materials are essential elements
pressures up to 25,000 bar, we concentrate on quality and durability in
of the equipment for high-pressure applications. every production phase – from the milling centers through to the final
Valves, fittings and tubing from Maximator for assembly stage and functional tests of the parts.
onshore and offshore production projects are
designed for productivity and secure system Our portfolio of standard components for high-pressure applications
both surface and subsea is available in a number of versions. These
operation. include valves and fittings with NTP or BSP-connections up to 1,050
bar, components of the Medium Pressure series (up to 1,550 bar –
Suitable for surface and subsea applications 22,500 psi), the High Pressure series (up to 4,500 bar – 65,000 psi)
We supply components for surface applications – for instance, for and the Ultra High Pressure series (up to 10,050 bar – 152,000 psi).
hydraulic control systems or injection systems for corrosion inhibitors We also supply an entire series for applications with H2S (up to 2,070
– as well as for subsea applications, for instance in subsea control bar – 30,000 psi), ball valves, valve actuators as well as adapters and
modules or testing equipment. accessories.
Our high-pressure valves, fittings and tubing are suitable for pressure With our experienced engineering team and state-of-the-art production
and function testing systems for subsea control modules or for flushing systems, we realize development requests flexibly and also test new
and pressure testing systems for subsea umbilical. products in our own service centers under a variety of conditions.
Valves, fittings and tubing up to 10,500 bar (152,000 psi):
• Needle valves, fittings and pipes (1/4– 1“)
• 2-way and 3-way ball valves (1/4– 9/16“)
• Anti-vibration collet gland assemblies, filters and
check valves
• Pneumatic and hydraulic actuated high pressure
needle valves
• Adapters and couplings (NPT, BSPP, JIC, etc.)
• Test and Product Certification (GOST, 3.1, etc.)
Special products
• Special valves made to specifications
• Special material available (Duplex, Super Duplex,
Inconel, Hastelloy, etc.)
• Special configuration (needle, ball and needle,
shut-off and relief valves (1x and 2x), etc.)
• API flange connections available
4|5
How do you keep your
hydraulics safe at high
pressure levels?
High-pressure pumps and systems from Maxima- High-pressure systems for fluids – also as rental units
Compact high-pressure systems for specific tasks and demanding test
tor allow reliable testing of pressurised hydraulic
procedures: Our mobile Liquid Power Packs and individually configurab-
equipment and components in oil and gas drilling le hydraulic systems guarantee process stability and very high pressure
and production operations. The compact units and levels. The high-quality machines comprise optimally aligned quality
systems also assume functions such as the calibra- components „made in Germany“: Valves, fittings and tubing – primarily
tion of pressure measuring instruments, the supply produced by our company and designed to satisfy even the strictest of
safety standards.
of pressure to hydraulic control systems for well
equipment or chemical injection. A high-quality stainless steel frame surrounds the compressed air po-
wered Power Packs, so that they work to the optimum even under the
toughest of operating and environmental conditions. The clearly struc-
Safe under extreme conditions: Maximator high-pressure pumps tured control panel, with a logical design, will ensure simple operation.
Our high-pressure pumps generate hydraulic pressure levels of up to Additional safety is provided by the sturdy bulkhead fitting connections.
7,000 bar – with oil, water or special media – extremely safe and cost
efficient. They are easy to handle and are also very versatile, even in We also supply an extensive array of high-pressure systems for fluids
explosive areas. The design is based on an oscillating pressure intensi- as rental units. Just contact us!
fier, they run extremely stably with compressed air (1-10 bar).
Pumps – performance and features:
• 17 different construction series for pressure levels
up to 7,000 bar and flow capacities up to 48 l/min
• Compressed air drive allows operation in
explosive areas
• Alternative drive media possible
• Optionally, also suitable for use with media
containing H2S
• Standstill when the set final pressure is reached
without energy consumption
6|7
How do you hit high gas
pressure levels safely on
drilling platforms?
Imperative for the oil and gas production, often a Powerful series and customised systems:
Booster stations for gases
challenge in practice: compressing technical ga-
The Maximator Gas Power Packs are a series of high-performance
ses. Maximator high-pressure gas boosters and booster stations to meet the high demands of onshore and offshore ap-
booster stations set the fluids exactly to the plications. All our know-how as a specialist for very high gas pressure
process requirements and generate high gas levels has gone into these systems: The weight-optimised, individually
pressure levels up to 2,400 bar reliably - directly configurable machines also work extremely safely even under the
toughest of conditions. Their control panels with logical design allow
on site. simple control at all times.
