3503-3 SEDCO 712 BOP – TOI NEW WELLHEAD FRAME ASSEMBLED WITH MAERSK COMPONENTS
A new BOP wellhead frame has been built and assembled with MAERSK supplied new CAMERON wellhead connector. This is done to promote a relatively quick swap out of existing VETCO wellhead connector with the new CIW wellhead configuration. The existing BOP wellhead frame was already designed to meet rigorous Rig Engineering standards Quality Assurance Procedure (QAP) No. 070 that meets Class and Client’s Engineering requirements of BOP frame structural strength integrity. For more information on this services of BOP frame analysis, refer to Specific Services Video section in this section, entitled 2150 BOP Frame Structural Integrity Check (Laser scan to FEA). A combination of panoramic colour laser scan and Leica Total Station TS 15 along with ML Tech survey system has been used to record the orientation of the bolt holes, key elevations of critical components making up the assembly. These information was then used for subsequent 2D, 3D CAD lay down for stack up height, general arrangement and for subsequent clash check and intervention for the foreseeable future needs such as template drilling, tree intervention etc. For video presentation of integrate engineering services from BOP components, through to design and stress assessments of BOP under various loadings condition, refer to Corporate Video, Integrated Services at our web site, in particular 3533 SEDCO 712 BOP – WELLHEAD FRAME AND CONNECTOR SWAP OUT.
3503-2 SEDCO 712 BOP – TOI NEW WELLHEAD FRAME
To allow for the fast change out of the wellhead connector, a new wellhead frame can be built and the new connector positioned and seated at the correct elevation for mating up with the BOP components at the same time as the mating flanges on the 4 corner API guide posts. This will allow for the existing frame with redundant connector be decommissioned and new frame with the required connector, be scoot in its place. To accommodate future interrogation of clash check risk, tree intervention etc., a 3D panoramic scan of the newly fabricated frame was done at the fabricator’s facilities. In addition to this panoramic scan, a Leica Total Station (TS 15) has also been deployed using ML Tech Software to record the position of the mating face and orientation of the bolt holes. For more information of the wellhead frame when the connector is positioned in receptive supporting ring inside the wellhead connector bucket that house this connector component, refer to 3503-3 SEDCO 712 BOP – TOI NEW WELLHEAD FRAME ASSEMBLED WITH MAERSK COMPONENTS – video in this section.
3503-1 SEDCO 712 BOP – MAERSK COMPONENTS FOR ASSEMBLY INCLUSION
Upcoming drilling operation requires the swap out of existing VETCO wellhead connector with MAERSK supplied CAMERON connector. Along with the new connector, MAERSK also supplied guide funnel to be incorporated in to new BOP wellhead frame assembly for the guideline-less re-entry. At the fabricator facility, these two components were laser scanned for inclusion in to the final assembly and fit up of the new wellhead frame. This colour laser scan data was also subsequently used as BOP General Arrangement / Stack Up CAD drawing and for subsequent dimensional interrogation in the future, should the needs arise. Guide cone scan was then used to generate Finite Element Assessment (FEA) Model for the funnel strength verification when the funnel is subjected to re-entry loads during the sliding contact between the wellhead and the guide funnel while the BOP is being aligned with the wellhead. For more information of the wellhead frame that house these components, refer to 3503-2 SEDCO 712 BOP – TOI NEW WELLHEAD FRAME – video in this section.
