Our Innovative Breakthrough Vessel:

ura 30 0

Sapura 3000 is the most advanced and versatile vessel for

conventional and deepwater construction activities in the
region .
This purpose-built combination vessel (pipelay and heavy
lifting) is unique in its overall capabilities, w ith dynamic
positioning in deep and shallow wa ter and fully revolving
mast crane capable of 3000ST lifts. Conventional S-Lay is
used for shallow water, pipelay and steep S-Lay or Hay for
deepwater pipelay and/or steel catenary riser installation in
water depths of up to 2000m.
SapuraAcergy has further enhanced the vessel's capabilities
by installing two (2) permanent Work Class Remotely
Operated Vehicles (WROVs) Due to the WROVs having
extreme ly long excursion capabilities, the need for a
standalone support vessel to monitor pipe touch-down
in many cases is not req uired . Driven by fibre optics, this

Strength and Depth

veh icle is the most sophisticated medium in the remote

construction market

Sapura 3000 has accommodation for up to 330 people

w ith full office facilities, recreation room, gymnasium and
helideck suitable for Sikorsky S92, providing a friendly and
conducive environment for offshore activities.
SapuraAcergy is committed to an incident-free workplace
and has taken the necessary precautionary steps to ensure
the Sapura 3000 and its crew adhere to the highest quality
and safety standards (1S0 9001 and OHSAS 18001 )
In addition, SapuraAcergy is certified with ISO 14001
for Environment Management System, Document of
Compliance (ISM Code) and International Ship Security
(ISPS Code) A ll the Management Systems are achieved
through SapuraAcergy's Integrated Management System
OMS) as certified by the American Bureau of Shipping
(ASS).

Sa u a 300 specifications
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MAIN PARTICULARS

PIPELAY CA PABILITY

Length

15~1.2m

Breadth mou lded

378m

Dept h to work deck, moulded

15.0m

Depth to freeboard deck, moulded

9.1m

Pipe size

6" to 60" diameler plus

concrete coating

No. of work stations

9 stations in total
6 off weld ing stations + 1 off NDTI

+ 1 off station for

Draft, m aximum loaded

6.5m

repair stiltion

Classification

A 1 (E) AMS DPS-2 Heavy LifV

corrooion coatingtol asting + 1

Pipe Laying Vessel

off field joint coaling

Flag

Bahama's

Helldeck

SUitable for Sikorsky S92

Accom modat ion capacity

330

Pi pe handl ing ((anes on the work deck

Transit speed

8-10 knots

Pi pe storage on work deck

Deck load capacity, work deck

10 IviT/sq. m

Endo co nveyor line to the bevelling statio n on work deck

Free deck area

2000sq. m

Bevelling station v'lith transverse conveyor

Cel ltre-Iay fi ring line S-Iay system con s,st ing of

and transfer vehicle on work deck

AC CO MM OD ATION

Pip e 21evator loader an d elevator for transport of th e pipe

A li cab ins have int pgra ted toiie t facilities eq uip ped w!ih vacu um sy~tern

to the freeboard deck through pipe load ing hatch

lO x l -perso n cabins
50 x 2-oerson cabi :i s
5.5 x 4~ p ~ r s o!l cdb,n ~,

Transverse chalfl conveyor & transf er v~hlcl es on freeboard deck

FtJ Uy ajr-co nd itioned accommodat ion eq u ipped w ith offices for ciients,

Line up slatlo n With seam rollers on freeboard deck

recreatio n mo m, gymnasiu m, v;deo roo m , nplicopter drrivaUd epc1rture roO I~ l ,

Pipe su pport ro ll ers ,n fll'ln g line on freebo ard deck

[nc:io conveyor line f o r j Cansport to t he ready rack tr ansverse

chain conveyor on the freebo ard deck (port )

prayer roo m, etc.

3 o ff l ensioners and A&R Winch

POWER GENERATION

Movabie work stations

in firing line

Stinger & stin ger handli ng system

Main diesel generat ors

6 x 4000kW

Emergency diesel generator

1 x 1000kVV

Transfer vehi cle fOl' tra nsport of rejected Joints to the kick out
en do con'leyor line on f reeboard deCK and subsequent removal
throu g h kICk o ul hatch by pipe handling crane (starboard)

PROPU LSION & DY N.II.M lC PO SITION ING

Non-retr ac tabl e

aziiTtwh

24 00kW

x 24 00 kW

Ten sione rs

3 x 80 lvlT

Thftl $ters (stern )

.Retractable a.z irnu th th ru sti.::rs

Kongsberg SDP22 CLASS II systelll

A&R winch
Line pull, max

360MT

Wire capacity

3000m of 109mm wire

AUXILIARY EQUIPMENT

\IVater makers
fI

Sewage treatment system

2 x 60T Iday capacity

Pipe Dav its

Suitabie for f ull complement

6 x SOivlT ca paci ty (C an be
installed on port or sl (:l rboard side)

Oily water separat or

Stinger

SA FETY EQ UIPM ENT

Total length

Li feboat 4 x 85 persons capacity

90m (adjustable geometry In

three sections)

Li te raft 100% cap aCily

fv1i!lirnurn overbend radius

70m

Spri nk ler sys-t ern In (lccornrn oda t!on

Fi re detectio n system in acco mmoda tio n
and rnachinery Sp dCt:S

Iv1a,xlm urn pipe depa rt ure angle

87deg
EqUipped with load cells,
underwater cranes & lig hts etc.

.. Waler mist system in engIne roo m

Stinger handling tackle capable

CO 2 fire fighting sys le~ 1

01 adjustment

Foam system for hefldeck

su rVival condi tion to t he minimum

TELECOMMU NICATIONS EQUIPMENT

IS eqUipped with backup tackle.

o f tJle stinger fro m

over bend radiUS. Ha ndling system

VSAT (Dual Antenna) w ith 1M bps Data Link

Stinger can be installedlremoved

GiV1DSS 512

using main crane.

