NJL-0080 rev3.

0
J-Lay Tower Huisman - Presentation Objectives

The presentation objectives are:

To introduce the J-lay tower and how it works

To describe the standard J-Lay process

To identify the critical issues to be looked at bid/project stage

To list various reliable information sources for a deeper

understanding.
2012 release:
Structure installation with PLET Handling System and WS2
Hang-Off Module
Pipelaying operation with Friction Clamps and Welding Rotator
ILT installation with Intermediate Working Platform
New Weld Rotating Floor

04.02.11 Page 2
 1. Overall Description of J-Lay Tower
2. J-Lay Tower Specification
3. Description of J-Lay Tower Process
a. DJs Transfer from CB To J-Lay Tower
Agenda b. Working Station 1
c. Working Station 2
d. Auxiliary Equipment (PHS, HOM, IWP)
e. A&R System
4. Detailed information

10.12.10 Page 3
J-Lay Tower Overall Description

04.02.11 Page 4
J-Lay Tower Overall Description

04.02.11 Page 5
 J-Lay Tower Overall Description

04.02.11 Page 6
 Top Tower ARW 109mm
wire sheaves

Travelling block

Travelling Friction Clamp

Pipe Roller Guide

Upper Line Up Tool

Lower Line Up Tool

Drawworks Work Station 1
Gimballing ring
JLTS Level A
Centre roller boxes (2 off)

JLTS Level B A&R Fairlead sheave

Intermediate Working
JLTS Level C + Power House Platform
Adjuster leg Stinger structure
J-lay tower support structure PLET Handling System
JLTS Level D
JLTS foundation
Work Station 2
Hang-Off Module 2
BOREALIS HULL Stinger roller boxes (2 off)
04.02.11 Page 7
 PES General Arrangement

1/ Work area (removable module)

15
2/ Palfinger crane 6 Mt @ 24m
3/ Crane boom rest
4/ JLEA support
5/ PET Winch (4 off) 23mt
6/ Main control room
7/ Pull-back winches (2 off) 6mt
8/ Storage area
9/ Personnel lift (removed)
10/ Bevelling station
11/ Pull-back winches (2 off) 6mt Image to be
updated
12/ Transfer car
13/ PET
15/ Pipe Reference Frame

04.02.11 Page 8
 1. Overall Description of J-Lay Tower
2. J-Lay Tower Specification
3. Description of J-Lay Tower Process
a. DJs Transfer from CB To J-Lay Tower
Agenda b. Working Station 1
c. Working Station 2
d. Auxiliary Equipment (PHS, HOM, IWP)
e. A&R System
4. Detailed information

10.12.10 Page 9
J-Lay Tower Specification

J-lay Tower working with Double Joints (DJs)

• Double jointing made onshore
• J-lay tower made for Double Joint with or without collar
• DJ storage on CB moored alongside S. Polaris / Borealis
• DJ prepared and bevelled on deck

2 Work Stations working simultaneously on pipe

• WS1: Welding (+AUT)
• WS2: (AUT +) Field Join Coating (FJC)

04.02.11 Page 10
J-Lay Tower Specification

Pipe Characteristics:
• Pipe steel from 4” up to 24” Outside Diameter
• Pipe + Coating up to 620mm OD for Friction Clamps
• 72” OD allowable for special items on pipe
• Double Joints length 19m to 26m
• Double Joints weight up to 40t
• Carbon Steel or Clad pipes
• Insulated pipe: Insulation coating 5LPP or Pipe in Pipe

04.02.11 Page 11
J-Lay Tower Specification

Pipe holding capacity: Nominal Top Static

pipe size pipe tension
• 750t Static / 937t Dynamic
4’’ 170 tons

6’’ 350 tons

A&R capacity: 8’’ 400 tons

• A/R Traction winch 325t Static / 360t 10’’ 530 tons

Dynamic 12’’ 620 tons

14’’ 750 tons

• Potential Heave Compensation capability
16’’ 750 tons

18’’ 750 tons

A/R Linear winch 750t Static / 937t Dynamic 20’’ 750 tons

(potential) 22’’ 750 tons

-> For J-lay tower full capacity use 24’’ 750 tons

04.02.11 Page 12
J-Lay Tower Specification

J-lay Tower certification:

