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
[email protected] www.aquaticsubsea.com
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
[email protected] www.aquaticsubsea.com
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
[email protected] www.aquaticsubsea.com
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?
[email protected] www.aquaticsubsea.com
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
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
[email protected] www.aquaticsubsea.com
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
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
[email protected] www.aquaticsubsea.com
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
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
[email protected] www.aquaticsubsea.com
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
The Solution
• Rapid repositioning around a region using standard sea freight methods• Designed to be installed on offshore support vessels with 18m+ beam
[email protected] www.aquaticsubsea.com
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
[email protected] www.aquaticsubsea.com
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)
[email protected] www.aquaticsubsea.com
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)
[email protected] www.aquaticsubsea.com
AOG 2015
• 9.7km of 218mm umbilical to install offshore Indonesia
Modular Carousel - Application
[email protected] www.aquaticsubsea.com
AOG 2015
• 9.7km of 218mm umbilical to install offshore Indonesia
• Vessel of opportunity identified in region
Modular Carousel - Application
[email protected] www.aquaticsubsea.com
AOG 2015
• 9.7km of 218mm umbilical to install offshore Indonesia
• Vessel of opportunity identified in region• Carousel mobilized & seafastened
Modular Carousel - Application
[email protected] www.aquaticsubsea.com
AOG 2015
• 9.7km of 218mm umbilical to install offshore Indonesia
• Vessel of opportunity identified in region• Carousel mobilized & seafastened• Product arrives on 3 reels
Modular Carousel - Application
[email protected] www.aquaticsubsea.com
AOG 2015
• 9.7km of 218mm umbilical to install offshore Indonesia
• Vessel of opportunity identified in region• Carousel mobilized & seafastened• Product arrives on 3 reels• Quayside transpooling & midline
connections made and tested
Modular Carousel - Application
[email protected] www.aquaticsubsea.com
AOG 2015
• 9.7km of 218mm umbilical to install offshore Indonesia
• Vessel of opportunity identified in region• Carousel mobilized & seafastened• Product arrives on 3 reels• Quayside transpooling & midline
connections made and tested• Installation commences
Modular Carousel - Application
[email protected] www.aquaticsubsea.com
AOG 2015
• 9.7km of 218mm umbilical to install offshore Indonesia
• Vessel of opportunity identified in region• Carousel mobilized & seafastened• Product arrives on 3 reels• Quayside transpooling & midline
connections made and tested• Installation commences• Vessel & carousel demobilized
Modular Carousel - Application
[email protected] www.aquaticsubsea.com
AOG 2015
• 9.7km of 218mm umbilical to install offshore Indonesia
• Vessel of opportunity identified in region• Carousel mobilized & seafastened• Product arrives on 3 reels• Quayside transpooling & midline
connections made and tested• Installation commences• Vessel & carousel demobilized
• CAN THE SAME BE DONE WITH REELS ?
Modular Carousel - Application
[email protected] www.aquaticsubsea.com
AOG 2015
Reel Size & Specification• Currently limited to 11.4m (plans for 12.3m)
Multiple Reel Installation – Areas of Development
[email protected] www.aquaticsubsea.com
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
Multiple Reel Installation – Areas of Development
[email protected] www.aquaticsubsea.com
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
• Need to increase to 14-16m (700Te+ capacity) to fulfil deepwater demand
Multiple Reel Installation – Areas of Development
[email protected] www.aquaticsubsea.com
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
• Need to increase to 14-16m (700Te+ capacity) to fulfil deepwater demand
• Increased size can introduce vessel instability
Multiple Reel Installation – Areas of Development
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
[email protected] www.aquaticsubsea.com
AOG 2015
Multiple Reel Installation – Areas of Development
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
[email protected] www.aquaticsubsea.com
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
Multiple Reel Installation – Areas of Development
[email protected] www.aquaticsubsea.com
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
Multiple Reel Installation – Areas of Development
[email protected] www.aquaticsubsea.com
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