offshore platform topsides raising using synchronized jacking · · 2014-04-25offshore platform...
TRANSCRIPT
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OFFSHORE PLATFORM TOPSIDES RAISING USING SYNCHRONIZED
JACKING
John GreevesTechnical Director
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Air Gap is Important!
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If Air Gap is too Small!
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If Air Gap is too Small!
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If Air Gap is too Small!
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If Air Gap is too Small!
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Why Could the Air Gap be too Small
• Original platform design was completed to old codes
• Seabed subsidence has occurred (reservoir consolidation)
• Platform consequence of failure has increased
• Design waves have got bigger (Gulf of Mexico post 2004 & 2005 hurricanes)
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Options for Remediation
• Wave load reduction (remove unused conductors, remove marine growth)
• Local member strengthening (grouting, clamps, additional members)
• Foundation reinforcement (retrofit skirt piles)
• Elevate the topsides
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Facility Damage without Platform Failure (partial success)
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Deck Raising by Jacking
Ekofisk 1987 (6 platforms, 4 simultaneously raised by 6m)
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Deck Raising by Jacking
• Ekofisk
– No additional lateral support
– Handling and installation of leg spools
– Bolted/flanged connections
• USD 600 Million (1987)
• 15,000 people involved at the peak
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Gulf of Mexico 2006
Two drilling/production platforms raised by 4.5m
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Gulf of Mexico 2006
• Two drilling and production platforms had reduced air gap due to seabed subsidence
• Operator planned on field life extension
• Required topsides to be raised by 15 feet (4.5m)
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Top of Jacket Walkway
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Options Considered
• Remove deck, add leg extensions, re-install deck
• Fabricate new replacement deck with longer leg sections
• Raise deck in-situ by jacking (precedence established by Conoco in the North Sea at the Ekofisk field)
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Selected Solution (Proprietary)
• Raising performed by hydraulic jacking
• Synchronized control using PLC (+/- 0.5 inch)
• Introduction of split leg sleeves (NEW)
– Legs fully encapsulated during raising
– Excellent lateral stability
– Redundant jacking solution
– Immediate storm safe pin-off condition
– Sleeves form the permanent leg extensions
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Split Sleeve Configuration
Solution covered by US Patents 7,780,375/8,002,500/8,353,643 and all associated international patents received, applied for and pending
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Bushing and Leg Cut Detail
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Typical Sleeves
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Bushing Installation
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Sleeve Installed Offshore
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Leg Pre-cut
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Well Bay Solution (leave in place)
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Leg Cut Sequence
• Legs are pre-cut 60% of circumference prior to installing sleeves (meets L-2 case)
• Cutting by regular torch
• Final leg cut is made after sleeves have been installed and jacks have been pre-loaded.
• Final leg cuts made through windows in the sleeve
• Continuous lateral leg containment
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Raising Control System
• Extension of each leg measured by 2 string potentiometers
• PLC control system measures all leg motions continuously and varies hydraulic flow to rams each leg as required (0 to 100% control)
• Orange alarm at +/- 0.5-inch out of synch.
• Red alarm at +/- 1-inch out of synch.
• Deck strength checked for +/- 2-inch out of synch
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Design Basis• Each leg cluster of 4 jacks designed as follows:
– Operation continues with loss of one jack
– Operation CAN continue with loss of two jacks
– Jacks are load balanced (common lines)
– Each jack fitted with an onboard counter balance valve (hard piped)
– Ram end support conditions true pins – reduce side load to near zero
– Provide a high capacity pin connection for temporary connection after leg is 100% cut (before and after jacking)
– Lock off leg in final elevation prior to full weld out
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Sleeve Design
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SIT under Full Working Load
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SIT Under Full Working Load
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Platform Raised in 90 minutes
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Typical Schedule
• Rig-up deck – 30 days
– Cut risers
– Cut well bay framing
– Retrofit all jacking steel
• Rig-up 32 rams and controls – 7 days
• Make final cut and jack +14 feet – 4 hours
• Weld out (L-1 condition) – 2 days
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Indonesia 2013
Three platforms & three bridge structures simultaneously raised by 4.0m
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FIELD LAYOUT
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Indonesia
• Complete field undergone subsidence
– Quarters platform
– Production Platform
– Compression platform
– Bridge linked
– Two Flare bridge supports
– Bridge support on the wellhead platform
• To be raised by 4 m to extend life by 12+ years
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Typical Configuration
Very low starting “hook height”
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Design Basis
• All legs full contained within sleeves at all times
• Operation can be performed with the loss of any one ram at each leg
• Fully reversible
• Storm safe pin-off detail
• PLC control of all rams– +/- 0.5 inches between legs per platform
– +/- 1.0 inches between platforms
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Versabar Equipment supply
• 6 no. HPU’s, 2 engines each
• 108 Stage 1 and Stage 2 RAMS 250Te capacity
• Control System and self contained Control Room
• Complement of spares and tools
• Designed and Manufactured by Versabar USA
• Design, Manufacturing x works 1 year
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Bridge Support Structure Raising
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Power Unit Positions
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SIT Under Full Working Load
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Stage 1 Storm Safe Pin-off
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Stage 2 Raising SIT
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Offshore Raising Works
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All decks raised by 4m
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Typical Deck
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Typical Leg RAMS
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Flare Bridge Frames
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Leg Cutting and Pin Assemblies
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Stage 2 Lift Complete
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Offshore Schedule
• Stage 1 rig-up in parallel to other installation works – 3 months, 300 man accommodation work barge
• Stage 1 raise (2 hours), RAM removal (2 days) & weld out (3 days) – Total 5 days
• Stage 2 rig-up – 1 week
• Stage 2 raise (4 hours) & Ram removal and weld out (5 days)
• Recommission platforms – (15 days)
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Closure
• Multiple solutions exist for deck raising by hydraulic jacking (single platform, entire complexes)
• Proven by multiple field applications on a worldwide basis
• Proven to be economic when compared against the alternatives
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Closure
• Scalable solution – 20,000+ tons topside
• High lateral stability
• Redundant configuration
• Reversible operation
• Weather insensitive (compared to other options)
• Fast (leg sleeves become leg extensions)
• Pin-off details provide storm safe condition