3475, 3502,3262,3297 AND 3298 PROSPECT WELL TESTING CAMPAIGN (MEETING DNV –OSS-101 WELL TEST SURVEY CH.3 SEC.6)
Well testing operations require a significant amount of deck space to accommodate interconnecting equipment/piping and in some cases, coil tubing machinery / equipment and supporting containers and workshop. These containers and specialised equipment tend to be heavy, tall and with large foot print. Furthermore, in order to spread the load over the deck area to reduce the amount of deck strengthening, a series of spreader beam grillage needs to be installed. Functional layout using grillage system is cumbersome and require careful placement of spreaders over the support so that it does not clash with ventilation mushrooms, emergency escape route, deck head etc. Functional layout also needs to take account of the day to day required space on the rig i.e. payload. As such, detail understanding of how the deck is used and integration with these equipment is a must. A panoramic 3D laser scan lends itself for this functional layout to allow for accurate measurement, clash check and placement of equipment back in to cloud scan, for different well test operators. Rig Engineering routinely supports clients in this aspect to provide the best functional layout, best use of deck structural system and clash check. Additionally, follow up simulation of how deck will respond to load, fabrication drawings of the grillage and on site follow up installation and Method Statement can also be provided. For this integrated Services refer to our Video on Integrated Services section.
3512 AMIRANTE MARPOL 73/78 ZERO DISCHARGE CAMPAIGN (DECK PENETRATIONS REGISTER)
Part of the planned Out Of Services work for AMIRANTE during Palumbo Shipyard 2014 is to meet MARPOL 73/78 to ensure that there is no uncontrolled discharge over board. This requires remedial action to meet the minimum requirements set forth in Annexe I, IV,V and VI dealing with prevention of pollution by oil, sewage, garbage and air respectively. Whilst the standard survey using conventional survey method consist of tape, DISTO and Total Station can easily be done from rig’s main deck upwards, the under deck access has not been provided to allow for the conventional survey method to be used. In conjunction with the owner Project Team and the needs to supply prefabricated piping manifold, pipe supports, ties in and avoid clash with existing As Built structure and piping components, a 3D Panoramic Laser Scan measurement method has been selected. Deck penetrations have been accounted for, register of all openings made and integrate in to Scope Of Work along with the rest of survey to arrive at design and fabrication package to meet Class Review and MARPOL compliance. Project Team’s requirements for not making penetration in to primary and special structural components have been ensured by bench mark position below nearby girder flange, the information of which is extracted from the laser scan campaign.
PUSNES Winch Wild Cat Damage and Repair Benchmarking (By Colour Laser Scan Technique)
A request has been made to attending Rig Engineering MSc graduate civil / structural engineers part way through 2014 Out Of Services (OOS) Yard Stay. Some tape measurements data are needed by client of the damaged / worn wild cat windlass, Pusnes D75 EAX double drum electric driven winch. This measurement is required to complete Original Equipment Manufacturer’s questionnaire for conditional assessment purpose. After an in situ visual inspection on the wildcat on the main deck of the rig, a technical discussion was made on how best to supply the required technical data. The target is not just to meet the request by OEM, but would include other pertinent data allowing welding engineer to study the cross section of the worn / damaged profile, radial pitch of the pockets, to promote weld sequence planning for the best grain refining welding repair method / technique. Pertinent data was extracted from prior works, done by Rig Engineering on the chain failure investigation and specification of new chain manufacturing. In the end, bespoke laser scan was specified for this application. A series of panoramic colour scan was then done to allow for sectioning, interrogation of the geometry, assess the needs to “shift the pockets back” to original position, required volume of weldment, and risk to chain shoulder damage etc. Laser scan data was subsequently exported to CAD format and dispatched to OEM for critical conditional assessment purpose.
3510 Amirante BOP Bespoke Laser Scan for BOP Unitisation
To ensure that the load path from BOP mechanical parts during stowage and BOP handling to the carrier and under the rotary table is as intended, Rig Engineering pays particular attention at the structural interface between the annular, well head connectors at the BOP and LMRP packages. Loss of contact between certain interface, allows load bypass and some parts of the frame takes additional loads. To ensure that the strict assessment to demonstrate the structural adequacy of the BOP frame to take various loads, Quality Assurance Procedure QAP070 “Engineering Assessment, Frame Supporting BOP Mechanical Components Calculation” was used throughout. Firstly, accurate stack up height of mechanical parts are dimensioned off line from the companion structural frame. Once both drawings are checked and QA, they are overlaid with each other and any small discrepancies arbitrated to ensure that load path is assured. Bespoke laser scan in combination with our engineering standard practice QAP70 allows for this detailed assessment. Laser scan data was used throughout to obtain this deliverable and the BOP scan data can be sliced, sectioned and interrogate in detail and any plastic deformation found from laser scan data, are investigated in full. Frame drawings can then be ported to our FEA software for subsequent detailed assessment as well as spatial / clash check.