INMARSAT Fleet

.......... -......... ., .........

'

Pipe handling cranes

1 oil

011 port Side &

1 off on

Capac!W - 4 0ST at

H EAVY LIFT CA PABILITY

st arbOcH d side.

Heavy Lift M ast Crane

4'3m Both cranes certified fo r man

29m ra dius. i\/i3xlrn ll m o utreach of

Capaci t y, ma in ho ist
3000ST" at 27m rad ius
( 25" over stern)
22005T at 3 1n1 radius
Cap acit y, mai n hois t revo lv ing
800 5T at 5 3m radi us
Capaci ty, au>~ lI ia r y h oist
2200ST at 9 1m radius
CapaC!ty, Wll' P nOIS!
* (Main hoist capaclW can be upqraded to 3000111 T)

iii
C'i

Vv'h ip hOIst is su itabie for 2000m o f hook tr"avel in sir,glf:l part reeving
\Nh ip iioist and auxi liary hOlst can be reeved together t o achieve subsea
Irfti nq ca pabti lt ji of approx 300ST f o r 'j aOOrn hcok travel o r app rox . 7005T
for 500 m o f hook tra vel

Anti-heeling System fo r Crane Operations

Ded icated p umps

1 x 1600cum /hr
3

x ! 200cum/ ll r

[ioll'1 g. EqUip ped Wit h an ti-co il 'sion

syst em.
OPTIONAL OPERATIONS
J-Iay System
Syste m is installed on starboard side when required
Designed f or rapid installation and removal with main crane
USIllg 360MT A&R Winch

Pipe size up to 20" d,amete r

Double joint Install ation
Installation of SCRs and flowlines

2 Un its of Wor k Class Rem o tely Oper ated Vehicles (WROVs)

~ Vehide Techn ica l SpecificatIon
(Dept h Ralin ;; 30 00m)
u

Usrng main crane

Using A&R winch via A-frame over port or starboard Side

Hydra ulic System

{1 x i 50 Shaf t HP Electric Mot or)

SU BSEA STRUCTURE INSTALLATION

lVla nipulators
(5-fu llCtio n Schi llin g Rigma'iter)
( 7-f u nctlo ~ Sctlfl lm g T4)

TeH1e r (\.1anagern en t Syste m (TMS)

~ SapUraAcerg~

Work Class Remotely Operated Vehicle

(WROV) Permanently Installed

On oar t
Sapura 3000 has further enhanced its capabilities by installing
two (2) work class ROVs systems - the Acergy Core Vehicles
(ACVs). The ACV is one of the most advanced ROV systems
available and is designed to support SURF, IMRand Survey
operations.
The ACV is driven by a 150SHP hydraulic system comprising
of a 21 Occ mam pump and 71 cc auxiliary pump. The ACV
is configured with four (4) Sub-Atlantic SA420 horizontal
thrusters and four (4) Sub-Atlantic SA300 vertical thrusters
giving a substantial bollard pull and a stabie vertical lift
capability. The ACV is also fitted with a subsea dynamic
positioning system "Station KeepTM" wh ich provides enhanced
control of the ROV during operations

Strength and Depth

ur

The ACV is fitted w ith a Schilling T4, 7-Function Master Slave

Manipulator and a 5-Function Grabber as a complimenting pair
to provide a very versati le range of manipulator operations .
The ROV system is designed to provide an efficient intervention
support to projects and is equipped with a high level of
structural intervention points. There is a range of hydl'aulic
and electrical connections for the operation of tooling and
auxiliary equipment The connections are all designed to be
easily accessible and are of a " Plug and Play" design for quick,
efficient change out of equipment
The Tether Management System (TMS) can accommodate up
to 1500m of tether for long excursion operations. Thisenables
the ,A.CV to perform touch down monitoring in deeper water
depths. To further enhance the excursion, the Til/IS unit is fitted
with two (2) SA420 thrusters to enable TMS heading hold and
offsets from launch point

ACV specifications
..

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. . . ....... . ........... ......

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VEHICLE TECHNICAL SPECIFICATION

HYDRAULIC SYSTEM

Depth Rating 3000m

Forward Thru st 1000kg bollard pull
Lateral Thrust 720kg bollard pull
Vertical Thru st 600kg bollard pull
Propulsion comprises of 8 Sub-Atlantic
th ruster un its
4 x SA420 vectored horizontal
4 x SA300 vert ica l
Speed : 3kts hori zontal and 20k ts
vertical

1 x 150 Shaft HP Electric Moto l"

Main Pump (Linde HPR 02 21 Occ)
Auxil iary Pump (Rexroth AWVS071)
Aux system can deliver 125 LPM
2 ~( 4way TC U for Thruster/Ancil lary
equipment
2 x 12 Station valve packs for
ma nipu lators and tooling
1 x High Flow Valvepack

MANIPULATORS
VEHICLE FRAME
Height 1.955m
Width 1.899m
Length 3.353m

5-function Schilling Rigmaster

7-function Schilling T4

TELEMETRY SYSTEM

Lift Point SWL 7.9Te

Schilling Digital Telemetry System
Through Frame Lift 3.0Te
(DTS)
. . . . . .. .. .. . .... .. . - . ......... .... , . . . .. ..... . . . .:

3 x DTS 16 Port Nodes

INTERNAL PAYLOAD CAPABILITY

300kg payload over standard ROV fit
Nomina lly 150kg on the Man ipulator Deck:
and 150kg on the Centre Deck
.

