Denver Mungroo Ric Manorath

Project Lead
 A & A Mechanical Contractors and
Company Limited
Specialized in: CONSTRUCTION, WELDING, FABRICATION,
FIELD MAINTENANCE, PIPEFITTING,
ULTRA HIGH PRESSURE HYDROBLASTING, GRITBLASTING & DIVING

45 Seukaran Trace Phone/ Fax: (868) 649-3455

Thick Village, Siparia Road, Cell: (868) 350-5492
Fyzabad, Trinidad, W.I. E-mail: admin@aamech-tt.com
AZARD ALI VAT Registration: 105711
MANAGING DIRECTOR

16th June 2021

FABRICATION AND INSTALLATION OF NEW

PROPOSED WELL S.878.FU3

PROCEDURE: TRIAL ASSEMBLY OF THE

MAIN DECK (PHASE 1)
EXECUTIVE SUMMARY:

The Scope of Work states that “The Contractor shall conduct a full assembly at their facility of all
components to ensure proper assembly prior to field installation. Weights for individual
components shall also be recorded for verification of lifting and rigging plans.” This Trial Assembly
procedure is focused on ensuring that no interference exists between the three main components (Main
Deck, Riser Guard and Boat Landing) and to understand how the components will be assembled offshore.
It is proposed that the assembly be done in two phases:

 Phase 1: Trial assembly of the main deck (on its own with no components)
 Phase 2: Trial assembly of the Boat Landing and the Riser Guard.

In Phase 1, the trial assembly of the main deck is to be completed using a 30 US ton crane. The crane will
have the ability to lift utilizing two blocks. This will allow for safe rotation of the deck from the upside
down position to the right side up position. The dummy pile is shall be pitched onto a 1” thick plate and
welded in place. The Deck is then placed over the dummy pile and braced in place. Once the trial assembly
is witnessed by HPCL representatives and approved, the deck will be removed and flipped back to its upside
down position and placed to rest. Once completed, the deck will now be sent to abrasive blast and paint as
per requirements of the Scope of Work.
OBJECTIVE:

Item “2.5.10” of the Scope of Work states the following:

“The Contractor shall conduct a full assembly at their facility of all components to ensure proper
assembly prior to field installation. Weights for individual components shall also be recorded for
verification of lifting and rigging plans.”
This Trial Assembly procedure is focused on ensuring that no interference exists between the
three (3) main components (Main Deck, Riser Guard and Boat Landing).

METHOD STATEMENT:

This procedure takes into account the use of a 30 US Ton crane and excavator to conduct a trial assembly
for the Main Deck. The Main deck is currently in an upside down position at the AAMCCL Fabrication
yard in Siparia. The following is a summary of information on the main deck.

Main Deck Information

 Dimensions: 24ft x 12ft x 12ft from top of deck to bottom of clamp
 Weight: 5.5 US Tons (inclusive of a 5% Factor of Safety)

Preparation phase
The excavator is used to position the 1” plate and spot the dummy pile for welding. In the preparation phase,
the dummy pile bracing, stop plates and WT beams are prepared. The planned position for the clamp is marked
on the dummy pile and stop plates welded in position just under the planned clamp position.

Installation phase
In the installation phase, a 30 US Ton crane is mobilized to lift the main deck. The main deck will be flipped
from an upside down position to a right side up position. The deck is then moved over the dummy pile and
installed in place on the dummy pile. The diagonal braces can then be installed, bolts on the clamp tightened
and the WT beams welded to the dummy pile.

