Pipe Lay

March 2003

Pipelay Equipment

Design and manufacturing of special projects

CONTENTS 1

INTRODUCTION 1.1.

GENERAL INFORMATION

1.2

CONCEPT

1.3

WORLDWIDE

1.4

RELIABLE

1.5

RELIABLE DELIVERIES

1.6

SHORT DELIVERY TIMES

1.7

RELATED

DESIGN SERVICE

EQUIPMENT

EQUIPMENT

2

ENGINEERING

3

DIFFERENT TYPES OF PIPELAY SYSTEMS 2.1

S-LAY -

RIGID PIPE

2.2

J-LAY -

RIGID PIPE

2.3

REEL-LAY -

2.4

C AROUSEL-LAY -

2.5

VERTICAL -LAY -

2.6

???-LAY

RIGID AND FLEXIBLE PIPE RIGID AND FLEXIBLE PIPE

FLEXIBLE PIPE

/

UMBILICALS

4

PIPELAY COMPONENTS

5

REEL-LAY SYSTEM - DEEP BLUE

6

J-LAY SYSTEM - B ALDER

7

REFERENCE LIST

8

CONTACT INFO

WWW .HUISMAN-ITREC.COM 2

1

INTRODUCTION

1.1 GENERAL INFORMATION Huisman Special Lifting equipment b.v. designs and builds equipment for the offshore construction industry. Pipelay is one of the sectors of the construction industry in which Huisman is active. Huisman has gained extensive experience with various pipelay methods, especially with pipelay in deep water. Huisman designs and builds pipelay equipment which is completely customized. The design is generally made, based solely on conceptual ideas of the client, functional requirements and information on the vessel to be outfitted with a pipelay spread.

1.2 CONCEPT DESIGN TURN K EY DELIVERY

TO STARTUP OF OPERATIONS

-

Huisman delivers pipelay equipment tailored to the needs of the client. All engineering is done in our main facility in Schiedam, The Netherlands. Fabrication is done in our workshops in The Netherlands as well as in the Czech Republic. Final assembly takes place in The Netherlands again. Our facility in Schiedam is located at a deep water berth. This means that installation of the equipment on board can be done at the Huisman quay. All equipment is tested during harbor and seatrials, prior to handover to the client. Our engineers may remain on board during the first commercial operation of the system, for assistance, trouble shooting and training of clients personnel. In other words, you may expect Turn Key delivery of an entire pipelay system on board of your vessel.

1.3 W ORLDWIDE

is necessary to maintain total control over all aspects of the project. This is achieved by combining engineering and fabrication and by having in-house expertise related to every aspect of the project. Because we do both engineering and fabrication, both activities can be done concurrently. This eliminates interface problems and allows considerable reduction of delivery time.

Huisman is one of the very few companies that do not have to rely on 3rd parties for engineering or delivery of key elements of a project, nor for operating, maintaining or servicing the equipment after delivery.

1.6 SHORT DELIVERY TIMES The experience gained with previous projects, as well as the fact that engineering and fabrication are completely integrated and take place concurrently where possible, make it possible to deliver in very short time.

1.7 RELATED EQUIPMENT Huisman provides other equipment besides pipelay related equipment, such as for instance various types of cranes, handling equipment for pipe, templates, ROV launch systems etc. This allows Huisman to consider other aspects of the pipelay process as well. This may for instance be pipe transfer from pipe carriers or pipe handling on board. A complete systems approach is possible which may result in optimization of the entire spread on board.

SERVICE

Huisman provides worldwide service for installations delivered. Our service bases are in Holland and in the Gulf of Mexico area. Besides regular service, we also do upgrades and various modifications as required, anywhere in the world.

1.4 RELIABLE EQUIPMENT The equipment delivered by Huisman usually is the core equipment on board the offshore construction vessel. Equipment failures in that case immediately cause the vessel to be idle. Equipment reliability is therefore of prime importance. All equipment is thoroughly tested in the workshop, prior to installation on board. The time the vessel is required for commissioning the equipment is minimal that way. The shoptesting program is aimed at keeping the start up period of a new system as short as possible. The pipelay installations delivered by Huisman so far have demonstrated to work with very little or no downtime due to equipment failures.

