Offshore Structure Installation
PRESENTED BY ASEP NURUL HAQ & LUH MADE DINA KUSUMADEWI
Engineering | Procurement | Construction | Installation
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Who we are
Asep Nurul Haq
Luhmade Dina Kusumadewi
Graduates from Teknik Sipil ITB
Both have been working in McDermott, an Oil &
Gas Construction Company for over 12 years
Asep is currently working in Marine Department as
Marine Field Engineer
Dina is currently working in Engineering Department
as Construction Support Engineer
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AGENDA
Offshore Installation
What, How, Who?
What are offshore structures?
How to install them?
What are the activities involved in
installation?
What equipment are involved in the
installation?
Who are involved during installation?
What are the important aspect to consider
during installation?
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THE BIG PICTURE
Offshore Field Production
Life Cycle
Exploration (seismic survey, seismic interpretation,
oil/ gas reserve estimate)
Commercial analysis (cost benefit, ROI) &
government approval for investment (if required)
Tender (Pre-qualification, Invitation to Tender/ Bid,
Technical Bid Evaluation, Commercial Bid
Evaluation)
Project Phase
Award & Project Kick Off
Design & Engineering
Material Procurement
Fabrication & Construction
Load Out
Offshore Installation <- Our focus today
Hook Up & Commissioning
Operation (production, maintenance, apply new
technology to increase production (HDD, fracking))
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EPCI starts with engineering
studies & conceptual designs
front-end engineering & design (FEED)
detailed engineering & design
transportation & installation engineering
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Procurement
sourcing for materials required for fabrication or installation
of offshore structure
engage subcontractors for service required
vessel chartering
equipment rentals
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Construction
jackets, piles & tripods
topsides & central processing platforms
living quarters
TLPs, SPARs, FPSOs
onshore modules
subsea production systems
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Installation
single and dual heavy lift
float-over installation
various pipeline installation
subsea installation support
decommissioning
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THE BIG PICTURE
TYPE OF OFFSHORE STRUCTURES & INSTALLATION ACTIVITIES
Jacket Installation Fabrication, NDT, FJC, hidrotest
Jacket transportation Subsea flange tie ins
Jacket launch/ lift at site FPSO/ TLP Installation
Jacket set down Mooring installation
Pile driving FPSO/ TLP positioning
Jacket leveling Hose/ umbilical tie ins
Pile grouting Subsea Structure Installation
Appurtenances installation PLET/ PLEM/ ILT
Pipeline Installation Rigid Jumper
Vessel positioning (moored/ DP) Umbilical Installation
Beach pull Main umbilical
Pipelay (welding, NDT, FJC) Flying leads
Trenching (pre-trenching/ post-trenching) Topside Installation
Hidrotest Lift
Tie In Spool Installation Float over
Tie in spool/ stalk on Hook Up
Metrology (measurement) Structure/ piping/ electrical/ instrument
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OFFSHORE PROJECTS
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ICHTHYS
Gas-Condensate Field
Development
engineering: more than 500,000 man-hours from engineering
offices across the globe
procurement: $600 million USD of in-field equipment
construction: 48 subsea structures weighing 28,660 ST
(26,000 MT) in total
installation: three deepwater installation vessels utilized over a
3-1/2 year period
First of a Kind
one of the worlds largest subsea gas field developments
Taking the Lead with Safety
recognized for outstanding HSE performance by INPEX
14 million project man-hours without an LTI
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PB-LITORAL-A
Production
Platform
client: PEMEX Exploracin y Produccin
services: engineering, procurement, construction,
transportation, installation, commissioning and start-up
facilities: total weight approximately 12,955 ST (12,000 MT)
location: Litoral Tabasco Tsimin-Xux field, Mexico
water depth: 85 feet (26 m)
yard: Altamira, Mexico
vessels: Derrick Barge 50, Intermac 600
First of a Kind
first float-over performed by McDermott for PEMEX
