EXTREME MODULARIZATION STRATEGY Case Study

THE WORLD…OUR PASSION

EXTREME MODULARIZATION STRATEGY

Case Study

Presented by :

Mr. ANDREA GAZZOLA

THE WORLD… …OUR PASSION

Project: INTEGRATION OF AN OFFSHORE PLATFORM

Site: Canada

Period: OCT 2016 – NOV 2016

(42 DAYS)


UTILITY PROCESS MODULE (UPM)

WEIGHT: 44,000 T

LENGTH: 71.5

WIDE: 103.75

HEIGHT: 60.5

MAIN MODULES


DRILLING EQUIPMENT SET (DES)

HEIGHT: 80M

WEIGHT: 3,250T

MAIN MODULES


DRILLING SUPPORT MODULE (DSM)

LENGTH: 54 M

WEIGHT: 3,900 T

MAIN MODULES


LIVING QUARTER MODULE (LQ)

LENGTH:58M

WIDTH: 17M

HEIGHT: 30M HIGH

WEIGHT: 4,000T

MAIN MODULES


ANCILLARIES MODULES:

HELIDECK: 115 T

LIFE BOAT STATIONS: 210 / 230 T

FLARE BOOM: 340 T

ANCILLARIES


INTEGRATION STRATEGY:

Modularized system


SKIDDING SYSTEM DEVELOPMENT FOR UPM: LOAD OUT KOREA – LOAD IN CANADA

FOR UPM MODULE A SPECIFIC SKIDDING SYSTEM HAD TO BE DEVELOPED TO TAKE INTO ACCOUT FOR:

- HIGH WEIGHT OF MODULE (44.000T)

- REQUIRED LOAD DISTRIBUTION ONTO PIER AT P.O.D.

- PUSH & PULL SYSTEM REQUIRED TO REDUCE WEIGHTS IMPOSED ONTO FINGER PIER AT P.O.A.

- REQUIRED WEIGHING OPERATION 2 WEEK BEFORE LOAD OUT

- REQUIRED SYNCRONIZED SYSTEM REMOTELY CONTROLLED TO CONTROL LOADS REAL TIME



- 64 SKID SHOES: 1,000 TON CAPACITY EACH

- SKID SHOES SYSTEM DEVELOPED BY FAGIOLI

- PUSH & PULL SYSTEM

- SYNCRONIZED SYSTEM REMOTELY CONTROLLED


Lift Capacity: 1,000 T / 1,200 t



KOREA CANADA



MODULAR LIFTING AND SKIDDING SYSTEM RE-DESIGNED FOR DES – DSM MODULES IN CANADA

FOR DES AND DSM MODULES THE EXISTING LIFTING AND SKIDDING FAGIOLI TECHNOLOGY HAD TO BE RE-DESIGNED TO TAKE INTO ACCOUT FOR:

- SPECIFIC MODULES GEOMETRY

- HIGH WEIGHT AND DIMENSIONS OF MODULES

- REQUIRED LOAD DISTRIBUTION ONTO PIER IN CANADA

- REQUIRED TRANSVERSAL SKIDDING AND JACK DOWN ONTO FINAL POSITION

- REDUCED TIME FOR INTEGRATION AFTER ARRIVAL OF THE 44K TON UPM MODULE


ELEVATOR Modularized Lifting System


• 12 SKID SHOES : 1,200 TON CAPACITY EACH

• ELEVATOR SYSTEM : 10,800 TON CAPACITY

• 2 KM SKID TRACKS

• MAIN GIRDERS : 35m

• 38 TOWER SECTIONS

• 16 STRAND JACKS UP TO 750 TON EACH


SPAIN: ADRIATIC LNG PROJECT

• WORLD’ s First Concrete Offshore LNG Receiving Terminal

• 12 + 6 modules from 700 to 4,800 ton



CHINA: BLAST FURNACE REPLACEMENT

• First Concrete Offshore LNG Receiving Terminal

• Replacent of an old top boiler section weighing 2,533 ton with a new one weighing 2,111 ton



CANADA PROJECT • Modularized system engineered by Fagioli



Modularized lifting system : DSM 3,900 T



Modularized lifting system : DES 3,250 T



REQUIRED EQUIPMENT FOR THE INSTALLATION OF THE LIVING QUARTER

FOR LQ MODULE AN INNOVATIVE SPMT AND BARGE INSTALLATION METHOD HAD TO BE ENGINEERED TO ACCOUT FOR:

