INSTALLATION OF TOPSIDE
USING FLOATOVER METHOD
Kuliah Tamu Fakultas Teknologi Kelautan - ITS
2 November 2010
By. Ir. Ice Achmad Kurniawan
1
Agenda
1.Why Floatover
2.Floatover Concept
3.Design Engineering
4.Barge Equipment and Appurtenances
5.Floatover Sequences
6. Procurement
7. Marine Spread
2
1. WHY FLOATOVER
Conventional method: LIFTING
WHY FLOATOVER
- Unavailability of suitable vessel with crane capability
to install heavy topside (>2000MT)
- Cost and schedule advantages of installing precommissioned, integrated, single-piece topsides.
- Desire to reduce increasingly expensive offshore
hook-up and commissioning time
- Now more demanding due to Scarce availability of
heavy-lift crane vessels for work in shallow waters
3
2. FLOATOVER CONCEPT
-
The topside module typically is placed on a barge or
heavy transport vessel positioned within (internal slot
of jacket) or around the legs (external) of a
pre-installed jacket
- The module then is settled onto the jacket legs by a
combination of vessel ballasting and a mechanical
lowering system.
- The operation of incrementally transferring the module
loads from the barge to the jacket (MATING
operation)
- Undocking, sufficient clearance, vessel move out from
the jacket
4
3. FLOATOVER
T&I DESIGN ENGINEERING
1. Deck Mating analysis
2. Barge Strength Check (load out & transportation
condition)
3. Transportation Analysis
4. Mooring Analysis
5. Seafastening Design
6. Floatover Rapid Ballast System Design
7. Jacket Structural Analysis (allowable limit during
floatover)
5
PROCESS DESIGN FLOW DIAGRAM
6
MATING ANALYSIS
•To simulate the barge’s motion characteristic and to identify the
loading on the jacket using a time domain analysis.
•Multiple load cases were identified from the initial stage, docking, load
transfer and undocking stage to represent the floatover method
•The load impact result shall be within allowable jacket design load
•Installation sea states criteria shall be established at up front stage as
an input for the analysis.
•Software use MOSES or LIFSIM
Seastate Input (Installation Criteria)
Head/stern sea Hs = 1.00 m Tz up to 7.5 s
Quartering sea Hs = 0.75 m Tz up to 7.5 s
Beam sea Hs = 0.50 m Tz up to 7.5 s
Output will be used to determine the flaotover workability
7
DSF-BARGE SEAFASTENING
8
TOPSIDE-DSF SEAFASTENING
9
LMU
10
DSU
11
PLAN LAYOUT LOAD OUT
12
LAY OUT FENDERING SYSTEM
13
JACKET
ALLOWABLE
IMPACT
LOAD
14
4. FLOATOVER OPT.SEQUENCES
•
•
•
•
•
•
•
Standby - The vessel is a safe distance from the substructure but connected to
the mooring system, preparation rapid ballast system or the hydraulic jacks are
under way
Docking - The vessel enters the substructure and alignment
Pre-Mating - When ballasting the vessel to match the leg mating units (LMU)
with receptors on top of the substructure legs and removing the remaining tie
downs, it is critical that the vessel motions be limited to suit the chosen LMU
geometry. No weight transfer yet occurs
Mating - The topsides is lowered onto the substructure by either rapid
ballasting of the vessel or by contracting the hydraulic jacks. The topsides
weight is transferred to the jacket completely
Post-mating - A gap is created between the deck support units (DSU) and the
vessel to ensure vessel motions will not cause contact between the two
Exit - The vessel is removed from the jacket slot.
Post Floatover
- Removal of premooring system, clean up installation aids from jacket if
required
- Process of welding & NDT examination between topside leg with jacket
transition pieces
- Final Survey
15
ANCHOR PATTERN
16
ELEVATION
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5. BARGE SYSTEM AND APPURTUNANCES
1. Rapid Ballast System: to perform the load transfer in the available 12hour tidal sequence, with specific rate. Can be external or internal
(modified from existing barge ballast system)
2. Fendering system was designed to ease the transition through the
jacket with sufficient clearances, which reduced the sway impact
loading upon docking.
3. The surge fenders were installed to lock the barge in its final docking
position.
4. LMU (elastomer-based leg mating unit): to reduce the vertical impact
forces (designed to support 50%) of the deck load during load transfer.
