Floatover - Installation - Final (Compatibility Mode) Quiz2 PDF

3/22/2013
Dr. S. Nallayarasu
Department of Ocean Engineering
Indian Institute of Technology Madras,
Chennai - 36
3/22/2013
Dr. S. Nallayarasu
Chennai - 36
Contents
Background
Modular Vs Float-over Comparison
Jacket and Geometry
Sequence
Active Vs Passive Systems
Weather Conditions
Components
Motion Analysis
Loads
Structural Design
3/22/2013
Dr. S. Nallayarasu
Chennai - 36
Background of the floatover concept

Oil companies are looking to exploit new and larger
reservoirs in their increasing quest to bridge the demand
supply gap
Thi
This h
has resulted
lt d in
i the
th increased
i
d sizes
i
off the
th decks
d k
required to process the reservoir fluids offshore
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Dr. S. Nallayarasu
Chennai - 36
Topside weight
The recent ONGC projects indicate large weight due to
combination of facilities and to maximise the production due
to increased price of oil
ICPR Process =11,000 Tonnes

MNP Process = 28,000 Tonnes
B193 Well Cum Process = 16,000 Tonnes
Availability of offshore lift vessels in the region
Upto 3000 MT, with some new vessels coming in the market
capacities 4000 / 7000 MT
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Dr. S. Nallayarasu
Chennai - 36

Large topside decks
+
Limited availability of offshore heavy lift
capacity
Multiple modular lifts offshore
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Dr. S. Nallayarasu
Chennai - 36
Modular Installation
Large Topsides The topsides weight for the process

platforms are ranging from 10000T to 30000T depending on
the platform requirements
Small crane capacity Many lifting cranes available in the

region has a lifting capacity is in the order of 2000T to 3500T
Thus the topsides will be split into smaller logical units

(module) and installed on the jacket one by one. This is to be
carefully worked out depending on the weight of the module
and its location.
The disadvantage of the modular installation is long offshore

t e for
time
o installation,
sta at o , hookup
oo up and
a d commissioning.
co
ss o
g
Several occasions the design of sub-assemblies and the

integration becomes a major task during engineering.
Dr. S. Nallayarasu
Chennai - 36
3/22/2013
Module
3
Module
4
Base
Module 1
Module
5
Module
6
Module
7
Base
Module 2
Float-over Installation
Total topsides transported to the site in Single Piece on a

deep draft or semi-sub barge
Jacket legs (inner) spaced such that the barge enter

b t
between
the
th legs.
l
The barge with topsides position in such a way that the

jacket legs and deck legs comes on vertical alignment using
precision alignment devices.
Barge brought to the location in slightly de-ballasted

position with a clear gap between the jacket leg top and
bottom of deck leg.
Ballasting down the barge makes the deck leg to make

contact with the jacket leg
This operation is called Float-Over
Dr. S. Nallayarasu
Chennai - 36
3/22/2013
LQ
Module
Top
structure
Base
structure
Barge
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Chennai - 36
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LQ
Module
Top
sides
Base
structure
Barge
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Chennai - 36
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SOME APPLICATION FLOATOVER

Deck Float Over
TLP Float
l
on Float
l
Off
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Chennai - 36
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Weather Conditions
Non-swell conditions are preferred and float over
operation has been done in the past with passive
systems in asia and other regions where the
significant wav height is less than 1.5m
1 5m
Swell conditions are not preferred but can use the
active systems
Typical weather window for floatover operations
around 36 to 48 hours
MOORING LINES
36000
TUG
TUG
Maximum WL during undocking (HAT + 0.15m Inst tolerance)

Minimum freeboard during undocking = 0.75m
El 1.2m Min WL for start docking
El 0.0m LAT
BARGE
JACKET
FLOATOVER ON JACKET STRUCTURE
TOPSIDE
FLOATOVER ON SPAR
3/22/2013
FLOATOVER ON SEMISUBMERSIBLE
Dr. S. Nallayarasu
Chennai - 36
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SEQUENCE
LOADOUT
TRANSPORTATION
DOCKING
MATING
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Chennai - 36
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Loadout on to vessel
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Dr. S. Nallayarasu
Chennai - 36
Float over principle

Fixed substructure
East Area GN
Deck on HTV
Black Marlin
Operator:
ExxonMobil
Weight: ~18000 mT
Location: Offshore
Nigeria
I
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Chennai - 36
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Float-over Sequence
load-out
Critical Factors in a Loadout Operation:

