HABITAT WELDING PROPOSAL – MALEO MOPU PRODUCER (glyn) / 29 September 2010

MIKE MASSON – 2 SEPT 2010/ 0850hrs

Topside Equipment
 Welding Control Van
 Power Module / Machinery Van
o Isolation transformer
o P/H machine’s
o Welding machines
 Welding winch, c/w umbilical
 Preheat winch, c/w umbilical’s   (two umbilical’s might be required depending on the preheat
requirement for the repair procedure)
 Main Services Umbilical  (comms, power, instruments, video & gas services)
 Hydraulic winch, c/w umbilical  
 Thermocouple umbilical (depending on the control system used for preheat)
 Topside Chiller c/w chiller hose for habitat   (to counter rise in habitat temperature when
preheat is in operation)?   
 Emergency generator
 Hydraulic Power Pack
 Spare Welding / Preheat Umbilical (dual purpose)
 Stores / Workshop containers
 Welding load out list to be generated for welding consumables, electrical & mechanical spares
etc.
 Welding data logger?  (automatic logger connected to welding output or manually logged?)

Habitat Services
 Umbilical entry point to secure umbilical’s coming in to the habitat
 Habitat Gas Panel
 Argon Panel
 2 x Welding Stations set for tig & stick welding (assuming that two welders would be welding at
the same time)
 Preheat ….. This would just be splitter cables connected to the P/H umbilical
 Preheat Control JB  (T/C or temp transmitters)
 Blower Scrubber system (fan & closed loop coil c/w sodasorb holder)
 Regen Blower?    
 110V Flood lights
 2 x 24V hand lights
 2 x video cameras (one to double as a hand held camera for weld inspection)
 Pan & Tilt unit (if required)?
 Communications (two wire comms for habitat up-link; PA bullhorn for habitat down-link; Sound
Powered Telephone)
 Instruments
o Arc Volts
o Temp / Humidity
o Radiation Monitor  (depending on inspection requirements)

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HABITAT WELDING PROPOSAL – MALEO MOPU PRODUCER (glyn) / 29 September 2010

MIKE MASSON – 2 SEPT 2010/1630hrs

See below rough estimate of what needs to be carried out on the SS7 welding equipment that should
make it acceptable to hire. 

  Topside Equipment
 Welding Control Van       PMS work outstanding on all equipment within the container
 2 x Welding machines
 1 x Preheat machine
 Welding / Preheat control panel
 Electrical & Gas Jumper Panel
 Video System
 Comms systems (Helle, PA & Through Water Comms)
 Welding control system
 Preheat control system
 Environmental monitoring system ….. Hallin could provide analysers for the panel which
would probably be the best option.
 Gas Panel
 Calibration of all Welding, Preheat & environmental instruments
 Calibration of gas panel gauge

 Power Module / Machinery Van          PMS work outstanding on all equipment within the
container
o Isolation transformer
o P/H machine
o PH control panel
o 440 & 220V distribution boards
o Electrical Jumper Panel

 Welding winch, c/w umbilical      

o PMS to be carried out on winch
o Welding umbilical will need to be purchased by Hallin

 Preheat winch, c/w umbilical’s  

o  PMS to be carried out on winch
o 2 x Umbilical’s to be tested & certified
o
 Main Services Umbilical  (comms, power, instruments, video & gas services)
o The umbilical would need to be re-terminated & configured for Hallin’s requirements.
o Probably better making up our own umbilical for a one off job?

 Hydraulic winch, c/w umbilical  

o PMS to be carried out on winch
o Umbilical to be tested & certified

 Multi Purpose Winch  (capable of installing three separate umbilical’s)

o PMS to be carried out on winch

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HABITAT WELDING PROPOSAL – MALEO MOPU PRODUCER (glyn) / 29 September 2010

 Welding System Interface Cables & Hoses  (list of requirements to be supplied by Hallin)
o PMS to be carried out on all cables
o PMS to be carried out on all hoses
o Function test & certification

 Topside Chiller c/w chiller hose for habitat  

o PMS to be carried out on chiller
o PMS to be carried out on hose
o Function test

 Emergency generator
o To be supplied by Hallin

 POPES Chair    (umbilical deployment system)

o PMS to be carried out

 Hydraulic Power Pack (twin pack in container)

o PMS to be carried out
o Available if required?