EXTERNAL PAYLOAD CAPABILITY

Undelslung 3000kg

Rear 1000kg

Side 250kg

Front 1000kg

VIDEO EQUIPMENT
T4 Man ipu lator Camera
Kongsberg OE15-l 02 SIT
Replacem ent
Kongsb erg OE 14-3 66 Colour Zoom
Kongsberg 0E15-1 08 PAL
2 x Electric Pan and Tilt Units

NAVIGATION
Tritech Super Seeking Obstacle
Avoidance Sonar
8 x 250W DSP&L Midwater Sea lites
2 x 70W DSP&L SeaArc 5000 HID lights
(Optional)
Seimac ST400AR Emergency Strobe

SENSORS
CDL M in ipos II RLG INS
RDI Navigat or 1200 DVL
Kongsberg MST324N Responder
Pa roscientific Digiquartz depth sensor

TETHER MANAG EMENT SYSTEM (TMS)

Length 2.3m
Width 1. 9m
Weight in Air 4.5Te
Weig ht in Water 3. 5Te
Lift Point SWL 12 5Te
Latch SWL 8.0Te
Tether 27 mm OD, 1500m long
35mm OD, 850 m long
Speed 0-50m/m in Avera ge
Line Pull 100kg

~ SapUraACerg~

DEEPWATER PROJECT

--

Kikeh Gas Pipeline System

for Kikeh Development Project
Introduction
The Kikeh Field was discovered in August 2003 and w as
the first offshore deepwater development in Malaysia.
The field's first oil production commenced in August 2007,

some 5 years after the commercial discovery of the block.

The Kikeh Field is located 11 Okm off the north-west coast
of Sabah, Malaysia in a water depth of approximately
1450m making the Kikeh gas pipeline the deepest rigid

Strength and Depth

pipeline installed in the Asia Pacific region to date, and a

major milestone for both SapuraAcergy and Malaysia.

SapuraAcergy was awarded the EPCIC contract by Murphy

Sabah Oil Company, Ltd. (the operator) for the Kikeh

Gas Pipeline System for the Kike h Development. The
project was successfu lly completed in 2008 with minimum
installation dow ntime.

Project Fact Sheet

Project Name

Kikeh Gas Pi peline System

Client

Murphy Sabah Oil Company Ltd

Contract Type

Engineering, Procurement, Construction,

Install ati on and Commissioning (EPCIC)

Water Depth

From Om (Shore) to 14S0m

Project Duration

2006 - 2008
Kikeh Phase 1 - Gas Export Pipeline
Ki keh Phase 2 - PLET Installation

Vessel Utilised

Sapura 3000

Scope of Work

Performance of offshore in sta llati on

works at Kikeh Field - EPCIC - wh ich
includes:
Deepwater tie-i n to t he Kikeh Field
.. Tie-in jumper co nnecting the PLE M to
the gas injecti on/export manifol d (G IM)
suppl ied/ instal led by oth ers;
ShalIO\A/ w ater tie-in f la nge located at
the pro posed Kinaba lu Deep and East
Platform loca ti on for future tie-i n;
Provision for deepwater t ie-in for future
tie-in at the Kikeh PLEM;
o

12" nomi nal di ameter carbon steel

pipeline from t he PLEM to the onshore
beach valve stati on at Labuan;

Onshore maintenance valve; and

Prov ision of operational pig la uncher
fo r operations/inspection/pigg ing

Project Overview
The Kikeh Field was developed utili sing dry tree wells
located on a Dry Tree Unit (DTU) floating platform and
subsea comp letions connected to a turret-moored Floating,
Production, Storage and Offloading (FPSO) vessel through a
system of su bsea ma nifolds, pipelines and ri sers.

PlpeliJle conditioning spread at shore work-site

Project Challenges
The Kikeh export pipeline contract involves the comp lete
EPCIC of a 138km, 12" diameter export pipeline installed
in water depths from the beach (Om) out into the Kikeh
field at 14S0m. The contract illCluded the line pipe
procurement and coating , shore cross ing wo rks, the
installation of pipeline end termination (PLET) in deepwat er,
the insta llation of a ti e-in jumper spool and an in-line
fut ure tap t ie-in at th e Kinabalu East/Deep Platform.
Subsea completion work w as performed utilisi ng the two
(2) permanen tly depl oyed ROVs on board the Sapura 3000
in 14S0m water depth. Th is included a SOm long spool
installation and pipeline pre-comm issioning operations.
The KGP project was completed with minimum downtime.

Challenge 1 - Shore Crossing

Treated and stabilised crude oil wi ll be periodically offloaded
from t he FPSO to shuttle tankers via tandem offloading.
Associated gas wil l initial ly be re-injected into the Kikeh
reservo ir until commissioning of the Kikeh Gas Pipeline (KGP)
system, after which the gas will be exported to the Labuan
Gas Te rminal (LGAST) plant on Labuan Island for sales to
the new PETRONAS Mega Metha no l plant. The KGP system
incl udes a shallow water tie-In fl ange located at the proposed
Kinabalu Deep and East platform w here infill gas may be
injected into the KG P at a future date.
SapuraAcergy was appointed for the performance of offshore
installation work at Kikeh Field for the Kikeh Gas Pipeline
System . The scope of work Includes the complete EPCIC of a
138km, 12 " diameter export pipeline insta ll ed in water depths
between 13S0m and 14S0m to shore (Om) The contract
included the line pipe procurement and coating, shore
crossing w orks, the installat ion of a deepw ater pipel ine end
term inat ion (PLET), tie- in jumper spool and an in-line fut ure
tap ti e-in at the Kinabalu East/Deep Platform.

