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Magazine Magazine Ivormatie is a publication of Iv-Groep | Volume 28 | May 2014 ormatie magazine Magazine Engineering Company with a Passion for Technology Jacket Lift System for Pieter Schelte | OCAP peak shaver | New GOP Flare Package | Grove Platform | Modification of life rafts of the Walrus Class submarine | Waterdunen tidal culvert May 2014, Volume 28, Number 2 Editorial Staff Iv-Groep, Marketing & Communications department Ivormatie A publication of Iv-Groep: • Iv-Oil & Gas • Iv-Infra • Iv-Industrie • Iv-Consult • Iv-Water • Iv-Bouw • Escher Process Modules • Muzada • Iv-AGA • Iv-Consult Malaysia • Iv-Infra USA • Nevesbu Editorial office Iv-Groep b.v. Postbus 1155 3350 CD Papendrecht [email protected] www.iv-groep.nl Copyright © 2014 Iv-Groep. All rights reserved. Reproduction in whole or in part requires written position Cover: Jacket Lift System of Allseas' Pieter Schelte 2 IVORMATIE MAGAZINE MAY 2014 Inside page of the cover: Waterdunen tidal culvert ormatie Content Iv-Consult co-designs the Jacket Lift System of Allseas' Pieter Schelte 4 A unique vessel Aegir Deepwater Construction Vessel 6 New pipe layer uses J-lay and R-lay Waterdunen tidal culvert 8 A unique hydraulic engineering project May 2014, Volume 28, Number 2 Grove Platform Editorial Staff Iv-Groep, Marketing & Communications department 12 Ivormatie A publication of Iv-Groep: OCAP peak shaver helps to ensure reliable supply of CO2 to greenhouse • Iv-Oil & Gas growers • Iv-Infra • Iv-Industrie 16 • Iv-Consult • Iv-Water • Iv-Bouw Producing poultry manure pellets • Escher Process Modules A challenging product results in a unique installation • Muzada • Iv-AGA 18 • Iv-Consult Malaysia • Iv-Infra USA • Nevesbu New GOP Flare Package for Kuwait Petroleum Europoort Editorial office Iv-Groep b.v. 22 Postbus 1155 3350 CD Papendrecht Modification of life rafts of the Walrus Class submarine [email protected] sure reliable supply of CO2 to greenhouse growers www.iv-groep.nl 24 A total package for wet and dry infrastructure projects worldwide 28 ENDIS renovation of post-war block of flats 32 Case study into sustainable solutions for post-war blocks of flats 3 Iv-Consult co-designs the Jacket Lift System of Allseas’ Pieter Schelte A unique vessel Allseas, a Swiss-based company with their main engineering office located in Delft, the Netherlands, is one of the major offshore pipelay and subsea construction companies in the world. Allseas will shortly enter the world of installation and decommissioning with their new vessel, the Pieter Schelte. The Pieter Schelte is a unique, dynamically positioned vessel for single-lift installation and decommissioning of large offshore oil and gas platforms, and installation of oil and gas pipelines. The Pieter Schelte will have a topsides lift capacity of 48,000 tonnes and a jacket lift capacity of 25,000 tonnes. In close cooperation with Allseas, Iv-Consult designed the Tilting Lift Beams of the Jacket Lift System. 4 IVORMATIE MAGAZINE MAY 2014 Special Structures & Equipment The Pieter Schelte vessel is currently under construction at Daewoo A light system with enormous capacity Shipbuilding and Marine Engineering (DSME) in Okpo, South Korea. This simple tilting method is, nevertheless, quite challenging in a With a length of 382 metres (1,253 feet) and a width of 124 metres structural way. This is due to the large variation in sizes, weights and (407 feet), the Pieter Schelte will be world’s largest vessel of its kind. dimensions of all the jackets to which the system is adaptable. But it With these dimensions, the Pieter Schelte is as large as two super is also due to the huge lift capacity of 25.000 tonnes that, together tankers, and in surface area it is equal to five soccer fields. The Jacket with its own weight, has to pass all structural and mechanical details Lift System (JLS) will be positioned at the stern of the vessel. from lift hook to the stern of the ship. The JLS has to be light and strong at the same time. For this reason, all steel used in the JLS is of Decommissioning a jacket S690 quality with plate thicknesses up to 120 millimetres. Although During the decommissioning process, the JLS will be hooked up to a the JLS beams are huge in size (approximately 150 x 17 x 9 metres), jacket after which it lifts the jacket to a certain vertical position. The there is not much space inside to provide room for all the main jacket is positioned next to the adjustable sledge system that runs hoisting and utility cables. At certain locations, it almost looks like a over the JLS beams. In this position, the JLS will tilt backwards and Swiss army knife with a lot of integrated functionalities. the lift weight will be transferred from the hook onto the sledges. Once in a horizontal position, the jacket can be sea fastened and An efficient design process