No 2Cleveland Institution of Engineers – 6 Feb 18
WELCOME
Neil EtheringtonBusiness Development Director
SHELL BRENT DELTA – PREPARATION IS THE QUAYThe story so far………..
No 6Cleveland Institution of Engineers – 6 Feb 18
THE ABLE GROUP TODAY
• Established 1966
• Privately owned
• Entrepreneurial
• Decisive
• Flexible
• Strong leadership
• Long term view
Ernst & Young Entrepreneur of the Year (Peter Stephenson, Able UK Ltd Executive Chairman) 2010
Long term strategy
Extensive funding ; No borrowings
£120m+ invested in last 5 years
£483M
asset base
No 7Cleveland Institution of Engineers – 6 Feb 18
ABLE – A DIVERSIFIED GROUP
ABLE Group• Port Development
• Construction – civil and marine
• Demolition
• Marine Recycling / Decommissioning
• Property / Management – UK land bank c. 2,150ha (5,320 acres)
• Land Reclamation
• Landfill
• Waste Management
• Quarrying
No 8Cleveland Institution of Engineers – 6 Feb 18
ABLE UK LIMITED – HISTORY AND DEVELOPMENT
An evolving process:
From Plant Hire to Demolition
to Waste Management to Construction
and on to Marine Decommissioning and Property Management and Development
No 9Cleveland Institution of Engineers – 6 Feb 18
THORPE MARSH POWER STATION
• Acquired 1995
• Power Station Demolition Contract
• Site cleared
• Section 36 Approval (to 2021)
• 1,575MW Gas Power Station
• Carlton Power
• Cooling Towers – 2012
• Construction 2018/19
No 10Cleveland Institution of Engineers – 6 Feb 18
ABLE HAS CONTINUED TO PIONEER NEW TECHNIQUES
AND SET INDUSTRY STANDARDS
DEMOLITION
No 11Cleveland Institution of Engineers – 6 Feb 18
DEMOLITION TRACK RECORD
Demolished / Dismantled Projects
Power Stations 12
Refineries 11
Tank Farms 13
Bridges 50
Buildings 770 +
Structures using explosives
80 +
Tonnes Equipment 80,000 +
No 12Cleveland Institution of Engineers – 6 Feb 18
MAJOR DEMOLITION CLIENTS INCLUDE:
• AMOCO
• BASF
• BHP Hamilton
• BP Chemicals
• BP Oil & Gas
• British Gas
• British Nuclear Fuels
• British Steel
• ConocoPhillips
• Ensco• EON• ICI• Innogy plc• Mobil /Exxon• NAM-Holland
• Newfield Petroleum• Nuclear Electric plc• Petrofac
• Phillips Petroleum - UK
• Phillips Petroleum - Norway
• Powergen
• RWE
• Sembcorp
• Shell UK
• Shell Exploration & Production
• Thames Water
• TotalFinaElf Norway
• TotalFinaElf UK
• UECC
• UK Atomic Energy Authority
No 13Cleveland Institution of Engineers – 6 Feb 18
OIL RIG DECOMMISSIONING
From onshore......to Offshore, onshore...........Oil Platform Decommissioning............
