Fixed Platforms - EPCI Platform for Vietnam

8/9/2019 Fixed Platforms - EPCI Platform for Vietnam

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22 • J. Ray NEWS jraymcdermo

Major achievementsWithin just 22.5 months, the deck fabrication was completed, ready

to sail, 100 percent mechanically complete, commissioned onshore

and with no carry-over work. In addition, the Su Tu Vang project dis-

tinguished itself for a number of other achievements reflective of its

lion-like qualities.

It took courage, for instance, to agree to the customer’s request to

assemble a detailed engineering team in Singapore in just one month

expanding a core team from J. Ray’s Jakarta office. And with more

than 80 percent of the engineering, procurement, project control and

ocated in Mekong Basin, in 170 feet of water, the massive

Su Tu Vang Central Processing Platform (CPP) is slated to

become Vietnam’s largest source of crude oil over the next

three years with the capacity to process 100,000 barrels of

oil and 160 million cubic feet of gas per day.

It is also an excellent example of J. Ray’s strong project manage-

ment and execution expertise. As a fully integrated EPCI project

– from FEED and preliminary engineering to installation, hook-up

and commissioning – it is comprised of a 4,400-ton, eight-leg jacket;

17,000-ton float-over topsides; 66-person, 1,323-ton living quarters

module; pipelines; umbilicals and PLEMs.

The project clearly demonstrates in-house capabilities to take on

large, challenging projects, and established a benchmark in the

industry for a project of this size and complexity.

Awarded to J. Ray in March 2006, the Su Tu Vang first steel-cut-

ting ceremony took place at the Batam Island, Indonesia, facility on

September 28. Twenty-four months later, the project enabled First

Oil – producing at an initial rate of 10,000 barrels per day – ahead of

schedule. Another benefit to the customer related to the project’s

EPCI status and single contractor was elimination of interface issuesand a smaller customer team required to oversee all aspects of work

at a central location.

“Most importantly, the Su Tu Vang project is viewed as a major suc-

cess by the customer,” said Scott Cummins, J. Ray Vice President and

General Manager of Asia Pacific operations. “We are proud of this

achievement and recognition of the value added through our EPCI

capabilities and project execution focus. We are also honored and

delighted that this is our second and most challenging project for

CuuLong Joint Operating Company (CLJOC) since the start of our

relationship in 2001.”

True to its name − “gold lion” in Vietnamese − the Su Tu Vang project

epitomizes courage, strength, resilience and unwavering focus.

L

Lion

ROARS

T h e

proudly



J. Ray NEWS •aymcdermott.com

project management personnel being new hires, building teamwork

was a courageous endeavor.

“Each new hire received an orientation package with details about

the project, schedule, targets and other information,” explained

Anwar Ali, Su Tu Vang Senior Project Director. “A break-down of the

project scope was provided to each discipline level and then to the

individual level. Team members were virtually integrated with the

customer at all levels and a seamless open-door policy was estab-

lished to facilitate the ability to make decisions in the best interest of

the project and to guide, encourage and motivate team members.”

Another bold move was adding construction of a 66-person, four-

storey, living quarters module to the work scope half-way through

the project.

“We had to take this on, or jeopardize the whole project, as the

original subcontractor was falling behind schedule,” Anwar added.

The strength of J. Ray’s projec t management and execution abilities

made other achievements possible. A project-centric focus allowed

the team to establish priorities and resource allocation, facilitating

construction and achieving 100 percent onshore commissioning.

Involvement of fabrication and operations personnel in construc-tability reviews during FEED, preliminary engineering and detailed

design resulted in a platform design that is optimum, well laid out,

and construction- and maintenance-friendly.

A post-award vendor management task force comprised of pack-

age engineers, quality engineers and expediting commissioning

personnel, ensured timely delivery of a majority of the packages

with minimum punch-list items. During the procurement stage, a

structured scope definition led to simplified site assembly of large

packages and minimized interface issues.

