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Abstract
This paper provides a detailed account of the successful
salvage operation aboard the Saipem 10000 through the
months of September, October and November, 2001.
The target of this operation was the recovery of a
Subsea Blowout Preventer Stack which was buried below the
sedimentary mudline in 6673 feet of water depth. (2034 metres)
The salvage operation involved the Saipem 10000
for 56 days. The equipment and human resources used in the
operation were predominantly belonging to the Saipem
Group.
Wherever applicable, the contribution of external
resources is acknowledged.
The loss of the Subsea system was the result of a
hoist system failure and occurred at the completion of an
exploratory well drilled by Total Fina Elf (TFE) offshore
Equatorial Guinea. The hook weight at the time of the loss
was 575 metric tonnes. The associated marine riser string was
also lost to the sea.
Innovative techniques, many empirical by nature,
were used during the salvage operation. The success of
methods used was achieved thanks to repetitive trial and error.
Persistence paid off and two separate world records were
broken during the salvage operation.
One record was set for the water depth in which high
torque hydraulic tooling was used to disconnect the joints of a
marine drilling riser.
The other record, since then broken by 151 feet, was the water
depth from which the Blowout Preventer Stack (BOP) was
retrieved.
Introduction and Background
The Saipem 10000 is an ultra deepwater drillship which can
operate in water depths of 10 000 feet, has a Class III
Dynamic
80 x 60 feet
60 x 20 feet
200 feet
2 000 000 lbs per rig.
5 000 000 lbs
OTC 15086
Semi
Submersibl
e
Standard DP
Drillship
Large DP
Drillship
Saipem
10000
Displacement (mT)
37000
22000
100000
96455
~ 18000
~ 22000
52800
59400
10 500
19000
25000
39890
Length (feet)
~ 330
534
835
747.4
2 at 3500
6 at 3000
6 at 7000
6 at 5440
6000
20000
22046
Width (feet)
~ 285
80
125
138
5600
4200
15000
18157
5000
6000
20000
11340
42
35
60
39.4
21.5 x 42
26 diameter
80 x 30
84 x 34
Personnel
100
128
200
172
OTC 15086
Figure 5
Weight [kg]
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Joint cumulative number
Total Optimistic wet weight [kg] cumulative
Figure 6
Wet weight per joint
15000
14000
13000
12000
11000
10000
Weight [kg]
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
-1000
-2000
1
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Joint cumulative number
Optimistic wet weight [kg] per joint
OTC 15086
Photograph No. 3
Photograph No.1
Photograph No.2
OTC 15086
Figure 7
Probability & Speculation Hypothesis
of BOP Attitude, following drop event..
1x
Slick
Type B
1x
Slick
Type B
1x
Slick
Type B
1x
Slick
Type B
1x
Slick
Type B
1 x Slick
Type B
ML
1x
Slick
Type
1x
15ft
Pup
Note
BOP
Inst.
Joint
Figure 8
Figure 9
SEABED HARDNESS TEST CHART
120
100
80
60
40
20
0
0
10
15
20
25
30
35
40
45
50
estimation of the depth of the BOP stack from crater depth and
the partially visible instrument joint and 15 foot pup joint.
Representatives from the derrick builder surveyed the
damaged structure to establish the extent of deformation
through the derrick structure with consideration to the
estimated highest value load that would be imposed during the
forthcoming salvage. It was considered that the structure
encompassing the supplementary drill centre was unaffected
then allowing operations to proceed.
An excavation company: formerly called Copipe
Systems Ltd (since renamed PSL Group) was contracted to
supply suitable excavation machines and their operating
personnel to assist in the salvage operation.
Further preparations included the use of a sub bottom profiler
sonar surveying instrument deployed from the Sonsub
Innovator ROVs. (2 identical spreads positioned residentially
port and starboard on the after deck of the Saipem 10000)
This instrument was largely unsuccessful, the visual plots on
surface being extremely difficult to interpret. Adjustments
and recalibration procedures proved to be ineffective.
Certainly the device provided very little information
concerning hardware that was buried beneath the seafloor.