• Lloyds Design appraisal for all J-lay Tower
• Lloyds manufacturing survey
• Lloyds witnessed and certified:
– 825t load test in Rotterdam before shipping in J-lay collar mode
– Friction Clamps load tested @ 825tons in Glasgow before
shipping
– 360t offshore load test of J-lay Tower with Friction clamps
before Pazflor Project
– A&R Winch 360t load test onboard Borealis before CLOV Project
• PES load tested up to 30 tons (WLL of 27.7tons) witnessed by
Lloyd’s Register
• BV certified J-lay Tower connection points to Borealis hull

04.02.11 Page 13
J-Lay Tower Specification

Gimballing Capacity
• Pipe lay angle from 0° to 180°
• Tower tilt angle up to 14°
• Installation Vessel bow/stern to the main swell
•Increase installation window 110O

(less weather downtime)

•Allow CB permanently moored
portside for DJ storage
50O

• Potential Active Gimballing

30O

04.02.11 Page 14
J-Lay Tower Specification
• Tower Azimuth angle (α) = barge pipelay direction
• Tower Tilt angle (β) = tower angle with vertical axis.

• Tower Pitch angle = angle in between tower and gimballing ring.

• Tower Roll angle = angle in between JLTS and gimballing ring.

04.02.11 Page 15
J-Lay Tower Specification

Pitch angle = angle in

between tower and
gimballing ring +/- 14°

Roll angle =angle in

between JLTS and
gimballing ring + 12°

04.02.11 Page 16
 1. Overall Description of J-Lay Tower
2. J-Lay Tower Specification
3. Description of J-Lay Tower Process
a. DJs Transfer from CB To J-Lay Tower
• Pipe Storage
• Pipe Rollers
Agenda • PES
b. Working Station 1
c. Working Station 2
d. Auxiliary Equipment (PHS, HOM, IWP)
e. A&R System
4. Detailed information

10.12.10 Page 17
Description of J-Lay System

• SJ’s and DJ’s are lifted onto the system

DJs stored
using the PMOC and the port side Dreggen by racks
crane at the aft of the vessel.
• This crane has a 36Te capacity, depending
on the pipe weight numerous sections can be
lifted onto the deck at a time.
• There is an area on deck where the pipe can
be stored before they are needed.
• The pipes can be placed onto two different
parts of the transport system
• Landing units
• Bridge Type Landing Units
• When possible the pipe section should be
introduced to the transport system at the
forward most part of the Pipe Landing Units.

04.02.11 Page 18
 Pipe Transportation System

Bumpers

Pipe Landing Unit

V-block

Bumpers

Bridge Type Landing Unit

Space for the pipe to transfer

to the transverse conveyor
04.02.11 Page 19
 Pipe Transportation System

Pipe Landing Units

• Two types of landing

unit exist within the
pipe transportation
system.
• Both landing units
can accommodate the
SJ and DJ sections.
• The Joint Handling
selection needs to be
checked to ensure the
correct pipe detection.
The system alters
between the two pipe
lengths.

Bridge Pipe Landing Units

04.02.11 Page 20
Pipe Landing Units

• Ability to carry out a controlled

landing of the pipe sections into the
transport system.
• The pipes slowed and directed into
the V-shaped cradles.
• 8m overall length allows for
multiple sections to be moving at
one time.

04.02.11 Page 21
Bridge Pipe Landing Units
• The angled vertical bumpers slow and guide
the sections onto the pipe elevator rollers.
• Due to the elevated bumpers and steelwork the
pipe can move underneath the frame from the
cradles towards the transverse conveyor.

