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1、Latest Progress in Floatover Technologies for Offshore Installations and Decommissioning,浮托技术发展现状及分类,浮托技术发展现状及分类,浮托技术发展现状：历史、现状、展望；浮托技术规范性分类；典型浮托安装主要过程；典型浮托安装主要设备；12种浮托技术简介;各类浮托技术特性及优缺点。,NOMENCLATURE,AHTS=Anchor Handling Tow Supply(tug)DP=Dynamic PositioningDSF=Deck Support FrameDSU=Deck Support Uni
2、tFPSO=Floating Production Storage OffloadingGBS=Gravity Base SubstructureGPS=Global Positioning SystemLMU=Leg Mating UnitLSF=Loadout Support FrameTLP=Tension Leg PlatformTML=Twin Marine Lifter,FLOATOVER TECHNOLOGIES,Conventional“Hi-Deck”TechniqueSmart-Leg TechniqueStrand-Jack Lifting TechniqueUNIDEC
3、K TechniqueFloatover Technique for SEMIs or TLPsT-Shape Barge TechniqueDP Vessel TechniqueVersa-Truss System TechniqueTwin-Barge TechniqueTML System TechniqueAmpelmann System TechniqueCatamaran Technique,Chronicle of Floatover Installations,1977:Brown&Root introduced the concept of the“Hi-Deck”insta
4、llation method1983:The 1st floatover installation of 18,600Te integrated topsides on a GBS in a relatively sheltered area for the Phillips Maureen Project1993:The floatover installation of 24,000Te Auger TLP Deck is the first open-sea application onto an in-place floating substructure in unsheltered
5、 deep water in GOM1997:The 1st shockless Smart-Leg System was used offshore Nigeria by McDermott-ETPM for the 4,100Te Ekpe topsides,Chronicle of Floatover Installations,1999:Versa-Truss installed three integrated topsides ranging from 4,200Te to 5,400Te in shallow waters of Lake Maracaibo,Venezuela2
6、000:Strand jack lifting installation was first developed by JGP to jack up a 300Te topsides more than 30m for Millom West gas platform in Irish Sea2003:The 1st installation of 9,000Te topsides in Gulf of Thailand was performed utilizing the DP II semisubmersible cargo barge Tai An Kou owned by COSCO
7、2005:Technip applied Unideck technique to install 18,000Te EAP GN Topsides in a swell condition offshore Nigeria,Chronicle of Floatover Installations,2006:Twin barge technique was applied by Technip to install the 3,400Te Kikeh topsides onto the first-ever spar outside GOM for the first time in 1,32
8、0m open waters offshore East Malaysia2006:The 1st installation of 21,800Te Lun-A topsides onto CGBS by a T-Shaped Barge offshore Sakhalin Island 2007:The world-record 28,800Te largest PA-B topsides onto CGBS by a T-Shaped Barge offshore Sakhalin Island,Floatover Installation of Lunskoye-A Topsides w
9、ith T-Shaped Barge in June 2006,Floatover Design Drive Factors,Size of Integrated Topsides:Weight,VCG,Dimensions Selection of Floatover Barge(s):single barge,twin barges,catamaran bargeLoad Transfer System&Separation System:e.g.LMUs&DSUsFixed Platforms v.s.Floating Platforms:except FPSOsShallow Wate
10、r v.s.Deep WaterBenign Environments v.s.Harsh Sea Conditions(including swell condition),Pros&Cons of Floatover Installations,Ease limited availability of heavy lift vesselsNo need for expensive mob/demob and day rates of heavy lift vesselsMinimize costly hook-up and commissioning periodsAllow more f
11、reedom of equipment layout within the deck compared to modular lifting designsEarly commitment during the conceptual design phaseSophisticated installation engineering&intensive field supportComplex floatover systemsLarge deck support frame&large leg spacing,“Our brain needs a bucket a category in w
12、hich to place a new idea.”Carmine Gallo,CLASSIFICATION OF FLOATOVER TECHNOLOGIES,Load Transfer System and/or Separation System:Mechanical Method:when mechanical devices are used as active load transfer systems and/or active separation systemsNon-mechanical Method:when only passive LMUs and/or DSUs a
13、re usedConfiguration of Floatover Barge(s)Single-Barge Method,Twin-Barge Method,Catamaran-Barge MethodConnection Types for Twin-Barge MethodRigid Connection Type,Hinged Connection Type,Flexible Connection Type,TYPICAL FLOATOVER PROCEDURES,Pre-Loadout PreparationsPre-Sailaway PreparationsPre-Floatove
14、r PreparationsDocking OperationMating OperationSeparation&Undocking OperationPost-Floatover Operation,Pre-Loadout Preparations,Upon weighing,the integrated topsides will be jacked up by a mega jacking system of hydraulic cylinders or lifted by strand jacksA tall DSF/LSF will be inserted under the to
15、psides prior to loadout operation,Pre-Sailaway Preparations,Complete seafastening(upper tiedowns and lower tiedowns)Complete floatover system preparationsFender SystemMooring Winches&Positioning WinchesRapid Ballast SystemBollards to connect with positioning tugsMost of all meet the sailaway criteri
16、a,Pre-Floatover Preparations,Upon arrival at site,the barge is connected with positioning tugs and a pre-installed positioning mooring system via an AHTS tug;Soft-line rigging preparations;Barge and substructure preparations;Function test GPS positioning monitoring system;Function test barge motion
17、monitoring system;Function test environmental measure system.,Docking Operation,Position Finally position the barge and align stabbing cones and LMU receptors,for example.,Mating Operation,Upon aligning the barge will be ballasted or active hydraulic devices will be used to transfer the topsides loa