Key personnel from in-house marine and hook-up groups

were involved throughout the various phases of the project to

Su Tu VangProject Experience

Jacket load-out and installation

4,000 tons, 8 legs•

4 conventional jacket roll ups•

Unique design for vertical launch•

Deck jack-up and load-out

17,000 tons•

Jack-up to insert load-out support frame•

4 strand jacks, 992-ton capacity each•

Deck height gain: 26 feet•

Distance pulled to quayside: 98 feet•

Break-out friction: 4.5%•

Pull distance to nal position: 656 feet•

42 portable submerged ballast pumps (capacity•

of each: 35,315 ft3 /hr) continually pumped

water to maintain constant level for 20 hours

Level within 1 inch despite a tidal•

range of 10 feet

Float-over installation

I-650 vessel used; second largest•

launch barge in the world

Rapid ballasting system triggered: 20•

minutes for 100 percent topsides load

transfer; 30 minutes to clear barge

10-point mooring system supplemented•

with soft mating lines



24 • J. Ray NEWS jraymcdermo

expeditiously address interface issues. Similarly,

commissioning and customer operations person-

nel were integrated into the project team. Their

continuous involvement in vendor data review and

participation in factory acceptance testing (FAT)

eliminated bottlenecks during system hand-over,

onshore commissioning and testing prior to load

out of the deck.

As a result, the project experience strengthened

J. Ray’s relationship with the customer and its repu-

tation in the wider market.

Resilience also came into play on a number of

occasions. The unique geometry of the Su Tu Vang

jacket – large, almost cuboid – combined with a

water depth of 170 feet at the proposed installation

site posed a host of design, fabrication and installa-

tion challenges.

First, the planned dimensions of the jacket, dic-

tated by the float-over methodology, topsides

layout requirements and water depth at installation

site, precluded the traditional horizontal load out

and launch.

Secondly, as the jacket was to be installed over

an existing 12-slot conductor template, it was

preferable that it self-upend and float with suffi-

cient clearance from the seabed. A vertical launch

was developed, but with constraints on the jacket

weight and launch barge geometry.

While many smaller jackets have been built ver-

tically at Batam Island in previous years, the sheersize and complexity of the Su Tu Vang CPP was

uniquely challenging.

Build height of the topsides took into account

the height and space requirement for the installa-

tion of the jacking assembly, eliminating the need

for any late modification to the framing facilities

prior to jack up. The sub-cellar deck framing was

designed in a way that allowed jacking columns

to be inserted without any interference. This mini-

mized installation work subsequent to the jacking

operation and enabled the complete sub-cellar

deck assembly to be inserted prior to jacking.

Lessons learnedAs prescribed in the project life cycle, Su Tu Vang

included a comprehensive review and implemen-

tation of “lessons learned” from the 2007 Arthit

project, which was the first use of Intermac 650

(I-650) for float-over installation, to carry out the

operation smoothly and efficiently.

From these lessons learned, I-650 was further

modified to adapt the barge for float-over opera-

tions. The layout was improved to optimize the use

of space on the barge’s deck, coiled polyrope mats

were added to prevent paint damage to the jacket

legs, and a new tank-gauging system and display

were installed at control rooms. Another major

change was a more robust mooring system that

allowed crews to essentially “walk” I-650 to the Su

Tu Vang jacket for float over.

As a result of incorporating Arthit’s lessonslearned, the Su Tu Vang float over was “picture per-

fect,” according to Anwar.

Thus taming the golden lion, these achievements

highlight the team work, dedication and ingenu-

ity required to ensure a successful, safe and speedy

completion of a major project. They also illustrate

and validate the significant synergies that are pos-

sible with early planning, design inputs and proper

coordination among all parties.

Following local tradition, the

Batam Island, Indonesia facility

uses the services of a rain stop-

per on important occasions.

Efforts to stop, delay or divert

unwelcome rainfall represent

one of the oldest traditions in

Indonesian cultural practices. It

is the only natural occurrence

that such intervention is applied.

Earthquakes, tsunamis, floods,

strong winds and thunder are

considered predestined through

Mother Nature and unable to be

predicted, stopped or diverted.