Shore crossing operations were performed by SapuraAcergy

from onboard the DLB Sea Horizon. The shore crossing
consisted of a 750m section of pipe being pul led from th e
lay barge offshore into the beach. Loads recorded during
the pu ll -in operatloh were up to 90Te in sections. The
opera ti on was completed successful ly allowing the DLS Sea
Horizon to continue with pipelay operation into a water
depth of 20m. Three (3) units of existing pipelines lequired
to be crossed requiring specifi c pipeline crossings were
constructed during t his pipe \ay sect ion.
Figure 1

Challenge 4 - Stinger Change-Out

Pipelay operations up to 120m WD vvere executed vvith
a single section stingel' (hinge section). However, to
acco mmodate pipe layin g operations in w ater depths
beyond 120m, an add itional section (section 2) needed
to be inst alled as a stinge r extension to enable a steeper
departure angle for the pipeline to faci litate deepe r water
pipelay operations to 1450m W D. In full operation t he total
stinger weight IS 700IVn with an overa ll length of 90 m.

Challenge 2 - Hook-Up of Pipeline to lGAST

The installation of a pipeline an d t he connection of
the pi peline at th e existing LGAST termi nal present ed
sign if icant chalieng es. W ith limite d access, SapuraAcergy
needed to construct an access fro m the ma in roa d in
Labu an down to t he pipe li ne pull -in iocation. Thi s iimited
space also pl'esented chall eng es for the pipel in e testi ng,
con ditio ning an d testing operations . The f inal con nection
of the offshol'e pi peline to the land section as shown in
Figure 2, req uired an open exca vation over 2m in depth t o
be const ru cted in t he tidal zone at the beach .
Figure 2

The final connect ion of t he offshore pipeline t o the

onshore section

Challenge 5 - Deepwater Pipe laydown

Pipelay operations con stru cted into the Kik eh Field (1450m)
where the pipeli ne needed to be laid into a 6m x 3m target
box on the seabed. The pipe was laid dow n in an S-Iay
configurati on, into the existing Kikeh Field in an area that
w as al ready popu lated w ith subsea stru ctures and fl exible
pipe . The Klkeh pipeli ne w as laid-dow n successfully inside
t he target box and maxi mum pipelay lay down t ension s
w ere reco rded at lOTe.

Challenge 6 - Deepwater Pipe Recovery and PlET

Installation

At a water depth of 60m, an in-li ne tee needed to be

insta ll ed durin g the pipelay opera ti on. The in-li ne, fu ture
tap tee (supplied by Oilstates), was inst all ed with an
integrated prote cti on frame making t he tot al weight of
the in-line joint 5MT

For the installation of the deepwater Pipeline End

Termination (PI,t T), the Sapu l'a 3000 was mobil ised w ith
a project specifi c pipe hang-off pl ati'orm that allowed th e
pipe to be recovere d in a J-Iay co nfi gul-ation and hung-off
on th e side of the vessel , a load of 84Te was experienced
at th e new hang-off ciamp . Once the pipe lay down head
'.Nas removed, the 83Te PI_ET was then up-ended and hung
into its nea r vertical position fo r conn ection to the subsea
pipeline The PLET and pipeline w ere welded, tested and
readied for subsea deployme nt

The fut ure tap tee now sits upright on the seabed for future
hook-u p from the Kinabalu B platform that w ill util ise t he
pipel ine to export sales gas to the LG.AST fac ility.

Once ail tests were complete, the pipel ine and PI_tT vvere
lifted (163Te) and successfully laid onto th e seabed into a
target box of 6m x 3m .

Challenge 3 - Future Tap Tee Installation

Figure 6

Insta Iialion of PLET

Challenge 7 - Subsea Jumper Installation

The final connection between the newly laid Kikeh pipeli ne
and the existing Gas man ifold was made using a subsea
jumper spool . The spool was 45.5m in length and needed
t o be installed f looded with" Superd ry" fl uid. This f luid
needed to be t urned into a gel prior to dep loym ent to
prevent loss du rin g co nnection operations.
The jumper spool was successfu lly fabricated and tested
onboa rd the Sapura 3000 by the onboard team and then
deployed and successfu lly connected using t he two (2) units
of work class ROVs. Once installed, the vertica l connections
were successfully tested followed by a subsea leak test on
the jumper to confirm its integrity in -sit u.

Achievements/Results
The Kikeh f ield is the fi rst deepwater development in
Ma laysia. In 2008, Sapura Acergy successfully com pleted
th e works at a maxim um depth of 1450m mak ing the
Kikeh gas export pipeli ne the deepest rigid pipeline
insta lled in t he .I'>.sia Pacific regio n to date and a major
milestone for SapuraAce rgy.
Additionally, t he PLET in sta llati on at 145 0m w ater depth
w ith a weight of 83MT, w as th e first of its kind in Malays ia,
and a sign ifi cant insta llati on achi eve ment for the
Sapura 3000.

Challenge 8 - Pipeline Testing, Pre-comm issioning,

Conditioning and Nit rogen Packing
Th e pre-co mmiss ioning services were co mp leted
successfully and w ithout a lost t im e incident wh ich
was a mag nifi cent result consideri ng th e challenges of
6600psig (445ba rg) test pressu re in such deepwater and
with complex subsea arch itecture. Without the use of an
innovative Gel isolation, the project would have been at
risk of inducing hydrates immediately upon start up (which
are expensive and difficult t o correct) as well as causing
potential de lays to prod ucti on.

