Offshore Constructions

OFFSHORE CONSTRUCTION

INTRODUCTION

Offshore construction is the installation of structures

and pipelines in a marine environment for the production and

transmission of oil and gas. Construction in the offshore

environment is a dangerous activity and where possible the

construction is modular in nature with the individual modules being

assembled onshore and using a crane vessel to lift the modules into

place. Oil platforms are key fixed installations from which drilling and

production activity is carried out. Drilling rigs are either floating vessels

for deeper water or jack-up designs which is a barge with lift able legs.

Both of these types of vessel are constructed in marine yards but are

often involved during the construction phase to pre-drill some

production wells. Specialist floating hotel vessels known as floats are

used to accommodate workers during the construction and hook-up

phases.

Other key factors in offshore construction are the weather window

which defines periods of relatively light weather during which

continuous construction or other offshore activity can take place. Safety

is another key construction parameter, the main hazard obviously being

a fall into the sea from which speedy recovery in cold waters is

essential.

The Offshore Construction is a major field of operation in the Oil and

Gas industry, there are many people involved in accurate surface and

subsurface positioning aspects. It will provide people with the solid basic

knowledge of the associated terminology, equipment and techniques

used in the offshore construction industry. The course guides you

sequentially through all aspects of various example construction

projects whilst covering also project procedures, HSE, and reporting _______________________________________________________________________________________________________

OFFSHORE CONSTRUCTION INDUSTRY, RAPCCE1

http://en.wikipedia.org/wiki/Safety

http://en.wikipedia.org/w/index.php?title=Weather_window&action=edit

http://en.wikipedia.org/wiki/Hook-up

http://en.wikipedia.org/wiki/Flotel

http://en.wikipedia.org/w/index.php?title=Jack-up&action=edit

http://en.wikipedia.org/wiki/Drilling_rig

http://en.wikipedia.org/wiki/Oil_platform

http://en.wikipedia.org/wiki/Crane_vessel

http://en.wikipedia.org/w/index.php?title=Onshore&action=edit

http://en.wikipedia.org/wiki/Offshore

http://en.wikipedia.org/wiki/Gas

http://en.wikipedia.org/wiki/Petroleum

http://en.wikipedia.org/wiki/Pipeline_transport

aspects. This course will beneficial to those co-operating with surveyors

and others involved in the daily operation of the Offshore Construction

industry.

OFFSHORE CONSTRUCTION INDUSTRY

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INTRODUCTION:

The Offshore Construction industry done a major field of operation for

the Oil and Gas industry, there are many people involved in accurate

surface and subsurface positioning aspects. Construction industry

provides people with the solid basic knowledge of the associated

terminology, equipment and techniques used in the offshore

construction industry. They also provide sequentially through all aspects

of various example construction projects whilst covering also project

procedures, HSE, and reporting aspects.

Offshore construction industry worked on offshore as well as onshore.

offshore work depending upon the onshore work. In on shore work there

are two main things are; technical work & commercial work.

Construction industry giving the HSE & technical ,training because at

every time the employee have to handle anew things.

Some times offshore construction industry done a onshore

construction also they done a construction for to get some petroleum

goods . all the oil & gas industry are depend on the offshore

construction industry .

Offshore construction industry is known as contractors and

subcontractors. They may be companies, partnerships or self-employed

individuals.

NEED OF OFFSHORE CONSTRUCTION INDUSTRY

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Man has found petroleum only in places where it seeped naturally

from the earth. Then in the 19th Century, man discovered ways to drill

water wells deep into the ground.

Sometimes these wells produced petroleum instead of water, and soon

the same techniques were being used to drill for oil. As the supply of

petroleum grew, ways of refining it into useful products were developed.

As the demand grew, this new technology for drilling holes could be

used to produce far more petroleum than ever before - if it could be

found.

On that time man needs to construct a structure or building on offshore

to store the natural products and research on the natural products.

All oil & gas are depend on the offshore construction industry because

of the construction industry they got a around 3000 bal. crude oil per

day . from one oil rig. for all this reason we need to be a offshore

construction industry in offshore business .

In the today’s world the new technology comes up because of this we

find out new source of natural resources for that we need a offshore

construction industry. offshore construction industry installing structure

and pipelines in marine environment for the production and

transmission of oil gas. And construction industry provide all the living

facility as well as protection facility to customer on oil platform.

Therefore offshore construction industry need of oil & gas industry.

.

CONSTRUCTION INDUSTRY ON ONSHORE & OFFSHORE

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ONSHORE WORK

TENDER FLOATING BY OIL COMPANY

The Client or customer floats a tender in market which contains contract

and bid documents. These two further include commercial terms,

technical terms, scope of work and bid specification

The Contractor or the Sub Contractor who makes the lowest bid gets

the contract

SURVEY:

When the company got the contract they send a 3 to 4 member team

on a construction field to see what type of work will be carried out like

modification or revamping.

SCOPE OF WORK :

After the survey of construction field they find out the scope of work

with the help of piping and instrumental diagram which is given by the

client

DRAWINGS:

They prepare the isometrics & structural drawing of new modification

of construction with the help of existing general arrangement drawing,

existing piping plant, & existing framing plant.

CALCULATION:

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After the drawing process is done then the project & operating

committee calculate the scope of work with the help of isometric

drawing & structural drawing which has been generated by construction

committee.

PROCUREMENT:

Is defined the structural & piping which is required during the

construction activity. Procurement is Depending on the scope of work

entrusted to , Purchase Order is released company or by the Clients.

Pursuant to this activity, regular Purchase Order specifications are

issued to facilitate vendor compliance, develop documents in

accordance with requirements and fulfill inspection requirements and

Third Party obligations.

INSPECTION:

Use of raw material during the construction activity will be inspected by

the respected quality control & quality assets department.

FABRICATION:

Fabrication will be carried out with the reference of approved drawing

which has been approved by the client & third party inspection.

Fabricated material will be inspected by the company’s quality control &

quality assets department then stage wise it offered to the third party &

client to inspected fabrication material.

After the final product comes OUT it will be transported on offshore

construction field to done the final construction activity by the way of

water transportation.

OFFSHORE WORK

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ROUTE PREPARATION ,

PIPE LAYING (CONSTRUCTION)

ROUTE PREPARATION:

The offshore pipeline must be laid on terrain

that is clear of geohazards, debris and

boulders. The seabed must be sufficiently flat

and in water that is deep enough for

construction and construction vessels to

operate. If these conditions do not occur

naturally, then seabed preparation by methods such as presweeping or

dredging may be required.

Seabed preparation may involve localized presweeping in areas

where there are sand waves or natural depressions on the sea floor.

Presweeping, which creates a more even surface on which to lay the

pipe, is expected to be necessary in the more mobile bed form (sand-

wave) areas of Torres Strait. Presweeping is often performed

immediately prior to pipe claying, because sand-wave environments are

typically dynamic and the preswept seabed surface may quickly resume

its naturally uneven profile. Sand wave presweeping is typically

performed by plugging or jetting. Volumes of sand

mobilized when using these techniques are small and tend to settle

locally.

PIPING CLAYING (CONSTRUCTION):

Pipe claying vessels are expected to be employed to install the pipeline

in the offshore .Vessels of this type typically operate as follows:

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• Sections of line pipe are stacked on the pipe claying vessel.

• Pipe ends are prepared for welding.

• Successive joints of line pipe are lined up and welded together.

• Welds are radio graphically inspected and repaired or replaced as

necessary.

• Anti-corrosion material (fusion-bonded epoxy) and a weight-coating

are applied to the welded joints.

• The pipeline is lowered to the seafloor.

A constant tension is applied to the pipeline as it is lowered from the

vessel to the seabed using a pipe claying arm (called a stinger). The

stinger extends from the stern of the pipe claying vessel and prevents

the pipeline from bending excessively between the vessel and the

seabed.

The laying of an offshore pipeline is generally a continuous process.

Barges (towed by tugs) or self-propelled vessels bring the line pipe and

other supplies to the pipe claying vessel. An offshore pipe claying

operation typically comprises:

• A pipe claying vessel.

• Up to three anchor-handling tugs (depending on pipe claying vessel

type )

• A general supply vessel.

• Line-pipe supply vessels in sufficient numbers to ensure a continuous

supply of line pipe to the pipe claying vessel.

• Bulk carriers to transport line pipe to a location from which the line

pipe supply vessels can supply line pipe to the pipe claying vessel.

• A dedicated survey vessel.

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IMPORTANT’S OF R & D DEPARTMENT IN CONSTRUCTION

INDUSTRY

In the past half-century, spectacular advances have been made in the

design, construction, and installation of structures for offshore oil

and gas production. From the original simple fixed four-pile platform

in 20 ft of water offshore Louisiana, the industry has evolved to today’s

use of permanent floating structures with sophisticated Facilities

designed to support production in fields exceeding 1 million

bbl of oil equivalent and operating in water depths exceeding

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7,000 ft.