Taking the Lead with Safety
2.9 million man-hours LTI free
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JULIA
Phase I
Development
client: Exxon Mobil Corporation
services: engineering, procurement, construction and
installation
facilities: subsea infrastructure, wells, manifold, umbilicals,
jumpers, flowlines, risers, pump station, pump modules,
transformer and topsides support equipment
location: Julia Field, Walker Ridge, Gulf of Mexico
water depth: 7,000 feet (2,133 m)
vessels: Derrick Barge 50, North Ocean 102
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OTIS
Deepwater
Subsea Tieback
client: LLOG Exploration Offshore
services: project management, engineering and installation
facilities: 70,000 feet (21,340 m) of insulated rigid flowline and
insulated steel catenary riser, control umbilical, PLEM jumper
and associated flying leads
location: Gulf of Mexico
water depth: 3,861 to 4,420 feet (1,176 m to 1,347 m)
spoolbase: Gulfport, Mississippi
vessels: Lay Vessel North Ocean 105
First of a Kind
first project executed from Gulfport Spoolbase
first installation of a steel catenary riser by Lay Vessel North
Ocean 105
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SAUDI ARAMCO
Lump Sum
Contract
full scale EPCI contract
utilizing specialized shallow water installation vessels and
fabrication yards in Dammam and Jebel Ali
13 jacket and decks
20 platform upgrades/electrification
30 miles of pipeline
104 miles (167 km) of cables and umbilicals
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JACK & ST MALO
Integrated
Subsea Solution
client: Chevron USA, Inc.
services: fabrication and installation
facilities: umbilicals, jumpers, flying leads, pump modules
and stations
location: Walker Ridge, Gulf of Mexico
water depth: 7,200 feet (2,200 m)
yard: Morgan City, Louisiana
vessels: North Ocean 102, Derrick Barge 50
First of a Kind
subsea landing of some of the industrys largest and
complex umbilical end terminations
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PAPA TERRA
Tension Leg
Wellhead Platform
client: Petrobras (with Chevron)
services: engineering, procurement, construction and
installation
facilities: Tension Leg Wellhead Platform (TLWP) hull,
topsides, tendons and risers
location: Campos Basin, Brazil
water depth: 3,871 feet (1,180 m)
yard: Morgan City, Louisiana and Wuchuan, China
vessels: Derrick Barge 50
First of a Kind
first use of dry-tree floating technology offshore Brazil
first Tension Leg Platform installation offshore South America
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SIAKAP NORTH PETAI
Rigid reel
Pipelay
client: Murphy Sabah Oil Co., Ltd.
services: engineering, procurement, construction,
installation and pre-commissioning
facilities: subsea infrastructure, risers, umbilicals, flowlines,
subsea hardware and controls
location: Siakap North-Petai, Block K, offshore Malaysia
water depth: 3,900 to 4,900 feet (1,190 m to 1,500 m)
yard: Batam Island, Indonesia
vessels: Lay Vessel North Ocean105, North Ocean 102 and
Emerald Sea
First of a Kind
first installation of rigid reeled pipe-in-pipe in Asia Pacific
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SU TU VANG
Central Processing
Platform
client: Cuu Long Joint Operating Company
services: engineering, procurement, construction, installation,
offshore hook-up and commissioning
facilities: 17,000 ST (15,400 MT) central processing platform,
4,400 ST (4,000 MT) jacket, 21 (1.6 km) miles of infield pipelines,
two PLEMs and 66-person living quarters
location: Vietnam in the Mekong Basin
water depth: 170 feet (52 m)
yard: Batam Island, Indonesia
vessels: Emerald Sea, Intermac 650 and Derrick Barge 30
First of a Kind
set industry benchmark for completing 17,000 ST (15,400 MT)
platform in 22.5 months
achieved first oil ahead of schedule
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PLATONG GAS II
Central Processing
Platform
client: Chevron Thailand Exploration & Production
services: engineering, procurement, construction and
installation
facilities: 20,944 ST (19,000 MT) deck and associated
200-person living quarters platform, flare tripod and three
bridges
location: Gulf of Thailand
water depth: 236 feet (72 m)
yard: Batam Island, Indonesia
vessels: Derrick Barge 101, Derrick Barge 50 & Intermac 600
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THE BIG PICTURE
WHAT NEEDS TO BE PREPARED FOR
INSTALLATION?