Former Northern Offshore Federation Company of the Year
No 14Cleveland Institution of Engineers – 6 Feb 18
Oil Platforms Year
Phillips Albusk Jell 1985
Shell Bravo 1994
Shell Dunlin 1994
Shell Cormorant A 1995
Shell Charlie 1996
Shell Leman Topsides 1996
BHP Esmond 1996
Shell Delta 1997
Shell Leman Jacket 1997
NAM K11 1998/9
TFE Frigg/Frǿy 2000/1
NAM K14 2001/2
Mobil Camelot CB 2002/3
Grove Platform 2004
BP North West Hutton 2008/9
ConocoPhillips Phoenix Module 2016
Shell Brent Delta Topside 2017
Shell Brent Bravo Topside 2019
Shell Brent Alpha Topside 2020
Shell Brent Alpha Jacket 2021
Shell Brent Charlie Topside 2022
TRACK RECORD….THE MARKET LEADER
• Over 80 structures received
• Undertaken at Able Seaton Port (initially) at Able Billingham Reach
No 15Cleveland Institution of Engineers – 6 Feb 18
BP NORTH WEST HUTTON – TOPSIDE AND JACKET REMOVAL
No 16Cleveland Institution of Engineers – 6 Feb 18
BP NORTH WEST HUTTON
• One of the largest projects to date
• 20,000t Topside
• 10,000t Jacket
• Reverse engineering
No 17Cleveland Institution of Engineers – 6 Feb 18
BP NORTH WEST HUTTON – REVERSE ENGINEERING
• Heerema
• Multiple barge movements - 22
• Two summer campaigns 2008/9
• Innovative re-use
No 18Cleveland Institution of Engineers – 6 Feb 18
MODULE SUPPORT FRAME (1,500T)
ADAPTED AND USED IN SEA TRIALS – PIONEERING SPIRIT
No 19Cleveland Institution of Engineers – 6 Feb 18
MOBILE ACCOMODATION UNIT (MAU)
• 3,116m2 of office and welfare accommodation• Top 2 floors available for office or overnight
accommodation
Green Apple
Award Winner
2013
No 20Cleveland Institution of Engineers – 6 Feb 18
MAU – ACCOMMODATION
3,116m2 of Office and Welfare Accommodation Kitchen for 120 staff
No 21Cleveland Institution of Engineers – 6 Feb 18
THE DEMOLITION PROCESS
• Survey (compare to plans)• Remove Hazardous Material• Soft Strip• Re-use; Re-furbish; Re-sale; Recycle
(the Best Practicable Environmental Option)• Sectioned Pull-down• Transfer to Scrap Handling Area• Scrap Steel Processing• Furnace Ready (sized)• Despatch – Road; Rail; Sea
No 22Cleveland Institution of Engineers – 6 Feb 18
THE RESULT
• BP NWH - Largest Oil Rig Re-cycling Project at the time
• On-Time
• On Budget
• LSA Removal
• Asbestos Removal
• 98.2% re-used/re-cycled
• No Lost Time Accidents
• A Satisfied Client
No 23Cleveland Institution of Engineers – 6 Feb 18
UK’s LARGEST OFFSHORE DECOMMISSIONING PROJECT
SHELL BRENT
No 24Cleveland Institution of Engineers – 6 Feb 18
SHELL BRENT
• 1976
• 4 billion barrels of oil
• 10% of all North Sea output
• 70% of all revenues paid as TAX
Source: SHELL UK
No 25Cleveland Institution of Engineers – 6 Feb 18
A COMPLEX MAJOR ENGINEERING PROJECT
Cessation of Production
• Delta 2011
• Alpha, Bravo 2014
• Charlie TBC
Alpha, Bravo & Charlie have multiple interconnections & interdependencies
• 140 wells• 4 topsides (106kT)• 1 steel jacket• 3 GBS• 2 subsea locations