Expansion into increasingly deeper waters in search of larger

reserves has presented operational challenges requiring ingenuity, risk

taking, and foresight. The ability to continually push the technological

envelope has historically been made possible by the joint R&D

efforts of operator companies, engineering and construction firms,

contractors, equipment manufacturers, and academia. This article will

highlight a few selected areas in which R&D has contributed to recent

operational successes or in which future R&D efforts undoubtedly

will be required to provide technological support for continued frontier

Pursuits and for meeting the associated challenges. Solutions from R&D

efforts can be broadly categorized according to their level of beneficial

impact on a project’s outcome and the immediacy of the need, whether

short-term or long-term. A breakthrough

Solution can be construed as one in which state-of-the-art

technology has been applied in a fashion that allows immediate and

significant gains. R&D also can improve current know-how by

advancing technology to newer generations that provide faster,

more economical or more viable alternatives to prior approaches.

Based on project involvement and knowledge of the offshore arena,

This article will attempt to categorize each of the areas accordingly

and discuss how this vital R&D activity should be protected.

GAS SOLUTION: (Example)

The increased demand for natural gas in the U.S. and globally,

supported by satisfactory market prices, makes the economic recovery,

processing, handling, and transportation of natural gas products an area

with immediate as well as long-term potential. Oil and gas

reserves have been, and continue to be, discovered in locations

remote to distribution infrastructure, such as deepwater Gulf of_______________________________________________________________________________________________________


Mexico, Newfoundland, West Africa, Malaysia, Trinidad, and Indonesia,

where the gas associated with oil production or gas reserves considered

small are disadvantaged economically. The industry has solved the

question of producing remote oil with floating production, storage, and

offloading (FPSO) vessels or with spars, tension leg platforms, subsea

completions, and other floating production systems that include subsea

oil pipelines, but we are still faced with the question, “What do we do

with smaller volumes of associated or produced gas?”

Technically feasible and economically viable gas solutions for

remote gas are emerging rapidly in the form of transportable,

marketable, and fungible gas products such as liquefied natural gas

(LNG), methanol, Fischer-Tropsch liquids, ammonia, urea,

diethyl ether (DME), and liquefied petroleum gases (propane,

butane). Organizing a commercial deal that connects a market for

the products with the gas source is the key. Bringing down capital

and operating costs is the facilitator, and the inventive process is

under way now.

Several innovations are now coming from research designed to

give clients the best options for commercializing their disadvantaged

gas. Immediate benefits are the elimination of gas flaring,

alternatives to costly gas reinjection, and the creation of marketable

gas products that, in themselves, can be a viable gas business. Some

of the most recently proposed gas solutions include:

• Barge-mounted gas-to-liquids process.

• FPSO-vessel-mounted methanol processing.

• Gasification of coal into Fischer-Tropsch liquids (methanol,

DME, diesel).

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• Development of horizontal steel LNG storage tanks in a

Perliteinsulatedconcrete “cold box” for onshore or offshore applications.

• A “short haul” concept for small LNG quantities (150–300

MMscf/D) including a concrete barge with new tank design to liquefy,

store, and offload LNG near the gasfield end, transport it 1,000 to

1,500 miles, and then have a similar regas barge at the destination.

• New regas technology using air exchangers to greatly reduce

fuel costs and air emissions.

• A concept to produce and store compressed natural gas on specially

designed shuttle tankers.

• LNG FPSO vessels for liquefying gas at offshore field locations

in the open ocean.

• LNG floating storage and regasification units for importing

LNG and re gasifying it in the open ocean. In addition to these

technologies, R&D needs to continue its focus on developing economical

products and processes that can be used for stranded and associated

gas so the products can be readily marketed. In that regard, ongoing

efforts need to be continued in the transport, storage, and offloading of

LNG.

R & D PROVIDE SAFETY AND SECURITY SOLUTION

Offshore assets, remotely operated or manned, are vulnerable to

Potential terrorist attacks. There are both topside and sub sea

components that warrant a continued need for R&D to develop methods

to safeguard these investments after installation. Significant

advancements have been made in the reliability and safety aspects, but

minimal consideration has been given to the protection of the asset._______________________________________________________________________________________________________


THE RELEVANT MARKETS OF OFFSHORE CONSTRUCTION

PRODUCT MARKET:

With regard to offshore construction, oil and gas installations are

considered to belong to the same product market, as many companies

tender for contracts for both types of installations and the orders derive

from the same set of customers. The same type of argument applies to

standing and floating installations where the choice from a demand

point of view depends on technical aspects such as the location of the

field and water depth. Offshore contracts may be awarded on piecemeal

basis with different contractors involved to perform different tasks.

Some customers award contracts on a turnkey basis, whereby one

contractor would be responsible for the entire project and, as the case

may be, would engage subcontractors. The abbreviation EPCI

(Engineering, Procurement, Construction and Installation) is used as an

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industry specific term for the activities required in order to complete

turnkey offshore projects. Third parties have generally confirmed the

suggested product market definition even though some third parties

have pointed out that pipe laying on some occasions have formed part

of EPCI contracts

GEOGRAPHIC MARKET:

The parties have submitted that the geographic scope of the market for

offshore construction (EPCI) is world wide as such services are being

provided wherever oil and gas fields and contracts are awarded on the

basis of world-wide tenders. The off shore construction market has in

previous decisions by the Commission been considered to be either

global or regional (e.g. the North Sea or the Norwegian Shelf). The third

parties participating in the Commissions market investigation have

generally supported that this market is global.

KEY FACTORS IN ECONOMIC SUCSESS

Three key elements that contribute to economic success in the offshore

are cost management, reduction in project development time, and

improved well performance. The degree to which firms achieve gains in

any or all of these areas will contribute heavily to their potential for

success or failure.

COST MANAGEMENT

Cost management includes both efforts to alter operations to offset

increased costs and measures to reduce costs associated with given

aspects of a project. An example of the first type of effort occurred

when recent increased demand for offshore rigs drove drilling rates up.

Companies had no control over the market-determined price but could

search for ways to minimize drilling time and therefore drilling costs.

The other type of cost management effort refers to the continual search _______________________________________________________________________________________________________


for cost-reduction techniques. Technology often is a major influence on

cost reduction.

Cost reductions are achieved in a number of other ways. day, and the

single Mystique well, which produces at Outsourcing of certain services

can allow for the sharing of 25 MMcf per day. resources to avoid the

cost of being on site 24 hours per

day. For example, inspection of operational equipment by qualified

contractor personnel and equipment on a part-time basis allows those

resources to be used for multiple projects. As costs are shared across a

larger volume of service, the costs associated with any one project

decline. Despite potential economic advantages, outsourcing is an area

of concern for the Minerals Management Service (MMS). The MMS has

issued a notice regarding possible

waivers from daily inspection requirements, which may prove essential

for marginally economic projects.23 Used equipment is becoming

another important factor even for deep-water operations. This approach

allows for both direct cost savings and reduction in delivery time to the

site. Another cost-saving option is sub sea well completions and

transportation tiebacks to nearby platforms for production processing.

This has been a promising approach to offshore development in deep

waters. This approach lowers overall

project cost by avoiding the cost of a production platform at the water’s

surface dedicated solely to a single project

REDUCTION IN PROJECT DEVELOPMENT TIME

The success of any construction project projects underscores the

importance of adequate planning to ensure both optimal resource

recovery and a strong economic return on investment. However, as

experience in offshore construction operations grows, companies’ need

for measured caution lessens and firms emphasize timely activity in

their approaches to project development. The goal is to

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accelerate development, which increases the expected net

financial return by yielding an earlier economic return and

reducing the carrying costs of early expenditures on leases, geology

and geophysical work, and exploratory drilling.

Eg. Design improvements between the Auger (initial production in 1994)

and Mars (initial production in 1996) projects, both at water depths of

approximately 2,900 feet, allowed Shell to cut the construction period to

9 months with a saving of $120 million.26 Accelerated development

enhances economic attractiveness by reducing project uncertainty

because adverse changes in market price for the commodity or factor

costs become more of a possibility as development time lengthens.

One approach to achieve revenues as soon as reasonable is the use of

a subsea completion and transportation of production to an existing

platform. A key advantage to this approach is that it provides an early

contribution to project returns while additional engineering and design

work for the full project proceeds. Another approach being developed

especially for deep-water project development is in the overlapping of

design phases and construction. Improvements in technology and

project management allowed Shell Deepwater to develop the project in

about the same calendar time. Development for offshore construction

projects in general had ranged up to 5 years previously, with deep

projects requiring up to 10 years. Recent field development has been

accelerated with the period from discovery to first production in shallow

water ranging between 6 and 18 months. Variables.Experience with

deep-water construction and operations has enabled development to

proceed much faster, with time from discovery to production declining

from 10 years to just over 2 years by 2001

WELL PERFORMANCE

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A third major factor behind favorable offshore economics for offshore

construction is the rather astonishing production

performance characteristics of large fields. This is seen clearly in deep-

water fields, which tend to have high permeability and pressure that

result in rapid flow to the well bore. Individual well flows of 100 million

cubic feet (MMcf) per day have been achieved at some fields,

Well performance is important of both ultimate product development &

speed of construction process Given that production performance

variables such as the initial flow rate dominate over drilling costs as a

major influence on profitability, a rational strategy is for the operator to

pursue well drilling and completion technology with an emphasis on

increased productivity despite increased costs. As long as the cost

increments are managed properly, the productivity gains may be well

justified.