Installation method
Engineering analysis
Vessel
Equipment our focus today
Subcontract services
Installation aids
Material procurement plan
Manpower plan
Logistic plan
Quality plan
Health Safety & Environment plan
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JACKET INSTALLATION
Jacket Load Out
Loading the jacket out from onshore to the transportation
barge
Depending on the weight of the jacket and availability of the
crane at the onshore fabrication yard, the jacket can be
loaded out by:
Jacket is lifted using onshore or offshore crane from
shore onto the barge
Jacket is placed on motor driven multi axle trailers and
then move onto the barge
Jacket is placed on skid beams and then pulled onto
the barge using strand jacks
The barge will be ballasted (take water in/ out) to ensure that
the barge remains at flat position to minimize stress induced to
the jacket
After load out, the jacket then secured (seafastened) onto the
barge by means of welded connection
Ayatsil Jacket Loadout
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JACKET INSTALLATION
Jacket Lift/ Launching
Lifted/ trailer load out will be lifted off its transportation
barge by work barge
Work barge needs to have sufficient lifting capacity
at its lift radius taking into consideration potential
clashes between transportation barge, work barge
(crane boom) & jacket
Skid beam load out will be launched from the barge to the
sea
Barge will be ballasted so the jacket tilts towards
the sea
Pushing jack/ pulling lugs is installed to break out
the initial friction force if required
Ayatsil Jacket Launching
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JACKET INSTALLATION
Jacket Upending & Setdown
Upending the jacket from its horizontal position
The jacket can be upended by the work barge crane and
assisted with ballasting (flooding) the inner compartment of
the jacket if required
The ballasting can be via manually operated valve using
reach rods or remotely operated hydraulic valve
A positioning system is pre-installed on the jacket to ensure
its standing in the correct location and heading. You dont
want the jacket to be in the wrong position, especially if the
pipeline been laid.
The jacket will then be disconnected from the crane. The
jacket load is supported by its mudmat
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JACKET INSTALLATION
Pile Installation
Pile upending ILT hooked up to the crane is stabbed at
the end of pile and grip the top of pile from the inside
Pile stabbing Pile is positioned into the jacket leg/ skirt
sleeve. The pile will then self penetrate due to its own
weight. ILT is released. Depending on jacket on bottom
stability, another pile can then be stabbed
Pile driving Hammer hooked up to work barge crane is
placed on top of pile. Hammer powered from the barge will
then drive the pile to target penetration
Dynamic pile monitoring by 3rd party is performed
Pile driving is sequenced to minimize soil disturbance for pile
located close together
After pile setup (usually 24 hrs), some piles will be restriked to
reconfirm pile static capacity
Video of pile driving
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JACKET INSTALLATION
Dynamic Pile Testing
Objectives To obtain:
Efficiency of piling hammer in driven piles
Driving stresses in driven piles
Assessment of pile integrity
Bearing capacity and load-settlement response of
pile
Test method: During the impact of the hammer, the stress
waves are measured using strain transducers and
accelerometers mounted on the pile (at least 1 diameter
away from the pile head). The force trace is obtained from
the strain measurements. From the acceleration trace, the
velocity trace is obtained by numerical integration.
