Bastion Technologies, Inc.

Oil & Gas and Petrochemical Division

Engineering Capabilities

17625 El Camino Real, Suite 330

Houston, Texas 77058

(281) 283-9330

www.BastionOGP.com

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About Us

Bastion Technologies, Inc. Oil &Gas and Petrochemical Division, (Bastion OGP) is a mechanical and structural engineering firm. We provide engineering analysis, design and drafting, risk and failure modes assessment, and training development for the offshore oil and gas industry. Bastion Technologies, a HUB, was founded in 1998 and employs over 400 employees approximately 250 of which are engineers. Bastion is ISO 9001:2008 certified. Our corporate office is located in Houston and we have branch offices at six other locations across the US including, White Sands NM, Huntsville AL, Washington DC, Johnson and Kennedy Space Centers and Glen Research Center. Our Oil & Gas and Petrochemical engineering team works from the corporate office in Houston, TX. Bastion has a three year average revenue of approximately $55MM.

Capabilities/Services

Structural and Mechanical Design

• Generate Conceptual Design

• Fabrication Design

• Create Detailed Drawings

• Form, Fit, and Function Analysis

Structural Analysis

• Stress Analysis/FEA Modeling

• Vibration and Fracture Analysis

• Dynamic/Non-Linear Analysis

Specialty Services

• FMECA – Risk Assessment

• Coupled Loads Analysis

• Procedural Development

• Training Development

Engineering Capability

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Structural and Mechanical Design

• Definition of technical performance requirements

• Development of design concepts and preliminary analysis

• Support customer system, component design, and Interface Control Document development

• Certification and QA/QC of mechanical systems and subsystems

• Provide design and checking support to meet engineering goals for system applications

• Provide Preliminary, Detailed, and Critical Design Review Support

Engineering Capability

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Structural/Mechanical Analysis

• Perform classical stress analysis and finite element analysis for structural and

mechanical systems

• Recommendations for design modifications and optimization

• Review of safety documents and identification of critical design issues

• Preparation of computational models for fracture analysis

• Perform structural beam instability, column buckling, beam-column, shear web

buckling, and shell stability analysis

• Perform engineering analysis tasks in the areas of dynamics, controls, and simulations

of dynamic systems

• Develop integrated loads and dynamic analysis for super structures

Engineering Capability

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Structural Engineering

Floating Production Semi-Submersible TRUSS JOINT MODELING AND ANALYSIS

Bastion Technologies, Inc. was contracted to model and analyze three new truss joint configurations for a new semi-submersible deepwater drill rig. The goal of such an analysis is to use less tubular connections to support the entire deck load thus decreasing weight and facilitating inspection. Bastion structural engineers built three different bar to beam element models and ran over 700 load cases per joint in order to determine the optimal design. All models were built using FEMAP and calculated with NASTRAN solver. All supporting structural analysis was performed per ABS code requirements. All three designs along with the associated recommendations were delivered to the client for consideration.

Entire Truss Structure Truss Joint FEA Model

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Bastion Technologies, Inc. performed a structural analysis on a flying lead pallet used to hold sub sea umbilicals for transportation, storage and installation. The pallets hold about 1,300 ft. of 3.5” diameter umbilical which is used for control related functions on sub sea installations. The fully wound weight of the structure is approximately 20,000 lbs. Bastion performed shell and structural strength assessments using NX/NASTRAN software and hand calculations for buckling due to lifting, transportation and storage of the umbilical. All required analysis adhere to DNV codes and standards.

STRENGTH & BUCKLING ASSESSMENT of FLYING LEAD PALLET DESIGN

Solidworks 3D Model of empty pallet

NX Nastran / FEMAP Model with applied 12,000 lb.ft. winding load case

BT #3062

Umbilical installation vessel

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BURNER BOOM FOUNDATION MODIFICATIONS and ANALYSIS

Our client needed a new foundation design for the relocation of the aft burner booms for a deepwater drillship. Bastion was contracted to analyze both burner boom foundations located on the aft end of the ship. Redesign and analysis was necessary as a result of changes in loading conditions and new requirements imposed since the completion of the original design. The new loading conditions require that the boom is capable of moving up and down between 0 degrees (horizontal) and 45 degrees in elevation. The boom will also be required to swing inboard and outboard while at any angle between these two inclinations. Further, the client required that all reinforcements to existing structure must be added above the deck to eliminate interference with existing structures below deck; specifically in the vicinity of the dynamic positioning control room. Any additional reinforcement was limited to approximately 350mm in height. The burner boom is designed in accordance with American Bureau of Shipping (ABS) rules and guidelines (ABS Rules for Building and Classing Mobile Offshore Drilling (Ref 4.2), and the guidelines of the American Institute of Steel Construction (AISC), Manual of Steel Construction, Allowable Stress Design (Ref 4.1).

