Equipo Off Shore

Marine Equipment & Operation
David N. EDELSON Senior Project Installation Manager TPUSA

Universidad de los Andes 28 June 2013
Agenda
1. Introductions
0830 to 0845
2. Subsea Pipelines Systems Installation Overview
0845 to 1000
3. Break
1000 to 1030
4. S-Lay & R-Lay Pipeline Installation Method
1030 to 1230
5. Lunch
1230 to 1400
6. Subsea Construction
1400 to 1530
7. Break
1530 to 1600
8. Structures Transport and Installation
1600 to 1730
9. Wrap-up and Final Questions
1730 to 1800
Copyright Technip and others.
About the Instructor

Title: Senior Project Installation Manager
Marine Operations Engineering
Company: Technip USA Inc.
Region: North America
Business Segment: Offshore
Education: BSc. Naval Architecture / Marine
Engineering
David N.
EDELSON
Experience: Over 28 years experience in

marine/offshore oil & gas industries involving
floating (drillship, FPSO, semi-submersible,
spar) and fixed (jackup, jacket, gravity base
structure) production and drilling facility design,
fabrication, upgrade, installation (including
topside floatover) and repair.
Contact:
dedelson@technip.com
+1 281-249-7923
TERMINOLOGY
Transportation & Installation
Shallow Water Field Development Systems

Fixed Steel Platform (Jacket)
Topside carrying processing
equipment and
accommodation
Rigid Subsea Pipeline
Rigid Riser installed on Jacket
Rigid Subsea Tie-in Spool
Trunk Line
Deepwater Field Development Systems

Floating Platform
(Spar, TLP, SemiSubmersible, FPSO)
Subsea Equipment
(Subsea / Wet Tree,
Manifold, Jumper, etc)
In-field Flowline with
PLET / PLEM / ILS
Riser (SCR, Flexible
Riser)
Deepwater Field Development Systems

MC
MC 503/547
503/547 3000
3000 fsw
fsw (914m)
(914m)
LLOG
LLOG Who
Who Dat
Dat Project
Project
Gulf
of
Mexico
Gulf of Mexico
Flexible
Flexible Risers
Risers
Gas Export Line
87,800 10 Gas Pipeline

to existing pipeline
94,700 14 Oil Pipeline
PLET
Dual 15,000 6 insulated flowlines

Dual 11,500 6 insulated flowlines
3 Jumpers
PLET
6 Jumpers
2 PLETS
4 Slot Subsea Manifold
Location A
2 PLETS
(2) Slot Subsea
Manifolds
Location E
Subsea Control Equipment (Umbilical, UTA, SDU, Flying Lead)

Export Lines to subsea T, platform or shore
Different Types of Rigid Subsea Pipelines

Deepwater In-Field Pipelines
Production, Water/Gas Injection and Gas Lift.
Small Diameters 6 to 10 (152mm 254mm)
Insulated
5LPP Five Layer Polypropylene
GSPU Glass Syntactic Polyurethane
Corrosion Coated
FBE Fusion Bonded Epoxy
3LPP Three Layer Polypropylene
3LPE Three Layer Polyethylene
Typically no concrete coatings

Short distances (Typically weight 5 to 20 km)
Shallow Water In-Field Pipelines
Same as above but concrete coated for stability and / or
trenched

Export and Trunk Lines
Oil and Gas Exporting
Large Diameters 12 to 48 (305mm 1,219mm)
Corrosion Coated
FBE Fusion Bonded Epoxy
3LPP Three Layer Polypropylene
3LPE Three Layer Polyethylene
Typically concrete coated for stability reasons

Long distances (typically 25 to 100 km to existing subsea
export networks or to the beach)

In-Field Pipe-in-Pipe
Typically for Production flowlines
Diameters 6 (152mm) in 10 (254mm) or
8 (203mm) in 10 (254mm)
Insulation coating on inner pipe
Aerogel
Polyurethane Foam
Corrosion coating on outer pipe (3LPP, etc)

Short distances
In-Field Pipeline Bundles
Pipeline bundle product integrates the required
flowlines, water injection, gas lift, chemical
injection and control systems necessary for
any subsea development and assembles them
within a large diameter steel carrier pipe.
Towhead structures incorporating equipment
and valves, designed specifically to the
requirements of the field, are attached at each
end of the bundle
10
Subsea Structures Installed with the Pipelines

PLET (Pipeline End Termination)
Single hub structures at the end of the
pipeline for connecting the pipeline to
the subsea Manifolds via jumpers
PLEM (Pipeline End Manifold)
Larger multiple hub (dual or triple)
structures at the end of the pipelines for
connecting the pipelines directly to the
X-mas trees via jumpers
ILS (In-line Sled / Structure)
Single or dual hub subsea structures in
the middle of the pipeline section to
connect the pipelines to existing or
future wells via Jumpers
11
Risers Connecting Pipelines to Platforms

Rigid Deep Water Steel Catenary Riser (SCR)
Typically used in deep and ultra deep waters
Flexible Riser
Typically used in medium to deep water
Rigid Shallow Water Riser
Fixed to the jacket structures via clamps
12
Power & Control from Platforms

Umbilicals
Conduit for electrical power and
communications, fiber optic
communications and hydraulic and
chemical services.
Umbilical Termination Assembly (UTA)
Terminates umbilical and provides single
or multiple outlet connections for electrical
power and communications, fiber optic
chemical services.
Subsea Distribution Unit (SDU)
Receives electrical power and
communications, fiber optic
chemical services from the UTA and
distributes to multiple users such as trees,
manifolds, pumping and boosting stations
and infield tie-ins.
13
PIPELINE INSTALLATION
Rigid Pipeline Systems Installation Methods

S-Lay
J-Lay
Reel Lay
Towing
15
What is S-Lay?
Bollard Pull
Water Depth
Top Tension
Bottom Tension
16
What is J-Lay?
Bollard Pull
Top Tension
Bottom Tension
17
What is Reel Lay?