04.02.11 Page 22
Pipe Storage
• The sections can be stored either on the CB or on the port side of main deck,
which has a capacity of 10t/m.
• It is possible to transfer a SJ from the storage area to the Landing Units in 3
minutes, the process is relatively fast once the sections are onboard. Both the
PMOC and port side Dreggen crane can be used to transfer the pipes.
• The number of pipes which can be stored depends on the diameter, possible
coating and whether they are SJ or DJ.

04.02.11 Page 23
 • Conveyor Rollers
Conveyor Rollers • Bevelling Station
• Beadstall Area

10.12.10 Page 24
 J-Lay – Pipe Movement in Transportation System

DJ Position 1 DJ Position 2 DJ Position 3

SJ Position 1&2 SJ Position 3&4 SJ Position 5&6
Conveyor 1

Conveyor 2

Section 1 – Conveyor 1
Section 2 – Transverse Conveyor Conveyor 3
Section 3 – Conveyor 2 and 3 with
Transverse Transport Carts (2 positions) S-lay firing line
Seam Rotation
Section 4 – Offline Seam Rotation Rollers Rollers and LUT
and LUT with Transverse Transport Carts
(4 positions)
Conveyor 4
Section 5 – Conveyors 4 and 5

Conveyor 5

PET

04.02.11 Page 25
Conveyor 1 and Transverse Conveyor
Once the pipe has reached the
end of Bridge Landing Units/
Conveyor 1, it moves onto the
transverse conveyor.
1. Ensure the Joint Handling
selection is correctly
assigned on the system
control panel.
2. Check that no personnel are
in the path of the conveyor.
3. Lower the pipe elevators on
Conveyor 1, only 2 are
needed for SJ but 3
elevators required for DJ.
4. Using the transverse
conveyor pick up the pipe
section and move to the
next position along.
5. Continue this sequential
process for all pipes.
Transverse Conveyor
Pipe Elevators

04.02.11 Page 26
Bevelling Station and Transverse Conveyors

Transverse Conveyors move the pipe sections from the bridge

landing units to Conveyor Line 2, via the bevelling station.

04.02.11 Page 27
Bevelling Station
• While the pipe sections are on the transverse
conveyors, the bevel stations can be moved
to carry out the process.
• Both single and double joints can be
prepared onboard within two bevelling
stations (one fixed and one mobile), each
with a pipe facing machine.
• The bevelling machines are suspended on
the Overhead Gantry Cranes to allow them
access in and out of the pipe section.

04.02.11 Page 28
Bevelling Station

• Trained operators use the pipe facing machines with a rotating faceplate and cutting tool to
get the correct bevel to reduce the time needed to weld on the firing line.
• During bevelling the pipe ends are cleaned with a wire brush to remove any possible corrosion
of foreign metal which would reduce the structural integrity of the pipeline. An inspection of the
inside of the pipe is also required.
• A bevel calliper is used to ensure that the pipe end has been prepared to the specification
required

04.02.11 Page 29
Pipe Transport System – Transverse Conveyor

Transverse
Conveyor 1

Transverse
Conveyor 2

Transverse
Conveyor 3

Fixed Roller Unit

V-shaped pipe cradle

04.02.11 Page 30
Pipe Transport System – Transverse Conveyor in Sequence
1. The Conveyor 1 pipe elevators are lowered to allow the transverse conveyor to pick up
the pipe.
2. While the pipe is lifted off the rollers, the next pipe section is moved out of the cradle pads
on the fixed beam.
3. When the pipe diameters get too large and interfere with the surrounding ‘V’ positions,
these spaces will have to left empty to stop obstruction. This is for pipe diameters greater
than 24 inches.
4. The pipe sections is moved into the adjacent conveyor rollers (Conveyor 2) using the
lifting mechanism.
5. The process is started repeated for more pipe sections by retracting the sliding
mechanism to the initial position.

04.02.11 Page 31
Pipe Transport System – Conveyor Transfer

04.02.11 Page 32
Pipe Transport System – Conveyor Lines 2 & 3

• On both conveyor 2 and 3 there is capacity for 3 SJ and 2 SJ respectively , but it is advised that only
one section is on the conveyor at any one time.
• The pipeline moves between the conveyors using the transverse transport carts, only 2 of the 3 carts
are needed for SJ whereas all are needed for DJ.
• The carts lift the pipe section between the two conveyor while moving along a rail guide steel frame,
the height can fluctuate +/- 325mm from the neutral position.

