Valeria Monobuoy Replacement—PVM SAS

The Challenge: Safe Underwater Isolation

PVM SAS, together with CENIT and the company BUZCA, faced the challenge of designing, building and installing a temporary sealing tool for the Pozos Colorados Terminal in Santa Marta (Magdalena). This activity was part of the Operational Continuity Module that would allow the start of one of the most important projects in the country: the replacement of the Valeria Monobuoy. This temporary tool was a critical solution, since it was to be installed in a submarine line in charge of transporting refined products for the national supply, ensuring a hermetic and stable seal during the period of inactivity of a section of the line.

The project required precise calculation of the line filling, dimensional analysis and hydraulic studies to guarantee the efficiency of the tool. Additionally, the team faced the challenge of securing the subsea installation at a precise point, considering depth limitations for diving personnel and adverse meteomarine conditions. To solve this, an underwater tracking device based on electromagnetic forces was implemented, which allowed the tool to be located with millimeter precision. The temporary installation lasted an estimated 120 days, coinciding with the monobuoy replacement period. One of the biggest technical challenges was to ensure that the tool provided a complete seal and remained in position in the face of pressure variations within the line.

Innovation Process and Solution

To address this technical challenge, the PVM SAS engineering team developed the RDS-8DS tool, an innovative subsea sealing system that combines a bi-directional mechanism with high precision sealing discs. This unique design ensures complete tightness in both flow directions, overcoming the limitations of conventional unidirectional systems.

The system incorporates a differential pressure-activated (18 psi ± 0.5 psi) unidirectional sealing module, which ensures mechanical locking of the tool after installation, eliminating the risk of axial displacement even under internal pressure variations of up to 150% of normal operating pressure. This feature proved critical to maintaining seal integrity during the required 120 days of temporary operation. The design of the RDS-8DS allows it to be deployed in extreme conditions, guaranteeing reliable sealing by means of discs made of high-strength materials. These components have demonstrated a minimum service life of 120 days in accelerated aging tests (ASTM D471), maintaining 95% of their initial mechanical properties.

Its bidirectional technology ensures total tightness (leakage < 0.1% according to API 6DSS) in reversible flows of up to 3 m/s, preventing cross-mixing between refined products. The system incorporates a self-locking mechanism that eliminates axial displacements (>2 mm) even under pressure variations of ±20%.

For accurate monitoring, an underwater tracking system was integrated with the following specifications: Frequency: 22 Hz (±0.5 Hz stability). Accuracy: ±0.3 m in dynamic conditions. Interfaces: Diver operable (up to 30 m) Transmitter: 316L stainless steel housing with IP68 protection

In field tests, the system achieved 99.7% reliability in continuous location for 4 months.

Project Results and Success

The RDS-8DS development process included a comprehensive validation protocol, structured in three phases:

1. Pressure testing:Simulations performed on a 1:1 scale pilot built by BUZCA at its Cartagena facilities, which allowed replicating the real operating conditions of the line.
2. Corrosion resistance:Accelerated tests in saline solution (3.5% NaCl, 40°C) for several hours.
3. Operational validation:Real-time tracking and location of the tool with divers, who were trained in and out of the water.

Thanks to this effort and the commitment of the PVM SAS, CENIT and BUZCA teams, the operational continuity functioned optimally and allowed the monobuoy change to be successfully executed, without affecting the country's hydrocarbon supply, the operation or the integrity of the subsea line itself.

Innovation Process and Solution To address this technical challenge, the PVM SAS engineering team developed the RDS-8DS tool, an innovative subsea sealing system that combines a bi-directional mechanism with high precision sealing discs. This unique design ensures complete tightness in both flow directions, overcoming the limitations of conventional unidirectional systems. The system incorporates a differential pressure-activated (18 psi ± 0.5 psi) unidirectional sealing module, which ensures mechanical locking of the tool after installation, eliminating the risk of axial displacement even under internal pressure variations of up to 150% of normal operating pressure. This feature proved critical to maintaining seal integrity during the required 120 days of temporary operation.

The design of the RDS-8DS allows it to be deployed in extreme conditions, guaranteeing reliable sealing by means of discs made of high-strength materials. These components have demonstrated a minimum service life of 120 days in accelerated aging tests (ASTM D471), maintaining 95% of their initial mechanical properties. Its bidirectional technology ensures total tightness (leakage < 0.1% according to API 6DSS) in reversible flows of up to 3 m/s, preventing cross-mixing between refined products. The system incorporates a self-locking mechanism that eliminates axial displacements (>2 mm) even under pressure variations of ±20%.

For accurate monitoring, an underwater tracking system was integrated with the following specifications:

• Frequency: 22 Hz (±0.5 Hz stability).
• Accuracy: ±0.3 m in dynamic conditions.
• Interfaces: Diver operable (up to 30 m)
• Transmitter: 316L stainless steel housing with IP68 protection

In field tests, the system achieved 99.7% reliability in continuous location for 4 months.

Project Results and Success

The RDS-8DS development process included a comprehensive validation protocol, structured in three phases:

1. Pressure testing:Simulations performed on a 1:1 scale pilot built by BUZCA at its Cartagena facilities, which allowed replicating the real operating conditions of the line.
2. Corrosion resistance:Accelerated tests in saline solution (3.5% NaCl, 40°C) for several hours.
3. Operational validation:Real-time tracking and location of the tool with divers, who were trained in and out of the water.

Thanks to this effort and the commitment of the PVM SAS, CENIT and BUZCA teams, the operational continuity functioned optimally and allowed the monobuoy change to be successfully executed, without affecting the country's hydrocarbon supply, the operation or the integrity of the subsea line itself. Commitment to Innovation and Efficiency This project demonstrates the capacity of PVM SAS to design customized, high-tech solutions for the offshore industry, reaffirming its commitment to innovation and operational efficiency.