The rain can be controlled,

however, by a unique rit-

ual called “Pawang Hujan.”

Performed at a rain-free spot

where a function or activity

is being held, the ceremony

involves burning incense and a

plate of fire to produce smoke

that on rising is believed to push

clouds away and make the rain

fall elsewhere or to actually stop

until after the rain-stopping rit-

ual ends.

A recent example at Batam

Island was on the 2 p.m. sched-

uled celebration of the Su Tu

Vang sail away. Torrential rain at

10 a.m. that day prompted the

services of a rain stopper, who

announced at noon that the rain

would stop at 1:30 p.m. It did,

and then started again at 4 p.m.

“I’ve seen it happen like thatmany times,” said Anwar Ali, Su

Tu Vang Senior Project Director.



jraymcdermo

Arthit/Gulf of Thailand This major project included the largest topsides – 18,700 tons – ever built in Asia Pacific; 5,400-ton,

90-inch diameter, eight-leg jacket and associated infrastructure; and innovative engineering of trans-

port and rapid-ballast float-over installation hardware. Despite a demanding schedule and conditions,

seamless integration of J. Ray’s worldwide capabilities ensured schedule certainty.

Engineering: Houston/New Orleans/Singapore – Float-over engineering design, testing and

conversion of Intermac 650 transport and oat-over installation barge • Batam Island Indonesia –

Construction engineering for topsides • Dubai, UAE – Installation engineering support

Procurement: Asia Pacific region

Construction: Batam Island, Indonesia – Topsides and jacket

Installation: Asia Pacic eet – Jacket • Intermac 650 – Topsides oat over

As an EPCI company, we not only providecomprehensive services – from concept

to commissioning – but offer the resource

commitment, contracting strategy and mature

project management systems to execute on

the most complex, fastest track projects.

Integrated services, worldw

Poinsettia/Northwest Coast of TrinidadJ. Ray undertook this fast-track EPCI field development project from FEED to installation under a con-

sortium with Fluor. Facilities include a 9,100-ton jacket, 4,658 tons of piles and a 4,267-ton topsides.

Engineering: Houston, Texas – FEED and detailed design of jacket

Procurement: Houston, Texas – Jacket and piles

Construction: Morgan City, Louisiana – Jacket and piles

Installation: Gulf of Mexico fleet – jacket and topsides

Houston, TexasNew Orleans, Louisiana

26 • J. Ray NEWS

Map Key

Engineering

Procurement

Construction

Installation

Morgan City, Louisiana



J. Ray NEWS •aymcdermott.com

resources

Su Tu Vang/Mekong Basin, VietnamJ. Ray’s regional Asia Pacific resources completed this challenging EPCI project, setting an industry

benchmark for the 17,000-ton float-over deck from FEED to First Oil.

Engineering: Jakarta, Indonesia – FEED and preliminary engineering • Singapore – Design and

detailed engineering for topsides and jacket • Dubai, UAE – Installation engineering support •

Houston, Texas – Float-over engineering and model testing

Procurement: Asia Pacific region

Construction: Batam Island, Indonesia – Topsides and jacket

Installation: Asia Pacic eet – Pipelines, cables, PLEMs and jacket • Intermac 650 – Topsides oat over

Reliance/Offshore IndiaJ. Ray completed this fast-track EPCI project in 18 months, mobilizing worldwide resources to meet

the challenging deadline on a 19,842-ton control and riser platform.

Engineering: Houston, Texas – Major engineering services • Dubai, UAE – Construction and installa -

tion engineering support

Procurement: Houston, Texas • Dubai, UAE • Morgan City, Louisiana

Construction: Morgan City, Louisiana – Jacket • Dubai, UAE – Topsides, living quarters modules,

piles and boat landing

Installation: Asia Pacific fleet’s DB101 construction vessel

Singapore

Jakarta, IndonesiaBatam, Indonesia

Dubai, UAE

Fixed Platforms - EPCI Platform for Vietnam

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