No 26Cleveland Institution of Engineers – 6 Feb 18
THE SCALE OF THE BRENT FACILITIES
400 m
300 m
200 m
100 m
Nelson’s ColumnLondon
Sydney Opera House
Sydney
Taj MahalAgra
Seoul TowerSeoul
Eiffel TowerParis
BrentDelta
London EyeLondon
No 27Cleveland Institution of Engineers – 6 Feb 18
PIONEERING SPIRIT
• 382m x 124m
• Single Lifts
• Up to 48,000t
• £2.5b
• World’s Largest Vessel
6x747 Jumbo Jets
LENGTH: 382m
No 30Cleveland Institution of Engineers – 6 Feb 18
RIVER TEES, NORTH EAST COAST, UK
ABLE SEATON PORT (ASP)
No 31Cleveland Institution of Engineers – 6 Feb 18
THE IDEAL EAST COAST LOCATION
NORTHERN NORTH SEA
CENTRAL NORTH SEA
SOUTHERN NORTH SEA
ABLE Seaton Port
100nm 200nm 400nm
No 32Cleveland Institution of Engineers – 6 Feb 18
ABLE SEATON PORT - SHELL BRENT FIELD
• Shell Brent Field c. 400 Nautical Miles from ASP
No 33Cleveland Institution of Engineers – 6 Feb 18
HISTORY – SINCE ABLE OWNERSHIP
1996 2004 2008 2009 2018
Site and QuaysDock Basin
c. £100m+ invested
No 34Cleveland Institution of Engineers – 6 Feb 18
ASP BASE PLAN
• Multi-user Facility
• 51 hectares (126 acres)
• 11 Quays
• Up to 20.5m of water @ MHWS
• Offices
• Workshops
• Fabrication Hall
• Stores
• Shot blast building
• Paint shop
• Extensive range of capital plant
• New Quays
• Quay 1
• Quay 6
• Potential Dry Dock
Dock Ramp
200m - 1:15
(6.6%)
Security Office
216m
386m
172m
150m
E5
E3
E2
E1
W1
E6
E8
2.83ha
Holding Basin -6.0m CD
(-9.5m CD Design Depth)
Dredge Box -11.0m CD
(-15.0m CD Design Depth)
Quay 11
Quay 10
E7
Carparking (3x 20No. bays)
Contractors compound
Quay 11b
E5
E4
E3
E2
E6
E8
Dredge Box -11.0m CD
(-15.0m CD Design Depth)
Quay 11
Dock Basin
(Dock Floor 9.5ha
-6.65m CD) Quay 10
Seaton Channel -6.0m CD
(-9.5m CD Design Depth)
East A
ccess R
oad
Car Park
E1
2.83ha
Proposed East Access Road
Proposed East Access Road
W1
Pro
posed W
est A
cce
ss R
oad
Proposed West A
ccess Road
Import Q
uay (Q
uay 1
)
Quay 9
Quay 6
Quay 7
Quay 8
Dock Basin
(Dock Floor 2.54ha
-8.50m CD)
Project:
Client:
Drawing Title:
Scale:
Drawing No: Revision:
Drawn By Checked By Approved By
Date:
PRELIMINARY
Comments Drn Chk AppDateRev.
A 29/06/16 Preliminary Issue KJH NE PMS
Key & Notes
ABLE Seaton Port
ABLE UK Limited
Base Plan
K Horn
29/06/2016
NTS@A3
ASP-001-00002 B
N Etherington
29/06/2016
P Stevenson
29/06/2016
N
Estate Boundary - 51ha
Heavy Load out Pad
Quay 10 - 65t/m²
Concrete Quay 6 - 60t/m²
Concrete Quay Pad
Quays 10 & 11 - 40t/m²
Concrete Pad
Concrete Quay
Quays 1 - 16t/m²
Hard Standing
10t/m² (50t/m² Patch Loading)
Dry/wet Dock
10t/m² (50t/m² Patch Loading)
Building Details:
E1 - Workshop: 14m x 34m 6m 476m²
E2 - Workshop: 76m x 26m x 11m 1,976m²
E3 - Workshop/Stores:
76m x 26m x 11m 1,976m²
E4 - Fabrication Shop
2 x 30t Overhead Cranes:
64m x 28m x 21.4m 1,792m²
E5 - Workshop: 40m x 25m x 11m 1,000m²
E6 - Workshop: 40m x 25m x 11m 1,000m²
E7 - Mobile Accommodation Unit 3,136m²
E8 - Waste Storage 575m²
W1 - Workshop: 41.5m x 20m x 6m 830m²