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JACKET INSTALLATION
Grouting
A process to inject cement into the void between pile and
jacket leg/ skirt sleeve (annulus)
Grouting the annulus is performed to ensure full load
transfer from the pile to the jacket
Grouting process:
Grout from silo is mixed in the mixing tank with sea
water/ filtered seawater/ additives (depending on
the specification)
Grout is pumped via hose and valve system from
top of jacket until annulus is completely filled
While pumping, samples are taken and tested to
ensure that the grout pumped meet the required
capacity
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PIPELINE INSTALLATION
Pipelay
Pipelaying is a process of laying pipeline onto the seabed
as per route.
Type of pipe, length of pipeline & water depth determines
the installation methods & the vessel used.
S Lay
Requires high tension to pipeline and vessel holding
power so only suitable for shallow water
Cheaper as only requires a moored barge (less
vessel MGO consumption)
J Lay
For deep water pipe
Uses Dynamically Positioned (DP) vessel
Pipe are joint onshore into pipe stalks which will then
be reeled onto the vessel
Flex lay
For flexible pipe
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PIPELINE INSTALLATION
Pipelay
For conventional conventional 12 m joints pipelaying using
moored barge, proses involved are
Barge positioning (anchor handling by anchor
handling tug)
Beach pull
Pipeline lifting from material barge
Pipeline End preparation
Joint Welding
NDT
Field joint coating
Pass pipeline through stinger
Upon completion of pipelay, an as laid survey is performed
to verify that the pipeline is installed at its intended corridor
If required, post-trenching of the pipeline is performed
Pipelay video
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PIPELINE INSTALLATION
Beach Pull
For pipeline coming inshore, the pipelay barge/ vessel will
be situated a distance away from the beach due to draft
limitation. The pipeline needs to be pulled from the pipelay
barge/ vessel to the beach, hence the name beach pull.
Cofferdam is erected at the beach pull site to protect the
pipeline from the along shore current that will increase the
load required to pull the pipeline
Activities involved in beach pull are:
Preparation of the cofferdam
Preparation of beach pull equipments such as
lucker winch and cable spooling machine
Lay messenger line between beach and pipelay
barge/ vessel
Beach pull operation
Removal of buoyancy on the pipeline if required
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PIPELINE INSTALLATION
Trenching & Burial
Trenching is required to protect the pipeline that comes
inshore from vessel anchor and to improve pipeline on
bottom stability.
Pre-trenching is an activity to create at trench at the
bottom of the seabed before laying the pipeline. Some of
the methods are by using:
Backhoe dredger on a barge
Cutter suction dredger
Post-trenching is an activity to create at trench at the
bottom of the seabed after laying the pipeline. Some of the
methods are:
Jet sled
Trenching ROV
Backfill/ burial/ rock dumping is dumping soil/ rock onto
pipeline with the same intent to protect the pipeline or for
cable/ pipeline crossing purpose
Trenching video
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PIPELINE INSTALLATION
Pigging
Running a pig through a pipeline to clean it and check if the pipeline is in good condition i.e. any buckling
Uses hydro acoustic pinger to transmit signal to allow us to locate the pig if its stuck
Utilizes high flow rate low pressure pump to propel the pig along the pipeline
Pigging video
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PIPELINE INSTALLATION
Hydrotesting
Pressurizing the pipeline/ tie in spool for > 24 hrs while
monitoring the pressure to check if theres any leak
indicated by pressure drop
Equipment used are:
Pressure chart
Pressure gauge
Digital pressure recorder
Dead weight tester
If pressure drop occurs, diver/ ROV will look for location of
leak indicated by fluorescent dye that was filled into the
riser/ pipeline
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PIPELINE INSTALLATION
