The different phases of a subsea lift from an offshore

construction vessel
Nord Stream Project
48 Midline Tie-Ins & Hyperbaric Welding
Arild Nedland Project Lead Engineer (Nord Stream Project)
Subsea Lifting Operations, Stavanger 04 December 2012
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Table of contents
1. Introduction of the Nord Stream Project.
2. Technip Scope of Work.
3. Project Execution (Animation)
4. Project Engineering
5. Offshore Lifting Operations
6. Summary & Recommendations
Introduction of the Nord Stream Project
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Nord Stream The new gas supply route for Europe
Nord Stream AG, is an international consortium of five
major companies established in 2005 for the planning,
construction and subsequent operation of two 1.224-
kimometre natural gas pipelines through the Baltic Sea.
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51%
15.5% 9% 15.5%
9%
Nord Stream Project
Nord Stream The new gas supply route for Europe
2 off 48 Gas Trunk lines from Russia to Germany
(World largest offshore pipelines ever laid & hyperbarically welded!!)
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Nord Stream Project
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Nord Stream Pipelines
KP
1220
KP 675 KP 297 KP 0
220 bar 200 bar 170 bar
34.6 mm 30.9 mm 26.8 mm
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Line 1 & Line 2
Worksites
Rock dumped
Line 1
Line 2
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Gravel Berms
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Pipeline Receivers / Launchers
48Pipeline Receivers&Launchers
Length 25m
Dry weightinAir 52Te
WaterfilledweightinAir(splashzoneincl plugs) 78Te
Technip Norge AS - SOW
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2011: Pipeline 1
Performed hyperbaric tie-in at KP 297 - Finland
Performed hyperbaric tie-in at KP 675 Sweden
27th of May 27th of June 2011 (58.75 days)
2012: Pipeline 2
Perform hyperbaric tie-in at KP 297 - Finland
Perform hyperbaric tie-in at KP 675 - Sweden
21st of May 7th of June 2011 (46.88 days)
Technip Scope of Work
Technip Norge was awarded in 2010 to perform; management,
engineering and tie-in works for Pipeline 1 & 2, while PRS
Technip was awarded to perform the hyperbaric tie-in (HTI)
welding operations for Pipeline 1 & 2.
The PRS hyperbaric welding spread was provided as a CPI
item to Technip Norge AS for execution of the hyperbaric welds.
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Tie-In Vessel DSV Skandi Arctic
Principal dimensions
Length overall 156.9 m
Length BP 137.7 m
Breadth 27 m
Diving system
Depth rating at 350 msw
24 divers in saturation
2 off bells
Cranage
Main hoist 400 Te at 11 m (harbour lift)
Auxiliary hoist 30 Te at 46 m
Additional lifting facilities
58 Te at 11 m (harbour lift)
5 Te at 15 m - Provision Crane
2 x 5 Te - Offshore cranes
Deck space
1,700 m at 10 Te/m
Accommodation
140 persons in 99 cabins
ROV
1 x 1500m Observation Class ROV
2 x 3000m Work Class ROVs
Pipeline Repair System (PRS) Spread
Hyperbaric Welding
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Hyperbaric welding is the process of welding at elevated pressures,
normally underwater. Hyperbaric welding can either take place wet in the
water itself or dry inside a specially constructed positive pressure
enclosure and hence a dry environment (Welding Habitat)
PRS - Pipe Handiling Frames (PHFs)
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PHF03
PHF07(Newbuild)
PHF04
PHF03 PHF04 PHF07(new Build)
Weightinair 82Te 86Te 82Te
WeightSubmerged 69Te 73Te 72Te
Liftingcapacities 120Te 120Te 150Te
Dimensions 13x7x7.6m 13x7x7.6m 12x8x11m
Welding Habitat
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The hyperbaric welding habitat is basically an open bottom cubic box, which is fixed to an alignment frame with 4 pins. The
alignment frame and habitat is supported on the seabed by 4 hydraulic lateral legs designed to compensate for seabed
irregularities and adjust for pipeline axis. The habitat has mating facilities for the power & control module (POCO), and the
transport container (TRACO).