~ SapUraACerg~

CONVENTIONAL PROJECT

Mumbai High South

Re-Development Project

Phase II (MHSRP-2)
Introduction
The Mumbai High South Re-Deve lop ment Project Phase II
(M HSRP-2) is a project by the Oil & Natural Gas
Corporation (ONGC) to support the re-development of the
Mumbai High South Field. Discovered in 1974, the field
was put on prod uction in May 1976. The MHSRP-2 project
was award ed t o Larsen & Toubro and includ es ma inly the

Strength and Depth

construction and installation of new p latforms, the laying

of pipe lines and subsea cable and the modification of
some existing platforms. Sapu raAcergy was appointed by
Larsen & To ubro to be the sub-contractor f or the offshore
insta llati on of the three (3) Wellh ead Platforms.

Project Fact Sheet

Project Contra ct Name

~umbaiHigh

Location

Mumbai, India

Client

& Natural_....Gas
Corporation
(ONGC)
Oil
. ,. . . .
...
..

Contract Type

Installation Subcontract related to the scope of w ork (Larsen & Toubro as the main contractor)

Water Depth

71 - 78m

Project Duration

2008 - 2009

Vessel Utilised

Sapura 3000

Scope of W ork

Installation of 3 Wellhead Platfo rms (RS 15, RS 16, RS 17), including

South Re-Development Project Phase II (M HSRP-2 ) - Wellhead Platforms

Pre- and post-installation debris survey

Heavy lift and installation of:
- 3 x 4-legged jackets from 1760 to 1820MT
- 3 x 4 piles of 72" and 78"
- 3 x 12 conductors of 30"
- Grouting of jacket leg annulus
- 3 decks (from 1258MT to 1970MT)
- 3 boat landings
Remova l of installation aids up to 25m depth

Jacket lih

Project Overview
The Mumbai High South Re-Development Projed
Phase II (M HSRP-2) was located in shallow water India,
approximately 87 NM west of Mumbai.

Driving of pile & hold back wire for pile free fa ll

for SapuraAcergy. The project was completed with

minimum installation down time with the Sapura 3000,
SapuraAcergy's state-of-the-art dynamically positioned
heavy lift and deepwater pipelay vessel.

The Project comprised of the installation of three Wellhead

platforms including jacket main piles, straight and curved
conductors, jacket appurtenances and topsides.

The MHSRP-2 contract involved the installation of th ree (3)

Wellhead platforms including jacket main piles, straight
and curved conductors, jacket appurtenances and topsides
at 71 m to 78m wa ter depths.

The Scope of \Nork included the project management,

procurement related to scope of work, installation
engineering, pre- and post-construction debl'is surveys
and installation.

The major challenges for this project were the LogistiCS

(documentation for authorities and daily management) and
the unexpected soil conditions at site (Initial hard layers
followed by soft layers).

Project Challenges
The Mumbai High South Re-Development Project Phase II
(MHSRP-2) was the first project out of Malaysian waters

The project was completed successfully by focusing on the

logistics management. The logistics team w orked closely
with Larsen and Toubro and agents to ensure that prope r
and timely documentation w as in place at all times .

-.--~

~':l

CONVENTIONAL PROJECT

._-------

KARRATHA

Devil Creek
Gas Plant
.-

DAMPIER TO BUNBURY GAS PIPELINE

BUffup

peninsula
HOO Shore
Crossing

Cape
Preston

Offshore Platform

Project Location

Port Hedland

r : -end

Karratha

II

Road
Pipeline

Exmouth

Onslow

Reservoir

HOD

..

..........

.....

..

"'

...

...

Horizontally Directionally Drilled

"..

,,

...

..

..

.............

.....

...

'

Devil Creek Development

Project from Apache Energy Ltd
in Australia

"'

Introduction
The Devil Creek Development Project is a greenfield gas
development which is located approximately 80km northwest
of Dampier Port off the coast of Western Australia.
The project comprises of an offshore gas production
platform, an onshore and offshore gas supply pipeline, a
gas processing plant and gas export pipeline tied into the
Dampier-to-Bunbury Natural Gas Pipeline.

Strength and Depth

SapuraAcergy was awarded the offshore pipeline and

platform installation . The Scope of Work includes t he
transportation and the installation of an unmanned
wellhead platform comprising of a four-legged jacket
and topside; together with a single 16 " x 91 km raw gas
pipeline which will link the wellhead platform to the
onshore gas plant.

""0

Project Fact Sheet

Project Name

Devil Creek Development Project

locat ion

App roximately 80km northwest of Dampier Port, North West Shelf, Australia

Client

Apache Energy Ltd.

Contract Type

Main Contractor for the Offshore Transport and Installation Works

Wat er Depth

Circa 60m

Project Duration

Offshore commencement: September 2010

Offsho re duration : circa 95 days (25 days shal low w ater pipela y, 62 days Sapura 3000,
8 days stabilisation)

Vessel Utilised

Sapura 3000

Scope of Work

Project manage ment

Industrial Relations (IR) management

.. Transport & installation engineering
Interfacing with clients other vendors
Transportation of client-provided materials
Fabrication of rigid tie-in spools
Offshore installation and testing
8
Mob & demob of insta llation activities
Q
As-built survey and as-bui lt report

Project Overview
The Devil Creek Development Project (DCDP)
has been ini t iated to recover and process the
gas reserves from the Reindeer gas field located
approximately 90km northw est of the Dampier
Port at w ater depth of 60m.

FlEINDEER l eu

The offsho re installation activities comprise of:

-.,

16 " x 91km pipeline

Pipeline stabilisation (45 x Rocks Bolts)
Wellhead Platform (1700Te drilled/grouted
piled Jacket + 450Te Topside)
o SSIV structure c/w protection frame
o Tie-in spools

.~

" Tie-in spool stabilisation (gravity anchors)

e Umbilical and umbilical stabilisation
(mattresses)
Umbilical pro tection frame
" Pre-commiSSioning

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The project will span a period of 15 months,

including 3 months of offshore installation work .
Preliminary planning and engineering work has
already begun in Kuala Lumpur and in Perth.
Offshore installation work is due to commence
in late 20 10, utilising the Sapura 3000 . Sapura
3000 w il l perform the heavy lifting , pipelaying
and subsea tie-in w ork.