18、d from the barge onto the substructure;Special multi-stiffness,multi-stage units may be required for large relative motions between deck and substructure;Many different kinds of mechanical devices have been invented to facilitate the load transfer system.,Separation&Undocking Operation,Having transf
19、erred the topsides load,the barge continues ballasting until safe clearance between the topsides structure underside and the DSF upside has been achieved.Then the barge will be withdrawn from the substructure slot with the help of mooring winches and positioning tugs.DSU to provide an increasing gap
20、 between DSF and topsides through the load transfer process until separation occurs.,PRIMARY EQUIPMENT SYSTEMS,Floatover Barge(s):carry,PRIMARY EQUIPMENT SYSTEMS,Docking/Positioning System:combination of spread mooring system,soft-line positioning system,and positioning tugs for barge approach,initi
21、al entry,docking,and undocking;Fendering System:In general three types of fendering systems should be provided for docking and undocking operations,i.e.,sway fenders,surge fenders,and guide fenders;Rapid Ballast System:required to transfer topsides load and ballast barge down to achieve safe clearan
22、ce between DSF and deck in a timely fashion,normally in four to six hours;GPS Positioning Monitoring System,Barge Motion Monitoring System,Environmental Measure System,etc.,TYPICAL FLOATOVER JACKET,Pre-Floatover,Post-Floatover,TYPICAL FLOATOVER BARGE,TYPICAL SWAY FENDER,SWAY FENDER,ADDITIONAL SUPPOR
23、T,FENDER SUPPORT,Sway Fender in Action,TYPICAL SURGE FENDER,Surge Fender Decomposition,Rubber Cone to absorb surge impactShims to adjust final position,Surge Fender to Align LMU&Stabbing Cone,TYPICAL STERN GUIDE FENDER,Stern Skidway&Its Support,Stern Guide Fender&Its Support,TYPICAL LEG MATING UNIT(
24、LMU),LMU Schematic Diagram,TYPICAL SAND DISH DSU,Prior to Separation,Upon Separation,TYPICAL SEAFASTENING DESIGN,Upper Tiedowns to be installed before loadout and to be removed before matingLower Tiedowns to be installed after loadout and to be removed during deck cleaning,Conventional Hi-Deck Techn
25、ique,Upon arrival ballast barge to a minimum draft with even keel&heelPosition barge&align with substructure slot with positioning tugs and mooring winchesConnect soft lines before docking,Dock into the slot with the help of soft-line winches,mooring winches,and positioning tugsAlign LMU mating cone
26、s and leg support receptors,Conventional Hi-Deck Technique,Ballast barge down to transfer the topsides load from barge onto the substructureLMUs to minimize impact load between Topsides and Substructure during mating,DSUs to minimize impact load between Topsides and DSF during separationContinue bal
27、lasting until achieving a safe clearanceUndock barge,Conventional Hi-Deck Technique,Shell Malampaya Platform in Place Floatover Installation of 11,500Te Topsides onto CGBS in 90m water depth offshore Philippines,South China Sea,Non-mechanical methodSingle large barge configurationOriginally develope
28、d by Brown&Root in 1983,Strand-Jack Lifting Technique,July 2000 JGP jacked up a 300Te topsides more than 30m for installation of Millom West gas platform in the Irish Sea;Successfully applied to installations of 4 integrated topsides ranging from 2,000Te to 6,200Te in 2002,2003,2008,and 2009,respect
29、ively,for the Apache/PetroChina Zhaodong Project;In extremely shallow near-shore waters in western Bohai Bay with a water depth of 1.78 m as per chart datum;No jacking up of the topsides is required prior to loadout.,Strand Jack Lifting Installation of 6200Te Topsides in extremely shallow water of B
30、ohai Bay for Apache Zhaodong Project,Strand-Jack Lifting Technique,Docking operation starts during rising tide with the help of a conventional docking system;Upon docking,aligning the stabbing cones of support legs with the pre-installed piles or the jacket piles;After removing all the tiedowns,lowe
31、r the 4 outer legs by about one foot a time one by one,otherwise it is difficult to insert over-curved strand wires through fixed anchors in a timely fashion;If necessary,simultaneously ballast the barge down to facilitate the deck mating;,General Arrangement of Equipment Layout on Deck,Strand-Jack
32、Lifting Technique,Continue lifting the topsides from the barge to the final design elevation at a speed of 0.3m per minute;Undock the barge once there is an adequate clearance;Level the topsides at the in-place elevation using strand jacks;Weld the shim blocks between the 4 outer leg sleeves and the
33、 4 outer legs before decommissioning and removing the strand jacks from the 4 outer legs upon relieving topsides load from the strand wires;,Lower the 4 inner legs onto the pre-installed piles and transfer the leg reaction load pre-defined by a finite element analysis to the 4 inner legs by using hy