OTC 15086
Figure 10
Crater top view
Sonar View
South
5mt
7mt
10mt
North
Figure 11
OTC 15086
Photograph No.5
OTC 15086
Figure 12
Step 1
Transponder
25m above
JetProp to
aid position
5m 30 min
Step 2
This acoustic positioning plot provided the first
quantatitive value for vertical defletion. The plot
shows that the extension tube of the LMRP flex joint,
the riser adapter and the instrumented jont were around
9.7 degrees from the vertical plane.
6m 15 min
Step 3
SE 146 DEG
LIKELY BROKEN !
PARTIALLY
COVERED BY MUD
MUX CABLE
7m 15 min
ONLY LINES CONNECTED
CRATER
ONLY LINES
CONNECTED
BLACK BOOSTER
RUBBER HOSE
Step 4
10m 15 min
Step 5
ROV
30m
Visibility
OTC 15086
Size of excavation
dictated by soil angle
repose
Figure 15
Phase Two
Soft Seabed
Assumed
position of
wellhead, 20m
from existing
crater.
3m
5m
25m
Approx
North
6
5
4
2a
3
1a
1c
1
10
OTC 15086
North
180 swathe
heading due West
East
West
3 metres
South
North
180 swathe
heading due West
R
West
East
3 metre
steps
North
180 swathe
heading due West
West
East
3 metre
steps
North
Transit distances,
steps and runs to be
confirmed following
analysis of ROV
survey data.
East
West
B OP
South
OTC 15086
11
Figure 20
Crater dwg. after last jet-prop
opt.22.10.2001
30 mt
Bare
Joint, type
A crack
Vertical
Riser Pup
Joint
30
mt
240
ROV
Riser
Pup
Joint
180 swathe
grab South
Due South
Figure 21
0.0m - Mud
37 m
Due North
45
-12 m
180 swathe
grab North
10 m
-16 m
LMRP
STACK
Riser
Pup
Joint
ROV
Figure 22
Due South
52 m
-7m
41
-12 m
North-South Section
- 31.10.01
N
5m
10 m
-16m
LMRP
STACK
12
OTC15086
Figure 23
37 m
45
-12 m
7m
-16 m
10 m
West-East Section - 31.10.01
Figure 24
0.0m- Mud Line
37 m
-7m
15 m
to
bottom
of crater
45
2.5m
-12 m
3.5m
-16 m
10m
LMRP
STACK
OTC 15086
13
Figure 25
14
OTC15086
Photograph No.8
Where:
Cr
p
A
V2
Zero,
increments
ms-1
ascending
Cr
0.5
Cr
0.6
Cr
0.7
Cr
0.8
Cr
0.9
Cr
1.0
Known
Net
Uplift
Const.
Const.
Const.
OTC 15086
15
Figure 26
Photograph No.9
Net weight
(kg)
Weight before
Intervention
5000
0
4500
0
4000
0
3500
0
3000
0
2500
0
2000
0
1500
0
1000
0
500
0
0
1 3 5 7 9 1 1 1 1 1 2 2 2 2 2 3 3 3
1 3 5 7 9 1 3 5 7 9 1 3 5
Joint
Number
Figure 27
Net Weight
(kg)
50000
45000
40000
35000
30000
25000
20000
15000
10000
Joint
Number
5000
0
1 1 1 1 1 2 2 2 2 2 3 3 3
1 3 5 7 91 3 5 7 9 1 3 5 7 9 1 3 5
16
OTC15086
Photograph No.10
Photograph No.12
Photograph No.11
OTC 15086
Photograph No.14
17
Photograph No.16
Figure 28
6 5/8 34.02# S135
D.P. Used pipe.
(Tensile Strength
4727.7 kN)
STRING FOR
BOP
RECOVERY #2
S10000
18/10/01
Photograph No.15
51/2 F.H.
2in. Chicksan
Line or 2in.
Flexible Hose
RISER HYDR.
RUNNING TOOL
500 /750 TON
Fitting to circulate
into the booster
line
18
Photograph No. 17
OTC 15086
Test Pins:
ABBVetco Gray
Tool CDE
Riser Handling /
Test Tool, HMF,
Class H, nom.