04.02.11 Page 33
 Pipe Transport System – Transverse Transport Cart

• The hydraulic system which controls the transverse transport carts are connected
to the crane HPU.
• These carts move the pipe from conveyor 3 towards the firing line through the
beadstall area without the need for any other equipment. The manner of the lift
means that the pipe is secure within the cradles.
• There are three carts but only two are required to move SJs, whereas all are
needed for DJs. These lifts are carried out through synchronised movements in a
secure manner.
• The vertical stroke of each cart is 650mm, which it can achieve in approximately
12 seconds, depending on the system configuration.

04.02.11 Page 34
Pipe Transport System – Transverse Transport Cart

04.02.11 Page 35
Conveyor System and Beadstall Area

• To assist the transverse movement

of the pipe, and in case of failure,
there are two 15T Overhead cranes.
These cranes will also be able to
assist in special cases (in-line
structures).
• It is possible to carry out a total
combined lift of 30T, the Max weight
of SJ and DJ.
• The cranes run the width of the
beadstall area between conveyors 3
and 4.
04.02.11 Page 36
 Beadstall Area – Offline Seam Rotation Rollers

• The rollers are operated by a proportional joystick which controls the speed and
direction of the rotation.
• The pipe sections are placed on the rollers primarily using the transverse
transport carts, the overhead gantry cranes can also be used.
• Hydraulic cylinders power the rollers which enable the pipe to be lifted from the
original position and rotated along the longitudinal axis.
• Only two of the three rollers are needed for SJ sections of pipe.
04.02.11 Page 37
Pipe Transport System – Conveyor Line 5

• Conveyor 5 is the final conveyor in the Pipe Transport System and is exclusively used by the J-lay
System (all other conveyors are used by both S-lay and J-lay.
• This conveyor links up to the PET lower transfer position

04.02.11 Page 38
 Pipe Elevator • PET
System • Pipe Erector

10.12.10 Page 39
Description of J-Lay Tower Process

Pipe Escalator Trolley lifting DJ from

bevelling station up to Erector

Image to be
updated

04.02.11 Page 40
Double Joint hand-over to Erector 1/2

3
2

1. Position check
2. Close Erector
Friction Clamp
gates
3. Close Erector
1 2 3 Top Bracket

04.02.11 Page 41
Double Joint hand-over to Erector 2/2

4 - Extend position pads (2 off per 5 - Open PET grippers to land DJ

friction clamp) onto position pads

6 - Squeeze DJ with all pads (8 off 7 - Recover PET to standby position

per friction
04.02.11 Page 42
clamp)
Double Joint in Erector

04.02.11 Page 43
Erector loading DJ into tower 1/2

Erector in Standby
position TFC in transfer
TFC raised to position
Erector loading DJ into tower transfer position Erection completion
04.02.11 Page 44
Erector loading DJ into tower 2/2

TFC lowered onto

DJ end

Erector locked in Handover position Line-up tools

vertical position Squeeze sequence deployment
04.02.11 Page 45
Description of J-Lay Tower Process
Erector back in horizontal Position Upper Line-up Tool

Lower Line-up Tool

04.02.11 Page 46
Description of J-Lay Tower Process
• DJ guided by upper and lower line up Upper Line Up Tool
tools before the erector clamps open.
• Travelling block lowers DJ until bottom
end reaches WS1.
• Once DJ bottom end has reached WS1,
control is taken by Welding Supervisor to
complete DJ line up prior to welding.
• DJ line up is performed with line up tools Lower Line Up Tool
(LUTs).
• LUTs can translate DJ in the
perpendicular plane.
• Travelling Friction Clamp can follow
translation movements