PRSWeldingHabitat
Dimensions 10.5x6x5.3m
Weightin Air 90Te
SubmergedWeight 72Te
Air Lift Bags (ALBs)
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Supplier: Seaflex (UK)
All air lift bags comply with IMCA D016-044 (AIR LIFT BAGS)
Supplied with
Inflation/deflation valves
Single point steel lift rings
Bottom operated dump valves
Air compressor spread (2 off)
onboard to inflate airbags
20TeALB
Dimensions 3.2mx5.5m
Product 20Te
Quantityusedforeachpipeline 68off
TotalALBsmobilisedonboard 32off(incl spares)
ALBs used to support PHFs during lifting operations
5Te
20Te
Footer can be customized 17
No Hyperbaric rescue receive facility in the
Baltic's that could receive the Skandi Arctic`s
HLB (Hyperbaric Life Boats).
A Modular Hyperbaric Rescue Receive
Facility (MHRRF) was built by Technip.
Located at Hargs Hamn in Sweden at equal
towing distances from the two tie-in
locations.
Hyperbaric Rescue Facility
48 Midline Tie-in & Hyperbaric
Welding Operations
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QUAY AREA
Mobilisation (Killingy)
Harbour Security
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PPE free access
Parking area
Project storage
area
Gas bank for
bunkering
PRIORITY ITEM
(POCO LARS, welding
container ,IPCON
LARS)
Storage areas for
habitat , PHFS
Mobilisation (Killingy)
Quayside Layout
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Premobilisationchecklist
MainPRSitemssuchasthePHFsandHabitatwere
postionedonquaypriortoarrivelofSkandiArctic
ThePRSequipmentwerelocatedatquaysidewithina
securearea,andinreachofthevesselmaincrane.
SkandiArcticmooredupstarboardside.
Projectfamilirisation
ConductmobilisationasperMobilisationManual
Mobilisation
Quayside Layout
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Mobilisation
Deck Layout
Mobilisation
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Deck Layout
PHF07
PHF03
PHF04
Habitat
Crowededdeck(tripandfallhazards)
PRSweldingspread,Subcontractor&projectspreads
Aircompressorspreads
Tuggerwinch spread
Dredging spread(WROV)
Pipeline cuttingspread
Mobilisation
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Seafastning Focus Points
Heavy & Swing Loads
Simultaneous Operations
Working at Heights (mobile lift )
Hook-up of 3rd Party Equipment to Ships Supply
Familiarisation Of 3rd Party Contractors about the project
Drop objects
Housekeeping
Welding, Burning & Sea fastening/securing Equipment
Communications with underdeck fire watchers
Welding in the wet weather (build weather protection)
Mobilisation
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Seafastning
Seafastningcalculations(allitems)
Inspectandcheckdocumantionofallequipment/spreads
tobemobilised
Powercables(HighVoltage) Protectioncover/grating
Bumperwalls
Safewalkwaysroute
Seafastning:Subcontractor(MPI,NDT&loadtest)
Finalinspectionofdeckbeforedeparture.
Transittoworksite
Transit Route
KP297
1st Tie-In Location
Norway (PRS Hagesund)
KP675
2nd Tie-In Location
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Animation Video
Also available on
Engineering
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o Project mangment incl HSEQ & Mangement
o Project Engineering
o Interface Mangement
o Logistic and Procurment mangement
o Pipeline Tie-in analysis work, incl verification of gravel berm design
o Lifting analysis to determine weather limitations for all lifting operations
o Offshore Operations
o As- Built documentation
Engineering
Main Engineering Scope
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Extensiveanalysisscope.
Variousanalysiswereperformed:
AsBuiltGravelBermStabilityAnalysis
GeotechnicalAnalysis(Soilandbearingcapacities)
SensitivityAnalysis(Worstcasescenarios)
Pipeline&AlignmentTieinAnalyses
Software:Orcaflex
TieInanalysishadamajorimpactonthefollowing
areas:
Pipelineconfigurationsandlimitations
CapacityandlimitationsofthePRSspread
Limitationsofthepipelinewhenliftedandshifted
(BendingMoment,Pipelinestressesetc)
LocationofPHFs,WeldingHabitat&AirliftBags(ALB)
Weldingheight
Tie-In Analysis
Tieinanalysiswasthekeyengineeringareafortheproject
Engineering
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AnAsBuiltGravelbermstabilityanalysiswas
performed.
Slope stability analyses of the asbuilt configuration.
