Engineering Aspects of Offshore Heavy-Lift & Transportation

Presentation to Aberdeen IStructE 24th February 2005 Jon Dunstan

Introduction
Just before the final positioning at sea, production platforms for the exploration of oil and natural gas are now assembled almost to the point of completion. This approach requires the ability to move and lift large and heavy items at the yard as well as transporting them by sea to their final location and installing them on the seabed. Industry has evolved to provide the tools and methods to facilitate this high level of completion. Work offshore can cost 10 x cost of onshore.

The Driving factors

Platform Designer & Fabricator -Minimise steel and equipment required for transport/installation phases -Maximise onshore hook-up and completions Transport & Installation (T&I) Contractor -Simplify lifts as far as possible -maximise access and flexibility for marine operations -Minimise weather sensitivity -Minimise danger to marine equipment -maximise onshore preparation Operator -Perform safe and quick installation, minimise risk -Minimise time between installation to first oil -Maximise efficiency/cost

The Basic steps

1.Design & Fabricate Structure Onshore 2.Hook-up & Commission as a far as possible 3.Transfer (Load-out) structure onto barge/vessel for ocean tow 4.Tow to construction location in the field 5. Remove structures from barge and position in field 6. Secure structure in position 7. Offshore Hook-Up, testing & Commissioning 8. Operation 9. Shutdown, decommissioning and removal STEPS 1 TO 3 DESIGNER/FABRICATOR STEPS 4 TO 6 TRANSPORT & INSTALLATION (T&I) CONTRACTOR STEPS 7 TO 8 PLATFORM OPERATOR

Pushing the limits

Offshore Structures

1000'
FIX ED PLA T FO RM
COMPLIANT TOWE R

1000 ft 2000 ft 3000 ft 4000 ft 5000 ft 6000 ft

2000'
TL P

3000'
FPS SPAR

4000'

5000'

Th e d e e p e s t o f t h e d e e p

SU BSEA COPLETIO N

6000'
FPSO

History of Construction Methods

Jackets Launched/towed Topsides Multiple Module Assembly (MSF & stacked modules, offshore hook-up)

The North Sea Boom

A need for increased capacity and specialist tools. A step change in design. The birth of the semi-submersible crane vessel (SSCV) - 6,350 mt lift capacity
Year 1960 1969 1972 1974 1976 1984 1985 1987 1989 2000 Vessel Hercules Challenger Champion Thor Odin Balder Hermod M7000 DB102 Thialf (ex. DB102) / S7000 Lift Capacity 250 tonnes 725 tonnes 1,135 tonnes 1,800 tonnes 2,722 tonnes 6,350 tonnes 8,165 tonnes 14,000 tonnes 12,000 tonnes 14,000 tonnes

Design Revolution
-One piece topsides (Integrated Deck) revolutionises offshore installation and hook-up. Lifted jackets avoid need to design jackets for launch
-Modules can be mechanically complete & commissioned 2 lifts only (1 x jacket, 1 x deck)

DESIGNING & PREPARING FOR PLATFORM TRANSPORT & INSTALLATION

Preparation
OPERATIONAL Structure weighing Dimensional Control DESIGN All temporary phases (loadout,
transport, lift, on-bottom stability, launch) assessed for strength Local checks at interface points Design of Grillage & Seafastening Lift Rigging Design Dynamic lift simulations Launch Analysis Pile Driveability checks

Checks Preinstall Lift Rigging Barge/vessel Arrival Barge Vessel Mooring Barge outfitting of grillage Installation of linkspan Transfer of Structure to quayside

Preparations Before loadout

Preconnection of Lift Slings to padeyes/padears/trunnions

Rigging Laydown & securing

Loadout
Transfer of structure from
fabrication yard onto barge/vessel Method of loadout -Lifted -Skidded -Trailers (SPMT)

Ballasting of barge to maintain

level platform between quayside and barge deck

Assessment of Loadout Condition

Reactions from trailers (onto structure) Calculation of No. of trailers required (typ. 30mt/axle) Skidshoe design/reactions- required winch/strand jack
capacity/design of anchor points Influence of acceleration Overall Stability Physical clearances Link span end reactions check on barge & quay Link span strength UDL loads on quay, linkspan and barge from trailers (standard barge capacity, 10-15mt/m2)

Introduction

Set-Down on Barge
onto Barge Grillage Packing/shimming for even load distribution (up to 48 support points) Acceptance by structure designer Barge ballasted to mimic tow

Gradual Load Transfer

Design of Grillage & Seafastening (1)

Loads
-Static -Dynamic -Lift/launch -Deck Set-down /mating -Fatigue -Wave slam -Details for simple removal & cutting offshore (gusset plates)
Grillage beams Loadout frame Seafastening braces

Design of Grillage & Seafastening (2)

Methods of Analysis of Transportation Loads 1. Full Dynamic Analysis
(irregular seastates, wave spectrum, consideration of phases, wave approach direction, natural periods, roll damping) -SACS -MOSES

2. Noble Denton 20 & 10 approach Simple Harmonic Motion Model -20 degrees roll in 10 seconds
-Simple spreadsheet, quasi-static assessment -Conservative (Pitch (B or S) +/- heave, Roll ( P or S) +/- heave)

Design of Grillage & Seafastening (3)

Noble Denton 20 & 10 calculation of forces at cargo CoG for Roll

Design of Grillage & Seafastening (3)

Seafastening Design

Dynamic loads only (Takes Fh only) Generally taken axially in braces or in bearing via shear stops Any resulting couple taken as vertical loads through grillage Allow 33% over normal allowable API/AISC stresses Gusset connections for easy removal (single plane strength only) Possibility of roll relief or roll addition

Barge/Vessel Strength
Support structure
(grillage) to transfer static loads and proportion of dynamic loads into barge/vessel superstructure Identification of barge transverse & longitudinal frame capacities Grillages span hardpoints Hog/Sag conditions for long structures (barge bending encouraged)

Transport to Field
Considerations: -Distance -Duration -Cost -risk -Vessel cost & availability
Tug & Barge Self Propelled Vessel

Jackets (Lift)

Single Crane Lift

Tandem (Dual Crane) Lift

Upending sequence

Jackets (Launch)

Barge Ballasted to stern

Launch over stern

Hook-Assisted Upend

Ballast Control Station

Piling

hammer Through-Leg Pile driving Piling sequence Piling Hammers ILT

Pile lift off from barge & Upend (190m each, 820mt)

Platform & jacket preparations

Bumpers/guides Stabbing cones Jacket levelling Leg cut-offs
Bumper Guide

Lift (Decks & Modules)

SINGLE CRANE LIFT

DUAL CRANE DECK LIFT

Designing for Lift

for Spreader Bars /frames -Lift Point design -Sling selection (sling/grommet/doubled) -Shackle selection -Bending Losses -Sling extension -Module tilt /CoG position -Rigging removals (hydraulic shackles)
-Requirement

Floatovers
-Well suited to benign environments (SE Asia /Middle East/Caspian/W Africa) -Jacket installed by launch -Deck towed out on barge or HLV -Legs overhang barge -Barge floated between jacket legs -Barge ballasted to set-down deck -No crane vessel required -Builds on old GBS technology

The Future
NORTH SEA -Few new structures -More subsea and upgrade work -Decommissioning TFE Frigg field -reverse installation -Weather limits -piecemeal removal -newbuild removal vessels REST OF WORLD -Move to deeper water requires floating facilities -Less construction work for jacket and deck construction

What can go wrong?

END
WITH THANKS TO HEEREMA MARINE CONTRACTORS