04.02.11 Page 47
 WS1 Working Station 1 Description

10.12.10 Page 48
Description of J-Lay Tower Process

Image
Welding to be
Rotating Floor Vertical Stroke
updated 1200mm

9 turns

Working Station Clamp

WS1 entrance

04.02.11 Page 49
 Description of J-Lay Tower Process

Image to be
updated

Next DJ arrival
WS1 Roof
fully open

Pipe catenary secured in

WSC

04.02.11 Page 50
Description of J-Lay Tower Process

Demagnetization Bevel cleaning

check

WS1 roof fully

close

04.02.11 Page 51
Description of J-Lay Tower Process

Line-up completed

Welding Supervisor
commands line-up tools
to align upper DJ

Internal Welding
Clamp lowering
through DJ

04.02.11 Page 52
Description of J-Lay Tower Process

Steel heating prior Ground connected Welding operation

to start welding to pipe

04.02.11 Page 53
Description of J-Lay Tower Process

• Welding completion
• (+ AUT if WS1)
• Clear WS1

• Load transfer from WSC to

TFC
• Unsqueeze WSC
• Pipe Lowering sequence Image to be
updated

04.02.11 Page 54
Description of J-Lay Tower Process
Travelling Block Travelling Block
lowering 24 meters final lowering

LUTs in
parking
position

Image to be
WS1 roof Image to be
openingImage to be updated
updated updated

04.02.11 Page 55
Description of J-Lay Tower Process
Once Catenary
TFC start TFC funnel that lowered:
raising to guide the DJ inside
top tower the friction clamp •WSC squeeze
pipe
•Load transfer
from TFC to
WSC
•Release TFC
pads from pipe
•Raise TFC back
to top of J-lay
Tower for
receiving new
DJ
Image to be
Image to be
updated
updated

04.02.11 Page 56
 WS2 Working Station 2 Description

10.12.10 Page 57
Description of J-Lay Tower Process

WS2 Overview
• WS2 adjusted to pipe length
• Floor always horizontal (6m x 5m)
• Roof perpendicular to the pipe
• Wind & Rain protection
• Possibility of FJ weld repair
• AUT in WS2 (if not in WS1)
• FJC in WS2
• Rigging handling possible from WS2
roof
• 3 Manipulators: 5tons, 3tons and
1ton
Image to be
updated

04.02.11 Page 58
Description of J-Lay Tower Process
AUT is chosen for NDT
• AUT performed in WS1 or in WS2 depending on cycle time; purpose is to
balance WS1 and WS2 critical path.
• AUT performed in WS1 for every critical weld or special item to be lowered.
• Direct reading of the scan

Spread:
• 3 technicians + 1 helper per shift (CLOV)
• Rings for various pipe
• Rotating scanning machine
• Calibration block (one per pipe WT and type)
• Need fresh water supply

04.02.11 Page 59
Description of J-Lay Tower Process

Ring setting
around pipe
AUT scanning
machine

Image to be
updated

04.02.11 Page 60
Description of J-Lay Tower Process
Field Joint Coating
• Joint Surface Preparation (Grit Blasting to cleanliness Sa2 1/2)
• Liquid Epoxy Application
• Preheating using induction coil
• Heat Shrink Sleeve installation
• Field Joint Coating Inspection and cooling

Spread:
• 1 technician + 3 helpers per shift (CLOV)
• Grit Blasting Machine + Induction Coil

04.02.11 Page 61
Description of J-Lay Tower Process

Closed Cycle
Abrasive
Blasting Unit

Grit Blasting Image to be

Frame updated

04.02.11 Page 62
Description of J-Lay Tower Process

Liquid Epoxy Induction Coil

manual (curing &
application preheating)

Image to be
updated Image to be
updated

04.02.11 Page 63
Description of J-Lay Tower Process

PE Heat Shrink
Sleeve
Application
(Canusa GTS-
80)

Image to be
updated

Water cooling
Torch Heating

Image to be Image to be
updated updated

04.02.11 Page 64
Description of J-Lay Tower Process

Water cooling
device

04.02.11 Page 65
Description of J-Lay Tower Process
5mT manipulator

1.5m
stroke 2m
stroke
Project Specific
frames for FJC
Image to be
equipments
handling updated