3511 BOP Data Capture for Stack Up and Space Out Drawings
As added value consisting of drafting and engineering services to the 3D Panoramic bespoke colour laser scan, Rig Engineering provides Stack Up and Space out drawings for client as part of the subsea information package for use with their client partners. Required dimension to allow for the manufacturing of the test tools are extracted and annotate on the space out drawings along with weight, dimensions, mechanical parts definition etc. as part of the BOP asset data management. We routinely supply the laser scan data to client’s team of engineers, OEM and in deed assist any team members to make use of the laser scan data to further their own campaign, such as DMAS installation, re unitisation purpose. Where required, our engineers can share screen and talk through clients or clients’s designated party and produce video walk through, section it and if absolutely required, produce bespoke CAD file specific for their needs. This processed is accommodated via ADOBE CONNECT. In this virtual meeting room, laser scan data can be interrogated and interactive engineering support discussion can take place on line and exact data to be extracted for the team can be fully assured, first time.
3479 Amirante New BOP Bridge Crane Project
Bespoken Engineering Purpose Laser Scan for Installation and Clash Check has been done for Transocean Project Team. Scanning strategy, resolution and extent has been put in place after Project Start Up Phase (PSU) with Transocean Inc. (TOI). Registered colour raw scan data was supplied along with native CAD format to allow CAMERON Original Equipment Manufacturer (OEM), to load up for subsequent engineering, clash check and work up installation sequence of their new BOP crane in to final installation and travel path check. Cameron preferred CAD file format were supplied to allow for AutoCAD and Inventor to process the bespoken scan. Additionally, POD file is also supplied to Transocean for information and independent clash check purpose. Colour laser scanning was carried out and QA by MSc Graduate Civil Structural Engineer fully conversant of the ensuing engineering needs.
3416 Island Constructor HP System Pre Installation Survey and Tie In Report
Prior to the start of the pre fabrication of the new high pressure well servicing system, Rig Engineering has been tasked to assist with the campaign by Enterprise Engineering Services. A two man team consisting of MSc graduate civil /structural engineers were dispatched to Norway, hand carrying laser scanning equipment as requested by client. The scanning system consists of colour 3D panoramic scanner, Total Station with ML Tech System tie in processing software. Bespoke laser and tie in scanning were done in accordance with client’s instruction on point of interests, area of the vessel and the tie in of the existing system to the new, proposed construction. Cloud scan and ML Tech survey system data were then post processed by OEM trained Rig Engineers, and the tie in coordinates were supplied in CAD format along with the camber of the deck to allow client to revise the fabrication drawings to account for As EXISTED states of the vessel. This results in complete site bolting /tie in installation process with no hot works involved.
2150 BOP Frame Structural Integrity Check (Laser scan to FEA)
To meet required standard of structural integrity check on the BOP frame, Rig Engineering has formulated Quality Assurance Procedure (QAP) No. 070 that meets Class and Client’s Engineering requirements. On site, to ensure that all the required data deemed necessary for the assessment by MSc. Civil Structural Engineer / QAP writer, are adequately captured, a bespoken colour laser scan of the BOP was done offshore. Graduate structural engineer did the laser scan, post process and do closed member wall thickness check using Cygnus through the paint measurement instrument. These data was then used firstly by us for Finite Element Assessment (FEA) to build structural model, followed by 2D design and Fabrication Drawings. All plastic deformation on each of the 4 legs disclosed by laser scanning technique, are assessed and adjusted in the design of new frame and strengthening of existing frame.