~~

Field Location

CONVENTIONAL PROJECT

Lan Do Block 06 .1 Phase III

Development Project
Introduction
The Lan Do Phase III Development Project is located in the
Block 06.1 which encompasses both Lan Tay and Lan Do
gas fields. Phase 1 of the Block 06.1 development project
was comp leted at the end of 2002 when the Lan Tay
Platform started feeding gas through the Nam Con Son
Pipeline (NCSP) to the Di nh Co gas processing termi nal in
Southern Vietnam.
In 2007, gas compression facilities were instailed on the
Lan Tay Platform as part of Phase II Development.

Strength and Depth

Block 06.1 - Phase III projec v ill deveto t he al Do '!eld

wh ich lies at offshore Vietnam . The field s loca ed 370 m
southeast of Vu ng Ta u city and 27 .6k east of ~h e
existing Lan Tay platform, in 190m wa ~ er depth.
SapuraAcerg y was awarded the subsea installation
services for the Lan Do Phase III Development Project f ro m
TNK Vi etnam BV in September 2011.

Project Fact Sheet

roject Contract Name

Block 06.1 Phase III - La n Do Develop ment Project

Location

Southern Vietnam (Lan Tay/Lan Do Field Vietnam)

Cl ient

TNK Vietnam BV

Contract Type

Subsea Installation Services

Water Depth

Approximately 190m

Vessel Utilised

Sapura 3000 - Pipelay and Umbilical Lay

Rockwater 2 - Tie-I ns and Pre-Commissioning

Scope of Work

Provision of Subsea Installation Services, incl uding:

Installat ion of a main and infi eld umbil ical including hydraulic and
electrical flying lead connecti ons t o w eil head 110 1, 1102 and SSI\I
Pipeline and umbilical trench ing
l_aying of a 12 -i nch gas pipeline (CRA) in cl uding an ILS
Insta llation of Rock support and prot ection
Insta llation of a PLET and t ie- in to the new pipeline
Inst allation of SSI\I and tie-in to th e existing platform and new pipeline
Installation of subsea jumpers between w ell 1101 and PI_ET, w ell 1102
and ILS
Pre-commissioning of t he pipe lin e syst em and umb ilica l
Fabricatio n SOW

Pipe Coating

Structural fabrication of ILS & PLET

W PQ for pipi ng welds

Project Overview
The Lan Do Phase III Develo pment Project is the first project for SapuraAcergy in Vietnam. Located in the Block 06.1 of the
Lan Do gas field, which is approximately 190m water depth of 370k m southeast of Vung Tau city and 27 .6km east of
existing Lan Tay Platfo rm,
SapuraAcergy scope of w ork covers project management, engineering, line pipe storage and coating, ons hore fabrication,
seabed remediation, flowline and in-line stru ctures inst allatio n, umbilical, su bsea tie-ins and all associat ed subsea surveys.
The scope of work also includes mechanical comp letion and commissioning support
The Lan Do Phase III Development Project co nsist of:

2 off veliical subsea we ll s located approxima tely 2.6km apart, tied back via a 12-inch 27 .6km rigid predom inantly
13% chrome flowline to a pre-installe d 12-inch inconel 625 clad carbon steel riser at the Lan Tay Platform, In line, the
flowline w ill include SSIV, ILS and PLET structures and have 35-off incone! 625 CRA clad ca rbon steel anode joints
installed along its length for anode placement A combined main and SSIV umbilical and an in-field umbilical with
associated contro l equipment and SUT structures w ill also be part of the scope ,

At the Lan Ta y Platform, topside (brownfield) modifications will include insta llation of piping and valves from the to p
of existing 12-inch Lan Do riser to a new tie-in point in the existing Lan Tay process facilities, installation of a new wet
gas fl ow-meter, installation of a J-t ube extension, installation of structural strengthening, pipe supports and service
platform, combined main and SSIV umbilical pull-in, hook-up and associated contro l system modifications.

~ SapUraAcerg~

Montara F"eld
Development Project
Introduction
The Montara oil & gas field w as first discovered in
March 1988 by BHP Billiton and was operated by
Coogee Resources in September 2003. Later, in
December 2008, PHEP Australasia (Ashmore Cartier)
Pty Ltd (a Thailand-based petroleum and natural gas
exploration company) acquired Coogee Resources and
took over as the operator of the field. The Montara
Development fie ld consists of the Montara, Swallow ,
Sw ift and Skua fields.

Strength and Depth

The field is located approximately 690km West of

Darw in, NT (Northern Territory).
Moving forward, the PHEP Australasia (Ashmore
Cartier) Pty Ltd awarded SapuraAcergy with the
Transportation and Installation contract for The
Montara Field Development Project.