Adequate design of gravel berms to prevent punch through
failure due to high loads, poor consolidation etc.
Punch through bearing capacity analysis
Sensitivety studies for PHFs and estimation of max.
Vertical & lateral load of lifted pipeline:
Lateral offset distances
Lift heights without causing bearing and slope failure.
Engineering
Geotechnical Verification Analysis
The analysis was performed to calculate the loads acting on the PHFs
during the whole operation and the loads acting on the pipelines
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The output from these sensitivity studies was the
allowable maximum vertical load of the pipeline
considering various offset distances of vertically
lifted and laterally shifted pipelines.
Geotechnical analysis was performed to identify
the maximum allowable load of lifted pipeline in
order to prevent punch through while lifting
and shifting the pipelines.
Positioning envelope for PHFs
Walking of PHFs
Engineering
Geotechnical Verification Analysis
No punch through failure was ever seen during the lifting operations!!
Airbags Pipeline Support
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Engineering
Large airbags was used to support the pipelines.
Alignment of pipeline ends during tiein.
Reduce overall load of pipelines when lifted and shifted which in turn
reduced the loads on the PHFs and gravel berms.
Increase lifted length of pipeline (Touchdown points)
Tie-In Analysis Output
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Engineering
Final location of PHFs.
PHFs loads
Final locations and qty of airbags
Lifted and shifted lengths of pipelines.
Retraction lengths
Lift and shift tables
Max 20cm sideways and vertical intervals
Tieinanalysiswasbasedonthenominalpipelaytolerancesof7mseperation
Lift & Shift Operations
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Lift and Shift Operations
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Lift and Shift Downstream pipeline towards
Upstream Pipeline Upstream
Mark 3rd rough cut
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2
3
Upstream
Perform 3rd Rough cut
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Pipeline Retractions
Lifted both pipelines to welding height
Marked final cut on Downstream (with overlength of approx 20mm)
Divers marked final cut on Downstream
Retract downstream pipeline 2 times
Define final cut mark on Downstream
Perform final cut
Downstream
Top view
Side view
Final Measurments
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Final pipeline alignment checks performed to ensure
Adequate overlength.
Pipeline configuration.
Ability to retract and align pipeline at welding height.
Lift and Shift Operations
63Te
21Te
45Te
47Te
28Te
45Te
Max Allowable load
on PHF during
retraction: 100Te
Final Alignment
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Final Alignment of pipelines
Ready for Habitat installation
Final alignment measurements was inline with the tie-in analyses
Lift and Shift Operations
Position Habitat
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Lift and slew habitat on deck.
Overboard and lower Habitat thru splashzone.
Lower Habitat to transfeer depth (10m above gravel)
Relocate vessel towards tie-in area.
Lower habitat slowly above tie-in area.
Lift pipeline ends into habitat claws.
Set up habitat (dewater, welding eqp etc.)
Conduct hyperbaric welding
Lift and Shift Operations
Offshore Lifting Operations
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Lifting Operation Flowchart Process
For subsea lifts consideration should be given to operational aspects including clearances, depth
reach capability of crane wire or winch system in the chosen configuration, environmental factors,
vessel and crane tip motions.
Reference is usually made to DNV Rules for Planning and Execution of Marine Operations, Part 2,
Chapter 5
Software in this project: Simplified method (Lifting spread sheet: DNV-RP-H103)
The basic steps of the Technip - Lifting Process Flow Chart are as follows:
Identify lift requirement
Categorise lift (i.e. Routine Lifts and Non Routine Lifts.)
Non- Routine: Straightforward, Difficult and Complex.
Produce Lift Plan (Individual / separate one for each object to be lifted (generic ones might be used, eg. container)
Risk assess lift
Tool Box Talk/Lifting Pocket Card
Carry out lift (When overboarding and lowering loads through water column divers to be located inside diving bell.)