Analysis of a representative deep-water gas project shows that possible

increases in drilling costs of 50 percent could be offset by flow rate

increases of only 19 percent (assuming all other project parameters

remain unchanged). These estimates show the economic incentive

behind research and development in drilling and completion

technologies that have resulted in very high flow rates.

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CASE STUDY

ONGC: OFFSHORE CRISIS MANAGEMENT

Background

In the offshore Oil & Natural Gas Corp. of

India (ONGC) offshore platform BHN

located in Arabian Sea, 100 miles (160 km)

from Mumbai (Bombay).

BHN Complex consists of BHN + MNW +

NF + NA Platforms, all bridge connected.

Mumbai high - North & South put together is producing about 260,000

barrels of oil and 10.2 million cubic feet of gas per day. BHN Complex

production was 40,000 bbl & 4 million Cft of gas per day. Out of 4 m gas

being produced, 2.4 is used for gas lift, utilities etc and balance is

pumped to Onshore, Uran. Mumbai High North has another Complex –

NQ. Its production was going thru BHN & hence also affected now.

Presently, ONGC have resumed production from South Fields which is

150,000 bbl/day + 7.5 million Cft of gas per day.

Noble Charlie Yester (NCY) drill rig on-site at time of incident at NA

Platform. IRM DP Vessel of ONGC ‘MSV Samudra Suraksha’ also in area

to transfer person to platform. BHN Platform was built by J Ray

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BHN COMPLEX

McDermott in Dubai and installed in working season 1980 - 81 under EIL

supervision. ONGC’s Insurance is covered by India’s United India

Insurance Company, re-insured with ACE, AIG and Zurich.

CRISIS ON OFFSHORE CONSTRUCTED LOCATION

The story starts with the bad weather, and a

cook cutting his finger in the galley of MSV

Samudra Suraksha. This is a DP-2 Multi Support

Vessel working for ONGC. The Master of the vessel

asked for an emergency chopper to send the

injured man to Bombay for treatment (Medivac).

Due to the rough seas The Chopper (helicopter) could not land on the

helideck of the said vessel. Therefore BHN being the nearest installation

(platform) to where the vessel was working decided to have the man

picked up and Airlifted from there to send to the Hospital.

While delivering the injured man to the Platform. (This is usually an

everyday operation of transferring personnel by way of a "Personnel

Basket" in the offshore oilfield), the vessel has to approach under the

crane of the Rig/ Platform and Persons will be lifted from the deck in a

conical shaped basket with the help of a crane.

Due to the High Seas at that time. Master of the vessel lost control; the

vessel was NOT on Dynamic Positioning system - This system keeps the

vessel at a fixed heading and holds position in high seas and strong

currents). The vessel’s Helideck hits the Platform’s Topsides, in the

process rupturing Aviation Turbine Fuel (ATF) lines; also, the vessel’s

hull-side hits gas pipeline (Riser). The Riser as well as ATF lines broke

and gas got mixed with the Air and due to metal-to-metal impact, spark

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caused the gas to ignite. Explosions took place simultaneously igniting

the BHN platform and the MSV Suraksha.

People on board the platform and the drilling rig jumped into the water

in groups of 4 after wearing life jackets. Majority of the people from BHN

platform rushed to the bridge connected MNW platform. Some took

to life rafts that were available. There were about 7 or 8 Supply vessels

on the scene.

Total persons on board BHN Complex (BHN + NF + MNW + NA) were

227, on the MSV Suraksha 84 and the Rig Noble Charlie Yester 73 a

Total of 384 persons.

The MSV had 6 divers who were in the compression chamber at the time

of the accident; they went through decompression with the help of MSV

Samudra Prabha (another ONGC owned DP 2 vessel) and brought to

surface. ONGC’s OSV Sindhu-7 later on towed MSV Samudra Suraksha

but before reaching Mumbai, about 8 nautical miles from shore,

Samudra Suraksha also sank.

Final Outcome:

BHN platform destroyed.

NF Platform Topsides substantially damaged.

NA Platform only surface painting damage.

Noble Charlie Yester (NCY) rig minimal damage.

A Helicopter at BHN also destroyed in the fire.

MSV Suraksha sank.

22 persons died (11 confirmed + 11 missing

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RECOVERY FROM CRISIS

A Committee has been formed by ONGC for investigation, comprising of

Mr. S.K. Manglik - Ex Chairman Of ONGC

Mr. H. S. Cheema - Ex Chairman Of Gas Authority of India

Mr. Ishwari Dutt - Ex Technical Director Of ONGC

ONGC’s immediate priority is to augment production from the Mumbai

High North Field. This to be initiated in several phases. Keeping this in

mind, ONGC have invited Expression Of Interest (EOI) as under:

- Wreck removal

- Charter Hire of FPSO

- Charter Hire of DP-2 MSV

This is part of ONGC’s Re-construction plan in phases broadly as under:

Short Term (1 to 2 months)

Revival of lift gas to MH South Well Platforms,

Resumption of production from NQ complex,

Diversion of well platforms of BHN to NQO / MH South.

Medium Term (6 to 12 months)

Laying of new pipelines to connect additional well platforms of

BHN,

Revival of well platforms connected to NA processing facilities,

Using FPSO for immediate revival,

Using an EPS near NA,

Commissioning of NA, BHF & MNW

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Long Term (2 years+)

Construction of new surface facilities

CONCLUSION

After due to deliberations and exploring possibilities for resumption of

hydrocarbon production from Mumbai High North field, it emerged that

attention needs be given in phased revival based on use of existing

facilities, installation of new facilities and probable time required for

modification jobs. Committee came to a conclusion that around 70% of

the affected production can be revived in about 4 weeks time, additional

6-7% can be revived by the end of Sept. ’05. Committee also concluded

that all the affected wells can be put back on production in about 6

month time. However, these may not produce optimally because of

increased back-pressure which some of the wells would face on account

of improper well fluid and gas lift line size.

ONGC’S management take important decision on reconstruction of

platform after the one week they float the tender on market and they

divide work in two parts and they give the contract to two different

company therefore they reconstruct the plat form with in the one year.

this all possible because of active management and management

person.

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CONCLUSION

ADVANSED TECHNOLOGY IN OFFSHORE CONSTRUCTION

In anticipation of increased activity by the

major oil companies in deep and ultra-deep

water, in particular in the South Atlantic, SBM

Has entered into a joint venture with the

Norwegian company Sol’s tad Shipping AS for a

new generation deepwater offshore construction and installation vessel,

placing a contract for the ship with the Ulstein Shipyard in Norway.

Boa Deep C ( worlds largest offshore construction vessel) -

Completed sea trials in mid-May and has since mobilized to begin work

on the Snohvit project in the North Sea. The ship's first project is being

undertaken in a joint venture with Acer Marine Contractors (AMC),

directly after which, the vessel will move on directly to the Kristin

project, where she will install moorings and manifolds .

In every respect a unique vessel, Boa Deep C is designed to carry

out subset construction work at great depths - up to 2000m - and makes

her owner, Boa Taubatkompaniet, a leading contractor in the offshore

construction marketplace, able to undertake sub sea installations,

mooring system and pipeline repairs, and template and anchor pattern

installations anywhere in the world, at depths

of up to 2000m.

Built in China at Jin Ling shipyard, and outfitted in Spain at

Factorias Vulcano shipyard, Boa Deep C is 120m overall and has a beam

of 27m, and was designed by Vik- Sandvik, the well-known Norwegian

naval architects. With a large deck area, a high deck

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loading capacity, deepwater 250tonne and 300tonne heave-

compensated cranes, a deepwater winch with a 500tonne line pull and

extensive accommodation, Boa Deep C also boats twin built-in

deepwater ROVs, and a 7.2m x 7.2m moon pool, a stern roller designed

for a downward pull of 750tonnes, and has a bollard pull of in excess of

260tonnes.

A very interesting feature of Boa Deep C is propulsion machinery

designed to operate in three modes according to operational

requirements, these being diesel-mechanical, for steaming; diesel

electric for use in DP mode; or diesel mechanical with electric booster

for maximum power in 'bollard-pull mode.’

The machinery is based on six Caterpillar 3600 engines: a pair of V16-

cylinder units on the main shafts, and two eight cylinder and two six

cylinder models used as genset drives. Each of the two Caterpillar

3616TA engines is rated at 6000kW (8160hp) and drives a Scana Volda

four-bladed 4.4m-diameter CP propeller in a nozzle via a Scana Volda

ACG1080 gearbox, the direct-drive arrangement being used when

steaming. For maximum bollard pull, power on each shaft can be

boosted by 3000Kw from a Siemens combined PTI/PTO (electric

motor/shaft alternator).

A diesel-electric mode is used for DP operations, and positioning

requirements are met by four 1425kW Brunvoll FU-80-LTC tunnel

thrusters (two aft and two forward) and a 1200kW Brunvoll AR-80-LNC

retractable azimuth thruster located abaft the forward bow thrusters.