Typical Burner Boom during gas flaring von Mises Stress 16.2 KSI

Helideck Struts (simple supports)

Sideshell (simple supports)

Frame 56

Frame 55 Bulkhead

(assumed simple supports)

Centerline Frame (simple supports + x axis rotational to approximate symmetry)

Girder simply supported

FEA model showing constraints for forward strut anchor beam substructure

Von Mises Stress on Deck Plate Forward strut anchor beam

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Structural Evaluation of Drilling Rig Mast With 750,000lb Hook Load Rating

Bastion was requested to conduct a structural analysis and evaluation of the mast of a drilling rig with a rated hook load of 750,000 pounds. The rig is a 1500 horsepower “slingshot” type land rig with an unguyed mast. The mast is an open truss type structure with a height of 148ft. The STAAD Pro structural engineering finite element program was used for the structural analysis. . The table below shows the mast front and side elevations taken from an assembly drawing. This is the final static load case table. It was created by varying the B750 hook static load, the stand percent and the wind speeds. This gave eight major static load cases. The analysis validated the rated hook load as a function of wind speed chart for the structure.

B750 Mast Static Load Cases

B750 Mast front and side elevations

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Strength and Buckling Analysis of Offshore Crane Pedestals

Bastion Technologies, Inc. was contracted to analyze the structural integrity of a relocated crane pedestal and its immediate supporting structures on the starboard side of Jack Up Vessel “Thule Energy Hull 051”. The crane is a Type C pedestal mounted rotating crane per the American Bureau of Shipping (ABS). A FEMAP model was created for both the crane pedestal cylindrical thick-wall column and three supporting deck panels with plate elements. The stress results were solved using MSC/NASTRAN solver. Additionally, a hand calculation and verification was provided to prove the subject structure has adequate buckling resistance strength according to ABS, AISC, and API codes. A report was written to show the designs specified in the reference drawings are structurally sound with respect to strength and buckling resistance when both the dead weight load and maximum operational loads are simultaneously applied at the top of the crane pedestal. The complete stress report addresses the strength and buckling assessments for this pedestal and its immediate supporting structure. The report was used to verify standards compliance of the crane pedestal design. The final report was submitted to ABS.

FEA of Major Principle stresses located around the pedestal manway Typical offshore Jack-Up Vessel

Pedestal and supporting structure FEA Math Model

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16” Flange von-Mises stress on flange face

A manufacturing company in Houma, LA was contracted to build metering skids for a major oil company. The fabricator used ASME B16.5 rated flanges as part of the construction. In order to maintain alignment, the fabricator machined the flange faces and consequently nullified the ASME rating. The fabricator asked Bastion Technologies to provide an analysis of the 12” and 16” sizes of the 150# flange in order to validate the performance per ASME B16.5. The 12” flange passed without condition, however the 16” would not pass the leak test under the torque conditions specified per B6. A special bolt torque procedure was generated in order to achieve the desired performance. The upper and lower torque limits were verified by FEA stress analysis and hand calculations.

Analysis and Re-rating of ASME B16.5 Flanges for Offshore Metering Skid Chevron-Shamrock Management

FEA and hand calculations for torque

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Design and Analysis for Installation of Utility Crane Pedestal on Noble Danny

Adkins BOP Transporter

Bastion Technologies was retained by Noble Drilling to provide a design and analysis of a utility crane pedestal. The pedestal is to be attached to the top of an existing BOP transporter for the Noble Danny Adkins semi-submersible rig. The crane pedestal was engineered for both strength and buckling. The Bastion Technologies engineering team coordinated the design with the customers engineers in an iterative process which produced a cost effective design ahead of schedule.

Top of transporter frame with pedestal attached

Fabrication drawings for utility crane pedestal

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Bastion Technologies was asked to provide an analysis of the Rhodia Chemical – Baytown Plant, tower deck walkway. Rhodia maintenance and operations employees expressed concerns that the walkway was not safe for personnel. Specifically, the employees had objection to the amount of flex allowed by the Chemgrate panels spanning the transverse supports of the walkway. Following analysis of the duct and walkway, it was determined that the panels did in fact allow excessive flex beyond that allowed by OSHA. Also, the transverse supports failed under the specified load condition per AISC. It was recommended to Rhodia Chemical that the walkway be condemned until modifications could be made to the design.