21in.
2 each Choke &
Kill, nom. 6in.
15K psi MWP
--------------------1 each Booster
Line, nom. 5in.
5K psi MWP
-------------------2 each Hydraulic
Lines.
nom. 2 7/8in.
5K psi MWP
--------------------1each Glycol line
nom. 3in. 15K psi
MWP
OTC 15086
19
Photograph No.21
Photograph No.19
Photograph No.22
Photograph No.20
Stabbing in
Note the angular difference due to slight stack
deviation from the vertical.
20
OTC 15086
Blue represents
circulation
h
Side Entry
Modified
Riser
Handling
Tool
Riser
Adapter
Flx .Jt
Upper
Ann.
Riser Conn
Lower
Ann
S/B Rams
CS Rams
UPR
MPR
LPR
W/H Conn
OPEN Valve
CLOSED Valve
OTC 15086
Figure 30
Final events depicted
diagrammatically over a
period of 4 days.
21
Day 4 Circulate at 5200 lt.min-1 and overpull 500 mT. Spot with
30MC Hi. Vis. Bentonite pill. Displace out 2nd Hi. Vis.
33MC pill. Stack moves at 445 mT
Day 3 Circulate at 4000 lt.min-1 increasing to 4900 lt.min-1.
Overpull varying between a min. of 200 mT and a max. of
495 mT
Day 2 Circulate at 4900 lt.min-1 increasing to 5200 lt.min-1.
Overpull varying between a min. of 200 mT and a max. of
495 mT.
Day 1 Circulate at 2400 lt.min-1, vary overpull between 170 495
mT.Work string every 1 hours. Increase flowrate to
4000 lt.min-1
Note returns SW side of BOP stack. Monitor Slope
Indicator
Photograph No.24
Photograph No.23
Photograph No.25
22
Photograph No.26
OTC 15086
View of the BOP Stack following jet washing, supported in the BOP
Carrier..
Acknowledgements
OTC 15086
23
Annex 1
6
17
18
SAIPEM 10000
Dropped Riser Configuration,
Composition & Buoyancy Analysis
16
15
19
20
14
24 September 2001
13
Note:
Black Arrows
indicate Optimistic
values, buoyancy
Blue Arrows
indicate
Pessimistic values,
buoyancy
Spaces indicate
HMF riser Box /
Pin Connections
12
11
10
4
5
10
Remnants of
deformed joint cut
with ROV tooling
11
Riser Joints
Debris Pile
12
Remnant
HP
Hose,
Termination
Joint Hyd.
Ring
13
Initial
Disconnection of
HMF Pin / Box
2
14
ML
1
1
24
OTC 15086
Annex 2
SAIPEM 10000
Riser Adapter Vetco.18in. 10M BX164 flange & inconel 635 ring groove
down. Fitted for Vetco HMF Class H
21in. riser. Fitted with:
2 ea. 15K C/K kickouts, nom.6in.
w/#6 CIW clamp hub: BX 154
r/groove, 2 ea. 5K rigid conduits
kickouts: nom. 24in.w/#1 CIW clamp
hub: BX 152 r/groove. 1 ea glycol inj
kickout: nom. 3in. 15K w/#6 CIW
clamp hub: BX 154. 1 ea. mud boost
line kickout w/ 5K hydraulic ball valve:
line nom. 5in. 5K.
RA
SPRING 2001
MBV
5in. ~ 7in.
5in. 300 000 lbs
6 5/8in. 600 000 lbs
KI
OGR IGR
Receiver
Plates:
LBOP / LMRP
UA
HARH4
CI
GI
Retractable Stabs
Shaffer 15M. nom. 3in.
female: internal retract
MNL
Lower Annular Shaffer
S by F Spherical 18in.
10M w / 18in. 10M BX 164 Studded top, 15M BX
- 164 Flange down.
Element: Nitrile, type SL,
rated at 10M.Low Temp
service: -26F
Notice of Modification
December 2000.