Tie In Spool
Tie in spool connects the pipeline to the riser on the jacket
After pipelay and jacket installation, metrology is performed to obtain measurement that will be used as basis for fabrication
After fabrication, the tie in spool then hidrotested and field joint coating applied
Completed tie in spool will then be lowered down by the barge crane
Diver will make up the flange connection
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FPSO INSTALLATION
FPSO Mooring Tower & Floating Hose Installation
Mooring tower turret for FPSO mooring
Connection between mooring tower to FPSO
Umbilical & hose pull in from FPSO to mooring tower
Installation of floating hose to incoming FSO
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Activities & Analysis for Jacket Installation
ACTIVITIES ENGINEERING ANALYSIS
JACKET LOAD OUT BARGE BALLAST ARRANGEMENT
JACKET INTEGRITY DURING LOAD OUT
JACKET TRANSPORTATION JACKET & BARGE TRANSPORTATION ANALYSIS
JACKET LAUNCH JACKET INTEGRITY DURING LAUNCH
JACKET LIFTING RIGGING ARRANGEMENT & LIFTING POINT
JACKET UPENDING JACKET BALLAST
JACKET SET DOWN JACKET ON BOTTOM STABILITY ANALYSIS
PILE UPENDING PILE INTEGRITY ANALYSIS
PILE STABBING PILE STICK UP ANALYSIS
PILE DRIVING PILE DRIVABILITY ANALYSIS
PILE WELDING -
PILE GROUTING -
TOPSIDE/ BRIDGE INSTALLATION RIGGING ARRANGEMENT & LIFING POINT
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JACKET INSTALLATION ANALYSIS
Pile Drivability Analysis
Pile needs to be checked against the following:
Upending stress
Stabbing stress (stick up calculation)
Pile stress during driving
Pile drivability analysis is essential for the selection of
appropriate hammer for the installation of offshore piles.
Example of commercial wave equation program GRLWEAP.
Static Soil Resistance at time of Driving (SRD) - The soil
resistance at time of driving (SRD) will determine the depth to
which a pile can be driven.
It should be noted that in drivability analysis for the selection of
hammer, it is conservative to over-estimate the SRD. An
underestimate of SRD can lead to premature refusal of piles
and has serious cost implications because of the need to
remobilize a larger hammer (pile refusal is often taken to be
300 blows per foot (0.3m)).
On the other hand, over-conservative estimate of SRD may
result in piles being driven deeper than the theoretical
estimate and may give the mistaken impression that the piles
are under-capacity.
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Activities & Analysis for Pipeline Installation
ACTIVITIES ENGINEERING ANALYSIS
ANCHOR HANDLING MOORING ANALYSIS
BEACH PULL PIPELINE BEACH PULL ANALYSIS
PIPELAY (USING STINGER) PIPELAY ANALYSIS
PIPELAY (USING DAVITS) DAVIT LIFT ANALYSIS
FIELD JOINT COATING -
PIGGING (GAUGING & CLEANING) -
HYDROTESTING -
NITROGEN PACKING -
TIE IN SPOOL METROLOGY -
TIE IN SPOOL FABRICATION & HYDROTEST -
TIE IN SPOOL INSTALLATION & FLANGE MAKE UP TIE IN SPOOL RIGGING ARRANGEMENT
PIPELINE TRENCHING PIPELINE STRESS DURING TRENCHING
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PIPELINE INSTALLATION ANALYSIS
Pipeline Installation
Stress Analysis
Pipeline installation stress analysis considers the following
loads:
internal pressure (operating pressure)
external pressure (hydrostatic pressure of sea)
bending (construction, spans, upheaval)
concentrated loads (construction, accidents)
Reference Code
DNV-OS-F101 Submarine Pipeline Systems
DNV-RP-D101 Structural Analysis of Piping Systems
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INSTALLATION VESSELS
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HEAVY LIFT & PIPELAY
Derrick Lay Vessel 2000
versatile combination heavy lift and pipelay vessel with 2,200 ST (2,000 MT) crane
multiple cranes for construction, pipeline and deep water installation
S-Lay capability from 4.5 to 60 inches with high strain, deep water stinger
pipelay operations in single or double joint configuration
DP3 compliant dynamic positioning system
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FLEX-LAY & RIGID PIPELAY
Lay Vessel North Ocean 105
modern reel pipelay vessel designed for global operations