Removal phase.
Upon acceptance by HPCL representatives, proceed to the Removal Phase by removing the deck from the
dummy pile and returning it to the rest position by rotating the deck back to an upside down position. For
more details, see the step by step method statement for completing this exercise in the table below:
 MAIN DECK - TRIAL ASSEMBLY STEP BY STEP GUIDE

Step Description of Works Sketch Reference

1.0 - Preparation Phase – Main Deck Trial Assembly
Place 1” thick (8ft x 20ft) plate in position on a level surface
1.1
using excavator. (See Table 1)
See Drawing 4
Scribe the position for placing the dummy pile onto the centre of
1.2
the plate.
Prepare diagonal braces:
1.3 See Drawing 1 (Detail 1)
W8 x 35# - 4pcs, 9ft long each, mitre ends),
Prepare horizontal supports:
1.4 See Drawing 1 (Detail 2)
WT5x24.5# - 4pcs, 2ft-1” long,
1.5 Prepare 2 pcs of (1” x 1” x 1” thick) stop plates. See Drawing 1 (Detail 3)
Cut Lugs of dimension 6” x 3” x 1” thick (Quantity: 2) for
1.6 See Drawing 6
installing on the dummy pile.

1.7 Install lugs at the top of the dummy pile (180 degrees apart)

Conduct Magnetic Particle Inspection (MPI) on the welding for

1.8 N/A
the dummy pile lug.
Lift Pile and place on 1” plate on the scribed circle using
1.9 See Drawing 4, (Weight of pile = 3.5 US Tons)
excavator. (See Table 1)
1.10 Weld Pile to Plate (3/8” welding). See Drawing 1 and Drawing 4

1.11 Mark position of bottom of clamp on the dummy pile. See Drawing 1

1.12 Install Clamp onto Main Deck. N/A

Upon completion of Preparation Work, proceed With
1.13 N/A
Installation Phase (Table 2.0).
 2.0 - Installation Phase – Main Deck Trial Assembly

2.1 Mobilize Equipment to perform lift. Excavator and Crane

2.2 Install Rated and Certified Rigging on Main Deck. See Drawing 3

Rotate deck from upside down position to right side up

2.3 See Drawing 5
position.
Lift main deck with clamp assembled to braces onto the dummy
2.4 See Drawing 1
pile and lower onto the stop plates.

2.5 Torque bolts with striking end / Impact Gun N/A

Position Diagonal Braces between Pile and Plate and weld in

2.6 See Drawing 1
place.

2.7 Tack weld 4pcs WT beams to the main deck and dummy Pile. See Drawing 1

2.8 Lower boom to place full load onto the clamp and dummy pile. N/A
Allow for HPCL to witness the Trial Assembly of the Main
Deck. The vertical dimension from all four corners of the main
2.9 deck to the ground level shall be verified to ensure no warping See Drawing 1
of the deck has occurred. Pictures of the trial assembly shall
also be taken.
Upon receipt of acceptance from HPCL proceed with the
2.10 N/A
Removal phase (3.0).
 3.0 - Removal Phase – Main Deck Trial Assembly
Place tension back on the crane to ensure structure is stable for
3.1 N/A
removal phase.

3.2 Remove tack welding between 4pcs of WT Beams and the N/A
dummy pile
3.3 Remove Diagonal Braces welded between the Pile and Plate N/A

3.4 Break torque on Main Deck clamp bolts N/A

3.5 Lift the Main Deck from pile N/A

Rotate deck from to right side up position to upside down
3.6 See Drawing 5
Position and place on supports.

3.7 Remove WT Beams from main Deck N/A

3.8 Remove welding between dummy pile and 1” thick plate N/A

3.9 Lift dummy pile and place in resting position on dunnage N/A
 CALCULATIONS:

Lug Design information and calculations for the Dummy Pile can be seen below:

Lug Design

Recommended Lug Design

 Plate Thickness: 1”
 Yield Strength: 50ksi
 Hole Diameter: 1-1/4”
 Base length of Lug: 6”
 Distance between edge of hole and edge of lug: 7/8”
 See Drawing 6 – Lifting Lug Detail for Dummy Pile
 Minimum 5/16” Weld throat

Tests
1: If dimension "a" >= (0.5x "d") Pass
2. If dimension "a"<(4 x "t") Pass

Failure mode 1: Tensile Failure

Factor of safety (F.S.) 6

F = (2 x 'a' x 't' x Pys) / F.S.

Max lifting force before tensile failure 14583.333 lbs

Failure Mode 2: Bearing Surface Failure
Factor of safety (F.S.) 2

F=(0.9 x Pys x t x PD) / 'F.S.'