Shear / Blind rams fitted with
tandem piston booster
operators..
Poslocks adjusted Jan 01
Flex Joint
LA
SBR
CSR
UIC UOC
UOK
UIK
Pressure
Temp.
Sensor
LOK
3in. ~ 5in
UPR
3in~5in
MPR
LIC
LOC
5in. ~ 7in.
LPR
IGI
OGI
LIK
BOP Connector
Vetco Heavy Duty, rated for 3000m water
depth. with extended neck to fit Vetco SG5
wellhead profile. 18in. 15M BX - 164
flange top.
SFI Code No. 3D31101
HD H4
W/H
18 w/h datum
OTC 15086
25
1 x 6.43 m
1 x 21.10 ft.
1 x 38.86 m
1 x 127.5 ft.
RKB Datum
Figure 1
24.38
80.0
1 x 4.27 m
1 x 14.0 ft.
Keel Joint
1 x 3.26 m
1 x 10.7 ft.
Intermediate Flex.
4.57 m
1 x 15.0 ft.
1 x 6.1m 1 x 4.6m
1 x 20 ft. 1 x 15 ft.
2 x 27.43
2 x 90 ft
1 x 6.1
1 x 20
3 x 27.43
3 x 90 ft
3x 27.43
3 x 90 ft
3 x 27.43
3 x 90
10 x 27.43
10 x 90 ft
22x 27.43
22 x 90 ft
20 x
27.43
20 x 90
1 x 27.43
1 x 90
6 x 27.43
6 x 90
1 x 27.43
1 x 90
1 x 4.572
1x 15
15ft. Pup
Riser Instrumentation Joint
6.1
20.0
6.33
20.77
LMRP
Static x & y inclinometers
14.18
46.53
7.85
25.76
~ 0.8 m
~ 3.8 m
~ 3.0 m
Mud Line
LBOP
18in. Wellhead
18in. W/H Housing
30in. Housing / GRA
Conductor Pipe
26
OTC 15086
Figure 2
Topsides arrangement
prior to event: Loss of
Subsea System
Travelling Block with
12 line reeve - up
Notes
Top
Drive
U it
Bales
Elevator
Riser
Handling
Tool
Not to Scale
Topsides hoist arrangement
shown immediately prior to the
event.
Note that Riser Spider is open to
facilitate continued hoisting.
Keel Joint shown mis aligned
with underside of Diverter
Housing.
Next step in this BOP Retrieval
Procedure is capture and store
the Auxiliary Lines Termination
Joint Hydraulic Ring beneath the
Support Ring.
Though not schematically
shown here, Keel Joint cladding
overlap with the through bore
of the Diverter Housing actually
caused by an out of trim
condition of the vessel.
Landin
g Joint
Telescopic Slip
Joint
Riser
Spide
Rig
Riser
Gimba
l
Diverter
Housing
Riser Gimbal
Shock
Absorbers
Rotary Kelly
Support Ring
Keel
J i t
Intermediat
e Flex Joint
Auxiliary Lines
Termination
Sea
Termination
Joint
OTC 15086
27
Figure 3
Topsides Arrangement
immediately following
event, Loss of Subsea
System
Notes
Not to Scale
Top Drive impacted on top of
Riser Spider & Riser Gimbal
Assembly.
Riser Gimbal shock absorbers
compressed to various reduced
heights.
Travelling Block
with 12 line reeve
up. Wireline parted
adjacent to drum
wire anchor. Line
free
D
e
r
r
i
c
k
Port
Riser
Spider
S
t
r
u
c
t
u
r
e
Riser
Gimbal
Shock
Riser
Gimb
l
Diverter
Housing
Bales
Rig
Rotary Kelly
Support Ring
Elevators fractured
and open within
confines of the Diverter
Housing
Sea
28
OTC 15086
Figure 4
Initial Static
Configuration
Riser Sting.
NORTH
Tracked Riser
String following
Dropped Stack
Event.
4
8
Slick to Black
Black to Yellow
1 Grey middle
Slick
GRA
1
9
Riser Debris
and Site of
MUX Cables
1 Square = 10 metres