SIMON STEVIN

Development of KirinsKoye Gas anD ConDensate fielD Umbilical installation

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1. Sakhalin III Project Description

The Sakhalin III Project is an oil and gas development program off the Sakhalin Island shore. The development includes four blocks (Vostochno-Odoptinsky, Ayashsky, Veninsky and Kirinsky) con-taining in total 5.1 billion barrels of crude oil and 1.4 trillion m³ of natural gas.

The Kirinsky Block is being developed by Gazprom Dobycha Shelf LLC, a subsidiary of Gazprom (owning also the Vostochno-Odoptinsky and Ayashsky licences).

The Kirinskoye Field

The Kirinskoye Field lies 28 km off the Sakhalin Island east shore, in the Sea of Okhotsk in water depths of approx. 90 m. The Kirinskoye Field will be developed by drilling and completing several subsea wells, connecting the subsea wells to a subsea manifold through a number of spools, as well as installing a number of infield umbilicals between the subsea wells and the manifold. The Kirinskoye Field has about 137 billion m³ of gas reserves and about 15.9 million tonnes of condensate reserves.

The Kirinskoye Gas and Condensate Field, part of the Kirinsky block, is Gazprom’s top development priority offshore Sakhalin. For the first time in Russia gas will be produced from the field by a subsea production system. Produced gas will be delivered to the onshore processing facility through offshore pipelines. Subsequently, a gas pipeline will convey it to the Sakhalin-Khabarovsk-Vladivostok gas transmission system’s main compressor station.

The scope

Main Contractor MRTS (Mezhregiontruboprovodstroy) awarded to Jan De Nul Group the installation of 4 infield umbilicals between the 4 subsea wells and the manifold, the flying lead installation, as well as rock installation works.

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2. Umbilical Installation Equipment

For this multifaceted scope the vessel ‘Simon Stevin’ was equipped with an umbilical installation equipment on the aft deck, and with a load of 30,000 tonnes of 40-70 mm rock material. This allowed the total scope of umbilical installation, flying lead installation and rock dumping works to be executed by means of only one vessel, resulting in considerable mobilisation cost savings.

The aft deck of the multipurpose vessel ‘Simon Stevin’ was equipped with 4 prepared umbilical reels holding the infield umbilicals with their Subsea Distribution Units (or SDUs) pre-fixed on the umbilicals. The umbilicals’ length varied between 1.27 and 7.37 km, the weight between 45 and 147 tonnes per reel.

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under roller drives

Guide-rails chuTe Tensioner

4 x reels

conTrol conTainer

In order to ensure a minimum bending radius of the umbilicals during installation, an in-depth study of the aft deck of the ‘Simon Stevin’ was performed, resulting in a detailed deck layout with guide rollers and an overboard chute for controlled guidance of the umbilical cable. The available deck space was efficiently filled in with monitoring containers, tensioner, SDU-base foundations, umbilical reels with supporting frames and under roller drives, winches and power packs. In addition to the vessel’s own work class ROV, a second ROV was placed on board for monitoring purposes during umbilical installation and simultaneous operations with two ROVs during flying lead installations.

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3. Umbilical Installation

Before starting the umbilical installation, the process was analysed by means of a computer simulation resulting in lengths of tie-back wires, required weight of clump weights, size of buoyancy blocks, tensioner settings and required vessel movements and timings in order to land the SDU in the predefined target box.

Thanks to the engineering phase and close monitoring of the settings during installation, the SDUs were positioned within 0.5 to 1 m of the target boxes. This is a remarkable result considering the fact that during installation, the paid-out cable length had to be monitored and compared with the distance to the target box at regular intervals, and this while adapting the route in order to avoid over or under length at the end of the installation.

The onboard equipment ensured the correct installation at a speed up to 250 m of umbilical per hour, following a curved umbilical route, and providing a pre-engineered catenary of the umbilical.

Each umbilical was successfully installed within the pre-ploughed V-shaped trench. The vessel’s work class ROV continuously monitored the touchdown point and position of the umbilical with its realtime multibeam data.

The umbilical installation for all 4 umbilicals was completed successfully within contractual time frame.

1. Fastening of tie-back rigging to the SDU on one side, and to the

clump weight on the other side.

2. Disconnection of the tie-back rigging by the ROV, and floating

back to the surface by means of the buoyance blocks.

3. Installation of the umbilical at a speed up to 250 m/h.

4. Umbilical as installed into the ploughed trench.

5. Installation of the end SDU.

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4. Rock Installation

During the season of 2012 also rock installation works with 40-70 mm rock material were required to protect the infield 10“ flowlines from the subsea wells to the manifold, the 20” pipeline and the 4.5” MEG line from the mani-fold to the onshore processing facility.

The rock installation works included backfilling, underfill, freespan correc-tion and pipeline stabilisation. The multifunctionally equipped ‘Simon Stevin’ was able to combine the rock installation works with the umbilical installa-tions. This resulted in a significant reduction of standby times for the vessel, since umbilical installation was not always possible due to simultaneous operations of the pipelay barge.

5. Flying Lead Installation

The ’Simon Stevin’ was equipped with 2 work class ROVs (WROV), which were simultaneously used during the installation of the flying leads.

A special subsea basket was loaded with a set of flying leads, 1 hydraulic flying lead and 2 electrical flying leads. The basket was then positioned on the seabed at a pre-determined location, equidistant from the SDUs and the manifold.

For the connection of the hydraulic flying leads, a special torque tool, supplied by FMC, was installed on the Quasar WROV. The connection of the electrical flying leads was done by means of the 7 function robotic arm of the WROV.

A total of 5 hydraulic flying leads and 10 electrical flying leads were successfully installed at a depth of 90.0 m.

1. Subsea installation basket loaded with 1 hydraulic flying lead and 2 electrical flying leads, ready for deployment

to the seabed.

2. Hydraulic flying lead being connected to the P5 Xmas Tree by the FMC Torque Tool.

3. WROV grabbing the connector from one of the electrical flying leads by means of the 7 function robotic arm.

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6. Installation of power cablesFor the installation of power cables, Jan De Nul Group’s vessel ‘Willem de Vlamingh’ is equipped with a 5,400 tonnes turntable.

sPeciFicaTions oF The TurnTaBle

Capacity 5,400 tonnes

Outer diameter 28 m

Inside outer basket diameter 27.4 m

Inner basket diameter 8 m

Basket wall height (open structure) 6 m

Max. speed at inner diameter 900 m/h

Ramp up to max. speed 45 s

Hydraulic driving motors 5

Loading arm movement degrees of freedom 3

Loading tower tensioner 5 Te

Deck tensioner 10 Te

sPeciFicaTions oF Willem de vlaminGh

Deadweight 6,500 tonnes

Length o.a. 115.0 m

Breadth 23.0 m

Draught loaded 5.35 m

Dynamic positioning DYNAPOS AM/AT R Class 2

Propulsion power 2 x 2,150 kW

Bow thruster power 2 x 1,500 kW

Total installed diesel power 8,975 kW

Speed 13.0 kn

Accommodation 35 + 24 (optional)

Built in 2011

Jan de nul GrouP (sofidra sa)

Luxembourg

info@jandenulgroup.com I www.jandenul.comDev

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