Rhodia Chemical – Baytown Analysis of Tower/Deck Walkway

FEA model of duct and transverse supports

Resultant deflection of cantilever walkway supports

Recommended grating support system for deck structure

Mechanical Engineering

LMRP Alignment Analysis December 2009

Bastion Technologies, Inc. was contracted by a leading deepwater drilling company to model and analyze the motion of a LMRP assembly for representative wellhead tilt. In performing the analysis Bastion engineers considered three different tilt scenarios, a 1 and 2 degree tilt about the cone pin axis and also a 2 degree tilt perpendicular to the cone pin axis. The goal was to analyze expected damage to the choke or kill slabs due to alignment error, calculate alignment error with tolerance effects using current pin design and analyze expected damage to cone pins and cone pin slot during engagement. ProE 3D was used in conjunction with NASTRAN 601 to perform the analysis. Bastion engineers determined the spherical pin design produced a constant alignment error which forced motion of the LMRP to be controlled by one set of spherical pins and the cone pin. This condition caused damaging wear to the cone pin and cone pin slot. Further, the misalignment at engagement of the choke/kill side stabs resulted in damage to the lands and likely leakage. It was determined that the defect was in the design of the spherical alignment pins. Removal of the spherical pins and replacement with a new straight pin design was recommended. The new straight alignment pin design resulted in an error of less than 0.077 degrees vs. 0.3 degrees when the spherical pins were used. The resultant forces at the stabs reduce the stress from a value above the Brinelling stress to a value of 37 KSI.

Collet Connector at 2 deg. Misalignment

von Mises Stress on Choke Side Stab New Alignment Pin Design

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Design and Analysis for Turret Locking System for Noble Discoverer

Noble Discoverer deepwater drill ship FEA of #2 Locking Pin

Exploded view of revised ring rail

guide shoe

The Noble Discoverer drill ship sustained minor damage after a mooring line failed in a storm while on station at the Ruru Well off the South Taranaki Coast, New Zealand. Noble Drilling hired Bastion Technologies to assist with the design and analysis of a modified turret locking and rotation system (LRS). The final design of the LRS incorporated a guide shoe, (2) double pin locks (shown below) and (4) hydraulic cylinders as part of a redundant system. The design was submitted to Noble Drilling an has been installed on Discoverer which is now on its way to Alaska.

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Crane Design, 500T Offshore Crane

Bastion Technologies was retained to provide structural engineering for the mast and boom of a 500 Ton offshore crane. This is pedestal crane to be installed on a jack-up work platform. The project scope presented numerous design challenges which were systematically solved within a condensed work schedule. Minimization of weight was of particular interest to the customer. Versus initial estimates, Bastion engineers were able to reduce gross weight by 24% while maintaining 96% of the desired design rating. The 500 ton crane is expected to be load tested and Commissioned in early 2012.

Von Mises stress results for mast

(total height - 54 feet)

Details of auxiliary boom assembly

General Arrangement 500

Ton offshore crane.

OIL STATES INDUSTRIES, INC. / BOP TRANSPORTER SYSTEM;

DESIGN and ANALYSIS

Bastion Technologies, Inc. recently supported the design and analysis of a new blow-out preventer stack transporter design to be implemented on three semi-submersible vessels for use in deepwater Gulf of Mexico offshore drilling. This system enables the operator to lift up riser assemblies or to position the blow out preventor during drilling operations. Our scope of work utilized both Solidworks for design and ANSYS software for analysis. The work entailed supporting the design of the transporter structure, which stands over 50 feet tall and is capable of lifting a 400 ton BOP stack frame. Other aspects of the project included engineering consultation on the design of the bridge system/riser hang-off, gear box installations and dynamic loading for variable frequency AC motor drives.

LMRP Lift Off and Cart Assembly

Transporter

Traverse drive system

Bridge design with tractor and traverse drive system All images are provided courtesy of Oil States Industries, Inc.

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Structural Engineering Modifications for Transocean Celtic Sea

Bastion was retained by Transocean to provide field engineering services for the GSF Celtic Sea Semi-submersible rig. The Celtic Sea was towed from Brazil to Cape Town, South Africa for extensive modifications. When the rig arrived Bastion engineers joined the Transocean team on site for approximately 4 months. Engineering design and analysis was provided on dozens of equipment systems throughout the vessel. Of chief concern to Transocean were the ROV platform reinforcements, new cement unit foundations, BOP support mods, cuttings dryer supports, and the I/WOCS foundations. The rig modifications were complete in late summer of 2011 and the rig was towed to its assigned drilling location off the coast of Angola where it will be operating under a 3 years lease to Esso (ExxonMobil).