Lay Distance
Bollard Pull
Lay Angle
Water Depth
Top Tension
Min Bend Radius

Bottom Tension
Touchdown Point
18
What is Towing?
Leading
Tug
TrailingTug
19
Comparison between the different methods

S-Lay
J-Lay
Reel Lay
Waterdepth
Very Shallow to Medium
Deep & Ultra Deep
Shallow to Deep
Pipeline Type
Export & Trunk
Export
In-Field
Outside Diameter
4 60 in (102 1524 mm)
Up to 24 in (610 mm)
Up to 18 in (457 mm)
Length
Short to Very Long
Short to Long
Short to Medium
Fabrication
On Vessel
On Vessel
On Shore (Spool Base)
Lay Speed
1 4 miles / day (1.6 6.4 km)
Slower than S-Lay
500 m/hr
Coatings
All Types
Corrosion
Corrosion & Insulation

(no concrete)
20
S-LAY PIPELINE INSTALLATION
S-Lay Using G1200 Vessel
22
G1200 Principle Dimensions

Length
162.3m
Breadth
37.8m
Depth (freeboard deck)
9.1m
Depth (main deck)
16.1m
Operating draft
5.8m 6.6m
23
G1200 Vessel Marine Systems

Class: Derrick and Pipe Laying Vessel, DPS-2, Self Propelled.
Power: 6 main engine/generator sets delivers a total output power of 25 MW
Thrusters:
Propulsion and DP: 2 ea. 4,500 kW azimuth thrusters
DP: 5 ea. 2,400 kW azimuth thrusters & 1 ea. 880 kW tunnel thruster
Mooring System:
8 each 110 ton electric mooring winches
915m x 64mm wire rope capacity
12 ton Flipper Delta anchors
Accommodation: 264
Transit Speed: up to 15 Knots
24
G1200 Vessel Capabilities

Variable deck load 4,000mt (5mt/m2)
Main Deck Pipe Storage Capacity
16
Bare
Pipe
16
Conc.
Coated
24 OD
Bare
Pipe
24 OD
Conc.
Coated
No. of
Joints
873
688
390
295
Length
(km)
10.6
8.4
4.8
3.6
Fuel 2,200mt
Fresh water 1,400mt
Endurance (days) 45 transit / 35 pipelay
Helideck Octagonal, 23m diameter,
suitable for Super Puma and Sikorsky
S61-N
25
G1200 Vessel Profile
26
Main Deck Layout

Piperack
Pipe Elevators
Pipe End Prep

27
Freeboard Deck Layout

Field Joint Coating
(FJC) Stations
Tensioners
A&R Winch
Pipe Elevator
NDE/Repair Stations
Welding Stations
28
Free Board Deck Pipe Transfer Equipment

NDE / Repair
Weld Station
Tensioner
FJC Station
29
Pipe Joints Route On the Main Deck
30
31
32
33
Pipe Joints Route On the Freeboard Deck
34
35
36
37
Pipeline Welding Techniques

Manual Welding
Standard up to +/- 20 years ago
Typically 300 bevel
Electrode Consumables
Semi-Automated Welding
Currently standard practice
U shaped bevel
Wire Consumables
38
Internal Line-Up Clamp (ILUC)

Internal alignment of two pipe joints
Copper backing shoe allows full
penetration weld from outside without
backing bars
Moves from connection to
connection
39
Non Destructive Examination (NDE)

Radiography (X-ray or Gamma ray)
X-ray source on pipe crawler inside pipeline to
shoot X-ray film of weld
Automatic Ultrasonic Testing (AUT)
Sound waves move through the inspected material.
Normally they follow a straight line, but when they hit
upon a defect, the sound waves are reflected. As a
result of the reflection of sound beams it is possible to
trace defects in the materials, even at a long distance
away from the surface of the material.
40
Field Joint Coatings

Line pipe supplied in average lengths of 40 (12.2m)
joints with coating except for ends (coating cut-back)
Pipe must be coated between joints to provide anticorrosion insulation protection and/or weight
Field joint coatings must withstand fabrication and
installation conditions:
Bending & Straightening (Flexibility,
Stiffness mismatch)
Interaction with rollers on barge and stinger
Environmental conditions during storage, installation and service
(Brittleness, Softening, UV Degradation)
Application process effects on the steel pipe (Cool down time, etc.)
41
Different Types of FJCs

Fusion Bonded Epoxy (FBE)
Works well with all types of corrosion parent
coatings (FBE, 3LPP, 3LPEetc)
Heat Shrink Sleeves (HSS)
Works well with all types of corrosion and
parent coatings. Very widely used in the Slay industry.
Injection Moulded Polyurethane (IMPU)
Works with PU based insulation parent
coatings (GSPU).
Injection Moulded Polypropylene (IMPP)
Works with PP based insulation parent
coatings (5LPP).
42
Heat Shrink Sleeve (HSS) Field Joint Coating
43
G1200 in Action
44
G1200 Main Pipelay Equipment

Tensioners:
4 @125mt Remacut, 500mT total during lay
4 @ 160mt, 640mT total on breaks in case of accidental flooding
A/R Winch: 400mT pull, 3000m x 108mm or 64mm low-rotation wire
Davits: 6 @ 50mT each
Deepwater stinger: 91m long, 900 departure at 84m radius (typical)
Maximum radius 366m
Shallow water stinger: 37m long with 152m 366m radius
45
Tensioners and Stern Rollers
46
Deep Water Stinger
47
Shallow Water Stinger
1 SECTIONS 38.5M
48
A&R Winch and Wire Routing
49
A&R Winch
50
Davits
51
Installation Analysis
WHY do we need to perform installation analysis?
To ensure we are within equipment capacity

To ensure product integrity is not compromised
To maximize weather window
To maximize installation efficiency
To develop innovative installation techniques
52
Installation Analysis Stages

WHEN Do We Need to Perform Analysis?
TENDER
Preliminary
calculations
Feasibility check
Vessel selection
Method
statement
PROJECT
EXECUTION
Detailed
engineering
phase
Deliverables
OFFSHORE
PHASE
Provide real-time
assistance to
critical steps
Provide help for
unplanned events
53
Static Analysis Acceptance Criteria

Stress Based Design (Mexico, Middle East.etc.)
Overbend Stress < 85 90% Section Modulus Yield Stress (SMYS)
Sagbend Stress < 72% SMYS
Strain Based Design
Overbend Strain Det Norske Veritas (DNV) Criteria
Sagbend Strain < 0.15%
54
Dynamic Analysis Acceptance Criteria