transported to a decommissioning site, where it can be easily rolled Iv-Consult’s primary contribution to the JLS is the overall structural off to shore with use of the sledges. design including all the tie in points for the external interfaces, such as the cross beam, jib, hang up frame, up enders and removable tail. In its resting position, the JLS is positioned horizontally. However, Besides the beams, the removable tail and jib are also designed by when it has to rise, two types of up enders will come into action. The Iv-Consult from the conceptual phase to the detailed phase. With inner up enders will push the beam upwards to a certain threshold the jib installed, hoisting and installation operations can also be after which the outer up enders can take over and rotate the JLS performed. into a vertical position. When the JLS rotates even further outwards over the stern, top cables will take over the load from the outer up Iv-Consult uses its experience with the design of special and ender. innovative handling structures. For the design activities, an automated and extended BIM environment is created in which all the interfaces by third parties are shown. The BIM environment is used for clash check, structural optimisation, E&I routing, maintenance access, fabrication feasibility, et cetera and is always up to date. In this way the process is much more efficient. Wouter Visser Department Manager Structural Design, Iv-Consult 5 Aegir Deepwater Construction Vessel New pipe layer uses J-lay and R-lay Heerema Marine Contractors (HMC) and Iv-Consult signed a master service agreement in October 2011. In the meantime, Iv-Consult has carried out various projects for HMC. Many of them focus on transport and engineering, with Iv-Consult directly supporting HMC’s core business as an offshore engineering contractor. Other more multidisciplinary projects require a combination of different specialisations such as structural, mechanical, naval and civil engineering. One of the most recent projects involving Iv-Consult as a consulting engineer is the new 'Aegir' pipe-laying vessel. The Aegir (named after the Norse God of the Sea) is a Deepwater Construction Vessel (DCV) capable of laying pipes by means of the 'J-lay' and 'R-lay' methods. 6 IVORMATIE MAGAZINE MAY 2014 Special Structures & Equipment J-lay Alternative method J-lay involves assembling pipe lengths on board in the ‘firing line’ HMC has come up with a different vision for the logistics of spooling and then inserting them in the loader. From the loader, this pipe because the Aegir has the facilities to take reels on board at the length is put into the correct orientation relative to the pipeline pipe-laying location. The reels provided with pipe at the spool base that hangs below the ship. The pipe length can then be welded and are placed on barges and then towed to the Aegir to be taken on lowered (the process used to put the pipe down into the water from board. A substantial amount of time is saved by leaving the Aegir the ship) after which a new pipe length follows. in position whilst the barges, loaded with reels, travel between the spool base and the Aegir. This, of course, requires additional During the pipe-laying process, the pipe is held (by means of investments for the use of barges and the development of a friction) and lowered in a controlled way. A number of tests were different spooling process. developed to ensure that under all operational conditions, the pipe does not slip and thus, move around in an uncontrolled manner. In HMC and Iv-Consult jointly developed the 'barge mooring' system cooperation with the Heerema design team, Iv-Consult developed and designed the foundations for the spool equipment at the spool the test equipment and provided the design for integrating the base in Carlyss in the United States. equipment on board the Aegir. During the spooling process, the barge is moored in a small harbour R-lay and the pipeline is made by repeatedly welding together long, With R-lay, smaller pipe diameters are laid by the controlled prefabricated lengths of pipe that are continuously wound on to the unwinding of reels. The reels (see illustration 1, beneath the crane) reel. This plastically deforms the pipe in the bend radius of the reel. are provided onshore with the pipeline beforehand, which is made Variations in the pre-stressing of the pipe are limited during this up of long lengths of pipe welded together. The great length of the process so as to avoid buckling of the pipe wall. reeled pipeline reduces the number of welding joints that need to be made offshore which speeds up the pipe-laying process. Passing ships, waves and similar circumstances will cause the barge to make movements that will affect the pre-stressing of the pipe and also workability at the welding station.
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