The Gas Power Packs are ideally protected by the high-quality stainless
Smart from the drive to the cooling steel frames, and also have line filters and an optional auxiliary cooler.
Our oscillating gas boosters of the DLE series compress technical The features improve availability and reduce wear.
gases and gas mixtures up to 2,400 bar, hydrogen up to 1,000 bar and
oxygen up to 350 bar. With the innovative drive that is operated with Above and beyond the compact booster stations, we also design and
compressed air or other technical gases (1 to 10 bar), they are suitable produce customized systems. We produce systems to customer specifi-
for a variety of environments, even where there is a risk of explosion. cations, depending on requirements, mounted on base plates, frame or
The separation of the drive and process gas and the effective cooling in outdoor casings, as well as manual or automatic control systems.
ensure absolute efficiency and safety.
High-pressure booster of the DLE series –
performance range:
• Compressed air driven booster for compressing
technical gases such as argon, helium, oxygen,
hydrogen and nitrogen up to 2,400 bar
• Effective gas compression thanks to broad-based
product range (single-acting, double-acting and
2-stage booster)
• High level of safety thanks to the physical
separation of the drive and process gas and also
additional connections for flushing the booster with
inert gases for applications with critical media
Gas or liquid sealed: mechanical seals keep pum- Achieve more performance
Thanks to our in-depth engineering expertise in pressure generation
ped media safely in the system for numerous pro-
and control of fluids and gases, we realise high-quality, excellently
cesses in the oil and gas production sector. Supply processed supply systems for mechanical seals. Reputed pump and
units guarantee that the dynamic seals function to compressor manufacturers in the oil and gas industry use our first rate
the optimum under tough conditions by cooling, systems out of conviction.
flushing, applying pressure and compensating
We supply customers with top quality standardised supply systems and
leaks – on drill platforms and on FPSO ships, as accessories. We also supply customised solutions for large projects,
well as in subsea production systems. such as our Seal Gas Conditioning Skids, for the supply of natural gas
to turbo compressors during start up and shutdown that significantly
Protect the production process improve the capacity of natural gas production systems.
Maximator supply systems offer specific solutions for mechanical
seals in crude oil, multiphase and water injection pumps, gas pum- We effectively satisfy the specifications of the relevant standards and
ping and boosting as well as on FPSO ships in cooling, heating or fire guidelines of the oil and gas industry (e.g. NACE MR0175, NORSOK,
extinguishing pumps. The systems remain extremely stable even when ASME, DNV, PED and ATEX). We procure and process special stain-
alternating process media are used or under temperature fluctuations. less steels (e.g. 6Mo, Duplex, Inconel, 316Ti). We test and certify our
They also ensure that the seals have long service lives and guarantee systems in compliance with the latest standards and special customer
extremely efficient operating times. requirements.
Maximator solutions for liquid sealed mechanical seals:
• Central feed-in units for several mechanical seals in compliance
with API 53b, Atex-conform with redundant pressure generation
• Air and water cooler in compliance with API 53b with a high
cooling output thanks to laser-welded ribbed tubing with low
flow resistance
• External circulation system acc. to API 54
• Thermosyphon vessels, nitrogen booster stations and emergency
supply systems in compliance with API 53a
Maximator solutions for gas sealed mechanical seals:
• Booster stations for increasing the pressure in compliance with
API 74 with redundant pressure generation and proportional
pressure control
• Monitoring, distribution and pressure control stations acc. to API 74
• Individually configurable Seal Gas Conditioning Skids to supply
turbo-compressors for transporting natural gas
• ATEX certified
• Tubing or Welding Pipe
10 | 11
How can you show that your
sub-sea technology is fit for
the future?
