modular carousel systems – application, innovation ... · modular carousel systems –...

AOG 2015

Modular Carousel Systems – Application, Innovation & Future DevelopmentAustraliasian Oil and Gas Conference 2015

Perth Convention Exhibition CentrePerth, Australia

[email protected] www.aquaticsubsea.com

AOG 2015

• The trend in subsea installation projects is “bigger” - larger and more complex product, deeper water and longer lengths

• Installation, replacement or recovery works at these depths requires specialist equipment

• In addition the drive to deeper waters for windfarms mean significant cable lengths are required, with greater diameter

• A typical multi-reel solution becomes inefficient for longer flexible installation based on current designs.

• The market has a requirement for a change in technology…..

Introduction


AOG 2015

• Project complexity increases with quantity of reels

• Offshore connections and testing are time consuming & increase risk

• Product weight & volume limitations• Large connectors result in ineffective

reel space utilization• Constraints placed on vessel – crane

reach, track length, crew space,• Loaded Reel weight limited to 500Te

Multiple Reel Installation – Limitations


AOG 2015

Carousel Installation - Limitations• Carousels tend to be purpose built into a standalone vessel or basket-style with

functional limitations• Mobilisation of carousel includes significant relocation cost of vessel• Carousel vessels tend to be locked into long term contracts• With deeper waters in mind, carousels tend to be too costly for mid-length tiebacks

or those on the upper limit of multiple reel usage.• Vessel cannot be readily used for other field work before/after installation


AOG 2015

Portability or Modularity• Less impact on the vessel and the ability to use a wider range of host vesselsEnhanced range of mobilisation ports• The ability to handle the equipment and product at compact quaysides• Options on the size and hence number of lifts to mobilise the machineOptimised Product Handling & Storage• A reel translated through 90 degrees• The ability to spool under tensionFaster Mobilisation & Demobilisation• Take the equipment to the vessel• The ability to use a vessel of opportunity already in the work region

Carousels – What Does the Market Want?


AOG 2015


The Solution

• A modular system, designed to break down into standard 40ft containers and shipped anywhere worldwide on commercial freight vessel

• Spatially optimized to suit typical field support or anchor handling vessels


AOG 2015


The Solution

• Heaviest single piece lift of 20Te maximum• Option to build up assemblies to allow for break-bulk repositioning• Assembly optimized to be within limitations of typical quayside strength

and onshore craneage


AOG 2015


The Solution

• Designed around proven carousel configuration• Modular support equipment including level winder & tensioner• Spatially optimized to balance product weight/volume capacity with vessel

structural limits• Tapered hub to maintain tight winding under self weight


AOG 2015


The Solution

• Rapid repositioning around a region using standard sea freight methods• Designed to be installed on offshore support vessels with 18m+ beam


AOG 2015


AOG 2015

System Flexibility

End Connection Storage on Roof

Capacity for Multiple Products

Adjustable False Roof:4.0m – 6.0m

Adjustable Hub Diameter: 4.0m – 6.0m


AOG 2015

Operational Evaluation (Product >20km)

Multiple Reel Fixed Carousel Modular Carousel

Continuous Lay

Connection Downtime Offshore Onshore Onshore

Range of Suitable Vessels High Low High

Product Integrity Risk Medium Low Low

Deck Space Requirement Low High High

Additional Offshore Resource Reel Supply Vessel None None

Vessel Multi-tasking (clear deck)


AOG 2015

Multiple Reel Fixed Carousel Modular Carousel

Up-Front Engineering Low High High

Product Fabrication Cost High Low Low

Product Relocation Cost Low High High

Vessel & Equipment Mobilisation Low High - V.High Medium

Transpooling / Deck Preparation Low High Medium

Offshore Lay / Installation High High Low

Impact of Schedule Slippage Low High - V.High Low - Medium

Relative Project Cost Evaluation (Product >20km)