DNV Simplified Criterion
Overbend
Sagbend stress < 87% SMYS

DNV Local Buckling Check
Overbend is considered Displacement Control up to the last roller in
contact with the pipe
Sagbend region is considered Load Control and it starts at the last
roller on the stinger tip section
55
Key Software
Pipelines Analysis
Offpipe, Orcaflex and Pipelay Rigid pipelines (S-lay configurations)
Orcaflex Flexibles, umbilicals
Structural Analysis
SACS General structural engineering
ANSYS Finite Element Analysis (FEA)
Naval Architecture
MOSES Mooring analysis
SESEAM Response Amplitude Operator (RAO) generation
Drafting
Autocad Drafting and Design
Inventor Animation and Design
56
Normal Lay and Dead Band Range
57
Vessel Rollers Set-up
58
Stinger Rollers Set-up
59
Stinger Rollers Set-up (Contd)
60
S-Lay Installation Activities

Start-up / Initiation
Normal Lay & Dead Band Range
Abandonment and Recovery
Laydown
Wet Buckle Recovery
Davit pick-up and Sweeping / Lateral Move
Shallow Water Risers / Spools Installation
Shallow Water Beach Pull
Above Water Tie-in
PLETs Installation (1st End / 2nd End)
SCR Installation (1st End and 2nd End)
Flooding, Gauging & Hydrotesting
61
Start-up / Initiation
62
A&R and Lay Down
63
Wet Buckle Recovery
64
Davit Pick-up & Sweeping In Shallow Water
65
Shallow Water Beach Pull
66
Shallow Water Risers/Spools Installation
67
Above Water Tie-In (AWTI)
68
1st End PLET Installation
69
2nd End PLET Handling System
70
2nd End PLET Installation
71
2nd End PLET Deployment
72
Firing Line / Stinger Clearances for ILS

Installation
73
SCR 1st End Installation (Lay Away)
74
SCR 2nd End Installation (Lay Towards)
75
Flooding, Gauging and Hydrotesting

Flooding and Cleaning
Done through Start-up/A&R heads
using Pig Launchers and Receivers and
foam / wire brush pigs
Gauging
Done to confirm no buckles in the
pipeline using a gauging pig with a
calibrated disc (Typ. 95% of the
smallest ID of the system)
Hydrotesting
The whole system is pressurized to
1.25 times the design pressure and
pressure is held for a minimum of 8 hrs
to confirm welds integrity and no
leakage.
76
Typical S-Lay Challenges

Stress Intensification at field Joints due to concrete coating on
main pipe
Restrictions on dimensions/weights during ILS installation
Weather limitations during pipe transfer from barges or pipe
carriers at <3m Hsig (significant wave height)
Pipe logistics can impact lay rates
High bottom tensions in shallow water
Offshore break downs / repairs / production delays are all on
critical path (more costly compared to onshore production at the
spool base)
77
WELDING PROCESSES
78
Welding Familiarization
Terminology
Welding Generic term referring to arc welding
Electrode Filler metal that supports the arc and fills the weld
joint (SMAW, FCAW, GMAW and SAW) or tungsten electrode
that supports the arc (GTAW). Filler metal is added
independently on GTAW.
Filler Metal Metal that becomes the welded connection
Weld Joint Design of the end of the parts that are going to be
welded, commonly a V or J groove design.
Base metal or parent material rolled, cast, forged metal part of
the pipe that remains unaffected by the welding process.
Heat Affected Zone (HAZ) The base metal next to the weld
that has metallurgically changed.
79
Spoolbase / Welding
Welding Familiarization
Parent Material (PM)

Heat Affected Zone (HAZ)
Fusion Line (FL)
Weld Metal (WM)
80
Spoolbase / Welding
Welding Processes & Positions
Different types of Welding exist. The quality of the welds, the level
of productivity required and the Client specifications will, amongst
other requirements, drive the choice.
Main techniques used on production sites:
81
SMAW
FCAW-G
GTAW
SAW
GMAW
Shield Metal Arc Welding (flux coated rod)

Flux Core Arc Welding Gas shielded
Gas Tungsten Arc Welding
Submerged Arc Welding
Gas Metal Arc Welding
Spoolbase / Welding
Welding Processes & Positions

Plate 1G, 2G, 3G and 4G
Pipe 1G, 2G, 5G and 6G
82
Spoolbase / Welding
Welding Processes: SMAW

Areas of use
All steel from 2mm upwards
Widespread use (pipeline, jacket,
fabrication shop)
Universal process
Positives
Simple, inexpensive, and highly
portable equipment
Electrode provides and regulates its
own flux
All positions
Less sensitive to wind or drafts
Negatives
Welder skills based
Limited welding speed

Slag removal
83
Spoolbase / Welding
Welding Processes: FCAW-G

Areas of use
Widespread use (pipeline,
jacket, fabrication shop)
Universal process
Positives
All positions
High productivity
Semi automatic process
Reduced welder skill
required
Negatives
Wire cost
Slag removal
Mechanical properties
84
Spoolbase / Welding
Welding Processes: GTAW

Areas of use
Thin sections
Non ferrous metals

High quality welding (SCR,
nuclear field)
Positives
Low thermal distortion
High quality welding

No slag, very clean process
Negatives
Low deposit rate, low productivity
Not practical for thick sections

Highly skilled welders required
85
Spoolbase / Welding
Welding Processes: SAW

Areas of use
Thick sections
Double jointing
Jacket legs
Positives
High productivity
Welder friendly
Reliable and simple
May be fully automatic
Negatives
Flux recycling
Slag removal
Flux storage
Practical in only the flat (1G) position
86
Spoolbase / Welding
Welding Processes: GMAW

Areas of use
Widespread use
Universal process
Positives
Easy automation
High productivity
Semi automatic process
Reduced welder skill required
Negatives
Sensitive to wind and draft
Weld quality (porosities, lack of

fusion)
Normally limited to flat (1G) and
horizontal (2G) positions
87
Spoolbase / Welding
Welding Processes - Summary
SMAW
FCAW-G
GMAW (auto)
SAW
GTAW
Productivity
++
++
--
Areas of use
Repairs
Flanges
Tie-Ins
Repairs
Jackets
Main flow lines & SCR