Vessel pumping capacity;
Vessel strength/skid beam design;
Pulling jack capacity and reliability;
Integrated deck weight and
skidding friction;
Tidal range;
Quayside dimensions.
Dr. S. Nallayarasu
Chennai - 36
3/22/2013
17
Float-over Sequence
sea transportation
Critical factors during sea transportation:

Vessel stability vs. deck weight/CG
height;
g ;
Global strength of vessel;
Local strength of vessel;
Sea fastening arrangement vs. motion
induced forces.
60.000 tons
@
37 00 m
37.00
12.000 tons
@
18.00 m
63.00 m
3/22/2013
42.00 m
Dr. S. Nallayarasu
Chennai - 36
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Float-over Sequence docking

Critical factors during docking operation:
Heading control of the vessel;

Transverse control of the vessel w/
away
a
ay fenders
d
and
a d cross
o lines;;
Longitudinal control of the vessel with
mooring lines and cross lines;
Control impact loads on jacket w/sway
fenders;
Maintain vertical clearances during
entry and withdrawal operations.
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Dr. S. Nallayarasu
Chennai - 36
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Float-over Sequence
mating: non-swell environments
Critical factors during mating operation
Limit horizontal excursion circle prior to lowering operation through

fenders & cross lines:
Minimize vertical impact loads between jacket & deck legs through
installed LMUs;
Minimize vertical impact loads between deck legs and vessel deck through
DSUs;
Achieve load transfer from vessel to jacket legs through vessel ballasting;
Continue vessel ballasting until sufficient vertical clearances for withdrawal
operation.
3/22/2013
Dr. S. Nallayarasu
Chennai - 36
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10
Float-over Sequence
mating: swell environments
Critical factors during mating operation

Limit stabbing cone horizontal excursion within designed circle by an anti-surge
y
;
system;
Minimize vertical impact loads between jacket & deck legs through hydraulic
cylinders and LMUs;
Minimize vertical impact loads between deck legs and vessel deck through quick
separation system (hydraulic cylinders) and DSUs;
Achieve load transfer from vessel to jacket legs through vessel ballasting and
cylinder extension/retraction;
Combined vessel ballasting and cylinder retraction for vertical clearances prior to
exit operation.
21
Dr. S. Nallayarasu
Chennai - 36
3/22/2013
History
40000
35000
Deck weight [st]
30000
25000
20000
15000
10000
5000
0
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
Year
Source : Dockwise
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Chennai - 36
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11
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12
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13
Load out
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Transportation
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Chennai - 36
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14
Positioning / Docking
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15
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Chennai - 36
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16
Ready for weight transfer
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Chennai - 36
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Ready for weight transfer
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17
LEG MATING UNITS

LEG MATING UNIT
RECEPTOR
CONE
ELASTOMERIC
BEARING
SAND JACK
JACKET
LEG
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Chennai - 36
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Weight transfer
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Weight transfer complete
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Chennai - 36
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Chennai - 36
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Undocking
3/22/2013
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Undocking complete
39
Dr. S. Nallayarasu
Chennai - 36
3/22/2013
Passive float-over methods
Load transfer only by vessel ballasting;

Moderate to mild wave climate w/o swells;
Sufficient draft fluctuation of the vessel to suit
requirement;
q
;
Utilization of LMUs and DSUs to reduce impact
loads;
Capacity >21000 tons.
Full load on
DSUs
Ballast
0% Load
3/22/2013
Partial load on
DSUs
0% Load
Ballast
Ballast
Partial load on
LMUs
Dr. S. Nallayarasu
Chennai - 36
Full load w/ Steelto-Steel contacts

40
20
Active float-over methods
Active lowering system w/ cylinders integrated with deck supports;

Applications in swell environments during installation seasons (5
of 12 months in West Africa environments);
R
Require
i an anti-surge
ti
system
t
to
t reduce
d
excursion
i
circle;
i l
Draft fluctuation insufficient to create gaps for entrance/exit
clearances;
Quick separation system is required to obtain vertical exit
clearances;
Capacity 18.000 tons or less so far.
3/22/2013
Dr. S. Nallayarasu
Chennai - 36
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Pontoon barge method
No slot required for fixed jackets;

Suitable for SPAR buoys;
Require a transfer operation prior
to installation;
i
ll i
Not suitable for long distance sea
voyage under pontoon barge
configuration;
One successful installation for
fixed jacket by ODL for Corocoro
WHP project;
One successful installation for
Kikeh Spar project
j
by Technip.
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Dr. S. Nallayarasu
Chennai - 36
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22
Friction fender concept
3/22/2013
Utilize friction to reduce vessel heave motions;