Max lifting force before Bearing Surface Failure 22500 lbs

Failure Mode 3: Shear Failure
Factor of safety (F.S.) 2

F=(2 x 0.4 x Pys x a x t) / 'F.S.'

Max lifting force before Shear Failure 17500

Failure Mode 4: Welding Failure
Factor of safety (F.S.) 2

F=(Cos45 x 'w' x 'L' x 'ws') / 'F.S.'

Max lifting force before Shear Failure 92806.875

Methods of Lug Failure
1. Failure in Tension: (using Yield Strength: 50ksi, Factor of safety of 6) = 14.583 kips (14,583 lbs).

2. Failure of Bearing Surface: (using Yield Strength: 50ksi, 1” Shackle pin, Factor of safety of 2) =
22.5 kips (22,500 lbs).

3. Shear Failure: (using Yield Strength: 50ksi, Factor of safety of 2) = 17.5 kips (17,500 lbs).

4. Welding Failure: (using 6010 Electrodes, 5/16” weld throat, Factor of safety of 2) = 92.806 kips
(92,806 lbs).

Reference: (David T. Ricker, "Design and Construction of Lifting Beams", Engineering Journal, 4th Quarter, 1991)

Bending

The load is supported at four (4) points as shown on Drawing 3.

At certain points of the lift, the load will be supported at two points only.
With a total estimated weight of 5.5 US tons and assuming equal distribution of weight at two points:

The maximum force = 2.75 US tons (5.5 kips). For the purpose of this calculation we shall assume the full
weight of the deck is supported with two slings between the two sling positions (16 feet apart).

Beam Information:
 W6x20#
 ASTM A992
 Length: 16 feet
 Load arrangement: Simple Beam (UDL),
Max bending moment: (WL2/8) = 11,000 lb-ft.
Where W = 343.75lb/ft.
L = 16ft

Max Bending Stress: (My/I) = 1,423,143.49lb/ft2 (9883 psi) or 9.883ksi (32.9% of YS), (27.5% of UTS)
Where M = 11,000 lb-ft.
y = 0.2583 ft.
I = 41.4 in4 (0.0019964958 ft4)

For A992 Steel,

 Ultimate Tensile Strength (UTS): 65ksi x Safety Factor (0.6) = 36ksi
 Yield Strength (YS) = 50 ksi x Safety Factor (0.6) = 30ksi

Max Deflection (at beam midspan): (5WL4/384EI) = 0.0352 ft. (or 0.42”)
Where ‘W’ = 343.75lb/ft.
‘L’ = 16ft
‘E’ = 29,000 ksi (4176000000lb/ft2)
‘I’ = 41.4 in4 (0.0019964958 ft4)

Reference: (AISC Manual of Steel Construction (ASD), Ninth Edition, 1989)

Stability

Centre of Gravity

The following assumptions are made:

The structure comprises of three sections (1” thick plate, Dummy Pile, Main Deck)

 1” thick plate assumptions:

o Shape – Cuboid (8ft x 20ft x 1” thick),
o Distance to centroid (d1) – 0.5”,
o Weight (W1) – 6,528 lbs (3.264 US tons)

 Dummy Pile assumptions:

o Shape – Cylindrical (12ft-10” x 42” Outer Diameter x 1.25” thick),
o Distance to centroid (d2) – 6ft-5” + 1” = 6.5ft,
o Weight (W2) – 6,988 lbs (3.5 US Tons)
  Main Deck assumptions:
o Shape – Cuboid (24ft x 12ft x 1ft),
o Distance to centroid (d3) – 0.5ft + 12ft-10” + 1” = 13.42ft,
o All Weight within cuboid (W3) – (6.0 US Tons)

Centre of gravity of the complete structure has to be calculate in three axes (x, y, z).
Datum (corner of 1” thick sheet) – assuming centre point of pile is the centre point of plate
 X axis – 10ft
 Y axis – 4ft
 Z axis – ((W1 x d1) + (W2 x d2) + (W3 x d3)) / (W1 + W2 + W3) = 8.1ft

Diagonal Beams
To prevent overturning of the 42” pipe, four (4) diagonal beams will be welded between the 42” pipe and
the 1” thick plate. W8 x 35# beams (of minimum length 9 feet) shall be used and temporarily welded
between the dummy pile and the 1” thick plate.