 Spare Welding / Preheat Umbilical (dual purpose)

o To be purchased by Hallin

 Stores / Workshop containers

o To be purchased by Hallin

 Paint Pots
o PMS to be carried out
o Certification

2 x Mechanical and 2 x Electrical technicians would be required to complete the work which would take
approx 6 to 8 weeks along with some labour.  Prior to starting the work an accurate scope of work
would be required to be in place with proper supervision.  How this is done can be discussed over the
coming days by the management team?

NOTE:
1. Apart from this equipment we would need to design the habitat equipment layout which would
be mostly plug-in JB’s with the end user equipment all controlled from the Control Shack. 
2. To do this there would be some modifications required to be carried out inside the WADS
control so we would have to reinstate the original wiring before we handed the equipment back
to SS7.
3. A separate launch umbilical might be required just to provide lights and video during the habitat
installation, all other internal services could be connected when the habitat is dry and the main
services fully connected

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HABITAT WELDING PROPOSAL – MALEO MOPU PRODUCER (glyn) / 29 September 2010

MIKE MASSON – 2 SEPT 2010/ 2019hrs

The Regen unit will be included in the Habitat equipment (see first list) that’s why I didn’t include it in
the last mail which was only for the topside equipment.  If we go ahead with the welding work we’ll
need to look carefully at the design of the Regen unit. 

In the past we have mounted the Regen motor & chemical stack inside a self contained unit that could
be sealed, launched subsea and pulled inside the habitat. After that it was just a case of opening the box
pull out the hoses and switch on.  That was on a structural weld which allowed for bottom entry to the
habitat but here we are facing a different problem, maybe a similar set-up could be used with the unit /
box being installed to the Habitat before it’s joined subsea?  

The rest of the habitat equipment fit out shouldn’t pose too much problems but once the job is
confirmed we will all need to sit down and come up with a practical design for the habitat internal
equipment, make out a realistic timeline to complete the work and finish off with a full function test of
the equipment.

MIKE MASSON – 2 SEPT 2010/ 2059hrs

It would make things a lot easier without the bottom seal & installing a false floor in the habitat.  This
would also make the fabrication / design of the diver entry a little easier.  The same goes for the
umbilical entry to the habitat as we’ll probably require approx 5 x umbilical’s (MSU, Preheat, Welding,
Chiller and Emergency Gas hose)

MIKE MASSON – 2 SEPT 2010/ 1836hrs

As discussed see below list of requirements for the welding system?   I’ll send you an updated single line
diagram for the welding equipment layout first thing in the morning.

Topside Equipment
 Welding Control Van
 Power Module / Machinery Van   (Subsea7 Hire)
o Isolation transformer
o P/H machine’s
o Welding machines
 Welding umbilical   
 Preheat  umbilical’s   (two umbilical’s might be required depending on the preheat requirement
for the repair procedure)
 Main Services Umbilical  (comms, power, instruments, video & gas services etc)
 Hydraulic winch, c/w umbilical
 Hydraulic Power Pack
 Thermocouple umbilical (depending on the control system used for preheat)
 Spare Thermocouple umbilical
 Topside Chiller c/w chiller hose for habitat   (to counter rise in habitat temperature when
preheat is in operation)?   

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HABITAT WELDING PROPOSAL – MALEO MOPU PRODUCER (glyn) / 29 September 2010

 Emergency generator
 Spare Welding / Preheat Umbilical (dual purpose)
 Stores / Workshop containers
 Welding load out list to be generated for welding consumables, electrical & mechanical spares
etc.
 Welding data logger?  (manually logged?)

Habitat Services
 Umbilical entry point to secure umbilical’s coming in to the habitat
 Habitat Gas Panel
 Argon Panel
 2 x Welding Stations set for tig & stick welding (assuming that two welders would be welding at
the same time)
 Preheat ….. This would just be splitter cables connected to the P/H umbilical
 Preheat Control JB  (T/C or temp transmitters)
 Blower Scrubber system (fan & closed loop coil c/w sodasorb holder)
 Regen Blower   
 110V Flood lights
 2 x 24V hand lights
 2 x video cameras (one to double as a hand held camera for weld inspection)
 Communications (two wire comms for habitat up-link; PA bullhorn for habitat down-link; Sound
Powered Telephone)
 Instruments
o Arc Volts
o Temp / Humidity
o Radiation Monitor  (depending on inspection requirements)

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