Double Joints
Double Joints
Piles
Root &hot pass SCR

Stainless steel
All
All, <6 (152mm)
>6 (152mm)
>12 (305mm)
All, Small OD x WT
7 to 10
12
16
21
Repair rate
< 3%
< 3%
< 4%
< 3%
< 2%
Cost to Use
--
++
++
Pipe sizes
Travel Speed
Inch /min
88
Spoolbase / Welding
AUTOMATIC WELDING
89
Automatic Welding (GMAW)

Advantages: High productivity, less welders skill dependent, reproducibility
Disadvantages: High cost, many equipments involved, not easy to deploy
Areas of use: Preferred process for spoolbases, S-Lay and J-Lay barges
Process: Single or Dual-torch downhill pulsed GMAW, all passes from
outside of the pipe
90
Spoolbase / Welding

Welding Position
5 G (horizontal pipe) - Spoolbase and SLay barge
91
Spoolbase / Welding

Welding Position
2 G (vertical pipe) JLay
92
Spoolbase / Welding
Automatic Welding Joint Design
93
Narrow Groove
Wide Groove
A = 3 to 5 Degrees
A = 25 to 30 Degrees
Spoolbase / Welding
Shielding Gas
Shields the weld puddle from the atmosphere
Ensures smooth transfer of molten droplets from the wire to the weld
pool
Substantial effect on the stability of the arc
Substantial effect on the behaviour of the weld pool, in particular, its
penetration
Typical gas mixture (Ar/CO2 50/50 or 80/20)
94
Spoolbase / Welding

Ancillary Equipment
Pipe Facing Machine (PFM)
Bevels the ends prior welding
95
Spoolbase / Welding
Ancillary Equipment
Pipe Facing Machine (PFM)
3 main parts:
o clamping assembly
o rotating assembly
o sliding tools holder
96
Spoolbase / Welding
Ancillary Equipment
Internal Line Up Clamp (ILUC)
Facilitates fitup of the two pipes
When fit with copper backing, it
allows the weld to be placed above,
but not fuse to it
97
Spoolbase / Welding

Ancillary Equipment
Internal Line Up Clamp (ILUC)
98
Spoolbase / Welding
Welding Procedures Qualifications

(WPQs)
99
Welding procedures Qualifications (WPQs)

Review Project
and Specifications
Production
Create Weld
Matrix
Create
pWPSs
Submit for Client

Approval
Submit for Client
Review
Start
Qualification
Program
Initial ECA Acceptance

Requirements
Create
WPSs
Welds are
NDE tested
Welds are
Reeled
Mechanically test
Welds
Final ECA Acceptance

Requirements
100
Spoolbase / Welding
Welding Procedures Qualifications (WPQs)

Typical Welding Procedure Specification (WPS)
101
Spoolbase / Welding
Technip GMAW Welding System

Technip in-house developed GMAW welding system
102
REEL LAY
103
Deep Blue Reel Lay Equipment

Top module
Main aligner
Main Reels
RD Tensioners
104
Subsea Installations:
Pipelay/Flexibles/Umbilical/Lifting/Subsea Construction
Deep Blue Reel Lay Process

Spooling at Theodore Spoolbase
Spooling lines
Spooling elbow and reel packing
105

Main Aligner
Upper Straightener
Lower
Straightener
106

Upper Tensioner
Max Capacity 275te
Lower Tensioner
Max Capacity 275te
107

Middle Floor
MWP
Movable Working
Platform
MWP Control
Room
108
HOM
(Hang Off Module)
MCR
(Master Control Room)
109

150Te starboard sheave
Stern roller
110

360Te capstan winch
360Te wire storage drum
360Te wire route up

port tower leg
111

Storage in Fwd Carrousel
112
Flex Chute

Flex Aligner
113
Deep Blue Pipelay Capabilities
114
Reel Lay (high productivity)

Lay rate 3280 ft / hr
Pipe sizes Single wall pipe 4 to 18
Pipe-in Pipe, max 8 x 12
J-Lay (large dia, ultra deepwater)

Lay rate: 160 upto 320ft /hr
Single pipe 2 quads/hour
Pipe-in-Pipe: 1 quad / hour
Pipe sizes single wall up to 30
Pipe-in-pipe 10 x 16
Deep Blue Reel Packing Analysis
115

Mobilization
On deck and outriggers
Equipment, Structures, Piles
116
Deep Blue
Outriggers

Straightening Trials and Tensioner Settings
117
Deep Blue Pipelaying
118
Distinctions Between S-Lay and R-Lay

S-lay can lay concrete coated pipe
S-lay can lay in very shallow water (no pipe/moon-pool clashing
issues)
Pipe experiences less strains during S-lay installation (0.3%
overbend strain compared to 2% reeling strain)
Advantageous for SCRs Fatigue (Sour Service)
Can lay large diameter pipelines (>18 OD)
Less residual torque in the pipe during PLET/ILS installation
(Less propensity to rotate)
Pipe production offshore vs onshore
119
Flexible & Umbilical Installations
120

The common methods available to install pipelines are:
Horizontal over gutter from reel winch
Horizontal over wheel from tensioners
Vertical through tensioners
Storage & Packing options
Reels
Carousels
Installation Process
Over-boarding requirements for intermediate connections and accessories
Deck space requirements for flexible/umbilical storage
Damage & Contingencies
121

Horizontal over gutter from reel winch
Lay tension < 20 Te
122

Horizontal over wheel from tensioners
Lay tension < 50 T
123

Vertical through tensioners
Lay tension < 450 T, water depth >75m
124
Flexible & Umbilical Storage

Standard Reels
Outer flange diameter 7.8m, 8.6m, 9.2m, 9.6m.
Standard hub width diameter 4.4m.
Capacity <180 t product
Usually small diameter, short length, typical infield
umbilical or riser in shallow water.
125

Laying baskets (2000T)
Dimensions 17.8m O.D, Hub 6m, Height 7m.
Capacity 2000t product
Usually large diameter, long length, typical
deepwater fexible riser, long control umbilical.
Laying basket 900 T
126
86 reel on an extended cradle
2000t carousel
86 Extended cradle (8.5m)
86 Standard installation cradle (7m)

127
Reel Packing Analysis Portable Reel
LENGTH = 4600m
Umbilical properties
O.D. = 114mm
WEIGHT = 30Kg/m
128
Reel Packing Analysis Quick Reference Graph
Based on 2.5m partition.