Image to be
updated Image to be
updated
3mT manipulator

04.02.11 Page 66
Description of J-Lay Tower Process
WS2 Roof Hinged position
• Roof hinged with FJC equipment
• Floor still available
• When floor in lowest position 14m
available between the floor and the
middle tower exit point.
• Purpose: structure installation on pipe

Image to be
updated

04.02.11 Page 67
Description of J-Lay Tower Process

Allows structures
installation

Roof hinged with

FJC equipment Roof hinged with
FJC equipment

04.02.11 Page 68
 PLET Handling System (PHS)
Auxiliary WS2 Hang-off Module (WS2 HOM)
Equipment Intermediate Working Platform
(IWP)

10.12.10 Page 69
PHS Description
• PHS Main Purpose:
- Improve safety during Structure installation operations
- Standardize Structure interfaces
- Installation Aid for In-Line Structure Installation
- Installation Aid for Laydown / Recovery PLET Installation
- Installation Aid for any other particular Item such as Riser Termination Assembly,
Flexjoint, etc….
- Limit RATS use

• PHS Main functions:

- Capture Structure from Crane in Horizontal position,
- upend it to vertical position
- Line-up Structure to pipe catenary help in WS2 HOM

04.02.11 Page 70
PLET Envelope and Interface component

• PLET weight:
– Up to 80tons static with
1.2 DAF
– Up to 100tons static with
1.0 DAF

• PLET envelope:

Interface
component:
24” piece of pipe

04.02.11 Page 71
PHS Description

PHS Lower
Friction Gripper

PHS Deployment to
Horizontal Position

Grippers
skiddable along
main beam to
accommodate
various PLETs
lengths
PLET PHS PHS Upper Friction
Interface Piece Gripper

04.02.11 Page 72
PHS Description

IWP

Laydown PLET
Installation

PHS ready to
receive PLET

Image to be Pipe catenary

updated hanging on WS2
HOM

04.02.11 Page 73
PHS Description

PHS Upending to
Tower Tilt angle

Use lifting cylinder to

raise PHS gripper Arms

04.02.11 Page 74
WS2 HOM Description

WS2 HOM purpose:

 Hold the pipe catenary in position, underneath

WS2 for PLET/ILT installation with PHS

Parameters SI Unit
Supplier Huisman
Maximum Pipe Catenary Load 750mT *
Maximum Pipe Diameter 24 inch

Cutback insulation 1125mm

(OD>24inch)

Free Passage Diameter 72inch

Image to be
Approximate Weight 23mT updated

* Under Lloyds validation process

04.02.11 Page 75
IWP Description

IWP purpose:

 Get access on top of ILTs for welding, NDT and

FJC operations
Plt #1

Parameters SI Unit Plt #2

Supplier SMST Plt #3&4

Working Load Limit 1mT

Vertical Stroke 2.8m

Working Area 3m x 3m

Free Passage Diameter 72inch

Approximate Weight 8mT

Extract from SMST Drawing 0911300-B-01-00

04.02.11 Page 76
IWP Description

Front View – IWP in Garage Position Front View – IWP in Firing Line Position

All platforms
skid inside
platform 1
Rotation Frame

Telescopic Mast

Tilt Frame
Base Frame
Image to be Image to be
updated updated

04.02.11 Page 77
IWP Description

JLTS Deck C View – IWP in position Room inside IWP for 10 meters ILT

Tower lower
Image to be part Lower CRB

updated

Stinger
rotation
pins

Access gangway

04.02.11 Page 78
In-Line Equipments on Special DJs

In-Line Equipments:
Make sure the equipment will
safely pass through the entire
J-Lay Process, including:
• Bevelling Stations Rollers,
• Transfer Cars, Image to be
• PES and Erector Frictions Pads, updated
• Not clash with Line-up tools,
• Can pass through WSC
(protection?)

 Need to perform a study to

determine all the “No Go
Areas” : all interferences
with tower tools.