Quay 6 Pad 122m x 60m (101t/m
Line Loading)
Stone Blanket
Quays 10 & 11 - 40t/m²
Heavy Load out Pad
Quay 1 - 40t/m²
ABLE UK Limited
ABLE House
Billingham Reach Industrial Estate
Teesside, TS23 1PX
United Kingdom
Tel: +44(0)1642 806080
Fax: +44(0)1642 655655
DRAFT
Concrete Quay
Quay 9 5t/m²
Quay Details:
Q1 80m long to -9.50mCD
Q6 130m long to -6.65mCD
Q7 156m long to -6.65mCD
Q8 156m long to -6.65mCD
Q9 50m long to -6.65mCD
Q10 146m long to -15.00mCD
Q11 146m long to -15.00mCD
B Dock basin and quay lengths amended KJH
11/01/2017 11:46:49
Quay6
No 35Cleveland Institution of Engineers – 6 Feb 18
QUAY 6 CONSTRUCTION
• 1,242 Piles (10,500t)
• 7,000m3 Concrete
• 7,500m2
• Load Capacity 45t/m2
• Line Load 100t/m2
• 120m Quay
• Start – Jan 14
• Finish – Dec 16
• Able Designed
No 37Cleveland Institution of Engineers – 6 Feb 18
QUAY 6
123.97
17.21
105
105
17.21
30.36 30.36
1515
1515
1515
15
17.7130.3630.3622.7722.77
+
4.39mAOD
(7.24CD)
4.83mAOD
(7.68CD)
+
5.0mAOD
(7.85CD) +
5.0mAOD
(7.85CD)
+
4.83mAOD
(7.68CD)
+1:200
1:200
1:200
+
4.39mAOD
(7.24CD)
1:200
1:200
60.72
45.54
ABLE UK Limited
ABLE House
Billingham Reach Industrial Estate
Teesside, TS23 1PX
United Kingdom
Tel: +44(0)1642 806080
Fax: +44(0)1642 655655
Project:
Client:
Drawing Title:
Scale:
Drawing No: Revision:
Drawn By Checked By Approved By
Date:
PRELIMINARY
Comments Drn Chk AppDateRev.
A 31/07/13 Preliminary Issue JMH
Key & Notes
ABLE Seaton Port Quay 6
ABLE UK Limited
Quay 6 Masterplan Without Levels
J Horsman
31/07/13
1:500 UNO @A3
ASP-001-00071 A
1. All levels are in metres above
Ordnance Datum (mAOD) unless
noted otherwise.
2. All dimensions are in metres
(m)unless noted otherwise.
Quay 6
Front row piles. 1270mm OD at
2.53m centres
• Available Q1 2017
• 125m
• c60m @ 45t/m2
• c60m @ 16t/m2
No 38Cleveland Institution of Engineers – 6 Feb 18
QUAY 6 GROUNDING BED CONSTRUCTION
• Area - 13,860m2 (70 tennis courts)
• 16,150t of stone
• 3,000t of gravel
No 40Cleveland Institution of Engineers – 6 Feb 18
ASP COFFERDAM REMOVAL
• 226 sheet piles average 20m long (4,500 linear metres combined)
• 84 tubular piles average 27.1 metres long (2,250 linear metres combined)
• 14,197m3 material (sand) extracted from cofferdam centre
No 42Cleveland Institution of Engineers – 6 Feb 18
• ABLE construction complete
• ASP capacity to process c. 300,000t steel per year
• The market is set to increase significantly
ASP QUAY 6 DOCK – WET DOCK BASIN
No 45Cleveland Institution of Engineers – 6 Feb 18
TIMELAPSE OF SHELL BRENT DELTA SKID-IN TO ASP QUAY 6
No 46Cleveland Institution of Engineers – 6 Feb 18
BRENT DECOMMISSIONING - ONSHORE DISPOSAL & DISMANTLING PROJECT OVERVIEW
No 47Cleveland Institution of Engineers – 6 Feb 18
SEQUENCE
• Preparation– Construct Q6– Construct Grounding Bed– Tow & moor (Allseas and Able UK)– Load-in (Allseas and Able UK)