Weights shown are the maximum pipe weight to accomplish the volume restriction for each outside diameter.
129

Tensioners
Bi-cat has 2 tracks or 1 track pair
130

Tensioners
Tri-cat has 3 tracks
131

Tensioners
Quad-cat has 4 tracks or 2 track pairs
132

Vertical Lay System (VLS04)
2 Tensioner 4 tracks
270 t Dynamic Safe Working Load (SWL)
Quad mode
135 t Dyn SWL Twin mode
3.68m contact length
280 t Dyn SWL A&R winch
2,500m wire A&R winch
280 t Dyn SWL Hang Off Table (HOT)
6 t SWL Harbor top crane / 12m reach
Min Diameter (Quad Mode)
90mm (3.54)
Min Diameter (Twin Mode)
70mm (2.75)
Max Diameter
600mm (23.6)
Max Opening
1.4m (4.6ft)
133

Portable Pipelay System (PPS01)
2 Tensioner 4 tracks
350 t Dyn SWL Quad mode
175 t Dyn SWL Twin mode
4.23m contact length
400 t Dyn SWL A&R winch
2,750m wire A&R winch
450 t Dyn SWL HOT
15 t SWL Harbor top crane / 15m reach
134
Min Diameter (Quad Mode)
100mm (3.9)
Min Diameter (Twin Mode)
50mm (1.9)
Max Diameter
600mm (23.6)
Max Opening
1.65m (5.41ft)

Example Deck Layout:
Manifold (x2)
Umbilical
Flexible Riser
Manifold
Umbilical
Mudmat
Umbilical
Flexible Riser
2,000t Carousel
135

Infield Umbilicals (x6)
Flying Leads (FL)
FL Spread
Infield Umbilicals (6 reels, 9.2m)
AHC Crane
136
PPS01
2,000t Carousel
Step 1
Unpack the 1st end pull-in end and
route onto the deck
137
Step 2
Route 1st end around horizontal and
vertical deflector
Step 3
Pass 1st end over gutter down
through tensioners

Step 4
Once arrived at HOT, connect 1st
end to pull in wire complete initiation
and lay
138
Step 5
Bring 2nd end over gutter using crane
and hold back winch
Step 6 C onnect 2nd end to A&R winch, open

tensioner and bring 2nd end to HOT

Step 7
Mount bend restrictor & anodes
(flexibles only)
139
Step 8
Secure 2nd end fitting in HOT
Step 9 Complete intermediate or Connector

connection and deploy

Step 10
Connect A&R Winch, take up
tension, open HOT and deploy
through splash zone
140

Infield umbilical packed on reel
Main umbilical trans-spooled in carousel
141
Pipelay/Flexibles/Umbili
cal/Lifting/Subsea
Construction
Subsea Construction & Lifting
142
Subsea Construction
143
Lift Engineering
What is the purpose of a
lifting engineering
assessment?
To understand operational
limitations
Lift is performed in a safe
and efficient manner
Adhere to the Technip
Lifting Procedures
Protect the asset!
144
Lifting
145
Crane Curves
Why use crane curves?
Lifting analysis maximum dynamic line tension
Is the lift feasible? Check against allowable maximum dynamic tension
Vessel mounted cranes have normally three different types of crane curves
Harbour Lift Crane Curves
- Sheltered water lift in port Hs = 0 m
Supply Boat Lift Crane Curves - Vessel to Vessel
Offshore Lift Crane Curves
- Deck & Subsea
What information does a crane curve provide?
Maximum hook elevation
Hook speeds & slewing restrictions
SWL vs Radius
SWL allowable static hook load
Allowable dynamic hook load = SWL * DAF
146
Simplified vs Engineered Rigging Design
147
Technip Lifting Operations Procedure (OOSCRN-010)
148
Pipelay/Flexibles/Umbili
cal/Lifting/Subsea
Construction
PRE-COMMISSIONING
155
Pre-commissioning Scope of Work

FLOWLINE (API, DNV-OS-F101)
UMBILICAL (ISO 13628-5)
Flooding
Interim Test during Storage / Pre Load Out Test
Cleaning
Monitoring during load out/transpooling
Gauging or Caliper Pigging
Post load-out test
Pig Detection
Transit Monitoring
Hydrostatic Testing
Testing prior to deployment
Pipeline Strength Test
Lay Monitoring
Spool/Jumper Leak Test
Umbilical Post Installation Testing
Leak Detection
Hydraulic Pressure Testing & Flushing
Flushing
Electrical Testing
Dewatering
Fiber Optic Testing
Air drying, Vacuum drying or Chemical Conditioning
Flying Lead Testing
Nitrogen Inerting/Packing
156
Umbilical Monitoring & Testing
Air Driven Hydrostatic Test Pumps

Pressure / Temperature
Digital Manometers
Dual Pen P/T Chart

Recorder
Fluid Cleanliness Analysis Kit
Insulation Resistance Tester
Continuity Resistance
Tester (Ohmmeter)
Time Domain Reflectometer
Fiber Optic Test Unit
157
157
Topside Pipeline Pre-commissioning
Typical Dewatering Spread including Air Compressor, Booster, Nitrogen Membrane

Operation Performed from a Support Vessel alongside the Platform
158
Subsea Pipeline Pre-commissioning
Typical Subsea Pigging/Testing Configuration
Subsea Pig Launcher / Receiver

Flooding / Testing Skid Deployment
159
159
Pipeline Pre-commissioning
Bi-Di Cleaning and Gauging Pigs
Standalone Pressure / Temperature Subsea Datalogger
Caliper Pig
160
160
Downline Spread (for subsea pigging / testing)
Flexible downline spread
Coil tubing deployment spread
161
PLATFORM TRANSPORT AND

INSTALLATION
162
Platform Installation
Typical Platform Make-up
Vent/Flare Boom
Topside or Deck
Jacket
Risers
Conductors
Piles/
Foundation &
Mudmats
163
Offshore Heavy Lift