Project Fact Sheet

Project Contract
Name

Montara Field Development Project: Engineering, Procurement, Load Out, Transportation and
Offshore Construction Activities associated with the Removal and Disposal of the Damaged
Montara WHP Topside, Transportation and Installation of Rigid Pipelines, Risers, Umbilicals,
Spools, Manifold, FPSO Mooring System and the New Montara WHP Replacement Topside

Location

Offshore, Darwin NT, Australia

Client

PTIEP Australasia (Ashmore) Cartier Pty Ltd

Contract Type

Transportation & Installation

Water Depth

Approx. 80m

Project Duration

Approx. 13 months

Vessel Utilised

Sapura 3000 (Heavy Lift) and Rockwater 2 (Diving Support Vessel)

Scope of Work

Removal and disposal of damaged Montara WHP Topside

Transportation and installation of:
-

New Montara WHP Topside

Rigid Pipelines
Risers
Umbilicals

Spools
Manifold
FPSO Mooring System

Project Overview
Installation of:
* 14", 10", 6" & 4" rigid pipelines

The Montara Field Development, consisting of the

Montara, Swallow, Swift and Skua fields, is located
approximately 690km West of Darwin, NT, in the

*
*
*
*

Ashmore Cartier permit area of the Timor Sea within

the AClRL3 retention lease. PTIEP Australasia (Ashmore
Cartier) Pty Ltd (PTIEP AA), the Operator, intends to

piled moorings, chain and STP Buoy

subsea manifold and riser base structures
flexible risers and statiddynamic umbilicals
rigid spools

develop these fields and operate the developed

Pipeline and umbilical stabilisation

facilities for commercial production of the oil reserves.

Pre-commissioning

The water depth throughout the fields varies

As built survey
Demobilisation of Marine spreads

approximately 80m. The Swift and Skua fields are

approximately 17km and 26km respectively north
northwest of the Montara field.

Offshore installation work will be performed by the

SapuraAcergy was awarded the Transportation and

by Rockwater 2 supplied by Subsea 7.

SapuraAcergy vessel, the Sapura 3000 and supported

Installation of the Montara Development Project. Its
scope of work consists of Engineering, Procurement,
Load Out, Transportation and Offshore Construction
Activities associated with the Removal and Disposal
of the Damaged Montara WHP Topside; as well as

12'1<

Transportation and Installation of Rigid Pipelines,

Risers, Umbilicals, Spools, Manifold, FPSO Mooring

-<70.,..,

System and the New Montara WHP Replacement

Topside.

!----;---'/

Detailed activities falling under the purview of

SapuraAcergy include:
Transportation of permanent works to site:
Mobilisation of marine spreads to perform the
offshore works

Pre-installation site survey

Removal of existing wellhead platform
Rigid spool piece fabrication

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Iwaki Platform
Decommissioning Project
Introduction
The Iwaki Gas field, operated by Offshore Iwaki
Petroleum Co. Ltd., was initially discovered offshore
Japan in 1973, developed in 1983 and ceased production
in 2007. Offshore Iwa ki Petroleum Co. Ltd.'s consortium
comp rises ExxonMobil, Yugen Kaisha and Tonen General
Sekiyu K.K.
Located approxi mately 40km east of Nahara Cho, in a
water depth of approxi mately 154 metres, the Iw aki
Platform consists of a steel jacket structure, topside
drilling, production modules and a 12 " diameter pipeline

Strength and Depth

for transporting gas from the field to the onshore plant

in Nahara Cho.
SapuraAcergy, using their key asset, the Sapura 3000,
was awa rded the Heavy Lift Subcontract of the
Decommission ing Scope . This subcontract includes lifting
and transporta tion of the topsides, Jacket and sections
of the 12 " gas export pipeline to an onshore location for
disposal by others. The decommissioning w ork w as
successfully com pleted in July 2010

Project Fact Sheet

conditions and downtime during installation, it was known

that measures vvould have to be taken to mitigate the
weather risk. This was carried out by physical measures to

Project Name

Iwaki Platform Decommissioning Project

location

Iwaki Field, Japan

Operator

Offshore !waki Petroleum Co. Ltd.

Client

Nippon Steel Engineering Ltd.

Contract Type

Heavy Lift Sub-Contract

Water Depth

154m

Project Duration

2009-2010
(Approximately 60 Days Vessel Onsite)

Vessel Utilised

Sapura 3000

Challenge 2 - Jacket Cutting Philosophy

Scope of Work

SapuraAcergy's scope includes the

following:

Traditionally, jacket cutting had been performed upon

enable lifting to continue in poor conditions and project

planning to ensure as many work faces were open at any

Removal of topside facilities and

module support frame
Cuttin g jacket members at
metres

EL-92

Lifting of upper section of jacket,

lowering onto seabed and toppling
Cutting and stabilising export
pipeline

one time. It was also essential to ensure that some of the

work faces were not sensitive to adverse weather.
The above strategy proved to be successful and allowed the
topsides operations to run almost in parallel to the less
sensitive subsea works.

completion of the topside removal. On review of previous

decommissioning offshme programmes, it was clear the
subsea cutting scope carried a huge schedu le and
operationa l risk. With this knowledge, SapuraAcergy
deve loped a method to mitigate these risks and reduce the
overall offshore
a f ull structural
w ithin each leg
model, each of

schedu le. This includes th e development of

mode l of the jacket which allowed the stress
and brace to be calcu lated. Within the
the planned module lifts was able to be

simulated and the resu lting changes in the leg and member"
stl"esses were able to be accessed. This method allowed the

Project Overvi ew

low stress liiembers to be identified, enabling a sequence of

stl"uctura l membe rs to be cut after each lift

The Iwaki Gas facility, commissioned in 1983, consists of

Challenge 3 - Subsea Cutting Equipment

offshore drilling, process and accommodation modules

installed on a jacket structure. A gas pipeline transports
gas from the field to the Offshore Iwaki Petroleum onshore
plant in Nahara Cho.