These thrusters are variable pitch and controllable speed, which allows

the optimization of power and fuel consumption and noise reduction

when operating in a DP 3 mode.

CASE STUDY

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OFFSHORE HOOK-UP AND CONSTRUCTION SERVICES

OFFSHORE HOOK-UP AND CONSTRUCTION

SERVICES

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INTRODUCTION:

Offshore Hook-Up And Construction Services ( India ) pvt. Ltd.,or

O.H.C.S.,as it is widely known, has been surviving the offshore oil & gas

industry, since its inspection, in the year 1981. it has since then been

providing design, engineering , fabrication , offshore installation , hook –

up , pre-commissioning , commissioning services to a cross – selection

of clients for a number of major offshore projects. OHCS clients include

all major world players in the offshore industry.

Offshore Hook-up and Construction Services (India) Pvt. Ltd.

(OHCS) is Engineering and Construction Company established in 1981.

Since inception, the Company has been involved with the Indian

Offshore Industry. The Company's main activities include Design, Detail

Engineering, Fabrication, Construction, Installation, Hook-up, Pre-

commissioning and Commissioning for new as well as existing facilities.

Areas of specialization include Offshore Projects involving new well

platforms, process platforms and extensive modification and hook-up

works on major existing offshore complexes

In addition to its participation in major offshore projects within

India, OHCS has crossed national boundaries and participated in

projects overseas. This continues to be one of out thrust areas.

Over the years, OHCS has evolved tested management systems and

has been successfully applying them to timely realize its tasks. We have

also been successful in developing a creative team of highly qualified

Project Managers and Discipline Engineers with a wealth of offshore

experience.

OHCS complies with specifications laid down by many of its well

known Clients / third party inspectors such as ONGCL, EIL, DNV to name

a few. Projects are normally carried out under OHCS's own Quality

Assurance System which, where necessary, can be further _______________________________________________________________________________________________________


supplemented with specific project requirements or other specified

standards. OHCS Project

Managers constantly ensure compliance to Contract Specifications,

execute and monitor the projects using the latest application software

for Quality Control, Planning, Designing, Testing and Inspection, etc.

OHCS uses Computer Aided Design and Drafting techniques for its

projects. In-house facilities include adequately experienced personnel,

computing hardware and application software. Besides these facilities,

OHCS has a well equipped library providing necessary technical support.

In the light of its fulfillment of customer requirements with quality as the

prime objective, O.H.C.S. has earned the prestigious award of ISO

9001: 2000 Certificate. O.H.C.S. is serving a number of offshore clients.

Clients include reputed multinational companies from India and abroad.

OHCS, with its progressive outlook and tight schedule control is

recognized for prompt mobilization and swift execution. The Company

believes in elaborate planning, proper mobilization, optimum utilization

of manpower and effective schedule control maintaining strict

compliance to quality requirements.

_______________________________________________________________________________________________________


_______________________________________________________________________________________________________


ISO 9000: 2001_______________________________________________________________________________________________________


QUALITY POLICY

Offshore Hook-Up And Construction service (India)PVT . LTD.

IS Committed To Comply With The Customer ‘S Requirement By

Providing Timely And Efficient Service In Field Of Fabrication ,

Installation , Testing , Pre-Commencing , Commencing , And

Adopting Suitable Measures For Continual Improvement Of The

Effectiveness Of The Quality Management System

DESIGN & DETAIL ENGINEERING

_______________________________________________________________________________________________________


OHCS's engineering team provides design, engineering and project

management services. It has in-house experience and expertise to

provide the aforesaid services for the disciplines of process,

instrumentation, piping, structural and electrical including inter-

disciplinary co-ordination for the Offshore Projects in particular and

other process industry in general. The design engineering team

specializes in providing detail engineering for major Re-design,

Revamping and Refurbishing works on the existing facilities at offshore.

With its participation in such projects, OHCS has systematically

compiled a library of 'As-Built' statistics and drawings and thus

commands a unique position as an engineering services agency.

Infrastructural support and facilities for Designing through drafting as

well as Computer Aided Designing are all available in-house.

It engineers support the client to liaise with the Client/Third Party

Inspectors/Vendors etc. during every facet of Detail Engineering also

assisting the client with various inputs required by them during the

Bidding/Proposal stage.

OHCS has a total commitment to engineering excellence, a knack

of finding the most creative design solutions to handle contingencies at

site and an uncompromising approach to quality. OHCS recognizes the

benefits of an effective Quality Assurance Programme in promoting and

achieving high Quality Standards of service and minimising costs &

delays to project schedules,

PLANNING

_______________________________________________________________________________________________________


Planning is an on-going process for each project. Planning is project

based and commences at the time of Bidding when a schedule is

prepared for the entire Project.

OFFSHORE PLANNING

Prior to the commencement of offshore activities, OHCS undertakes

the planning of the offshore works in order to prepare itself for the work.

The following activities are planned :

Micro schedule of project with Primavera P3/MS Projects software.

Mobilization plan for Manpower / Construction Equipment.

Man hours estimation by trade.

Preparation of execution related procedures.

Preparation of S-curves for project progress planning / monitoring.

Preparation of Fabrication Drawings from Engineering Drawings.

Quantification of scope of work from AFC Drawings.

The work activity description cards or job cards are prepared one for

each scheduled activities. It defines the nature of required job,

materials required, description of tasks involved, estimated job duration

& manpower. The work activities defined at the planning stage include

not only the scheduled offshore works but also the onshore fabrication

works.

SUPPORT ACTIVITIES

_______________________________________________________________________________________________________


While the planning exercise is in progress, OHCS will be developing its

land based support programme preparation for the offshore work. The

logistics of personnel and material form an important link between

office and offshore. Once the hook-up is in progress, the base will be the

focus of the project for technical, logistics and communication support.

PROCUREMENT

OHCS provides integrated procurement services commencing from

preparation of Request For Quotations (RFQ), to Technical specification,

identification of vendors, floating bids, evaluating bids, preparation of

purchase specification for procurement and release of Purchase Orders

to the technically acceptable vendors.

RFQ'S are generally developed as per Client's Bid Specifications duly

supplemented with engineering inputs. Enquiries are solicited from

approved vendors and technical evaluations of the proposals made and

Client's approval sought for the recommended vendors.

Depending on the scope of work entrusted to OHCS, Purchase Order is

released by OHCS or by the Clients. Pursuant to this activity, regular

Purchase Order specifications are issued to facilitate vendor compliance,

develop documents in accordance with requirements and fulfill

inspection requirements and Third Party obligations.

FABRICATION

OHCS has two fully equipped Workshops with Customs Bonded

Warehouse & In bond Manufacturing Facilities to undertake extensive

fabrication work both at Onshore in its workshop and at offshore while _______________________________________________________________________________________________________


executing installation works. The workshop is equipped with the most

modern construction equipments, machines and fabrication facilities.

OHCS has independently developed various fabrication procedures and

welding procedures complying with bid specifications. These have been

duly approved by third party inspectors namely DNV, EIL, EICA, LRS, BV,

etc. for compliance with bid technical requirements. OHCS has an

experienced team of qualified welders duly vetted by various

consultants, like the ones mentioned above.

OHCS documentation work and qualification work in this respect cover

all materials from Carbon Steel to the most exotic materials known in

the process industry, viz. DSS, INCOLOY, INCOLOY CLAD,Cu-Ni, etc.

Fabrication is carried out as per AFC drawings and Client's Bid

Specifications with respect to tolerances and quality of work. All

consumables comply with technical specifications and compatibility with

the parent materials. An independent in-house QA / QC system ensures

fabrication standards of the highest quality. Third party inspection

requirements are duly adhered to. With prior Quality Management

effectively implemented, OHCS has seldom encountered any noticeable

rejection or re-work needs.

FABRICATION FACILITIES

Workshop I (W168 – 50000 Sq.ft.) : (Custom Bonded Warehousing

Facilities) : Well equipped workshop with 250 HP Power & two

Overhead Cranes of Capacity 25/5 tons each and span of 14 meters

each to provide upto 300T per month of Steel fabrication and 3000 inch

dia of Pipe Welding of various material such as Cu-Ni, Incoloy DSS and

_______________________________________________________________________________________________________


Cladded pipes etc. Also fabrication of Pressure Vessels (medium range)

can be undertaken.

Workshop II (W175 – 7500 Sq.ft) : Well equipped workshop with

Power, Overhead Gantry, etc. to provide upto 100T per month of Steel

fabrication and 2000 inch dia of CS Piping.

INSTALLATION, HOOK-UP, TESTING, PRE-COMMISSIONING

AND COMMISSIONING

OHCS has the requisite expertise in installation of Equipments, Piping,

Instrumentation, Electrical & Structural works connected with Oil / Gas

Production Platforms.

OHCS has also undertaken major Hook-up / Testing and Pre-

commissioning works for various major International Contractors.

In this key area of work, OHCS's capabilities emanate from a very close

collaboration between Construction & Engineering personnel whose

backgrounds combine to provide the speedy solution to problems

frequently encountered in offshore projects Fine details such as general

equipment redundancy, installation aids, backup tooling, skilled floating

manpower, further enhance work capabilities. OHCS's successful track

record is the result of the interactive approach of its team to offshore

projects from planning stage to commissioning.