1.5 RELIABLE DELIVERIES Huisman has a long track record of delivering large scale and complex projects in time. Delivery against Lump Sum prices avoids costly budget overruns. In order to assure this deliver reliability, it

800t Mast Crane for Pipelay Barge Jascon 5, CPL 2003

3

2 ENGINEERING

3 DIFFERENT TYPES OF PIPELAY SYSTEMS

Huisman will take complete responsibility for all aspects of a project. In order to be able to do that, we have in house expertise of all disciplines involved. This allows us to maintain control over every part and phase of a project which is necessary to meet, both a short delivery time and a properly functioning installation. Huisman may provide the following engineering services in relation to pipelay systems: -

concept development basic and detailed engineering mechanical / hydraulic / electrical engineering pipe bending and straightening analysis control systems design, including 3rd party equipment evaluating motion behavior of the vessel workability analysis vessel engineering related to integration of the equipment on the vessel - FMEA analysis

As pipelay moved into deeper water, vertically oriented integrated pipelay systems where introduced. This was a radical change of the face of the pipelay industry. The majority of these deepwater pipelay systems were delivered by Huisman. In this chapter the different basic types of pipelay systems are shown. Most pipelay systems are according to any of these layouts. Also combinations are possible however. Especially combinations of J-lay and flex-lay, or reel-lay and J-lay have been made. Also other combinations are conceivable. Typical layouts of J-lay and reel lay systems, indicating the main system components, are shown on page 10 and 12.

3.1 S-LAY -

RIGID PIPE

Pipe joints are welded in a horizontal position. The pipe is guided to the seabed over a stinger with large bending radius, which maintains pipe bending in the elastic range. The pipe is lowered using tensioners.

S-lay

MAIN ADVANTAGES:

- high production rate because welding is done at multiple stations simultaneously - no plastic bending of pipe - allows laying of concrete coated pipe MAIN DISADVANTAGES: - very long stinger required when laying in deep water - large vessel thrust required in deep water

The development of the Saipem J-lay tower: from design, by atist impression to ‘the real thing’

3.2 J-LAY -

RIGID PIPE

Pipe joints are welded in an inclined position, corresponding to the top angle of the pipe catenery to the seabed. The pipe is lowered with a traveling block engaging with collars on the pipe. MAIN ADVANTAGES:

- no or smaller stinger required - no plastic bending of pipe MAIN DISADVANTAGES: - low production rate due to single station welding and coating - collars on pipes required (costs)


The disadvantages can be mitigated with a 2 workstation layout. This increases the layrate and it allows pipelowering with tensioners. A much larger height of the tower is required however. Lay speed can also be increased by using longer pipe stalks. This also increases the required tower height.

3.4 C AROUSEL -LAY -

RIGID AND FLEXIBLE PIPE

Large lengths of pipe are welded onshore and spooled on horizontal reels on board the lay vessel. During pipelay the pipe is unspooled from the carousel. Straightening of the pipe is required before it is over boarded.

J-lay Carousel-lay

MAIN ADVANTAGES:

- very high production rate - pipe welding onshore under controlled circumstances MAIN DISADVANTAGES:

3.3 REEL-LAY -

RIGID AND FLEXIBLE PIPE

Large lengths of pipe are welded onshore and spooled on vertical reels on board the lay vessel. During pipelay the pipe is unspooled from the reel. Straightening of the pipe is required before it is over boarded.

Reel-lay

- dedicated spoolbase required for pipe preparation - pipe is bend plastically - tensioners need to move vertically to match the pipe elevation - very long stinger required when laying in deep water

3.5 V ERTICAL-LAY -

FLEXIBLE PIPE

/

UMBILICALS

Flexible pipe is stored on reels, carousels or baskets. During pipelay the pipe is unspooled over a tower. A vertically mounted tensioner lowers the pipe to the seabed.

Vertical-lay - flexible pipe

MAIN ADVANTAGES:

- very high production rate - pipe welding onshore under controlled circumstances MAIN DISADVANTAGES: - dedicated spool base required for pipe preparation - pipe is bend plastically - laying of concrete coated pipe impossible

MAIN ADVANTAGES: - pipe is not bend under tension - equipment is portable - location on stern, side or at moonpool MAIN DISADVANTAGES: - not suitable for rigid pipe

5

3.6 ???-LAY - RIGID PIPE / FLEXIBLE PIPE

pressure. In general tensioner configurations for different applications are as indicated below.

/

PIPE IN PIPE

/ ‘???

PIPE’

New concepts developed by our clients may be realized. Huisman will use the expertise gained with previous projects to assist with the development of any new concept.