5. DSU (Deck Support Unit), elastomer to reduce vertical impact between
DSF and topside during the deck load transfer
6. DSF (Deck Support Frame), structure to support topside during load
out, transportation and floatover
7. Barge Motion Monitoring System, electronic system to monitor motion
of the barge (6 degree of freedom, the motion will be compared with
mating analysis)
8. Positioning System
9. Wave Rider Buoys
18
BARGE GENERAL LAYOUT
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6. PROCUREMENTS
1. S45 PREPARATION AND FENDERING SYSTEM
2. LINKBEAMs & LIGHT SKIDBEAMs FABRICATION
3. 3RD PARTY MARINE SPREADS CHARTER
(Various)
4. EXTERNAL RAPID BALLAST SYSTEM
5. SURVEY AND POSITIONING
6. WEATHER FORECAST
7. CATERING SERVICE
8. INSTALLATION AIDS
9. VSAT LINK SERVICE
10. AGENCY SERVICE
11.ROV
13. NDT
7. MARINE SPREAD
1.1 X TRANSPORTATION BARGE (S45)
2.1 X TOWING TUG 14,200BHP
3.2 X AHT 10,800BHP C/W KARMFORKS
4.1 X AHT 7000BHP
5.1 X AWB (Accommodation Work Barge),
120PAX CAPACITY, 120T CRANE
6.1 X CREW BOAT, 80 PAX CAPACITY
7.1 X ZODIAC BOAT
1.Project Description
NORTH BELUT
WHP-C
CPP Topside
MALAYSIA
DUYONG
22" x 10 km
INDONESIA
WHP-D
gas phase - 16" x 37 km
liquid phase - 12" x 37 km
18" x 100 km
ADGF PLEM
HIU
SUBSEA
KERISI
PLEM
24" x 93 km
gas phase - 16" x 23 km
liquid phase - 12" x 23 km
16" x 0.5 km
CPP
BELANAK
FPSO/ FSO
WHP-K
KERISI
The NBCPP topside is a large, complex integrated deck with a not to exceed weight of 14,000
MT. The field is located approximately 60km east-north-east of the Belanak FPSO installed
in the Belanak Field, located on the Block B of the Indonesian sector of the Natuna Field.
22
2.Project Phases
Load out of CPP
Topside on S45
Location:
S45 mobilize to
Topside Fabrication Yard
Transportation of CPP
Topside
Sailaway
Location:
Block B of Natuna
Sea – Indonesia
Installation of CPP
Topside using Floatover method
on CPP Jacket
The NBCPP is located in 95.2 m
water depth
23
3. Scope of Work
Main Scope of Work:
• Provision of expertise, manpower, plant, equipment, Contractor’s Spread,
consumables and all other items necessary to transport CPP Topside
components from the fabrication yard to the North Belut offshore Site
and install them safely and efficiently.
24
4.Project Key Milestones
Date
Activity
11 June 2007
Contract Effective Date
3 Jan 2009
S45 transfer to Sintai for Fendering System and
Preparation Work
1 May 2009
S45 mobilized to PTMI Yard
16 May 2009
CPP Topside loaded out onto S45 barge
1st June 2009
Sailaway of CPP Topside
6th June 2009
CPP Topside Installed using Floatover method
7th June 2009
All vessels demobilized from site
25
5.Interfaces with Other
Company’s Contractor
No
Description
PT Technip
PT Mc Dermot
PT Saipem
X
Review + supply barge
data, check barge
strength and stability for
load out
1
All loadout planning, engineering
and AFC dwg
2
Load out operation
3
Structural Load out Analysis
(Reaction load)
X
R
4
Transportaton Analysis
R
X
5
Mating Analysis
R
X
6
Installation Aids fixed by welding
to jacket structures
7
DSF
R
X
R
Supply material,
Fabricate and pre
install
Design and supply AFC
dwg and MTO
Design
Supply material,
Fabricate
R
8
CPP Topside
Design
Supply material,
Fabricate
9
LMU (OKI)
Design,
Fabricate
Install
10
Seafastening
R
Supply material,
Fabricate and install
Design and supply AFC
dwg and MTO
R
R, may request to
use assistance
Design and install
11
External Rapid Ballast System
Floatover
R = Review
X = Responsibility
Project Photos
LOAD OUT
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TOWING
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PRE-MATING
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FLOATOVER
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FLOATOVER
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FLOATOVER
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FLOATOVER
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FLOATOVER
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FLOATOVER
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FLOATOVER