Platform Installation - Definitions

Piles
Piles or driven piles serve as a foundation for an offshore platform. Its a steel
tubular member consisting of a driving head, the body & the driving shoe. Piles are
fabricated by welding together rolled steel plates, usually 1.5m in length. The
diameter & pile length depends upon the soil characteristics & magnitude of
loads to be supported.
Jacket
Jacket is a space frame structure made of tubular steel members. The jacket legs
and braces transmit environmental and topside loads into the piles & subsequently
into the seabed. Jackets typically have three, four, six or eight legs. Jackets with
three legs are known as tripods. Jackets with single caisson type leg also exist. The
base of the jacket has mud mats, which increase the bearing surface & thus
support the weight of the jacket in un piled condition.
Conductors
Conductors are tubular steel members housing the casing pipes for the well.
Conductors provides structural support for the internal well tubing and casing
strings. A conductor is installed through the guides of an existing jacket. Lateral
support is provided to the conductor by guides at the platform's horizontal
elevations
164
Offshore Heavy Lift

Definitions
Riser
A riser is the vertical part of a subsea pipeline, which delivers hydrocarbons to &
from the platform facilities above sea. It is a pressurized pipe & runs along the face
of the jacket. Riser may be preinstalled on the jackets, installed offshore or any time
during the life span of a platform. Risers are secured to the jacket by mechanical
clamping.
Deck
The deck is the main visible portion of an offshore platform. A deck can have
multiple levels, each fabricated with a grid of steel beams supported by tubular
columns. Depending upon functions of a platform the deck size varies. A processing
platform has huge deck consisting of separator modules, injection modules,
processing modules, pumping modules, power generation units, controlling office &
accommodation modules as well. The well head platforms on the other hand have
relatively very small decks.
Others
There are some tertiary items that are important for the completion/working of an
offshore platform. These consist of flare booms, boat landings, riser guards, bridges
etc.
165
Offshore Heavy Lift

Jacket Installation Launch Barge (Typical)
166
Offshore Heavy Lift

Jacket Installation Load Out
167
Offshore Heavy Lift

JACKET
Skidding and
Launch Beam
168
Offshore Heavy Lift

WINCHES
TRAILERS
169
Offshore Heavy Lift

Jacket Installation - Loadout
FABRICATION
GRILLAGE
FABRICATION
STANDS
HEAVY DUTY
TRAILER
170
Offshore Heavy Lift

171
Offshore Heavy Lift

Jacket Installation - Seafastening
Based upon the size

of the jacket, loading
criterion, the sea
fastening is designed.
However a typical
looks like as shown.
Tie Down
Brace
Tie downs are subjected to both static & dynamic loading. Gravity & inertial
loads are calculated for all anticipated barge accelerations, angles of roll &
pitch during the design storm adopted for the tow to site. Wind Loads are
also consider for jackets with huge surface area. Computer programs are
used for stress analysis. Manual calculations are done in accordance with
AISC allowable stress criterion & marine warranty guidelines.
172
Offshore Heavy Lift

173
Offshore Heavy Lift

STOPPER
174
Offshore Heavy Lift

DETAIL 2
Jacket Installation Offshore Transportation
For transportation
purposes, a two
phase motion
analysis is carried
out.
Vessel motion response (six degrees of freedom) to regular waves for a

range of wave periods is derived in the form of vessel response amplitude
operators.(RAOs). Then the response to irregular waves is derived from
significant height and wave period. The results shall comply with Marine
warranty specifications, for intact & damaged cases.
175
Offshore Heavy Lift

Jacket Installation - Options
A JACKET CAN BE LOWERED INTO WATER IN THE FOLLOWING WAYS
176
Offshore Heavy Lift

Jacket Installation - Launch

Once at location the transportation
barge is ballasted / deballasted to
get the required trim for launch.
Seafastening would already be cut.
The jacket slides down into water as
it gains momentum.
177
Offshore Heavy Lift

Jacket Installation - Launch
178
Offshore Heavy Lift

Jacket Installation - Lift

A lift can be made on either
the stern or on the side of the
construction vessel. Capacity
of an offshore rated crane is
more on stern (considered
fixed) & lesser on the side
(considered rotating).
A lift chart represents the lift
capabilities of a crane. It
defines a capacity for a
specific lift radius & the relative
hook height. It is always
advisable to have reserve
hook height & capacity when
planning a lift.
179
Offshore Heavy Lift

Jacket Installation Horizontal Lift

A horizontal lift refers to the jacket
lifted horizontally off the
material/cargo barge. A horizontal
lift is always followed by upending.
There are always two different sets
of rigging for lifting & upending in
this case.
180
Offshore Heavy Lift

Jacket Installation Vertical Lift

A vertical lift refers to the jacket
lifted vertically off the
material/cargo barge. a vertical
lift doesnt require upending &
saves the need of another set of
rigging. Lift chart shall be
thoroughly checked when
planning vertical lifts.
181
Offshore Heavy Lift

Jacket Installation - Lift Plan Example
182
Jacket Installation - Upending
A Jacket can be Upended in the Following Ways
183
Offshore Heavy Lift

Jacket Installation Self-Upending
Large jackets have extensive

ballasting & control systems
installed to permit flooding &
venting.
The sequence of flooding
and venting is predetermined
for safe upending of the
jacket.
The jackets may require
external/detachable
buoyancy units to assist free
floating & keep the center of
buoyancy above the center of
gravity, to ease self
upending.
184
Offshore Heavy Lift

Jacket Installation Single Block Upending

After the jacket is lifted and
lowered into water, the
upending slings (preinstalled) are hooked to the
crane block.
The crane upends the
jacket as defined by the
procedure.
SLINGS BEING HOOKED
JACKET BEING UPENDED

185
Offshore Heavy Lift

Jacket Installation Single Block Upending
186
Offshore Heavy Lift

Jacket Installation Double Block Upending

For shorter, horizontally
loaded jackets, upending
can be done in air. This
can be done if the crane
has two independent travel
blocks & both rated for the
calculated loading.
The lift shall be planned
such that, both blocks &
rigging stay clear of each
other at all times.
Ideally both the blocks shall
fall straight to connect to
lift/upending slings.
187
Offshore Heavy Lift