- SPECIFIC REQUIRED LQ MODULE POSITION ON UPM STORED ON FINGER PIER IN CANADA

- REQUIRED INCREASED ELEVATION OF LQ MODULE TO AVOID POSSIBLE ICEBERG CLASH WHEN INSTALLED ONTO GBS

- AVOID OFFSHORE INSTALLATION BY HEAVY LIFT VESSEL TO REDUCE COSTS AND INTEGRATION SCHEDULE

- GRANT A FAST AND SAFE INSTALLATION METHOD TO AVOID SCHEDULE IMPACT OF POSSIBLE ADVERSE WEATHER

CONDITIONS



• 230 AXLE LINES SPMTS

• NO. 12 TRANSPORT BEAMS

• NO. 10 SUPPORT TOWERS

• NO. 4 TOWER LIFT PROVIDED WITH WITH NO. 8 X

L750 STRAND JACKS



• LQ LIFTED AT A HEIGTH OF 15 M



• Barge: 140 m long; 36 m wide


LIVING QUARTER LOAD OUT


LIVING QUARTER: FINAL INSTALLATION


Installation of Helideck (115 ton) by means of Fagioli LR11350 Crawler Crane

CONVENTIONAL LIFTING SYSTEM USED FOR THE INSTALLATION OF ANCILLARY MODULES

Installation of Helideck



Installation of Flare Boom

Installation of Flare Boom (340 ton) by means of Fagioli LR11350 Crawler Crane and Shear-leg



Installation of Life Boat Stations (East / West)

Installation of Life Boat Stations (210 ton / 230 ton) by means of Fagioli LR11350 Crawler Crane (West Side ) onto the LQ module and Shear-leg (East side)


PROJECT EXECUTION

EXECUTION FIGURES

INTEGRATION PHASE: 42 DAYS

SEPT 2016 OCT 2016 INSTALLATION OF DSM INSTALLATION OF DES INSTALLATION OF LQ


EXECUTION FIGURES


THE INDUSTRY REQUIRES TO MINIMIZE TIME FOR

ENGINEERING, FABRICATION, INTEGRATION AND

COMMISSIONING AS WELL AS INCREASING COST EFFICIENCY,

QUALITY CONTROL AND SAFETY. IS MORE AND MORE LEADING

TO AN EXTREME MODULARIZATION STRATEGY.

CONCLUSIONS

EXTREME MODULARIZATION STRATEGY REQUIRES THE DESIGN

OF NEW LIFTING AND TRANSPORT SYSTEMS LIKE FAGIOLI

ELEVATOR AND SKIDDING SYSTEMS WHICH NEED THEMSELVES

TO BE MODULAR IN ORDER TO BE EASILY RECONFIGURATED

AND TRANSPORTED FROM/TO SITE.


THE RAISE OF THE EXTREME MODULARIZATION

CONTRUCTION STRATEGY MAY LEAD TYPICAL

CONSTRUTION EQUPMENT, AS SPMT AND LARGE

CAPACITY CRANES, TO BE SEEN BY CLIENTS AS

«ACCESSORIES» TO MAIN LIFTING/TRANSPORT

SYSTEMS.

IN THE WORSE CASES, DUE TO THE PRESENT LOW

MARKET CONDITIONS, CLIENT MAY BE MISSLEAD TO SEE

THE TYPICAL CONSTRUTION EQUPMENT AS A

«COMODITY» WITHOUT GIVING IT THE CORRECT VALUE.

CONCLUSIONS


- LEADING HEAVY LIFT AND HEAVY HAULAGE GLOBAL

SERVICE PROVIDERS NEED TO DEVELOP NEW

TECHNOLOGIES AND ADAPT ITS ORGANIZATIONS IN

TERMS OF SALES, ENGINEERING AND PROJECT

MANAGEMENT TO FOLLOW THE NEW INDUSTRY

STANDADS, STANDARDS WHICH WERE ALMOST

UNTHINKABLE JUST FEW YEARS AGO

CONCLUSIONS

EXTREME MODULARIZATION STRATEGY Case Study

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