In order to red uce ris k and improve schedu le, it was

concluded that "Fly to Place" cutting equipment was required.
Following a market revievv, it INas found that although the
cutti!ig tool ing to complete the cuts was ava ilab le, a rel iab le

The Iwaki platform has 8 legs, weighs 20,735MT and stands

ROV delivery syst em was not. ,6.fter a demanding selection

process, which cumu lated in a 400te diamond w ir"e

in 154 metres of water. The platform is located 40km off

the east coast of Japan and was the first ever installed
offshore Japan. It is also the largest to be decommissioned

compressiorl cut being perfmmed, Proserv offshore were

awarded the jacket cutting subcontract.
The ROV delivery system was identified as the criticai

in Japan. The Iwaki platform was shut down in 2007.

component to enable cutting operations to be carried out off

SapuraAcergy Sdn Bhd was awarded a sub-contract in May

2009 for the Iwaki Platform Decommissioning Project which
included:

t he critica l path. SapuraAcergy, Proserv and TMT worked

together t o design, build, complete factory acceptance 2nd site
testin9 of the ROV delivery system. Refiliements were made
t hrou9hout this process which ensured a fuHy integrated and
rigor"ously tested system

'Nas

taken offshore.

.. Removal of 16 modular topside lifts ranging from

e
$

10MT to 1100MT
118 subsea cuts, at a depth of 92m
Removal of 16 No. pile sections

Cutting and removal of a section of 12" pipeline

~ Lifting the jacket, lowering to seabed and toppling (to
create an artificial reef)
This proJect, worth an estimated US$60 million, was
successfully completed on behalf of Nippon Steel
Engineering Co. Ltd., in July 2010.

Project Challenges
Challenge 1 - Environmental Conditions
From historical weather data and knowledge of the sea

,6.11 subsea cutting operations We(2 performed off the critical

path and without Impact on the topside lifting and jacket
removal scope .

Challenge 4 - The Jacket lift

Challenge 5 - logistics

During the engineering phase, it was determined that

the actual lift weight of the jacket could vary
significantly, depending on the amount of marine
growth and integrity of the jacket legs for instance. In
order to mitigate the risk associated with a large range
of weights, it was decided to seal the jacket legs,
de-ballast them and use the buoyancy created. A
method of ballasting and gradually increasing the load
on the crane , in stages, was developed such that the
actua l lift w eight could be accurately and predictably
mainta ined . In fact, a buoyancy of 1543MT w as
gained from 78 % of the leg length being filled w ith air
resulting in the crane experiencing a total weight of
1050MT.

One of the key challenges to overcome, was the sourcing,

transport, storage and maintenance of the required equipment
Also, due to the remote location, it was essential to have
adequate con t ingency and spares to mitigate the risk of
downtime. The fo llowing list provides an indication of the
magn itude of equipment which was carried on the Sapura 3000:

200MT of fabri cated insta llat ion aids

70 heavy lift slings up to 14" in diametel'
75 heavy lift shackles up to 700T
14 subsea cutting too ls
360m of diamond wi re
64MT of ga rnet (g rit)
1400m of w ire rope
9 comp ressors
1800m of air hose
Air diving spread

Lessons Learnt
The Iwaki Decommissioni ng project w as SapuraAcergy's first venture into decommissioning w ork an d hence w e have gai ned
extensive and detailed first-hand knowledge of the uniq ue challenge s associated w ith decommissioning. The follow ing highlig hts
just of few of the lessons learnt

lesson 1: Risk Analysis - As Installed

Step 1

Afr"iva! at the j'Naki field; !wdki Platform

Li ft 10; Platform after Cargo Barge 2

Departure

Step 4

Lift 13; Platform after the removal of

Ivlodule 7, 6 and 5.

Lilt 15; Plat!orrn afT er the removal of

Step 7

The Iwakl Platform was successfLlllj

removed .

The Iwaki Platform was more than 28 years old when decommi ss ioned. One
of the key risks is the reliability of the provided information with regards to
original configuration, modifications, inherent structural defects, weight and
weight growth. For this project, the information provided by our client,
Nippon Steel, was very accurate, with excellent records being maintained.
This information, coupled with many on-site visits proved invaluable in the
efficient planning and execution of the works.

Step 2

Li ft 7; Platform af ter Cargo Barge 1

Departure

Step 5

Lift 15 ; Platform after rem oval of all

modules

Step 3

Lesson 2: Regulatory Compliances

It was a cha llenge for Sapura;'\cergy to ensure the compliance with the
Japanese regulatory !-equi!-ements especially \;vhen English is not widely
used as t he medium of communication. ,6.s such, an engagement of a
local lega l consultant in Tokyo has facilitated SapuraAcergy to establish
a Japan Branch Office (1BO) in !waki-City, Fukushima-pref ecture,
application of a Construction LKense for SapuraAcergy, application of
Aviation ljght License for Sapura 3000, personnel \/is q fulfillment and
othel- loca! requirements pri or to the execution of the offshol-e
ca mpaign in Japan by Sapura 3000. A Sapur-aAcergy JBO representative
and loca l Project Engineer was appointed to administer the JBO. Having
a loca l employee has helped the communications between SapuraAcergy
with the loca l client, suppliers, contractors, government and the
community. It is also learnt t hat lengthy pel'iod is required for any
fonnalities in Japan. in addition, al! documentation shal! be tl-ansiatea ill
Japanese. As slIch, it is essential to prepare a complete documentation
t o shorten the process. The JBO is closed and Construction License is
cancelled I-ight after the completion of the pmject. A.II requirements
were achieved on time or ahead of schedule.

Ach ievements/ResuIts
The Iwaki Platform Decommissioning Project was
SapuraAcergy's maiden decommissioning project
Some key facts include
.. Approximately 276,500 manhollrs were expended
onboard the Sapura 3000
e The

total vessel duration was 92 days, of which

approximately 60 days were on site. This was two

days longer than planned
e

Seven critical path weather days were incurred

.. Zero lost time incidents were incurred

.. Invaluable experience has been gained from the
Iwaki decommissioning project - this shall enable
SapuraAcergy to execute even more challenging
projects III the future, with confidence we shall
deliver.