OHCS offers assistance during Installation to Client by Providing

support services and skilled manpower for the following :

Jacket Installation

Topside Modules Installation

Piles Installation

_______________________________________________________________________________________________________


Riser Installation

Riser Clamp Installation

Removal of Temporary Decks

Stabbing new Decks

Installation of accessories like :

(1)Boat Landing

(2)Barge Bumpers

(3)Deck Cranes etc.

Stripping of Wells and Provision of Bullets during Installation

Pipe laying Mode

PRE-COMMISSIONING

OHCS offers complete spectrum of activities involving pre-

commissioning related works . OHCS engineers check :

Whether the works carried out are in line with P & ID’s

Assist in inert gas purging , drying etc. prior to flow of

hydrocarbons.

Some of the other activities include : pre – commissioning of

equipments :

Cranes

Fire water pumps

Diesel generator

Instrument air compressor

Pumps

Vessel

Pre – commissioning of electrical / instrumentation systems :

Switchgears

Panels

_______________________________________________________________________________________________________


Simulation of interlocks

Relay settings

Loop checks

Set point check etc

Distribution

Motors

Rotation

Calibration

Continuity checks

Disciplines :

Multi disciplinary engineers drawn from OHCS ‘s commissioning team

assist client / owner & inspectors in these activities involving :

Process

Instrumentation

Piping

Mechanical

Electrical

COMMISSIONING

Commissioning of the facilities in general is carried out by the owner

and pertain to introduction of hydrocarbon after the whole system has

been simulated in pre commissioning checks

OHCS’s role in these activities is limited to assist the main contractor /

owner in these activities as follows :

Co-ordination / logistics with various vendors.

Keeping a check on all parameters during 72 hrs test run as per

consultant / owner checklist by providing professional personnel.

Preparation of as- built documents.

_______________________________________________________________________________________________________


Preparation of list / replacement list for spare parts viz. chemicals,

lube charges, gaskets, fuses, etc.

MAINTENANCE

OHCS is well knit with experienced personnel to provide regular

maintenance required at offshore platforms. The team has invaluable

know-how and experience in the preventive maintenance of major

equipments on platforms.

OHCS has undertaken critical maintenance works for ONGCL at very

short mobilisation notice, at times when there has been a rupture/leak

in Oil / Gas lines or other platform facilities.

Various other services offered by OHCS are :

Supply of special Construction Equipment and Material.

Supply of skilled / semi-skilled manpower.

QUALITY CONTROL, INSPECTION,TESTING & CALIBRATION

OHCS has an independent Quality control Department with state of

the art equipments for carrying out activities like Welder Tests, all Non-

Destructive Tests, Physical & Chemical Tests, Equipment Calibration as

per latest International Standards, as a back-up to reinforce its

construction activities.

The main activities of the Quality Control Department include :

Maintaining Quality Standards for the Organisation as per ISO:9001-

2000.

Preparation of Quality Plans based on International codes and

Standards, in line with requirements of job specifications.

_______________________________________________________________________________________________________


Quality Control at all stages, namely material receipt, in-process &

final inspection, including liaison with Third Party Inspectors like

DNV, EIL, LR, BV, etc.

OHCS has been providing Quality Assurance to it’s Clients/Customers

from the very beginning which has been highlighted by the fact that

OHCS is the first Offshore Company in India having ISO-9001:2000

Certificate.

OHCS is the only Company which through it’s Sister concern OFFSHORE

TESTING & INSPECTION SERVICES (full fledge Laboratory) holds ALL

essential equipment’s required for effective Quality Control at all stages

of the Project.

OHCS has an independent Quality Control Dept. with all important

Master Calibration Instruments [traceable to National / International

Standards], Welding Procedures for all important alloys duly approved

by 3rd Party Inspectors and NDT facilities available in-house. Services

offered by OHCS as a backup to reinforce it’s Construction activities also

includes:

Preparation of Welding Procedure Specification and conducting

Procedure Qualification Test under 3rd Party Inspection Agency.

Conducting Welder Performance Tests for Client / Customer under

reputed 3rd Party Inspection agencies viz. DNV, ABS, EIL etc.

Calibration of Instruments

Quality Control at all stages of Hook-up / Modification.

Inspection of Customer Supplied Products w.r.t. Purchase

Specifications, approved Drawings & Documents for Client /

Customer.

It’s QA/QC Engineers are totally familiar with the following

Codes, Standards & Specifications :

_______________________________________________________________________________________________________


API (American Petroleum Institute) Standard

ASME (American Society of Mechanical Engineers) Codes

DNV (Det Norske Veritas) Offshore Rules & Recommended

Practices

ANSI (American National Standard Institution) Standards

ABS (American Bureau of Shipping) Rules

HEALTH SAFETY & ENVIRONMENTAL PLAN

OHCS recognizes the importance of protecting the Health, the Safety

and the Environment during its Operations. Therefore, it is OHCS’s

intention to pro-actively work with Employees, Clients, Subcontractors,

Public and Government Agencies in order to achieve the highest

possible standards of Health, Safety and Environmental protection,

sustaining individual awareness of safety issues.

The objectives to which OHCS assigns the greatest importance

are :-

The prevention of exposure to risk in all areas of its operations on

the basis that all accidents are preventable.

Compliance with relevant legislation and the application of more

stringent standards where OHCS considers it appropriate.

_______________________________________________________________________________________________________


The protection of the Health of its employees and of those who

may be affected by its operations.

The prevention of damage to the environment that could be

caused by its operation.

OHCS seeks to achieve these objectives by :-

Ensuring an appropriate level of employee training in relation to

Health, Safety and Environmental Protection in all areas of its

operations.

The use of an effective two-ways communication system for all

Health, Safety and Environment issues.

Providing adequate human, technical and financial resources.

Clearly defining the duties and responsibilities of all employees

with regards to HSE.

Continually improving its Health, Safety and Environment

Management System by firm management principles in line with

current industry standards.

HEALTH, SAFETY & ENVIRONMENT POLICY

OFFSHORE HOOK-UP AND CONSTRUCTION SERVICES (INDIA)

PVT. LTD. SHALL FOLLOW APPLICABLE LAWS AND RELEVANT

INDUSTRY STANDARDS OF PRACTICE CONCERNING PROTECTION

OF HEALTH AND SAFETY OF ITS EMPLOYEES IN THE

WORK PLACE AND THE PROTECTION OF THE ENVIRONMENT

WHICH WILL BE THE COMPANY’S PRIMARY GOAL TO TAKE SUCH

ACTIONS AS REASONABLE AND NECESSARY TO ACHIEVE SUCH

GOAL AND CARRY OUT THIS POLICY

_______________________________________________________________________________________________________


TURNOVER OF OHCS (I) PVT. LTD.

5.92

11.47

22.7121.84

18.10

0

5

10

15

20

25

20

01

-20

02

20

02

-20

03

20

03

-20

04

20

04

-20

05

20

05

-20

06

YEAR

TU

RN

OV

ER

T/O inCrs.

Growth rate of OHCS

TURNOVER TABEL OF O.H.C.S.

As per the above chart from 2001 to 2003-2004 the company

_______________________________________________________________________________________________________

OFFSHORE CONSTRUCTION INDUSTRY, RAPCCE

Sr no Year Turn over in crs.

1 March-01 – March 02 5.92

2 March-02 – March 03 11.47

3 March-03 - March-04 22.71

4 March-04 - March-05 21.84

5 March-05 – March 06 18.1

42

may rapid progress with its turnover rising from 5.92 crs. In

2001-02 to 22.71 crs. In 2003-04 but later on turn over decline

18.10 crs. In 2005-2006 because of non availability or

unavailability of contract.

LIST OF MAJOR PROJECTS EXECUTED BY OHCS

Sr No

Period Client Project Nature Of Work

1 Aug 03-May 04

Hyundai Heavy Industries Co. Ltd – South Korea

MHB – PL PROJECT

Pre Fabrication Of Piping Spools / Structural DeckExtension For Top Side Modification At Seven Plat Forms Execution Of Works At Offshore & Riser Tie-Ins At 14 Location

2 Dec 03-Mar 04

Hyundai Heavy Industries Co. Ltd – South Korea

GA Hook- Up Hook – Up Of New 4 Legged Project Well Platform GA & Modification Of Existing Facilities At “ LA ” Platform For CEIL / Lamprell Energy Ltd.

3 Jul 03- Oct 03 Hyundai Heavy Industries Co. Ltd – South Korea

Block 5 Dev Project

Hook – Up And Modification Works On 4 Compressors Modules , 3 Quarters , 3 Wellhead Platforms , 3 Flare Decks , 1 Water Injection Platforms ( 14 Modules ) And Six Inter Connection Bridges At Al Shaheen Field Of Maersk Oil Qatar As

4 Jun02 – Dec03

Oil & Natural Gas Corporation Ltd. – INDIA

F.G. Skid Replacement

Design , Engineering , Supply , Installation , Demolition Of Existing F.G. Skid At SHP / SHQ Platform

5 Apr 02-Apr 03

J . Ray Mcdermott Eastern Hemisphere Ltd. - Dubai

N11- N12 Platform Project

Fabrication Of Spool Pipe , Support Deck Extension And Associated Modification

_______________________________________________________________________________________________________


Of Existing Facilities On 18 Platform And Hook – Up Of 2 New Platforms.