• Handover• Make Safe• Survey• Isolate• Soft-strip• Hazardous material removal• Structural destruct• Processing, recycling and disposal• Target 98.5% recycle rate with a contracted target of 97%
No 49Cleveland Institution of Engineers – 6 Feb 18
DELTA DESTRUCT
BRENT DECOMMISSIONING PROJECT
ONSHORE DISMANTLING & DISPOSAL
No 50Cleveland Institution of Engineers – 6 Feb 18
WEIGHT
• Allseas recorded weight Brent Delta:
– 23,727 mT (+/- 5% accuracy)
• AMEC weight report (rev 10, Jan 2017)
– gross dry weight 23,702 mT
– net dry weight 22,687mT
• Load-in stool weight: 1,726 mT
• Contract weight 23,560 mT
No 51Cleveland Institution of Engineers – 6 Feb 18
PRELIMINARY DECOMMISSIONING SEQUENCING
• Utilise existing information pre-arrival
• 3D model
• Inventories
• Drawings
• CoG
• Establish high level sequencing
No 52Cleveland Institution of Engineers – 6 Feb 18
PRELIMINARY DECOMMISSIONING SEQUENCING
• Assess stages
• Confirm preliminary engineering
• Review PCIP etc.
No 54Cleveland Institution of Engineers – 6 Feb 18
ENGINEERING – CDM COMPLIANCE
Method
By Calculation
Proofing Checking
Structural Engineer
By Calculation
Structural Engineer
Select [PC] Assess [PC] Check [PD]
No 55Cleveland Institution of Engineers – 6 Feb 18
DETAILED RAMS
• Visual inspection in Navisworks model
• Physical survey of the proposed method with Topmen Burners
• Preparation of sequence drawings
• Visual overview with Structural Engineer of proposed method
No 56Cleveland Institution of Engineers – 6 Feb 18
• Write RAMS and amend drawings to suit Structural Calculations i.e. Dimensions of Cuts etc.
• Issue Complete RAMS to Principal Designer for Review
• Address comments
• Re-issue if necessary
DETAILED RAMS
No 57Cleveland Institution of Engineers – 6 Feb 18
DETAILED RAMS
• Run through the RAMS with Topmen and Operatives involved.
• Enabling Works
• Exclusion Zone confirmed clear for Final Cuts
• Structure cut and dropped in to secure Exclusion Zone
• Landings, leading edges surveyed for damage or snagging materials.
• Structure split and taken to a safe Processing Area.
No 63Cleveland Institution of Engineers – 6 Feb 18
DELTA DESTRUCT – RECYCLING
BRENT DECOMMISSIONING PROJECT
ONSHORE DISMANTLING & DISPOSAL
No 64Cleveland Institution of Engineers – 6 Feb 18
HIGHLIGHTS
• Food– charitable
• Bedding– charitable
• Mattresses– charitable
• Equipment– Resale and reuse
• Valuable metals recovery in electrical equipment
• Recovery of diesel and gas oil
No 65Cleveland Institution of Engineers – 6 Feb 18
WASTE MANAGEMENT
• c. 1.7%
• Comprises:– 1.5% Non-hazardous
– 0.2% Hazardous• Chemical (production & drilling) 0.016%
• LSA 0.057%
• Diesel 0.031%
• Hydraulic Oil 0.011%
• Crude Oil 0.050%
• Water (biocide) 0.013%
• PCB 0.001%
• Mercury 0.001%
No 66Cleveland Institution of Engineers – 6 Feb 18
SEATON MEADOWS LANDFILL
• 600m by road
• Specialist Waste Facility
• Fully licensed
• Estimated life to 2030
No 67Cleveland Institution of Engineers – 6 Feb 18
CONTRACT CONTRIBUTION (JOBS)