Jacket Installation Double Block Upending
MAIN BLOCK AUXILIARY BLOCK
188
Offshore Heavy Lift

Jacket Installation Setting On Bottom

Once upended the jacket has
to be maneuvered to the
TO
proposed location on the
seabed. The jacket is brought OPERATE
closer to the proposed location
& lowered within the installation
tolerances.
Normally the jacket legs are
closed on both sides, having
positive pressure & have to be
flooded (using reach rod)before
setting it down.
REACH
ROD
Flooding can also be done

during upending through a
manifold installed on top of
jacket.
189
Offshore Heavy Lift

Jacket Installation Setting On Bottom
Connecting hoses to
flooding manifold,
before upending.
Removing flooding
manifold post
upending. Jacket set
on bottom.
190
Offshore Heavy Lift

Jacket Installation - Piling

Once the jacket is set on
bottom, a temporary
connection/walkway is
established. The walkway is
called the gangway.
Normally the jacket legs on
top are closed & have to be
prepared/opened for piling.
This refers to removal of
closure plates.
There is no access around the
jacket legs in most of the
cases thus, temporary access
platforms have to be installed
or scaffolding erected.
191
Offshore Heavy Lift


Generally the first section
of pile for any leg is
labeled as P1 for that
particular leg. The
following sections have
same denomination.
For smaller jacket P1 can
penetrate below seabed
to support itself, but for
longer jackets the weight
has to be supported by the
jacket itself.
Based upon the jacket on
bottom stability response,
piling sequence is
suggested and has to be
followed on site.
192
Offshore Heavy Lift

ON BOTTOM STABILITY EXTRACT

MIN SAFETY
FACTOR IN ANY
OF THE CASE
SHALL BE
1.2

Piles are transported on
the cargo barges. Piles
have to be upended from
the horizontal position &
then inserted in the jacket
legs.
The self weight of the pile
induces bending stresses
in the pile & shall not
exceed the allowable.
If the stresses are beyond
allowable, multiple lift
points are required during
upending of the pile.
193
Offshore Heavy Lift

The pile is upended from one end

using an internal lifting tool (ILT).
The ILT has serrated reciprocating
gripping surfaces which engage to the
inside of the pile.
Jacket Installation Pile Upending
INTERNAL
LIFTING TOOL
PILE
PILES ON
DECK
194
Offshore Heavy Lift

Jacket Installation Pile Stabbing

Generally the P1s are the
longest section in the entire pile
make. Pile makeup is detailing
of whole length of pile, number
of sections, drive shoe, drive
head, bom etc. The P1s are
lowered directly into the leg &
have the drive shoe at front.
The jacket legs at the bottom
have sealing diaphragms.
Sometimes the drive shoes
have small wedges to easily
pierce through the diaphrag.
Pile On Speed
195
Offshore Heavy Lift


The subsequent pile sections
have preinstalled guides, which
eases stabbing as well as align
the latter pile to the former pile.
The suspended weight of the
pile induces a bending moment
(as shown).
The length of the pile sticking
up from the point of reference
is called the Stickup. It is
generally taken from the first
horizontal brace elevation.
Stabbing guides are designed
to withstand the bending
stresses.
196
Offshore Heavy Lift

Jacket Installation Piling

The stabbing guide serves no
purpose once the welding is
complete between two piles.
STICKUP
The pile itself shall also be

capable of withstanding the
bending stresses due to self
weight. The hammer weight
constitutes the maximum to the
bending moment as it is placed on
the pile top. Thus the bending
stresses at the point of reference
shall consider self weight moment
& moment due to weight of the
hammer & hoses etc.
The calculations are based upon
API RP 2A.
197
Offshore Heavy Lift

Jacket Installation Piling & Welding

The pile sections are welded
together & checked for any weld
flaws using ultrasonic testing.
A hydraulic hammer is used to
hammer the piles into the
seabed. The size & rating of the
hammer is based upon the
resistance to driving predicted
during the driving.
The principle behind pile driving
prediction & hammer selection
is the wave equation analysis.
GRL WEAP is the leading
software used to do the
drivability analysis.
198
Offshore Heavy Lift

Jacket Installation Piling

When all piles are stabbed
& sticking up, care shall
be taken that there is
enough space available
for the hammer to be set &
that the piles are not
clashing with each other.
This shall be done during
the engineering stage,
prior to fabrication of piles.
199
Offshore Heavy Lift

PILING IN
PROGRESS
PILING COMPLETED
200
Offshore Heavy Lift

Jacket Installation - Leveling

The jacket shall be installed
within the installation
tolerances.
The jacket levels are checked
after initial setup, during piling
& post piling.
If the jacket is out of tolerances
in level, the jacket has to be
leveled. The jacket side which
is high is either pushed down
or the lower side is pulled up
using hydraulic jacks.
another method is the direct
hookup method. The lower
side is picked up by crane.
201
Offshore Heavy Lift

Jacket Installation - Leveling
Once the required levels

are achieved the jacket is
secured to the piles using
temporary dog plates or
tension bars.
Typically, for a four legged
jacket, to continue piling
any two diagonal legs shall
be dogged at all times,
post leveling.
The dog plates & t-bars
shall be engineered for the
anticipated loads.
202
Offshore Heavy Lift


The pile drivability considers the actual location soil report to make accurate
driving predictions. As soil characteristics may vary over a short distance or
there could be localized rock formations, surprises are not uncommon.
The construction vessel shall be equipped with pile refusal remedial
equipment. Refusal is a criterion set forth by API RP 2A & it also depends
upon the usable energy of the hammer, within the allowable pile stresses.
Refusal occurs if there is unforeseen delay between subsequent pile driving
(leading to soil setup) or the pile encounters a rock layer ahead of the shoe.
For such cases a pile top drilling rig is used to remove the soil plug & drill to
the penetration depth.
Drilling is always followed by main pile grouting (re-forming the plug) or
insert piles + grouting, to attain the required foundation capacity. The
annulus between a driven pile & jacket leg is grouted to enhance rigidity &
composite characteristics. It is a two stage process. First, a certain length
is grouted & as grout settles, the remaining length is grouted until the jacket
top.
203
Offshore Heavy Lift