AOG 2015

• 9.7km of 218mm umbilical to install offshore Indonesia

Modular Carousel - Application


AOG 2015


• Vessel of opportunity identified in region



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• Vessel of opportunity identified in region• Carousel mobilized & seafastened



AOG 2015


• Vessel of opportunity identified in region• Carousel mobilized & seafastened• Product arrives on 3 reels



AOG 2015


• Vessel of opportunity identified in region• Carousel mobilized & seafastened• Product arrives on 3 reels• Quayside transpooling & midline

connections made and tested



AOG 2015



connections made and tested• Installation commences



AOG 2015



connections made and tested• Installation commences• Vessel & carousel demobilized



AOG 2015



connections made and tested• Installation commences• Vessel & carousel demobilized

• CAN THE SAME BE DONE WITH REELS ?



AOG 2015

Reel Size & Specification• Currently limited to 11.4m (plans for 12.3m)

Multiple Reel Installation – Areas of Development


AOG 2015

Reel Size & Specification• Currently limited to 11.4m (plans for 12.3m)• Weight of reel increases significantly with

size due to shape and need for additional structural support

• Reels are viewed as a consumable item so minimal scope for technical development



AOG 2015




• Need to increase to 14-16m (700Te+ capacity) to fulfil deepwater demand



AOG 2015




• Need to increase to 14-16m (700Te+ capacity) to fulfil deepwater demand

• Increased size can introduce vessel instability


Reel Diameter(m)

WindForce (kgf) Factor (%)

8.6m 3,680 100%9.8m 4,780 130%11.4m 6,475 176%12.0m 7,170 195%14.0m 9,750 265%16.0m 12,740 346%

Lateral Wind Force based on 6 reel system and Wind Speed of 25knots


AOG 2015


0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

5,000

‐

200.00

400.00

600.00

800.00

1,000.00

1,200.00

1,400.00

1,600.00

1,800.00

2,000.00

8 9 10 11 12 13 14 15 16 17

Prod

uct Len

gth (m

)

Weight (Metric

Ton

nes)

Reel Diameter (metres)

Reel Capacity ‐ 10in x 13.5in Pipe with 3.5m Reel Partition

Weight (Empty) Weight (Flooded) Product Length

Carousel: 4,891m

Carousel: 1,500Te


AOG 2015

Reel Drive Size & Specification• Limited by common deck capacity of 10Te/m2

• Reel drive footprint must increase to distribute reel load into deck resulting in wider equipment

• Formal operational guidelines will need to be imposed

• Must remain modular, road transportable and within container limits

• Difficulties in maintaining commercial edge over carousel systems



AOG 2015

• Customers have expressed the need for increased capacity for product for a wide range of vessel options which could be easily mobilised

• A modular carousel remains to be one of the most competent, versatile and cost effective means of installing long flexible products

• Developments are ongoing to make the mobilisation process of a modular carousel more efficient

• There is scope for increasing the size of offshore reels and drive systems, at the expense of deck footprint and vessel stability limits

• Next steps– Commercial analysis: Cost of product/connectors vs. Installation Method– Fabrication feasibility: Can reels be made cost effectively using alternative

materials?

In Summary

www.aquaticsubsea.com

Aquatic Asia Pacific Pte Ltd

Loyang Offshore Supply Base25 Loyang CrescentMailbox No. 5046Tops Avenue 1Block 103, #04-03Singapore508988Tel: +65 6681 5633

Aquatic Engineering & Construction Ltd

900 ThreadneedleSuite 300Houston TX 77079Tel: +1 832 399 5000Fax: +1 832 399 5001

Tern Place House Tern Place, Bridge of DonAberdeen, AB23 8JXTel: +44 1224 452300Fax: +44 1224 452349

South View PlacePeterheadAB42 3GUTel: +44 1779 475035Fax: +44 1779 483820

THANK YOU

modular carousel systems – application, innovation ... · modular carousel systems –...

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