Thanks to innovative technologies, the oil and gas Safe testing of the equipment
Our test systems significantly reduce the test effort and supply ideally
industry now exploits sources which until recently
documented and conclusive results. We develop the smart technologies
seemed totally inconceivable. For suppliers of on- based on our 50 years of experience in the high-pressure and testing
and offshore exploration production systems first technology, hydraulics and pneumatics fields, whilst also concentrating
rate test equipment is the key to success: it allows on the best possible features.
them to provide reliable proof of the safety,
We always orient the design of the systems on the respective require-
durability and performance of their technologies ments: for instance, a compact design, an integrated test device or a
under operational conditions. modular system with separate control and pressure generation unit. In
terms of the functions, we can realise almost any wishes by integrating
Solutions for every testing requirement several pressure circuits with various media in one system. In addition,
Maximator test equipment allows the quality to be verified for nu- our systems are also sound insulated for use in workshops, they are
merous exploration and production products in compliance with nati- equipped with a digital process data recording system and the com-
onal and international standards. Test parameters and test processes ponents and line equipment have nominal widths that are optimised to
can be adjusted flexibly to specific requirements, and test records can very short testing times. We guarantee maximum safety for the users
be designed individually for tests on Hydraulic Power Units and also by means of intelligent technical elements, such as signaling or colour-
components. coded pressure circuits.
Our solutions for testing systems:
• HPU (Hydraulic Power Unit) for leak and
pressure tests
• Pressure generation systems for hyperbaric
chambers
• Hydraulic systems for pressure fatigue tests
• Hydraulic systems and booster stations for
leak tests
• Standard and stainless steel flushing sys-
tems (for oil and water glycol fluid)
We are testing:
• Wellhead, Xmas Tree and BOP
• Hydraulic Power Units (HPU)
• Subsea Control Modules
• Subsea Umbilical
• Pressure control and shut-off equipment
• Well equipment
12 | 13
How can you operate wellheads
with a flick of the switch?
Blowout preventer and wellhead equipment allows Expand functions modularly - depending on the application
The hydraulic functions can be combined for the sequential closing in
specific access to subsea production facilities – to
compact units via the modular Maximator Surface Control Panels. Our
remove crude oil or natural gas as well as to inject innovative series comprising three modules allows control functions to
fluids or gases. Our MAXIMATOR Surface Control be adapted easily. A hydraulic manifold block acts as a basic module
Panels allow users to control, in a safe way, all the via which the communication with the Emergency Shutdown Panels
hydraulic or pneumatic functions installed on the and the control unit of the SSV is realised. It also has a pressure switch
for monitoring the pressure, pressure accumulation and measuring
Wellhead / Xmas Tree. instruments, compressed air and manual operated low-pressure and
high-pressure pumps as well as a hydraulic tank. Additional control
systems can be integrated: with a second module for further SSVs and
a third module for a SCSSV up to 10,000 psi.
Reliable control of the valves
Wellheads are equipped with fail-to-safe safety valves, whose design The Surface Control Panels made of high-quality 316 steel in a sturdy
varies depending on the system. Standard features include a Surface block design have impressed many of our customers across the world.
Safety Valve (SSV) and a Surface Controlled Subsurface Safety Valve The durable and reliable equipment can be operated easily due to the
(SCSSV) for the process control and safety shutdown. These safety logical design of the modules. Maximator high-pressure pumps offer a
valves are controlled via the Surface Control Panels – and in an emer- real added value as they can be operated manually or with compressed
gency, the Emergency Shutdown Panels assume the control function. air, thereby allowing automation.
Performance of our Standard Surface Panels:
• Standard Surface Panels for up to three hydraulic functions
• Maximum operating pressure: 5,000 psi for SSVs
and 10,000 psi for SCSSV
• Hydraulic interlocks to ensure correct opening and
closing sequences
• Manifold Block design reduces potential leak areas
and the quantity of fittings
• Modular design allows simple extension and interchangability of
the control panel from 1 to maximum 3 hydraulic functions.
• High-pressure pumps can be operated both manually
and also automatically via compressed air
• Stainless steel frame (316SS) for extreme
ambient conditions
• Stand mounted
14 | 15
How can you operate wellheads
at 3000 metres below
sea level?
Maximator Customized Control Systems allow the Powerful equipment for safe functions
Our Customized Control Systems incorporate a Hydraulic Power Unit
complex structure of the wellhead equipment to
with compressed air or electrical operated high-pressure pumps for
be controlled at deep sea levels – a fundamental generating the pressure. The backup power supply is supplied by the
requirement for oil and gas production in difficult- integrated hydraulic accumulator and manual operated Maximator
to-access reservoirs and complex exploration high-pressure pumps. The user operates the hydraulic control unit
processes. securely using the logical panel design. The emergency shutdown is
realised via optional Emergency Shut-down Panels – either manually or
automatically. Acoustic or visual warnings from various safety systems
reliably indicate malfunctions.