6 Apr02-May02 Hyundai Heavy Industries Co. Ltd – South Korea

LA/LB Platform Project

Hook-Up Of Topside FacilitiesFor LA/LB Platform

Sr No Period Client Project Nature Of Work

7 Jan 02 – Apr 02 Larsen & toubro ltd - INDIA ACM-HRC

Installation Of Additional Compressor Module At HRC Platform And Its Integration With The Systems

8 Nov 00- may01 Hyundai Heavy Industries Co. Ltd – South Korea

WIPRP- 1 Project

Onshore fabrication of riser clamps / pipe spools and modification of 13 platforms at offshore

9 Dec 99 – may 00 Kvaemer energy ltd - U.K. TG revamp at

SLQ

3 x LM 2500 TG revamping at SLQ / BHS Bombay High

10 Sep 99 - oct 99 Brown & root energy services –SINGAPORE

NF riser replacement project

Replacement of 30 ( oil ) and 26( gas ) raiser at NF platform Bombay high

11 Oct 99-dce99 Mazagon docks ltd - INDIA BHN-RP project

Fabrication & welding of C.S. / SS/ pipe spools / piping for HHN revamping project of ONGCL under bonded warehouse of OHCS total fabrication was approx. 20000 dia .

12 Dec 98-Apr 99 Hyundai Heavy Industries Co. Ltd – South Korea BCP-B project

Modification of BPB / BLQ – II and hook-up of BCP-B platform

13 Feb 98- May 99 Larsen & toubro ltd - INDIAHRC AND modfns. Hook-up

Modification at HA,HRA, HRG & WIH platform and hook-up of HRC platform

_______________________________________________________________________________________________________


14 Feb 98 – May 98 Subtect middle east – SHARJAH

Clamp on conductor project

Provision of additional conductors on seven existing platforms in Bombay high north field

LIST OF PROJECTS EXECUTED AS ON 30 TH JUNE 2005

Sr No

Period Client Project Nature Of Work

1 Jun04 – may05 Saipem S.P.A. – ITALY Sabrata Platform Project

Hook-up of one well cum process platform, living quarter , flare deck for saipem S.P.A. ( Italy ),

2 Aug04- Nov04Hyundai Heavy Industries Co. Ltd – South Korea

MUT-PL project

Modification & fabrication of existing facilities BCPA,SHP,SHG,ICP,NQP &MNW platform & fabrication of riser clamps

3 Dec 04 – may 05Hyundai Heavy Industries Co. Ltd – South Korea

MSP project Hook-up pre-commissioning ,commissioning of new MSP platform

4 Aug03-may04Hyundai Heavy Industries Co. Ltd – South Korea

MHB-PL project

Pre-fabrication of piping spool / structural deck extension for top side modification at seven platforms , execution works at offshore

5 Dec03-mar04 Hyundai Heavy Industries Co. Ltd – South Korea

GA Hook- Up

Hook – Up Of New 4 Legged Project Well Platform GA & Modification Of Existing Facilities At “ LA ” Platform For CEIL / Lamprell Energy Ltd.

6 Jul 03- Oct 03 Kvaemer energy ltd - U.K Block 5 Dev Project

Hook – Up And Modification Works On 4 Compressors Modules , 3 Quarters , 3 Wellhead Platforms , 3 Flare Decks , 1 Water Injection Platforms ( 14 Modules ) And Six Inter Connection Bridges At Al Shaheen Field Of Maersk Oil Qatar As

_______________________________________________________________________________________________________


7 Jul 02 Bharat heavy electrical ltd –INDIA

Revamping of turbine ventilation system

Material procurement onshore duct fabrication of new ducting for BHN turbine ventilation system

8

Jun02 – Dec03 Oil & Natural Gas Corporation Ltd. – INDIA

F.G. Skid Replacement

Design , Engineering , Supply , Installation , Demolition Of Existing F.G. Skid At SHP / SHQ Platform

9

Apr 02-Apr 03 J . Ray Mcdermott Eastern Hemisphere Ltd. - Dubai

N11- N12 Platform Project

Fabrication Of Spool Pipe , Support Deck Extension And Associated ModificationOf Existing Facilities On 18 Platform And Hook – Up Of 2 New Platforms.

LIST OF MAJOR PROJECT EXECUTED BY OHCS

Sr No Client Project Nature Of Work

1Samsung heavy industries -

KOREA BE

Pre-engineering survey & detail engineering for

modification to platform under BE project

2Hyundai Heavy Industries Co.

Ltd – Korea SBHT


electrical and instrumentation for

modification 2 platform under SBHT project

3National petroleum

construction company –ABU DHABI

SHG


modification to existing facilities on 13 existing

platforms.

4 Oil & natural gas corporation ltd – INDIA

GLPM


modification to existing facilities on NJ, N6, N3 , NH

platform

5 ETPM-FRANCE HUT

Pre-engineering survey & detail engineering for HRA

platform and URAN terminal modification to HUT project

6National petroleum

construction company –ABU HQRST-FPre-engineering survey &

detail engineering for

_______________________________________________________________________________________________________


DHABI

modification to HA-HE platform under ONGC’S

HRQST-F platform

7 Snamprogretti – saipem – ITALY GLPN

Pre- engineering survey of 55 platforms at Bombay high

for incorporation of gas lift facility under ONGC’S GLPN

project

8 OTP / SOFRESID – FRANCE WIPPM


modification to 11 platforms under ONGC’S WIPPM project

J. RAY Mc DERMOTT, INC.

_______________________________________________________________________________________________________


J. RAY Mc DERMOTT, INC.

COMPANY PROFILE

J. Ray McDermott is a privately owned Oil & Gas Industry Construction

Company providing a range of products and services to the Industry,

Worldwide, ranging from General Fabrication, Engineering & Project

Management, Offshore Construction Services through to the supply of

Drilling Structures and Rebuilt Land Rigs, Rig Refurbishment etc

J. Ray McDermott is a leading worldwide marine solutions company with

fabrication facilities in the Americas, Middle East, Caspian and Asia

Pacific. Services include design, fabrication, transportation and

installation of offshore platforms, and installation of offshore pipelines.

JRM operates a diversified fleet of vessels for the marine construction

industry. Most of our primary vessels are combination derrick and lay

barges, making the fleet one of the most versatile in the world. Our

global fleet is located in the Gulf of Mexico, Asia Pacific, the Middle East,

and the Caspian

HISTORY

_______________________________________________________________________________________________________


In the late 1940’s oil and gas companies began to realize the potential

of fields under the waters of the Gulf of Mexico. Technology made

offshore fields a primary source for the world’s petroleum. In the early

days of offshore production, facilities were placed in shallow water and

within sight of land. J. Ray McDermott had floating equipment for

marshland work, and as interest in the Gulf picked up, the company

formed joint ventures and made acquisitions that allowed it to pioneer

the construction and installation of platforms and pipelines to support

drilling and development near shore.

By the mid-1970’s, J. Ray McDermott was one of the world’s leading

marine contractors, providing services in every major offshore oil and

gas province. As offshore fields became a primary source for petroleum,

specialized equipment was developed to allow production in water

thousands of feet deep and many miles from land.

