How to float out and install a 19,600-ton offshore platform?
Mammoet has achieved a significant milestone by loading out and installing a massive 19,600-ton offshore platform. This accomplishment is a part of the Azeri Central East (ACE) project, which is the next phase of development of the BP-operated Azeri-Chirag-Deepwater Gunashli (ACG) field in the Caspian Sea.
Mammoet’s scope included the weighing, jack-up, load-out and floatover installation operations of the 19,600-tonne production, drilling, and quarters (PDQ) platform. Leveraging its comprehensive engineering capabilities, Mammoet ensured the precise transfer of the platform’s topsides unit from the quayside onto the transportation barge STB-1 and subsequently onto the jacket foundation offshore.
Prior to its departure, the topsides unit underwent meticulous commissioning and operational testing onshore, significantly reducing offshore installation and start-up activities.
Engineered solutions
With the help of Mammoet’s Mega Jack 5200, the topsides unit was lifted to a height of 17 meters and placed on a customized loadout support frame at the quayside. Using four 900-tonne strandjacks, break-out jacks, a high-capacity ballast system, load monitoring quay jacks consisting of six 600-tonne jacks, and mooring winches, the unit was skidded onto the barge. Finally, the unit was sea-fastened and secured for transport to the ACG field.
Upon arrival at the designated field location, Mammoet executed the installation of the topside unit onto the jacket foundation through a floatover operation. The barge was positioned over the substructure and the topsides unit was then lowered onto the substructure while maintaining the barge’s position.
The barge’s internal ballasting and winching system was enhanced with Mammoet’s float-over winches and configurable high-flow rapid ballast system. This enhancement added an additional flow capability of approximately 32,000m3/hr. This centrally controlled and monitored ballast system ensured real-time oversight, guaranteeing operational continuity and a safe floatover process.
This unit, comprising vital oil and gas processing facilities, an integrated drilling rig, a gas compressor, and living quarters, was constructed by Azfen in the Bayil fabrication yard, utilizing local infrastructure and resources.
Beyond load-out and installation
Mammoet played a key role in the integration of the platform’s DES and MDSM modules, totalling 2,400 and 2,350 tonnes respectively. The combination of Mammoet’s jacking and skidding systems, along with SPMTs, ensured a seamless and secure operation.
Looking ahead, drilling is expected to commence in the coming months with the delivery of ACE’s first oil projected to begin in early 2024.
Dan Kempin, Business Development Manager for Mammoet, commented, “As we continue to redefine industry standards through our innovative solutions and steadfast commitment to safety, the successful loadout of this massive topsides unit stands as a testament to Mammoet’s dedication to excellence in engineered heavy lifting and transport.”
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