3363 Mud Gas Separator System Engineering Services (Laser Scan to Multi Engineering Services)
During recent yard stay of Out Of Services (OOS) Period, Rig Engineering resident Senior Project Surveyor has been tasked by client to gather information relating to Mud Gas Separator Project. The full engineering scope of works at the time was not confirmed. To ensure that all the range of engineering services can be processed such as CAD & Graphics, Pressure Vessel, Pressure Retaining Engineering Services highlighted in our WEB site, it has been recommended and accepted by client that the best survey method will be that of 3D panoramic laser scan. However, this will not be a standard general laser scan but bespoken solution is deployed to take in to account of no access and the range of the ensuing engineering services that needs to be done as a follow-up such Finite Element Assessment method and 2D and 3D fabrication drawings and design. Presently, the engineering bespoken cloud scan is being used for the ensuing 3D design incorporating J FLOW system to fabrication stage. Gathered data are maintained for any ensuing FEA and design works as required by client for the foreseeable future.
Design Appraisal and Design Performance Evaluation and Optimization
Rig Engineering has formed alliances with selected owner’s operations engineer, rig teams and project engineer in validating the feasibility of their own conceptual design and proposed construction. This process is also extended to selected fabricator alliance who wishes to validate their own design and use Rig Engineering facilities to review and improve the performance of the design, enhancement and optimize the construction to suit a particular contract. In this instance, all the geometry, required payloads, class conformance requirements are supplied to Rig Engineering for screening and reporting purpose. Where required, a full integrated “Reverse Engineering” of existing system can be measured with or without the use of 3D Panoramic laser scan, Total Station and DISTO measurement system suited to tasks at hands. Class Submittal and Design Verification Report (DVR) is routinely done to suit client’s requirements. For more information refer to WEB site Home Page at SERVICES pull down menu.
2108 Jack Up Global Strength RE Assessment due to Wastage
Rig Engineering has been tasked by rig owner of a Friede & Goldman L-780 MOD II Independent Leg Cantilever Jack Up, to carry out Global Strength Assessment of the rig in the as new and wasted condition. The objective of this Finite Element Assessment is to carry out a Fitness for Purpose of the vessel to allow for the orderly planning of the hull gauging and crop and renewal process to be done in a defined and controlled manner. The FEA model of the hull and leg has been constructed which also include the helideck, jack house and leg construction. For detailed information refer to Rig Engineering WEB site pull down menu entitled “ CASESTUDY” Load and load case, taking in to account of specific environmental criteria, has been included and the assessment was done in accordance with Society of Naval Architects and Marine Engineers, SNAME. The maximum, tolerable allowable minimum thickness along with the Fitness for Purpose stress levels have been computed by Rig Engineering MSc graduated civil / structural engineers, which leads to minimum crop and renewal remedial actions until such time as the orderly planned Special Periodical Survey (SPS) can be carried out at the convenient time.
3474 Post Shipyard BOP Data Capturing and Update Subsea Stack Up Drawings for Well Control Purpose
After the recent conclusion of the planned Out Of Services (OOS) Campaign, changes in the SEDCO704 BOP structural framing are to be captured along with the height changes of the mechanical parts of BOP components within the frame. With this in mind, along with no access for the conventional measuring method, demanded accuracy for the tool joints space out and the foreseeable needs to do further design to integrate DMAS System and re assessment of the BOP frame strength, a bespoken survey system /survey team was done. The team consists of Project Surveyor along with MSc graduate civil / structural engineer who is fully conversant with the required data under Rig Engineering Quality Assurance Procedure (QAP) No 070 “ Engineering Assessment, Frame Supporting BOP Mechanical Components Calculation”, a bespoken combination of 3D Panoramic scan and ML Tech system were deployed to capture all the relevant data for immediate and foreseeable future requirements of structural integrity check for DMAS going through splash zone, combined loading on the new modified frame etc. This is done to preclude the use of general panoramic scan practice that may require additional survey to be done at a later date since the engineering aspects requirements may not have been used in the general panoramic scanning strategy.