The beams shall be installed 90 degrees apart and shall reach to a vertical height of 8.25ft up the 42” pipe.
The beams shall also be installed at an angle outside of the area of the pipe bracings (x position) instead of
+ position) as shown on drawing.

Horizontal Beams
To prevent shifting of the main deck while being installed on the dummy pile, four horizontal WT beams
shall be welded between the main deck and the dummy pile to keep the structure centred around the dummy
pile. WT5x24.5# beams shall be welded to the dummy pile and upon contact with the main deck and bolting
of the main deck pipe support to the main deck clamp gusset plates, the WT beams shall then be tack welded
to the main deck.

Weld Failure: (E70xx electrode, Welt throat: ¼”, Factor of Safety: 2) = 148.5 kips (148,500 lbs) - (approx.
74 tons)
As for the allowable axial loading of the W8x35# I beam (9ft length, Yie ld strength 36ksi), = 186ksi (or
186,000 psi). See excerpt below from AISC Steel Construction Manual (9th Edition).
 EQUIPMENT TO BE UTILIZED

EXCAVATOR (used in positioning the 1” thick plate and to spot the dummy pile on said plate)

MODEL: CAT 320 CL

Table 1 – Excavator Load Table

Weight of Plate: 3.28 US Tons (6,560 lbs)

Weight of Dummy Pile: 3.5 US Tons (7000 lbs)

With excavator arm outstretched to a height of 15ft and forward distance of 20 feet Excavator is able to lift 9800 lbs
(4.9 US Tons)
CRANE

Model: RTC 8030 Series II - 30 US Tons

Company: AMCO Weld

Table 2 - Crane Load Tables

Table 3 - Crane Boom Lengths

Diagonal braces to be installed using W8 x 35# I-beams set at 8.25ft up the dummy pile. Bracing to be installed after the crane lifts the main deck
into position on top the stop plates (highlighted in red). This will allow the clamp to reach the desired position.
 Slings A – 12ft long (belt Sling Arrangement)

According to Charts, Crane will be capable of

lifting 24,300lbs (12.15 US Tons)

24ft

Drawing 2 – Elevation View of Crane

 Belt Slings:
 Quantity: 6
 Installation Method: Choke
 Minimum Rating: 3 Tons (Choked)
 Length: 12ft
 Angle: 45
 Choke Around: W6x15# I beam at
four points (SL-A, SL-B. SL-C, SL-D)

Shackles:
SL-B
 Quantity: 6
 Type: Safety Screw Pin Shackles
SL-A  Minimum Rating: 2 Tons

SL-D

SL-C

Drawing 3 – Sling Positioning

 DRAWING 5 - GUIDE FOR FLIPPING MAIN DECK

From Resting Position

Pt. A

Step 1: From the upside down position, lift one side (Pt. A) of the main
deck and install dunnage. Install slings required for tilt (see list below).

Pt. A
Pt. B

Step 2: With dunnage in place, lift the deck at both sides in a controlled manner
using two lifting blocks on crane until the deck is rotated into a vertical position.

Pt. B

Switch position
of Pt. A

Step 3: Disconnect Point A (Pt. A) from underside and switch to

topside slings while deck is suspended at Pt. B
 Pt. B
Pt. A

Step 4: Lift the deck into a level position suspended on Pt. A only

Pt. A

Step 5: Main Deck is now completely suspended on Pt. (Pt. A)

 Rigging Required:
o Six Slings (minimum capacity 3 ton each),
o Six Shackles (minimum capacity: 3 US Ton each),

 Lifting Equipment: Crane and Excavator.

 Same procedure can be done in reverse to go from Right Side up to upside Down.

 Tag lines to be used on the deck during lift and slings to be protected when chocked on beam
to prevent damage to slings during lift (proposed to use uncertified slings).
DRAWING 6 – LIFTING LUG DETAIL FOR
DUMMY PILE