04.02.11 Page 79
 PLET Handling System (PHS)
WS2 Hang-off Module (WS2 HOM)
A&R System Intermediate Working Platform
(IWP)
Overboarding Platform & Sheave

10.12.10 Page 80
A&R Winch Operations

• A/R Traction winch 325t Static / 360t Dynamic

– Potential Heave Comp* (325/360t at seabed)
(* hydraulic and extensive modification required)

– 109mm wire length: 3200m

• A/R operations up to 200tons Static:

– Rerouting of Borealis S-lay A&R winch (200mtons)
– Use of special DJ with quick connector system

• A/R operations above 325 tons Static:

– Rerouting of Borealis S-lay A&R winch (600mtons)
– Use of special DJ with quick connector system

04.02.11 Page 81
A&R Winch Operations – 325t

A&R Winch
secured inside
Upper LUT

Palfinger Crane
WS1 Roof
opening

5 meters
Laydown Head
with PLR
incorporated

Image to be
updated

04.02.11 Page 82
A&R Winch Operations – 325t

A&R Fairlead Sheave

A deflecting point for A&R wires

Allows up to 45° angle
Capacity (SWL):
Fairlead Sheave
• 750t up to α=7°
• 375t up to α= 15°
• 185t up to α= 30°
• 110t up to α= 45°
Retractable system to avoid clash
when performing PLETs
installation: Image to be
updated

04.02.11 Page 83
A&R Winch Operations – 325t

Fairlead Stinger Retraction

Sheave

The Stinger structure can

be retracted to clear the
firing line to allow
structure laydown
Maximum tilt = 33° Image to be
(Depending on tower updated
pitch angle)

04.02.11 Page 84
A&R Winch Operations – 325t

A&R Fairlead Sheave

A deflecting point for A&R wires Fairlead Sheave

Allows up to 45° angle rotation to
accomodate
Capacity (SWL): pipeline Azimuth
•750t up to α=7°
•375t up to α= 15°
•185t up to α= 30°
•110t up to α= 45°
Retractable system to avoid clash
when performing PLETs
installation:

Fairlead Sheave
deployment

04.02.11 Page 85
A&R System – 200mT A&R System
• The main component of this
system is the 200mT Drum
Winch; used along with A&R
sheaves and spooling
device.
• The 200mT A&R winch has a
working load of 160mT
nominal/ 200mT dynamic.
• A&R Storage Winch: Max
line pull 20t/ 130t
emergency line pull
• The A&R wire is 3000m of
76mm non-rotational cable.
• This A&R System is
equipped with a constant
tension mode which has a
deadband range of 25% of
the CT set value, 150mT –
250mT.

04.02.11 Page 86
A&R System – 200mT A&R System
• All four of the winch motors have a fail safe brake in the event of a failure to the
system or an unsafe environment.
• The spooling device reduces the angle of the wire and as a result increases the
performance of the drum and the wire rope.
• The wire from the 200mT winch is directed into the firing line using two sheaves.
The upper wire controls the wire through the roof to the lower sheave.
• When the height and position of the tensioner changes, the A&R wire can still be
supplied with no conflict due to the travelling sheave box, the lower sheave.

04.02.11 Page 87
A&R System – 600mT A&R System
• The system consists of a traction winch, a storage winch with spooling device
and a sheave box.
• Storage winch needs to be in Constant Tension mode while the Traction winch
is being operated.
• This system can also be used in tandem with the tensioners.
• The 600mT Traction Winch has a capacity of 500t Nominal/ 680t Dynamic.
• Emergency lowering capacity of 680t.
• Emergency holding capacity of 765t.

Traction winch

Storage winch
04.02.11 Page 88
A&R System – 600mT A&R System (cont.)
• The system is operated by the 600mt Traction
Winch, this can only be done if the storage
winch is in CT mode.
• Traction winch contains two drums mounted on
a single frame powered by 4 electric drives.
The basis of the winch is a build up of friction
between the winch drum and the wire rope.
• A&R wire is wound over the 2 drums of the
Traction Winch but stored on the Storage
Winch.
• The wire is directed into the firing line using
the deployment sheave box, which has to be
locked in the upward position before the
system can be loaded. When the system is not
in use the sheave box needs to be lower in the
storage position using the tilting cylinder.
• There is a spooling device on the 20mT
Storage winch which optimise the fleet angle of
the wire rope and the spooling behaviour.