pipelay capability from 2 to 16 inches with maximum coating/flexible product of 24 inches
2,750 ST (2,500 MT) reel payload (subject to deck loading conditions)
pipelay tower with 440 ST (400 MT) tensioner and tilting angles from 28 to 90 degrees
500 ST (450 MT) & 165 ST (150 MT) A&R system capable of pipe abandonment or subsea lowering to 10,000 feet (3,050 m)
two portside AHC main cranes, 110 ST (100 MT) and 440 ST (400 MT), for subsea lifts and construction support
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FLEX-LAY
North Ocean 102
modern flex-lay vessel designed for global operations
6,600 ST (6,000 MT) carousel capacity (subject to deck loading conditions)
pipelay capability from 2 to 16.5 inches
flex-lay tower with 330 ST (300 MT) single tensioner
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CONSTRUCTION SUPPORT,
DIVE SUPPORT & FLEX-LAY
Emerald Sea
flexible flowline, umbilical and cable installation vessel with diving and ROV capability
maximum flexible flowline product deployment approximately 12 inches inside diameter
1,874 ST (1,700 MT) below deck turntable carousel with articulated loading arm
12-man, three-man bell, saturation diving system
55 ST (50 MT) pedestal crane
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FLEX-LAY
Lay Vessel 108
Modern, efficient and versatile flexible and umbilical lay system
165 ST (150 MT) Vertical Lay Tower & 165 ST (150 MT) A&R system
Reel Drive System (RDS) 5 reels at 440 ST (400 MT) each
Optional 2,200 ST (2,000 MT) carousel
3,750 ST (3,400 MT) overall product payload @ 90% fuel load
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HEAVY LIFT & S-LAY
Derrick Barge 30
derrick/lay barge with heavy lift and pipelay capabilities
heavy lift crane with 3,080 ST (2,800 MT) capacity
pipelay capability from 4 to 60 inches
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LAUNCH & FLOAT-OVER
Intermac 650
second largest float-over installation vessel in the world
launches jackets up to 27,500 ST (25,000 MT)
carries cargo up to 22,000 ST (20,000 MT)
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JACKET INSTALLATION EQUIPMENTS
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INSTALLATION EQUIPMENTS
Hydraulic Hammers
Hydraulically powered hammer to drive the jacket pile to
target penetration
The hammer will be driven by Hydraulic Power Unit on the
work barge connected to the hammer via high pressure
hydraulic hose
At least 2 hammers are mobilized, starter hammer and final
driving hammer.
Basis for starter hammer selection will be the stick up
analysis which gives max weight of hammer allowable so
pile is not buckled at maximum stick up. Basis of final
hammer selection is the pile driving analysis that will
determine the blow energy required at target penetration.
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INSTALLATION EQUIPMENTS
ILT (In Line Tool)
Tool that grips the inside of the pile so we can lift the pile
and stab it into the jacket
The ILT is relies on hydraulic pressure from HPU located at
the work barge
Basis of selection is pile inner diameter
The ILT diameter can be adjusted to a certain extent by
changing the wedges/ inserts
The ILT has a fail safe mechanism so that in the absence of
pressure, it will not release its grip
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INSTALLATION EQUIPMENTS
Leveling Tool
Tool that grips the pile and the jacket to level the jacket to
the required levelness. Most client dont appreciate a tilted
platform.
Selection of leveling tool is usually determined during the
design phase because the point of contact/ interface of
the leveling tool to the jacket and the pile needs to suit
each other. Forces that is exerted by the leveling should
also needs to be account during the jacket integrity check
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INSTALLATION EQUIPMENTS
Diving Spread
Diving equipment consists of:
Dive bell
Launch and recovery system
Air mixing system
Umbilical for air delivery system
Diver decompression chamber
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QUESTIONS & ANSWERS
Please raise your hand
if you have a question
for the presenters.
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