M I L E S T O N E S

1950 - Installed first all-concrete platform in Gulf of Mexico

1954 - Constructed first offshore platform in 100 m’ water depth

1956 - Established Morgan City yard, first fabrication facility dedicated

solely for offshore structures

1961 - First jacket installed by "Stacking" method - precursor of later

multi-piece jackets

1966 - Acquired diving company

1976 - Designed, provided fabrication technology for, and installed

Exxon’s record 850’, two-section Hondo platform off Santa Barbara, CA

1978 - Fabricated and installed first platform in water depth greater

than 1,000’. Shell Cognac (1040’ water depth) remains the world’s only

three-piece deep water structure and was recognized with an

achievement award by the American Society of Civil Engineers

1986 - Built Shear Leg Crane - lifting capacity of 5,000 short tons

1988 - Acquired dynamically positioned 4,400 short-ton capacity DB50,

world’s largest self-propelled monohull crane vessel

_______________________________________________________________________________________________________


1989 - Installed deepest pipeline between Shell’s Bullwinkle and Boxer

platforms. The pipeline depth at Bullwinkle makes it deepest ever

installed in Gulf of Mexico - 1350’ water depth

1991 - Fabricated and installed world’s largest offshore sulfur extraction

complex for Freeport McMoran Resource Partners’ Main Pass mine

1993 - First use of J-Lay sets pipe-lay depth record in 2,860’ water

depth for Shell Auger project

1996 - Fabricated topsides and installed hull and deck for Oryx

Neptune, world’s first production spar

1997 - Completed modules for Shell’s Ursa, largest platform in the Gulf

of Mexico and the world’s deepest TLP in 4,000’ water depth

1998 - Installed the first Sea-Star "Mini-TLP, British-Borneo's Morpeth, in

1,200 ft. water depth

1999 - Completed British-Borneo's Allegheny Mini-TLP hull and deck

installation with associated design, procurement and installation of sub

sea pipelines and SCRs in 3,300 ft. water depth

2000 - Installed Shell Brutus pipelines, 16 miles of 20", which was the

deepest S-Lay pipeline in 3,010 ft. water depth

2000 - BP awards contract to construct the topsides for four of it's

deepwater projects in Gulf of Mexico

2001 - EPCI award of Murphy's Medusa Truss Spar - first Spar hull to be

built outside of Pori, Finland

2001 - EPCI award of Domion Resources Devil's Tower Spar

2002 - EPCI award of Murphy's Frontrunner Truss Spar

2002 - Wins sub sea development installation contract for BP Aspen

Project

2003 - 12,125 ton Amenam Kpono AMP1 production deck leaves Dubai

headed for the coast of Nigeria

2003 - P.T. McDermott Indonesia successfully completed fabrication of

the world's deepest dry-tree spar hull for the Devil's tower field in the

Gulf of Mexico

2003 - JRM completes deepwater Medusa Spar Project - the first spar

platform in the world delivered on a full scope engineer-procure-install-

_______________________________________________________________________________________________________


construct ("EPIC") basis

2004 - JRM successfully completed Devils Tower and Front Runner EPCI

SparProjects

2004 - McDermott Caspian Contractors, Inc. (MCCI) completed

fabrication, load out and sail away of Central Azeri topsides, the largest

deck ever in the Caspian, consuming 10 million man-hours without a

single lost time accident and utilizing 80% local Azerbaijani workforce

2004 - P.T. McDermott Indonesia successfully completed fabrication,

integration and onshore mechanical completion of the Floating

Production, Storage and Offloading (FPSO) vessel - Belanak Natuna

2004 - JRM's Morgan City Yard completed three of four Deepwater

Development projects (Holstein, Mad Dog and Thunder Horse)

PLANNING

Planning is an on-going process for each project. Planning is project

based and commences at the time of Bidding when a schedule is

prepared for the entire Project.

OFFSHORE PLANNING

Prior to the commencement of offshore activities, JRM undertakes

the planning of the offshore works in order to prepare itself for the work.

The following activities are planned :

Micro schedule of project with Primavera P3/MS Projects software.

Mobilization plan for Manpower / Construction Equipment.

Man hours estimation by trade.

Preparation of execution related procedures.

Preparation of S-curves for project progress planning / monitoring.

Preparation of Fabrication Drawings from Engineering Drawings.

Quantification of scope of work from AFC Drawings.

_______________________________________________________________________________________________________


The work activity description cards or job cards are prepared one for

each scheduled activities. It defines the nature of required job,

materials required, description of tasks involved, estimated job duration

& manpower. The work activities defined at the planning stage include

not only the scheduled offshore works but also the onshore fabrication

works.

FABRICATION

J. Ray McDermott (JRM) has fabrication locations in Batam, Dubai,

Harbor Island, and Morgan City.

JRM's fabrication yards are strategically positioned around the world to

service the oil and gas industry. Our fabrication yards are all qualified to

ISO 9000 standards, and each is capable of building to multiple industry

standards.

Although our fabrication bases are strategically placed to serve their

geographic regions, their cost-effective and high-quality products are

also exported to other regions of the world. We continue to provide

facilities to West Africa from both the United States and the Middle East,

and are poised to provide cost-effective fabrication services for Central

and South America from both locations

Working closely with our engineering groups as well as our marine

operations, JRM fabricators fully understand the project requirements of

both. That understanding helps knock down interface barriers, even

when another company performs the engineering or offshore installation

_______________________________________________________________________________________________________


http://www.jraymcdermott.com/mcy/mcy_fab.htm

http://www.jraymcdermott.com/hi/hi_fab.htm

http://www.jraymcdermott.com/dubai/dubai_fab.htm

http://www.jraymcdermott.com/batam/batam_fab.htm

FACILITIES

JRM special area of work and interest has been the execution and

management of major modifications and refurbishments of existing

facilities on offshore well platforms and process complexes. With its

deep involvement in this work over the last decade and a half, JRM has

compiled well documented as-built data and drawings for almost all the

major Indian offshore platforms and projects with which it has been

associated along with other major International Contractors. This

provides the inherent strength and advantage to JRM in swiftly

executing all modification projects. Its capabilities and strengths in this

area have been fully recognised by all the major contractors who have

engaged and continue to engage its expertise for the total services of

modification and refurbishment work. This continues to be its major

forte.

Captive construction manpower employed by JRM acts as a nucleus on

which additional manpower is built, depending upon workload. The

Construction Division is headed by a Project Manager (Construction) and

assisted by a team of field engineers, workforce of various specialized

trades like welders, fitters, grinders, cutters, scaffolders, riggers,

mechanics, electricians, technicians, crane operators, logistic personnel

etc.

JRM has its offshore work team from senior, experienced marine

construction personnel up to supervisory level on a permanent basis.

The construction team is supported on the platform by project personnel

whose responsibilities are keyed to specific areas, systems and

disciplines. These personnel are linked to the craft supervisors and

establish priorities, interpret drawings, identify & rectify shortages, etc.

Within an area, various disciplines work simultaneously, however,

limited by safety considerations and reasonable access to the work.

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JRM supervisory personnel and high level workers execute offshore

activities for platform topside works as per the planned schedules.

Services offered by JRM include Top side Hook-up / Modification of

Platform module with the following :

Piping Installation & Hook-up

Equipments Installation & Hook-up

Electrical / Instrumentation Installation & Hook-up

Internal revamping of Separators / Pressure Vessel

Structural Installation

Riser Tie-ins & associated modifications

Fire & Gas Detection System

MAINTENANCE

JRM is well knit with experienced personnel to provide regular

maintenance required at offshore platforms. The team has invaluable

know-how and experience in the preventive maintenance of major

equipments on platforms.

JRM has undertaken critical maintenance works for ONGCL at very short

mobilization notice, at times when there has been a rupture/leak in Oil /

Gas lines or other platform facilities.

Various other services offered by JRM are :

Supply of special Construction Equipment and Material.

Supply of skilled / semi-skilled manpower.

HEALTH & SAFETY ENVIRONMENT POLICY _______________________________________________________________________________________________________


J. Ray McDermott, Inc. considers the protection of human Health, Safety,

and the Environment for all its employees, contractors, customers, and

the community to be of primary importance. As such the Company will

maintain a Health, Safety and Environmental (HSES) program

conforming to the best management practices of marine and

construction operations. The overall success of the HSES program is

based on the following:

Management commitment, planning, and accountability:

Management is responsible and accountable for protecting

employees, assets, and the environment in accordance with the

Company Charter and Philosophy. In addition, the prevention of

injuries, illnesses and pollution must be made a priority during

project planning, operations, maintenance and construction

activities.

Employee participation and accountability: Managers and

supervisors are accountable for the actions of their subordinates

and will always reinforce safe work behaviors. All employees are

responsible for stopping and reporting unsafe acts and conditions,

and for following Company HSES policies and procedures.

Compliance: The Company will comply with all applicable Health,

Safety & Environmental regulations, codes, and standards, and

will develop and enforce procedures that provide instruction to all

employees identifying their responsibilities for meeting or

exceeding these requirements.

Training : The Company will provide training to ensure

understanding of good HSES practices, Company procedures and

regulatory requirements.

Continuous Improvement : The Company will strive for

continuous improvement in its HSES performance through regular

measurement and review of its objectives, targets, programs,

procedures and processes. Managers, supervisors, employees,

contractors, customers, and vendors must work together to

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develop proper attitudes, practice and promote proper work

habits, use good judgment, and comply with all applicable HSES

rules and regulations to ensure J. Ray McDermott, Inc. is a safe

and respectable environment in which to work.

QUALITY

JRM is an API approved company for the Design, Manufacture,

Repair, Upgrade, Installation and Decommissioning of Hoisting

Equipment and Drilling Structures; Provision of Rig Audits and

Inspection/Survey Services.

The company is dedicated to complete integrity of its operations and

services and this is reflected in the commitment to Quality .

The company has developed and implemented a Quality Management

System that complies with the requirements of both ISO 14001, OSHAS

18001 and ISM, provides a framework for all JRM Business Units

Project & operation committee

This committee deals with all matters relating to Projects and

Operations both onshore and offshore. The main aim is to establish

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common objectives for the contracting community in project execution

and implementation. It works closely with the employment practices

committee and is responsible for the compilation of the projected

workload surveys that forecast resource requirements for the year

ahead. The predictions, coupled with those from the Employment

Practices Committee, give the association the facility to accurately

project future resource requirements.

The Committee also addresses new directives introduced by the

Dubai Union and legislation set out by the Government. The potential

impact of the recent Pressure Equipment Directive is typical of the items

tackled. A common contracting position is being established and there

will be discussions with other bodies to reach an industry-wide

consensus.