Operational Feedback
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General Guideline
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Lift clearance drawing
Rigging Specification summary
Technip Lifting Procedure - Lift Plan
Offshore Lifting Operations
Offshore Lifting Operations
Engineering - Cover all parts of the lift
Lift from deck of vessel (Deployment)
Lift in air
Lift through splash zone
Lowering
Landing
Recovery
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Planning and exceution of Offshore Lift
Offshore Lifting Operations
Engineering - Cover all parts of the lift
Object description (Weight, shape, CoG & dimension of load/object etc)
Vessel description & Environmental data
Lift rigging design
Deployment installation analysis
Deck layout and routing
Lift Plan
Risk Assessments
Lift from deck of vessel (Deployment)
Crane height vs crane capacity
Installation of lift rigging on deck (work at heights, safety harness, man lift etc)
Removal of seafastening
Overboarding route (clear deck, deck railing, tugger wires, taglines etc)
Weather Criteria (crane tip motions: Wind)
Sequence of lifts
Lift in air
Overboard at a safe location away from subsea assets.
Lift through splash zone
Limitations (crane capacity, slack slings, snap loads etc)
Lowering speed (slamming, slack slings, time to flood members of object etc)
Vessel heading
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Planning and exceution of Offshore Lift
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Deploy PHF03
Deploy PHF04 Deploy PHF07
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2
3
4
Offshore Lifting Operations
Deployment of PHFs
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Perform pre-lift meeting (TBT)
Establish safe overboarding area (-50m)
Use deck support to orientate/guide object (Taglines, winch etc)
Ballast vessel as required (heavy lift)
Use deck barriers (only key personnel)
Lift, slew and overboard object
Lower through splazhsone
Deployment of habitat
Offshore Lifting Operations
Offshore Lifting Operations
Lowering
Lowering in normal sealift mode
Entanglement of wires if used (WROV to monitor)
Lower until object is a few meters above seabed.
Transfer object subsea from lowering location to final location
Orientation clumpweight, guide posts etc required??)
Landing
Installation tolerances (heading, orientation, inclination etc)
Ensure stability of load on seabed.
Reduction of tension in crane wire.
Switch to CT (Constant Tension) immediately after landing
Ensure back tension is sufficient to keep control of inclination during landing (soil penetration /
failure etc)
Come down on tension gradually and switch to empty hook mode.
Disconnect rigging and recover crane once installation requirements are met.
Recovery
Prepare deck, rigging and personnel before recovery
Risk asses / Tool Box Talk / deck barriers, vessel stability etc
Installation of rigging subsea by divers /WROV
Crane capacity after lift off
Suction, entrapped water etc
Establish recovery sequence (safe recovery area)
Recover and seafasten object on deck
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Planning and exceution of Lift cont.
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Carry out a pre-lift meeting
Install lift rigging
Lift habitat clear from gravel/pipe
Offset vessel to recovery area
Recover habitat to 40m MSW
WROV to Install deck tugger
Recover habitat to deck and seafsten
Offshore Lifting Operations
Recovery of habitat
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Recover PHF03
-Deck tugger
Recover PHF04
-Deck tugger
Recover PHF07
-Deck tugger)
Recovery - reverse operation
Offshore Lifting Operations
Summary & Recommendations
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Deployment and Recovery of PHFs & Habitat
Perfect weather conditions for deployment and recovery operations.
Taglines used as support when overboarding PHFs & Habitat
Deck tugger winches was used as support aids to position the Habitat and PHFs on
deck during recovery.
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Summary
Recovery of PLRs & Pipe Sections
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Summary
Hyperbaric Welds (Final results)
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Hyperbaric Welds - Line 1 in 2011
Hyperbaric Welds - Line 2 in 2012
Delivery of gas through Line 1 started in November 2011, and in October 2012 for Line 2.
Combined, they have the capacity to transport 55 billion cubic metres of gas annually.
Important aspects when planning and executing offshore lifts:
Conduct regular meetings with key personnel and sub-contractors in the early phase of project planning.
Get an good overview and understanding of the equipment planned to be used, before and during the
offshore operation.
Integration / Buy in to the engineering from all involved parties (ownership).
Include lessons learned and experience feedbacks from similar/previous projects.
HSE / Safety Plan to avoid working at height and under suspended loads
Deck lay-out, including slewing path and safety / stretch escape routes
Winches and wires for controlling loads in air
Crane capacity curves clearly understood, also for recovery (alarm settings)
Roles / Responsibilities clearly defined and ensure good Co-ordination / Communication with offshore
personnel
Learn from mobilisation (crane settings, ballasting requirements, load handling) and previous experience
/ lesson learned
Plan for Contingencies!
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questions?
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The End