Control every detail We have successfully applied our engineering know-how of Custo-
We adapt the Customized Control Systems to suit the requirements at mized Surface Control Panels in numerous projects – for instance for
the installation site, and to accommodate the functions that need to calculations and certifications, e.g. DNV 2.7-1 with FEA, stress tests,
be controlled, the communication with the production systems and the tests of welded joints etc. We also have extensive experience in the
applicable standards and guidelines. In the design process, we take acceptance field – both for inspections by customers and also external
into particular account the size of the wellhead equipment, especially audits by e.g. TÜV, American Bureau of Shipping (ABS), German Lloyd or
for reasons of safety. The design is based on application techniques Lloyds Register of Shipping.
to ensure that our Customized Control Systems are equipped for the
respective tasks - also for mobile applications.
Our services for Customized Control Systems:
• Customized Control Systems to control multiple hydraulic
functions on BOPs and Xmas Trees during wireline or
workover operations
• Remote controlled ESD Panels with pneumatic timers
for sequential shut-down
• Pneumatic, Electric or manual high-pressure pumps
• Frame: Stainless steel version or offshore coating
• Compact design with semi-automatic and automatic
hose reels for the hydraulic hoses
• DNV 2.7-1 certification
• ATEX Zone 1 certified
• Full bank of accumulator to ensure a quick closing
of the BOP in case of energy failure
16 | 17
How are hydraulic supplies for
the Arctic and the oceans made
as reliable as a Swiss watch?
A clean hydraulic system is imperative for constant Cleanliness for durable components
Depending on the required volume flow, we manufacture our HPUs with
and precise valve performance in subsea produc-
integrated or separate piston accumulator systems. Additional heating
tion systems. Hydraulic Power Units (HPU) provides systems can be fitted for Arctic or harsh environments. Maximator
an optimised power supply – even for kilometre- HPUs have dual redundant filter systems with electrical clogging indi-
long umbilical and subsea distributor stations. cator. The units have separate storage tanks for effective separation of
Installed on onshore and offshore platforms or clean and soiled fluids for the supply and return lines.
FPSO vessels, the units secure the production Our installations ensure that the hydraulic systems achieve maximum
operations. purity (e.g. AS4059 D Class 6 B-F). This in turn increases the service
life of all hydraulic components. With the embedded PLC, the units
Maximator develops and produces HPUs for direct or multiplexed work independently so that the operating effort by the user is low.
subsea production systems. Standard or customised HPUs are used The integrated components are made of 316ss stainless steel – on
for installation, for testing and for flushing applications. The units work request, we can also use special materials. When handling the various
independently with pressure circuits for low-pressure from 200 to 350 media, such as mineral oils, water/glycol mixes or also environmentally
bar and high-pressure from 700 bar to 1,050 bar. Redundant electric friendly biodegradable synthetic oils, we have extensive experience and
and pneumatic high-pressure pumps generate the pressure for the will be glad to advise you.
subsea operations.
Performance of the Maximator HPUs:
• Offshore-proven components
• Redundant pressure generation with electrical
or pneumatic pumps
• Standard and individual solutions
• Integrated or remote control (PLC)
• Protected from environmental influences (IP Rating)
• Combined low and high-pressure circuits
• Suitable for operation in areas with gas atmospheres
or as an open frame version (Skid-Design)
• ATEX Zone 1 certified
• Designed for 20 years operation
18 | 19
How can you use high pressure
to concentrate on your core
competencies?
20 | 21
We systematically achieve goods results.
Your project is created
• Nomination of an interdisciplinary team,
procurement of the components with a
longer delivery time
• Confirmation of the project scope
Standard CEEP-Process
Analysis of your task Development of your solution
• Review of the tender and the • System design and design review, design
system design and control of the components, review of
• Generation of a specific quotation the details
• Documentation release
MAXIMATOR Multi-Stage-Engineering
Factory Commissioning
» Production » acceptance
» and service
Europe
MAXITECH MAXIMATOR AS
MAXIMATOR UK MAXIMATOR BeNeLux
MAXIMATOR Iberica MAXIFES
MAXIMATOR Swiss
MAXIMATOR Austria
MAXIMATOR Italy
Asia
North America
MAXIMATOR Turkey
MAXIMATOR Test LLC. MAXIMATOR Korea
MAXIMATOR AIM MAXIMATOR Japan
MAXPRO MAXIMATOR Shanghai
MAXIMATOR M.E.
MAXIMATOR India
MAXIMATOR Far East
22 | 23
» Visit our website:
www.maximator.de
3999.2648 | 11/2014