‘???-lay’

Type of pipe

l l a a i c n t r t f s f s o o k i z v e e p a d r o a c r p / n h o t r t y

rigid pipe - concrete coating rigid pipe - no concr. coating flexible pipe umbilicals

H H/V V H

2 2/4 4 2

r s l e l r o

e r e e z s u e u e s s q p r

PU on springs PU fixed Cast Iron fixed PU fixed

low moderate high low

4 track tensioners with high squeeze load capacity are very compact. 2 track tensioners for low squeeze loads are very large machines, in relation to their tension capacity. Huisman has delivered the following tensioners so far: 2 tracks: 20 / 37t 4 tracks: 60 / 75 / 160 / 275t A total of 24 tensioners have been delivered over the last 5 years 275t tensioner

4 PIPELAY COMPONENTS Huisman has delivered complete pipelay systems as well as individual system components. Typical components for pipelay systems, delivered are: -

Pipe tensioners A&R winches Hang off clamps Pipe straighteners Line up systems Pipe storage reels Carousels Pipe handling equipment, lifts, conveyors etc. Pipe transfer cranes Stinger handling systems

4.1 PIPE

TENSIONERS

Tensioners are the central element of most pipelay systems. Their function is to hold the weight of the pipe hanging off the vessel to the seabed, while paying it out at controlled speed. The type of tensioner required, depends on the type of pipe to be laid as well as the configuration of the lay system. Tensioners may be divided in track type and linear tensioners. Both types of tensioners are patented.

Our tensioners are of a modular design. This means that configuration changes between 4 and 2 tracks are possible. The tensioners further are extremely compact.

LINEAR TENSIONERS Linear tensioners have been proposed for applications where a very high tension is required. These tensioners work according to the moving clamp principle. Specific to this type of tensioners is that they operate with a very high squeeze pressure. A disadvantage of the moving clamp principle is that it reduces the production speed. Huisman has delivered and tested a 400 ton moving clamp which would be part of a 1600t tensioner, based on a compact multiple clamp principle.

TRACK TYPE TENSIONERS Track type tensioners for different applications are categorized by number of tracks, type of pads that grip the pipe and squeeze


4.2 A & R WINCHES With increasing water depth, the required top tensions increase. The required capacity for Abandon & Recovery winches increases together wit the tensioner capacity. Apart form that, the increased water depth calls for larger cable lengths to be handled by the winch. The typical length of A&R wires for current water depths is 3000 m (10.000 ft). 120t A&R winch for Toisa Perseus, Subsea 7, being tested at the Huisman quay

4.3 H ANG OFF CLAMPS Hang off modules are used in vertically oriented pipelay systems, to hold the pipe during welding of a new pipesection. The capacity has to be sufficient to hold the weight of the pipe, also in case of flooding of the pipeline. Hang off clamps may be made skiddeable to move the pipeline in relation to the vessel. The clamp may support the pipeline using collars on the pipeline, or alternatively hold the pipe on friction.

4.4 PIPE

STRAIGHTENERS

Pipe straighteners are required in case the pipe is reeled. They remove the curvature of the pipe which remains after plastic bending of the pipe on the reel. Straighteners work on the principle of 3 point counterbending of the pipe.

Huisman has developed a traction winch system for this application. The winch is of a unique design, aimed at minimizing wear of the wire. The design is further 300t traction winch extremely compact in relation to its capacity. A&R winch systems have been designed up to 650t pulling capacity. This corresponds to the maximum size of wire, currently available at 3000 m length. Traction winch systems up to 300t have been delivered.

7

4.5 LINE UP SYSTEMS To weld in a J-lay configuration the pipes to each other, line up systems are being developed and built by Huisman-Itrec.

4.6 PIPE STORAGE REELS Large driving systems keep the tension in the pipe while reeled. Storage capacity of the reels can be up to 2500t.

Two carousels below deck

4.8 PIPE HANDLING EQUIPMENT,

LIFTS, CONVEYORS ETC.

Huisman-Itrec has developed for several clients handling equipment: a 16t Pedestal Mounted Offshore Crane for pipe transfer, a welding street for (the new) p.l.v. Midnight Express and several pipe rackers. Storage, transport and handling of pipes can also be done in standard (patented) 40ft sea containers.

4.7 C AROUSELS Flexible pipelaying is mostly done from horizontal reels. These carousels can be stored eighter on or below deck.