• 50 jobs new/safeguarded
• 4 New Apprenticeships (Hartlepool College):– Engineering Maintenance (Level 3 Diploma)
– 2 x Engineering Technical Support (CAD) (Level 3 Diploma)
– Welding (Level 3 Diploma)
No 68Cleveland Institution of Engineers – 6 Feb 18
THE ABLE WORKFORCE
ABLE SEATON PORT, Hartlepool (by residence)
Tees Valley 81.5%
Hartlepool 49.0%
Stockton 5.5%
Middlesbrough 19.0%
Redcar 2.5%
Darlington 5.5%
Co Durham 10.5%
Tyne & Wear 8.0%
N Yorks 0.0%
Total 100.0%
ABLE HQ, Stockton (by residence)
Tees Valley 77.5%
Hartlepool 20.0%
Stockton 34.5%
Middlesbrough 15.0%
Redcar 2.0%
Darlington 6.0%
Co Durham 10.5%
Tyne & Wear 2.0%
N Yorks 10.0%
Total 100.0%
2% AGENCY STAFF NO ZERO HOURS CONTRACTSCOMMITTED TO KEEPING JOBS IN THE LOCAL COMMUNITY
No 69Cleveland Institution of Engineers – 6 Feb 18
CONTRACT CONTRIBUTION
• SEATON CAREW MASTERPLAN £100,000– Outdoor Play area
• SHELL BRENT DELTA EVENTS– VIP EVENT (Tuesday) 90+ (MPs; Mayor; OGA; LEP etc)
– BRENT STAFF & PENSIONERS 150 + (Wednesday)
– EDUCATION 150 + students (Thursday)
• English Martyrs; High Tunstall; St Hilds; Manor Community Academy: Dyke House
– COMMUNITY 350 + residents (Saturday)
• 3 Sessions: 104; 114; 125 registered to date
No 70Cleveland Institution of Engineers – 6 Feb 18
CONTRACT
• Investment - £28m
• Period: 2015-2025
• c. 50 jobs safeguarded/created
• 100,000t – c. 97% + to be re-
cycled
• Unique facility
• Re-affirms ABLE as Market
Leader
No 73Cleveland Institution of Engineers – 6 Feb 18
HORNSEA 1 FOUNDATION PACKAGE
• 1,200MW
• World’s largest offshore wind farm
• Power > 1m homes
• 174 Siemens Turbines
• Foundation Package:
• Q4 17 to Q3 18
No 74Cleveland Institution of Engineers – 6 Feb 18
HOW01 – FEEDER PORT - ASP
• Awarded contract Oct ‘17
• 174No. MP & TP to be handled at ASP
• 1000Te/300t per piece
• Use of quays
• Land storage
• Contract underway
No 75Cleveland Institution of Engineers – 6 Feb 18
HOW01 – VESSELS - ASP
• Geosea Innovation– 2012– DP2 Jack-Up– 147.5m x 42.0m– 1,500t crane capacity– 100 POB
• SAL – Svenja– 2010– General Cargo– 160.6m x 27.8m– Geared
• Plus North Sea Barges
No 76Cleveland Institution of Engineers – 6 Feb 18
DREDGING SUBCONTRACT ASP
• Major capital dredge to the channel approach to ASP (£6m)
• Reducing channel depth in Seaton Channel and Holding Basin
• Clearing Quay 10/11
• -9.5m CD
• From circa -6m CD
• Completed Dec 17
• Increase unrestricted access windows to ASP
No 77Cleveland Institution of Engineers – 6 Feb 18
VEHICLE DISTRIBUTION
739 acres total net operational area
438 acres developed
300 acres occupied
No 78Cleveland Institution of Engineers – 6 Feb 18
BMW CONTRACT
• BMW – 9 year contract
• 16,979+ spaces (c. 100 acres)
• 5,300m2 – Pre-Delivery Inspection (PDI) facility
No 81Cleveland Institution of Engineers – 6 Feb 18
PROJECT MILESTONES
• PDI
– Building complete
– BMW occupied 13th
Nov
– High standard of completion
– In advance of contractual commitment to BMW