The committee will be focusing on working practices to see how

best to improve the methods in operation by members and others

in the industry.

HUMAN RESOURCE

J .Ray McDermott is a leading worldwide marine construction company.

Our services include design, fabrication, transportation, and installation

of new and refurbished offshore platforms, installation of offshore

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pipelines, and design and installation of sub sea facilities for the

offshore oil and gas industry.

The diversity of our services reflects the company's commitment to

the world's energy future. The fulfillment of that commitment begins

with our employees. We offer not only the chance to play a key role in

solving the world's energy problems, but also a career opportunity with

a company that promotes from within and helps you grow to your fullest

potential.

P h i l o s o p h y

The success of J. Ray McDermott is dependent upon its employees. To

create and maintain a competitive advantage, J. Ray McDermott

requires a work force that is motivated, skilled, effectively led and

managed.

As such, we recognize the importance of quality employee programs for

recruiting, development, motivation and retention. With facilities

located around the world, we are committed to creating a challenging

and rewarding work environment for each facility whereby employees

are goal focused and motivated through these people oriented

programs.

Within J. Ray McDermott's Company Charter our values and guiding

principles describes how we conduct ourselves with colleagues, our

customers, vendors and communities as we go about accomplishing the

mission, vision and goals of our company.

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J. Ray Mc Dermott Around The World

JRM located in many country also they got a construction contract from

many country. In India they got a contract from ONGC & Reliance. JRM is

one of biggest offshore construction company therefore they got a

contract from many country.

JRM located country are as follows :

Dubai

Batam

Jakarta

Morgan city

Harbor island

Singapore

Malaysia

India ( Mumbai only )

Perth

Houston

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On Shore Job Execution Is Same Of Both Organizations Are As

Follows:

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OFFSHORE CONSTRUCTION INDUSTRY, RAPCCE

FLOATING OF TENDER BY ONGCL & OTHER INTERNATIONAL COMPANIES

PROPOSAL

LETTER OF INTENT

DRAWING AND DOCUMENTS

PROJECT PLANNING

MATERIAL RECEPTION AND INSPECTION

QA / QC

MARKING & CUTTING

FIT UP

WELDING

NDT

GRIT BLASTING

60

PAINTING

PACKING

TRANSPORT TO OFFSHORE ETC.

ONSHORE JOB EXECUTION IN DETAIL (OHCS & J. Ray McDermott)

TENDER FLOATING BY OIL COMPANY

The Client or customer floats a tender in market which contains contract

and bid documents. These two further include commercial terms, technical

terms, scope of work and bid specification.

PROPOSAL

After studying the tender OHCS prepares a proposal. Proposal has two

aspects :

1. Technical : This includes :-

Scope of work

Terms and conditions

Background i.e. previous projects undertaken

Resources which include :

a. Manpower

b. Equipment

c. Organisation chart

d. Project Schedule

2. Commercial : All price related terms are included in this.

LETTER OF INTENT

The Contractor or the Sub Contractor who makes the lowest bid gets the

contract. The Client if directly gives the contract to a Company then, that

Company is a Contractor. The Contractor may grant parts of the project

further to some other Company. Then that Company becomes sub-

Contractor.

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After contract has been given to the Contractor a letter of Intent or LOI is

given to it by the client. It includes a parameter called Liquidated

Damages (LD). If the Contractor fails to complete the job within the given

time the Client imposes LD on it. LD means that a certain percentage

(given in LOI) of money it is supposed to give to the Contractor would be

deducted per day after the allocated time period is over.

DRAWINGS AND DOCUMENTS

After contract copy is signed by Client and Contractor the Contractor is

given the drawings and documents for the project.

PROJECT PLANNING

Project planning is done by contract as to how to go by the project. It

includes parameters like :

Manpower mobilization i.e. when and how many workers should

be working on a particular aspect of the job.

Equipment

Project material

Project monitoring which is done to ensure whether the project is

being completed as per the given time. It is done using Daily

Progress Reports [DPR] and next day plans.

Job sequence

Micro schedules and activity breakup.

RECEPTION OF MATERIAL

Material received is of two kinds :

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(a) Free issue material : It is the material that the Client gives to

Contractor.

(b) Self procured material : It is the material that the

Contractor itself has to arrange (is part

of lump sum cost).

INSPECTION OF MATERIAL

Inspection of material is done by the Third Party Agency. It checks

whether the grade and heat no. of the material matches with the Test

Certificate (TC). After the inspection is done material inspection report

(MIR) is prepared. This has to be signed by the Third Party Agency before

carrying out the project further. So if the material is as per code it is

approved by Third Party for fabrication.

QUALITY ASSURANCE / QUALITY CONTROL (QA / QC)

QA/QC means work procedure to be carried out to assure quality. This

includes :

a. Execution Procedure : Which includes micro schedules of

project. The whole activity is broken up into parts so that each

part can be completed within given time constraints with

expected quality.

b. Fabrication Procedure : Which includes methods to be used

for fabrication.

c. NDT Procedure : This includes methods of Non-destructive

Testing (NDT) to be used for evaluation of joints. The various

methods of NDT are Radiography, Ultrasonic Testing, Magnetic

Particle and Dye Penetrate Inspection.

The documents of the QA/QC are submitted to the Client for approval.

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MARKING AND CUTTING

After material is approved for fabrication grinding of pipes and fittings is

done to make the surface smooth. Bevel preparation should as per degree.

FIT UP

The fit up of pipes before welding is witnessed by the Third Party Agency.

It checks where the orientation is as per drawing or not, ID of the material

and whether the gap between the fit up is accurate or not. A fit up report

is prepared which has to be signed by the Third Party Agency.

WELDING

Two types of welding are generally done for pipes.

(a) Gas Tungsten Arc Welding [GTAW] : It is a welding process that

uses a non-consumable tungsten electrode to produce the weld. The weld

area is protected from atmospheric contamination by a shielding gas

usually an inert gas such as argon and a filler metal is normally used,

though some welds, known as autogenous welds don’t require it. A

constant current welding power supply produces energy which is

conducted across the arc through a column of highly ionized gas and metal

vapours known as Plasma.

This process grants the operator greater control over the weld than SMAW

or Submerged Metal Arc Welding allowing for stronger, higher quality

welds. However, GTAW is more complex and difficult to master and further

more it is significantly slower than other welding techniques. This welding

has fewer defects then SMAW because of inert gas.

_______________________________________________________________________________________________________


(b) Shielded Metal Arc Welding [SMAW] : It is also known as manual

metal arc (MMA) welding or informally as stick welding is a manual arc

welding process that uses a consumable electrode coated in flux to lay the

weld. A electric current in the form of either AC or DC from a welding

power supply is used to form an electric arc between the electrode and

metals to be joined. As the weld is laid, the flux coating of electrode

disintegrates, giving off vapours that serve as shielding gas and providing

a layer of slag, both of which protect the weld area from atmospheric

contamination.

Because of the versatility of the process and simplicity of its equipment

and operation, SMAW is a very popular welding process. It dominates

other welding processes in the maintenance and repair industry. SMAW

continues to be used extensively in construction of steel structures and

industrial fabrication. The process is primarily used to weld iron and steel

(including stainless steel) but aluminum, nickel and copper alloys can also

be welded with this method.

In piping a combination of GTAW and SMAW is used. GTAW is used for

making root and hot pass and SMAW is used for filling and capping.

PAINTING

Within 2 hours of Grit blasting a primer coat of Zinc silicate of thickness 40

– 50µ is applied. It is a preparatory coating put on materials before

painting. Primary insures better adhesion of paint to the surface, increases

paint durability and provides additional protection for the material being

painted.

_______________________________________________________________________________________________________


After priming at least 8 hrs should be given to the material before applying

first coat of paint. Its thickness should be around 75µ. After yet another

12 hrs second coat of paint is applied. This also must have a thickness of

75µ.

After painting is done the coat is checked by the Third Party Agency using

a coat meter. The thickness should come around 300µ.

A painting report is prepared which is signed by Third Party Agency.

PACKING

After painting report is cleared the product is finished. The product is

packed in respective box, container, rack etc. depending upon size,

material and use . Packing list is prepared and product is put in respective

package. After this inspection of product is done as per packing list and

then packed items are stored in a safe area. Water contact is avoided.

TRANSPORTATION :

After the packaging the final product packages are transported at offshore

construction area by ship because these final products are very heavy

therefore the product packages are transfer by use of water transportation.

CONCLUSION:

Both the industry are well reputed in the world because of there

construction work. Some times J RAY McDermott given the contract to

OHCS so we see that they have a good business relation. Both

company’s are tack care of there employees. They play important role

in successes of country economic growth. Both the company have the

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domestic as well as international client. They have a similar working

strategy.

BIBLIOGRAPHY:

Books:

Production Technology 1 & 2, By Mr. O.P. Khanna

Website:

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www.google.com

www.altavista.com

www.jraymcdomott.com

www.ohcs.com

www.hook-upoffshore.com

_______________________________________________________________________________________________________


http://www.hook-upoffshore.com/

http://www.ohcs.com/

http://www.jraymcdomott.com/

http://www.altavista.com/

http://www.google.com/