4.9

Stinger Handling System being tested in the Huisman workshop

PIPE TRANSFER CRANES

For the further handling of the pipes Huisman-Itrec developed a large variety of pedestal cranes of special designed pipe handling cranes 16t pedestal crane

5 CSO DEEP BLUE PIPE LAY SYSTEMS A N EXAMPLE OF A MULTIPLE PIPE LAY SYSTEM ; J-LAY , LED-LAY AND FLEX -LAY ON ONE VESSEL. REEL L AY (RIGID PIPES) pipe diameters tension capacity speed storage capacity reels

100 - 600 [mm] 550 [t] 33 [m/min] 2 * 2500[t]

FLEX L AY pipe diameters tension capacity speed

100 - 600 [mm] = 4-24 [inch] 550 [t] = 1212 [kips] 33 [m/min] = 108 [ft/min]

J-LAY lengths of pipe tension capacity

48 [m] 550 [t]

total height of structure 65 [m]

4.10 STINGER HANDLING SYSTEMS For S-lay system a stinger is needed to guide the pipe while lowering it to the sea bed. Huisman-Itrec developed a stinger handling system to control the angle and position of the stinger.

REE-

= 4-24 [inch] = 1212 [kips] = 108 [ft/min] = 2* 5500 [kips]

= 160 [ft] = 1212 [kips] = 213 [ft]

tower angle adjustment 30 - 90 [degr] See next page for more info about the components of CSO Deep Blue.

9

10 ton service crane

aligner 20 m diameter

straightener tower angle adjuster

pipe centralizer 2 pc main pipe reels 2500t cap.

275t tensioner reel drive unit

pipe centralizer 150 ton A&R winch

275t tensioner 40 ton tensioners for pipe spooling pipe deflector

Hang Off Clamp

300

ton

A&R

winch (traction type)


Reeled, flex and J-lay systems on Deep Blue, CSO, 2001

11

6 J-LAY SYSTEM B ALDER


13

7 REFERENCE LIST

r a e Y

y n a p m o C

l e s s e V

e p y T

6 9 9 1

Stolt Offshore

Seaway Falcon

rigid pipe

7 9 9 1

Halliburton Subsea

misc.

7 9 9 1

Halliburton Subsea

m te s y S

r t e e m . ia p d a c e n ip p io . s x n a e M T

flexible pipe

horizontal firing line 12" adjustable ramp reel drive system 16"

10t

Toisa Perseus

flexible pipe

Vertical lay system

16"

120t

-- tensioners

Halliburton Subsea

Toisa Perseus

flexible pipe

carousels

16"

20t

--

8 9 9 1

DSND

Lochnaghar

flexible pipe

bundle lay

16"

110t

-- tensioners

9 9 9 1

Stolt Offshore

Seaway Eagle

Vertical lay system

60t

-- tensioners

9 9 9 1

110t

-- tensioners

9 9 9 1

2000t tensioners

7 9 9 1

75t

t o le b a e d r a g p U

m t e s y s g r in e w lo e ip P

DSND

flexible pipe rigid pipe Kommander 3000 flexible pipe

bundle lay

16" 5" 16"

Saipem

S7000

J-Lay System

32"

525t

Reel Lay J-lay

16" 26" 16" 30" 30" 16"

550t 550t 550t 1050t 525t 160t

1 0 0 2

rigid pipe

Coflexip Stena Offshore CSO "Deep Blue" rigid pipe rigid pipe flexible pipe 2 Balder rigid pipe 0 Heerema 0 2 rigid pipe 3 0 Torch Midnight Express rigid pipe 0

J-lay - quad joints J-lay - hex joints Reel Lay

2

Seaway Falcon

Toisa Perseus


300t tensioner 40t direct from reel

--

-- tensioners 880t winch system -- tensioners -- winch system 800t winch system -- tensioners

Seaway Eagle

Midnight Express

Saipem 7000

15

Overview of the Huisman office and quay, with the loadout of the J-lay tower for Balder, Heerema 2002

Huisman-Itrec P.O.Box 150 - 3115 HH Schiedam Admiraal Trompstraat 2 - 3115 HH Schiedam Harbourno. 561 The Netherlands Telephone: +31(0)10-245 22 22 Fax: +31(0)10-245 22 20 E-Mail: [email protected] Internet:http:\\www.huisman-itrec.com Huisman US Inc. 801 Travis suite 2100 Houston 77002 TX USA Tel: + 1 (0) 281 586 7676 Fax: + 1 (0) 281 586 7878 E-mail: [email protected] March 2003 Huisman Special Lifting Equipment B.V including its subsidiaries and/or affiliates. This leaflet is distributed by Huisman Special Lifting Equipment B.V. (Huisman) and may not be copied, reproduced, distributed or disclosed to or by any other without the express prior written authority of Huisman’s Management. This leaflet shall not be deemed to make any representation or warranty as to the accuracy or completeness of the information reflected therein and may not be used for any other purpose than to invite Huisman’s sales department in writing to provide additional information. On the products as described in this leaflet, patents are pending, three dimensional marks can be reserved by Law as well.

Design and manufacturing of special projects

Pipe Lay

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