04.02.11 Page 89
A&R System – 600mT A&R System (cont.)
• The A&R wire follows the line of the
S-lay firing line
• Halfway down the S-lay firing is a
sheave which allows the A&R wire
to be redirected through a hatch
and out towards the J-Lay system
• The overboarding platform and
sheave allows the A&R wire to be
used for J-Lay operations

04.02.11 Page 90
A&R System – 600mT A&R System (cont.)

Exit hatch from S-lay

firing line

Route of A&R wire across

starboard deck to
overboarding sheave

04.02.11 Page 91
 1. Overall Description of J-Lay Tower
2. J-Lay Tower Specification
3. Description of J-Lay Tower Process
a. DJs Transfer from CB To J-Lay Tower
Agenda b. Working Station 1
c. Working Station 2
d. Auxiliary Equipments (PHS, HOM, IWP)
e. A&R Winch Operations
4. Detailed information

04.02.11 Page 92
J-lay Tower detailed information

Also in J-lay Tower Huisman C-doc Database:

• NJL-0184 J-lay Master Document

Also available on the Seven Borealis SharePoint Site.

04.02.11 Page 93
Abbreviations and definitions
• AHC Active Heave Compensator • HOM Hang Off Module
• HPU Hydraulic Power Unit
• ARW Abandonment & Recovery
Winch • ID Internal Diameter
• A&R or A/R Abandonment & • IWC Internal Welding Clamp
Recovery
• JLEA J-Lay Erector Arm
• AUT Automated Ultrasonic
Testing • JLTS J-Lay Tower Structure
• CB Cargo Barge • LUT Line Up Tool
• CRB Centraliser Roller Box • LLUT Lower LUT
• DJ Double Joint • MBL Minimum Breaking Load
• DMA Dead Man Anchor • MCR Main Control Room
• ENDO Roller: Deck conveyor rollers • MWS Marine Warranty Surveyor
at bevelling station
• NDT Non Destructive Testing
• EPU Electrical Power Unit
• OD Outside Diameter
• FC Friction Clamp
• FJC Field Joint Coating
• FJ Field Joint
• HC Head Clamp
• HOBM Hang Off Bushing Module

04.02.11 Page 94
Abbreviations and definitions (cont.)
• PE Pipe Erector • SOP Standard Operating Procedure
• PES Pipe Escalator System • SP Suction Pile
• PET Pipe Escalator Trolley • SRB Stinger Roller Box
• PFM Pipe Facing Machine (Pipe • SWL Safe Working Load
bevelling machine)
• PHS PLET Handling System • TB Travelling Block
• PiP Pipe in Pipe • ULUT Upper LUT
• Pipe A string of DJ • UMS Umbilical Management System
• PRG Pipe Roller Guide
• ViV Vortex Induced Vibration
• PTW Permit To Work
• WRF Welding Rotating Floor
• RAT Rope Access Technician
• WSC Work Station Control
• ROV Remote Operated Vehicle
• SCADA Supervisory Control & Data • WS1 Work Station 1
Acquisition • WS2 Work Station 2
• SCR Steel Catenary Riser • WT Wall Thickness
• SJ Single Joint • WU Welding Umbilical
•

04.02.11 Page 95
Key Contacts

Malcolm Mike Hibbard Jean-Baptiste

Seeley Ship Operations Pose
Project Technical Manager Project Manager –
Director – Equipment (OR)
Borealis Project

04.02.11 Page 96
• QUESTIONS / COMMENTS

Please feel free to contact Robert Adam for any further

information.
• Also available in the same
collection:

04.02.11 Page 97
 seabed-to-surface
www.subsea7.com

10.12.10 Page 98