Jacket Installation Pile Top Drilling
204
Offshore Heavy Lift

Jacket Installation Leg Grouting
MECHANICAL/WIPER TYPE
INFLATABLE TYPE
TYPE OF GROUT SEALS
205
Offshore Heavy Lift

GROUT PLUG FORMATION
Jacket Installation Pile to Jacket Connection

The piles to jacket
connection is done using
either shim or crown plates.
piles are centralized using
temporary wedges before
the crowns are setup.
206
Offshore Heavy Lift

Jacket Installation Pile Top Cut Off

During the course of the
installation a tide gauge is
deployed subsea or installed
on the jacket. The tide gauge
establishes the mean sea
level at that location & the
jacket top elevation is found.
The pile cut off elevation is
marked, relative to the
established jacket top
elevation.
field engineers verify the cutoff calculations & physical
measurements are done
before cut-off.
TIDE GAUGE
207
Offshore Heavy Lift

Deck Installation - Fabrication

THE DECK FABRICATION MOSTLY FOLLOWS THIS SEQUENCE
SIMULTANEOUS
OPERATIONS
ALLOCATED YARD
AREA
FABRICATION
STANDS & GRILLAGE +
CANS
APPROVED
DRAWINGS
MATERIALS
PREPARATION
PAINTING OF ALL THE DECKS &

TERTIARY STEEL
WELDING OF PIPE SUPPORTS,
ELECTRICAL &
INSTRUMENTION SUPPORTS
SUPPORTS
FABRICATION OF FRAMINGS,
LEG EXTENSIONS, BRACES &
COMPLETION OF PLATING
ASSEMBLY OF LEGS & BRACES
MOUNTING OF
EQUIPMENTS , PIPING
& ASSEMBLY OF DECKS
INSTALLING STAIRS,
INSTALLATION AIDS
RUNNING ELECTRICAL
CABLES
RUNNING HYDRAULLIC
& UTILITY LINES
SAFETY EQUIPMENTS &
FINAL PAINT/TOUCHUP
COMPLETION
208
Offshore Heavy Lift

209
Offshore Heavy Lift

210
Offshore Heavy Lift

Deck Installation - Loadout

As described earlier for the
jackets, the decks are loaded
out in a similar way.
Huge decks can be skid on to
the loadout barge using low
friction skid frames, whereas
trailers are more widely used.
211
Offshore Heavy Lift

Deck Installation Offshore Options

DECKS CAN BE INSTALLED IN THE FOLLOWING WAYS
SINGLE
LIFT
FLOAT
OVERS
MULTIPLE
LIFTS
DECK INSTALLATION
212
Offshore Heavy Lift

Deck Installation Float Over

Float over is a process
where the deck is lowered
on to the installed jacket
by ballasting/deballasting
the cargo barge/vessel.
Floatover jackets are
designed to receive the
carrying vessel between
the legs.
213
Offshore Heavy Lift

Deck Installation Float Over
214
Offshore Heavy Lift

Deck Installation Single Lift
Decks within the capacity of

the vessel cranes can be
installed in a single lift. The
lift can be made either on
the side or stern, depending
upon the size, weight & list
radius.
215
Deck Installation Single Lift

Some construction barges
have two cranes working
simultaneously to lift heavy
decks. Though the lift is
single, it utilizes two blocks.
Two blocks from a same
crane can also be used for
lighter decks.
It can also be lifted &
installed in tandem, with
two different barges & two
different cranes lifting &
installing in a synchronized
manner.
216
Deck Installation Multiple Modules
The decks can be installed

as modules as well if the
decks are too heavy and too
big.
For example, an eight-legged
deck can be installed as two
four-legged decks & then
joined offshore.
217
Deck Installation - Lift Plan Example
Ventboom, helideck, compressor, equipment

removed from top deck
Access scaffolding installed
Riser pipes, stairs, etc removed and
secured
Rigging installed
Deck leg to Jacket leg weld removed by arc
gouging
Deck lifted and set into preinstalled grillage
on cargo barge
218
Platform Installation - Completion

Once the deck is stabbed,
welding of the deck legs to
the piles is completed.
Boatlandings can be
installed before or after the
deck installation, based
upon planned schedule &
access under the deck
overhang.
Similarly, the riserguards
can be installed before or
after deck installation.
219
Platform Installation - Completion
Vent/flare booms are installed after deck

installation & the piping spool to the flare
boom piping are installed.
Other completion activities include
painting of welded areas, riser hook-ups,
pipe supports, stairs to jacket, swing
ropes, navigation lights, padeye hatch
closing & sealing.
220
Platform Installation - Complete
221
Thank you for your Attention
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Marine Equipment & Operation

David N. EDELSON Senior Project Installation Manager TPUSA

2. Subsea Pipelines Systems Installation Overview

4. S-Lay & R-Lay Pipeline Installation Method

8. Structures Transport and Installation

9. Wrap-up and Final Questions

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About the Instructor

Experience: Over 28 years experience in

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Transportation & Installation

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Shallow Water Field Development Systems

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Deepwater Field Development Systems

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Deepwater Field Development Systems

87,800 10 Gas Pipeline

Dual 15,000 6 insulated flowlines

Subsea Control Equipment (Umbilical, UTA, SDU, Flying Lead)

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Different Types of Rigid Subsea Pipelines

Typically no concrete coatings

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Different Types of Rigid Subsea Pipelines

Typically concrete coated for stability reasons

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Different Types of Rigid Subsea Pipelines

Corrosion coating on outer pipe (3LPP, etc)

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Subsea Structures Installed with the Pipelines

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Risers Connecting Pipelines to Platforms

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Power & Control from Platforms

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Transportation & Installation

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Rigid Pipeline Systems Installation Methods

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What is Reel Lay?

Min Bend Radius

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Comparison between the different methods

Very Shallow to Medium

Deep & Ultra Deep

Export & Trunk

4 60 in (102 1524 mm)

Short to Very Long

On Shore (Spool Base)

1 4 miles / day (1.6 6.4 km)

Slower than S-Lay

Corrosion & Insulation

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S-LAY PIPELINE INSTALLATION

Transportation & Installation

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S-Lay Using G1200 Vessel

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G1200 Principle Dimensions

Depth (freeboard deck)