Eliminate hydraulic cylinders to improve system
reliability;
Suitable for floating and fixed platform topsides
installations;
Dr. S. Nallayarasu
Chennai - 36
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Improve pontoon barge method

Loadout directly onto two pontoon barges at
fabrication yard;
Purposely built pontoon barges;
Suitable for transportation
p
under harsh environments;;
Suitable for both fixed and floating platforms;
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Dr. S. Nallayarasu
Chennai - 36
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23
Outrigger concept
For high CG heavy decks, stability, not displacement, is the big

challenge;
Increase stability by adding removable sponsons far away from vessel
CL;
Whole system, sponsons plus truss, is independently maneuvered and
transported;
Increase transport speed by adding self-propulsion systems to the
sponsons;
Suitable for transverse loadout;
Internal development is underway.
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Dr. S. Nallayarasu
Chennai - 36
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Components
Loadout Support Frame (LSF)

Fenders
Leg Mating Unit (LMU)
(
)
Jacks.
24
Motion Analysis
Motion analysis and the reaction forces on sway and surge
fenders needs to evaluated
These
ese forces
o ces will be used to
o a
analyse
a yse the
e jac
jacket
e a
and
d dec
deck
structure prior to mating.
Loading Stages
0% Load Transfer Stage

50% Load Transfer Stage
100% Load
d Transfer
f Stage
Post Mating Loads
25
DOCKING LOADS
Typical Loads (Payload 6,000 T)

LOAD DESCRIPTION
0% Load transfer maximum

LMU -X-dir load
LMU -Y-dir load
LMU -Z-dir load
50% Load transfer
maximum LMU -X-dir load
50% Load transfer
maximum LMU -Y-dir
Y dir load
50% Load transfer
maximum LMU -Z-dir load
100% Load transfer
maximum LSF -Z-dir load
SWAY
SURGE
(Tonnes)
(Tonnes)
PRE-MATING
514
81
HEAVE
(Tonnes)
450
170
788
194
242
179
971
502
82
2498
146
70
1973
203
2861
1191
POST-MATING
5
26
Conclusions
Float-over is a mature installation method;
Float-over is a competitive alternative for:
Integrated decks beyond crane vessel capacity;
Integrated decks to be installed in remote areas;
Less environmentally sensitive than lifting option.
Improvements to be expected in the fields of:
Workability and system reliability under swell
environments;
Installation capacity for heavy and high CG topsides;
Alternative float-over system such as pontoon barge
method.
3/22/2013
Dr. S. Nallayarasu
Chennai - 36
53
27

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3/22/2013

Background of the floatover concept

Background of the floatover concept

ICPR Process =11,000 Tonnes

Availability of offshore lift vessels in the region

Background of the floatover concept

Multiple modular lifts offshore

Large Topsides The topsides weight for the process

Small crane capacity Many lifting cranes available in the

Thus the topsides will be split into smaller logical units

The disadvantage of the modular installation is long offshore

Several occasions the design of sub-assemblies and the

Total topsides transported to the site in Single Piece on a

Jacket legs (inner) spaced such that the barge enter

The barge with topsides position in such a way that the

Barge brought to the location in slightly de-ballasted

Ballasting down the barge makes the deck leg to make

This operation is called Float-Over

SOME APPLICATION FLOATOVER

Maximum WL during undocking (HAT + 0.15m Inst tolerance)

Float over principle

Critical Factors in a Loadout Operation:

Critical factors during sea transportation:

Float-over Sequence docking

Heading control of the vessel;

Critical factors during mating operation

Limit horizontal excursion circle prior to lowering operation through

Critical factors during mating operation

Deck weight [st]

Ready for weight transfer

Ready for weight transfer

LEG MATING UNITS

Weight transfer complete

Passive float-over methods

Load transfer only by vessel ballasting;

Full load w/ Steelto-Steel contacts

Active float-over methods

Active lowering system w/ cylinders integrated with deck supports;

Pontoon barge method

No slot required for fixed jackets;

Friction fender concept

Utilize friction to reduce vessel heave motions;

Improve pontoon barge method

For high CG heavy decks, stability, not displacement, is the big

Loadout Support Frame (LSF)

0% Load Transfer Stage

Typical Loads (Payload 6,000 T)

0% Load transfer maximum

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