SUBSEA LIFETIME EXTENSION OF A WELLHEAD PLATFORM

Transcription

1 SUBSEA LIFETIME EXTENSION OF A WELLHEAD PLATFORM MAERSK DAN PLATFORM - DENMARK 4 th February 2016, Subsea Expo, Aberdeen Bert van der Velden, Commercial Director 1

2 INDEX 01 INTRODUCTION 02 PREPARATIONS & MOBILISATION 03 SURVEY / PHOTOGRAMMETRY 04 FABRICATION 05 INSTALLATION 06 FACTS & SUMMARY 2

3 BACKGROUND Dan Bravo platform constructed in 1971 Dan field is an important Hub in Maersk Oil Danish Sector infrastructure Platform has structural integrity issues after 30 years lifespan Maersk decided for 40 years lifetime extension program 3 years lifetime extension program started topside and subsea Subsea works awarded to Boskalis Subsea Services 3

4 SCOPE OF WORK Period: 2013/2014/2015 Location: Danish sector, North Sea Scope: Cleaning and 3D Modeling of Jacket (Photogrammetry) Fabrication of reinforcement structures Installation of new conductor guide level, K-node reinforcement clamps, boatlandings and Anode clamps Removal of redundant structures Equipment/Services: EDT Protea (Air/ROV) & Constructor (SAT/ROV) WROV Systems Rope Access, Diamond Wire Cutting, Photogrammetry 4

5 CONDUCTOR GUIDE LEVEL 2 levels to be removed 1 new level to be installed (clamped) Built up from modular/bolted parts to fit in between existing structure 5

6 CHALLENGES Unknown dimensional tolerances of steel structures due to deflections, subsidence Largest Subsea 3D Photogrammetry ever Vessel access underneath platform bridges Weather sensitivity of splash zone works Platform crane of no use Working from 0-45 meters of water depth Air diving 0-25m, splash zone works SAT diving 25-45m 6

7 INDEX 01 INTRODUCTION 02 PREPARATIONS & MOBILISATION 03 SURVEY / PHOTOGRAMMETRY 04 FABRICATION 05 INSTALLATION 06 FACTS & SUMMARY 7

8 PREPARATIONS Thorough preparations were key to success for the project Project site office in Esbjerg, Denmark Site visit prior to engineering/rope access plans Focus on Safety, Incident Free campaign 3D Simulations & Animations for cross hauling and installing of structures within existing jacket structure Detailed engineering of 3D photogrammetry. Special Tooling (jacket cleaning, diamond wire cutting machines, flush grinding of wells) Design & Installation of two auxiliary cranes on the platform jacket to accommodate cross hauling and handshake with vessel crane. Mobilisation of vessels, equipment and personnel 8

9 3D ANIMATIONS CROSS HAULING 9

10 SPECIAL TOOLING DEVELOPED 10

11 TOOLING - FLUSHGRINDING OF WELDS 11

12 AUXILIARY CRANES (2) INSTALLED 12

13 DP3 DSV PROTEA AIR + WROV 13

14 PROTEA DAN 14

15 DP2 DSV CONSTRUCTOR SAT/ROV 15

16 INDEX 01 INTRODUCTION 02 PREPARATIONS & MOBILISATION 03 SURVEY / PHOTOGRAMMETRY 04 FABRICATION 05 INSTALLATION 06 FACTS & SUMMARY 17

17 SURVEY / INSPECTION Survey in of Installation Areas Measuring of clamp installation area Identifying any obstructions Grout valves Anodes Welds Weld CVI Close visual inspection of welds Undercut Defects Corrosion 18

18 3D PHOTOGRAMMETRY 3D Geometry model by subsea photography and computer post processing of images High accuracy required for steel-to-steel reinforcement structures Required cleaning to bare metal of members/nodes Installation of markers by Divers Photography by (W)ROV systems 19

19 3D PHOTOGRAMMETRY Requirements: Member dimensions Angles between members Member ovality Location of welds Height of weld cap Deliverables: Millimetre and sub-millimetre accuracy Reliable results Same accuracy on all three axes 20

20 SOME NUMBERS MARKERS 224 SCALE BARS 351 U-SCALE BARS 2238 SINGLE MARKERS PHOTOS

21 CLEANING & PHOTO-SHOOT 22

22 SOME PHOTOGRAMMETRY RESULTS MEMBER OVALITY (MM) NODE ANGLES 23

23 INDEX 01 INTRODUCTION 02 PREPARATIONS & MOBILISATION 03 SURVEY / PHOTOGRAMMETRY 04 FABRICATION 05 INSTALLATION 06 FACTS & SUMMARY 24

24 FABRICATION (CONDUCTOR GUIDE) 25

25 FABRICATION (CONDUCTOR GUIDE) 26

26 FABRICATION (K-NODE) 27

27 FABRICATION (K-NODE) 28

28 K-NODE FABRICATION INSTALLATION OF SHIM PLATES Contact surface Point loads on weld caps 29

29 INDEX 01 INTRODUCTION 02 PREPARATIONS & MOBILISATION 03 CLEANING / PHOTOGRAMMETRY 04 FABRICATION 05 INSTALLATION 06 FACTS & SUMMARY 30

30 PROXIMITY OF PLATFORMS / BRIDGES 31

31 CONDUCTOR GUIDE LEVEL INSTALLATION 32

32 CONDUCTOR GUIDE LEVEL INSTALLATION 33

33 CONDUCTOR GUIDE LEVEL INSTALLATION 34

34 CONDUCTOR GUIDE LEVEL INSTALLATION 35

35 CONDUCTOR GUIDE LEVEL INSTALLATION 36

36 CONDUCTOR GUIDE LEVEL INSTALLATION 37

37 K-NODE INSTALLATION 38

38 K-NODE INSTALLATION OVERBOARDING & INSTALLATION OF CLAMPS Dedicated lifting frames Outer clamp Inner clamp 39

39 K-NODE INSTALLATION 40

40 CONDUCTOR GUIDE LEVEL INSTALLATION 41

41 K-NODE INSTALLATION (2014) FIXATION OF CLAMPS Outer clamp Inner clamp Bolting system: Rotabolt Tension control Pre-tension Hydraulic tensioning Hydraulic torqueing Tensioning spread components Pump Jacks Reaction nuts PLC data logger 42

42 CONDUCTOR GUIDE LEVEL INSTALLATION 43

43 INDEX 01 INTRODUCTION 02 PREPARATIONS & MOBILISATION 03 CLEANING / PHOTOGRAMMETRY 04 FABRICATION 05 INSTALLATION 06 FACTS & SUMMARY 44

44 SUMMARY & FACTS Lifetime extension: 40 years Weight of new steel installed: 136 MT Number of Markers/bars for Photogrammetry : 2900 Number of Photos taken: Number of Rotabolts installed: vessel days Project personnel: 320 people Manhours: hours LTI (Lost Time Injuries): 0 Video 45

45 FEEDBACK CLIENT 46

46 THANK YOU FOR YOUR ATTENTION 47