34、draulic collar jacks;Weld the shim blocks between the 4 inner leg sleeves and the 4 inner legs before decommissioning and removing the hydraulic screwed locking collar jacks and strand jacks from the 4 inner legs;Mechanical method with single barge configuration,Illustration of Strand Jack Lifting I
35、nstallation,Smart-Leg Technique,Mechanical method with single barge configurationETPM developed and patented the shockless Smart-Leg System;Use hydraulic jacks to neutralize the vertical movements of barge and to transfer topsides weight from barge to jacket;Lock the deck at the peak height of the m
36、otion and take place at the precise time when the deck leg vertical speed is zero;Eliminate the kinetic energy and the risk of impact;Deck mating is completed in just a few seconds,less than the swell period;,Hydraulic Jack Assemblies Accommodated in Deck Legs right above Jacket Legs,Smart-Leg Techn
37、ique,After partial load transfer occurs,say 50%load transfer,the remaining load transfer can be achieved by ballasting the barge;Further jacking up the deck to the point where the Smart Shoes can be actuated to collapse with explosive split nuts;Thus yielding a 2.7m undocking clearance;Lack of contr
38、olling the final elevation of the topsides and its levelness;Do not allow a single failure;The 1st successful application was completed offshore Nigeria in June 1997 by McDermott-ETPM for the 4,100Te Ekpe topsides in a water depth of 50m.,Smart Shoes with Explosive Collapsible Mechanism,UNIDECK Tech
39、nique,Technip engineered this mechanical method with single-barge configuration;12 successful floatovers completed,including 3 in West Africa;The largest 18,000Te topsides was executed in early November 2005;Unideck technique enables short-time installation duration suitable to the swell conditions;
40、The technique combines ballasting and jacking to improve the stability of the barge during transportation;The active hydraulic system is used to achieve the docking clearance by jacking up before entering the slot;,Hydraulic Jacks Can Elevate and Quickly Lower the Deck,UNIDECK Technique,Initial 50%l
41、oad transfer by lowering jacks within duration of only one minute;Mating operation will be completed by ballasting down barge and extending jacks 2nd time;When the 75%load transfer is completed,a rapid ram retraction is performed within one second to complete the 100%load transfer;Thus achieving an
42、instant 1.5m gap for safe undocking,Typical Support Structure with Cylinder Jacks Elevated,Ampelmann System Technique,Developed in early 2005 by the Delft University of Technology and the Ampelmann Company to allow easy,fast and safe access from a moving vessel to offshore structures,even in high wa
43、ves;A platform supported on 6 hydraulic cylinders,capable of compensating the barge motions in six degrees of freedom;The topsides are placed on multiple Ampelmann systems;By measuring the vessel motions,the six hydraulic cylinders can extend or retract in real time by a monitor and control system;,
44、Thus maintaining the topsides in very small motions related to fixed substructures,but not floating substructures;The barge can move freely in between the slot while the topsides are held in virtually still;This results in that the barge will transfer no horizontal forces onto the substructure.A mec
45、hanical menthod with single barge configuration.,Ampelmann System Technique,A semi-active Amplemann system is developed to combine one central passive jack and six active jacks to separately withstand the static and dynamic loads,respectively;Therefore reducing the power requirements of this operati
46、ng system;The central passive cylinder will be set to such pressure equal to the static reaction load while the six active hydraulic cylinders will take the dynamic loads;,Semi-Active Ampelmann System with Six Active Hydraulic Cylinders and One Central Passive Cylinder,Ampelmann System Technique,Flo
47、atover installation requires a minimum of four Amplemann systems and four conventional passive hydraulic jacks to provide eight supports for 12,000Te topsides with one redundancy in case of single Amplemann system failure;Geometry of the Amplemann system will have a large effect on the system perfor
48、mance;Subject to the financial feasibility and technical reliability of complex mechanism and complicated control/monitor system.,Deck Layout with Four Semi-Active Ampelmann Systems and Four Passive Supports,Twin-Barge Technique,In November 2006,the twin-barge floatover technology was applied to ins
49、tall the 3,400Te Kikeh topsides onto the first-ever spar outside of the Gulf of Mexico for the first time in 1320m open waters,offshore East Malaysia,South China Sea;Upon hooking up the 10 semi-taut mooring lines,the spar hull is ballasted by both solids and variables to achieve a freeboard of 4.3m
50、prior to mating;Then towed to the offload operation base;The twin floatover barges are equipped with deck supporting frames and maneuvering/positioning equipment,Twin-Barge Configuration with Positioning Spread Approaching toward Pre-Installed Spar Hull,Twin-Barge Technique,The floatover barges are