GSF Celtic Sea under tow

BOP stack support modifications

Railings and deployment structure for life boat cradle and launcher

FIELD ENGINEERING

Risk Assessment

Procedural & Safety Training Development

Deep Water Dropped Objects

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Vessel Verification Practice Failure Modes Effects and Criticality

Analysis (FMECA)

Bastion Technologies was awarded a two year contract to provide consulting engineering, statistical analysis, risk assessment and FMEA/FMECA for a major oil company in Houston. Bastion obtained significant FMECA experience as an aerospace engineering contractor to NASA and the US Department of Defense since 1998. The services provided by Bastion are part of the qualified procurement process. Our effort provides an additional level confidence that the vessel selected is the correct vessel for the task, and the vessel/equipment on-board is fit for service. If deficiencies are discovered, Bastion will make recommendations either to use an alternate vessel/operator/procedure or will provide procedural or physical recommendation hat will mitigate the risk and/or consequences. The customer calls this process the Vessel Verification Practice.

Lift plan for Mad Dog topside

S7000 Criticality Matrix (8x8) per customer

Fault Tree Analysis for S7000

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Safety and Procedural Development and Training

2012

March April May June July August September October

Field Shut-In Allowances/Contingency Milestone

Page 1 of 1

8/23/2011

ATLANTIS SS2 CHANGE-OUT

DaysEnd

Date

Start

DateField / Activity

0d

4/1

12:00AM

4/1

12:00AM

South Atlantis Production

Shutin

12d

4/12

12:00PM

4/1

12:00AM

De-Oil South End of Field

0d

4/12

12:00PM

4/12

12:00PM

North Atlantis Production

Shutin

0d

4/12

12:00PM

4/12

12:00PM

All Production Down

15d

7/26

6:00PM

4/12

12:00PM

De-Oil North End of Field

0d

4/27

10:00AM

4/27

10:00AM

Field De-Oiled

De-construction Begins

27d

5/24

10:00AM

4/27

10:00AM

De-Construction Activities

46d

6/22

12:00PM

5/7

12:00PM

Construction Activities

Install and Test

4d

6/26

12:00PM

6/22

12:00PM

Internal System Test

12d

8/12

2:00PM

6/26

12:00PM

Dewatering Activities

0d

7/8

12:00PM

7/8

12:00PM

Oil Production Starts

29d

8/6

12:00PM

7/8

12:00PM

Allowances

10d

8/16

12:00PM

8/6

12:00PM

Contingency

4/1 Partial Field Shut-In

4/12

4/12 Full Field Shut-In

4/12 4/27

4/27 De-Construction Begins

4/27 5/24

5/7Construction Begins

6/22

6/22 6/26

6/26 7/8

7/8Field Start-Up

7/8 8/6

8/6 8/16

BP Confidential

SS2 Change-Out Durations: - Deterministic = 99 days (no allowances) - P50 Duration = 138 days

Manifold and

pigging loop

installation

Close proximity

SIMOPS

procedure

Schedule for

refurbishment of

production field

Bastion Technologies was asked by a major oil company to provide assistance with development of safety, equipment and installation procedures training for a large production field refurbishment. This project was in very deep water and the schedule was highly expedited. Coordination was required with dozens of other engineering and services contractors to successfully complete the task. The training systems developed by Bastion, a total of five, were presented to several hundred management, engineering and installation professionals throughout the 8 month operation. Bastion also provided interactive operations procedures that were used by the “company men” to direct the activities of the project.

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Deep Water Dropped Objects Analysis

Bastion technologies was retained to conduct a study of the excursion distribution of objects dropped in deep water. A total of 7 different geometries were included in the study. Objects included a manifold, jumper, mudmat, spreader bar and a special case with a coupled spreader bar and jumper. The trajectories for the objects were calculated using a proprietary coupled loads analytical tool developed in the aerospace industry and used to derive debris dispersion patterns for exploding objects at altitude. The analysis resulted in the affirmation of the high probability of large excursions of some object geometries. Bastion recommended a modification to the procedures for raising and lowering objects to the sea floor and a mitigation for the design of the spreader bar.