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HomeIndonesia flow station lifted in simultaneous jacking operation
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Indonesia flow station lifted in simultaneous jacking operation
01/22/2014
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The LIMA flow station offshore Jakarta, Indonesia
The LIMA flow station offshore Jakarta, Indonesia, before a simultaneous lift of
all structures restored the installation's air gap. All photos courtesy Versaba
r Inc.
Lift counters effects of subsidence and extends operational life
Lakis Zenios
Versabar Inc.
Nasrullah
Pertamina Hulu Energi Offshore North West Java
Over the life of a production facility, reservoir pressure will reduce as oil an

d gas flow to the surface. This reduction in reservoir pressure may result in lo
cal compaction and consolidation of reservoir rock. Depending upon the local geo
logy, such reservoir compaction may also lead to subsidence. For a fixed offshor
e platform, one consequence of seabed subsidence is the reduction of the air gap
between the average sea level and the underside of the topside, which increases
the potential for inundation of the deck in extreme storm conditions. This puts
the platform at risk for structural failure under storm loading conditions. As
the probability of extreme waves entering the deck increases with further subsid
ence, some form of remediation will generally be required to ensure that the off
shore platform continues to maintain satisfactory levels of structural reliabili
ty.
The LIMA flow station off the coast of Jakarta, Indonesia, was built in 1973 by
Atlantic Richfield Indonesia Inc. It consists of a production platform, a compre
ssion platform, a living quarters platform, three bridges, and flare support str
uctures. The installation was one of 11 flow stations acquired by Pertamina in 2
009 with the purchase of BP subsidiary BP West Java and its operated interest in
the Offshore North West Java concession.
Versabar's Deck Raising System
Versabar's Deck Raising System uses split sleeves to encapsulate the legs throug
hout the raising process.
Although the LIMA flow station had operated normally without remediation, subsid
ence had significantly reduced the facility's air gap over the years. Operator P
T. Pertamina Hulu Energi Offshore North West Java (PHE ONWJ) was concerned that
platform safety could be compromised before the planned end of the station's pro
duction life in 2026. PHE ONWJ thoroughly evaluated various options to remediate
the risk of subsidence, including conventional lifting, on/off operation, const
ruction of new platforms, the use of a mobile offshore production unit, a floatover barge for deck-raising, and deck-raising by hydraulic jacking system. Addit
ional criteria such as technical feasibility, commercial matters, period of shut
down needed, project schedule, and risks were considered during the evaluation.
PHE ONWJ concluded that deck-raising by hydraulic jacking offered the best costeffective and technically sound solution to restore a safe distance between each
platform's cellar deck and the mean sea level.
The bridge-linked platform complex needed to be raised 4 m (13 ft) to increase t
he air gap on three platforms and their supporting structures. Versabar's patent
ed Deck Raising System was selected to raise the entire LIMA flow station simult
aneously. The LIMA Subsidence Remediation Project would be the first such operat
ion to use a synchronized hydraulic jacking system with programmable logic contr
oller (PLC) combined with encapsulated leg-sleeves.
PHE ONWJ awarded two contracts: one to PT. SAS International, to
cialty deck-raising equipment and services, and one to PT. Timas
), for engineering, procurement, construction, and installation.
bcontracted by PT. SAS International to furnish all synchronized
ng equipment.

provide all spe

Suplindo (Timas
Versabar was su
hydraulic jacki

The company's deck-raising technology was developed in 2006, when a Gulf of Mexi
co operator needed to raise the topsides on two 8-leg drilling and production pl
atforms. Using hydraulically and electronically synchronized rams, each platform
was successfully elevated 14 ft (4.27 m) in less than two hours. The technology
uses split sleeves to encapsulate the legs throughout the raising process. This
encapsulation provides a high degree of lateral stability during the raising op
eration and subsequently forms the permanent leg extensions.
The custom engineered HPUs (hydraulic power units) that operate the rams incorpo
rate a redundant design using two of everything where applicable, starting with
the use of twin 200-hp diesel engine and hydraulic pump arrangements, each with

its own fuel supply and cooling capability. In the unlikely event of an engine o
r pump failure during the raising operation, the units were designed to be able
to continue the raising process unaffected. The HPUs also integrate a failsafe d
esign into the control scheme so that in the event of a lost control or hydrauli
c signal, all operations would automatically halt until the matter was resolved.
Versabar
Versabar conducted extensive tests on a full-scale platform model in Houston bef
ore deploying equipment to the LIMA flow station site.
Versabar
One of the platforms during the simultaneous lift.
Testing and deployment
For the LIMA flow station project, Versabar provided detailed engineering, fabri
cation, and testing of all deck raising equipment, leg extension sleeves, and ot
her raising appurtenances. Two types of rams were custom engineered to raise the
platforms in two stages, and a third type of ram was used to simultaneously rai
se the supporting bridge structures.
Prior to mobilization, Versabar built a full-scale, detailed deck and bridge con
struction mirroring one of the platforms in order to perform an accurate system
integration test (SIT) at the company's Houston facility. Each stage of the lift
was performed, with split sleeves installed on the legs and leg pins inserted a
t each point of the raising operation, as they would be offshore. The mock-up to
pside and connecting bridge were raised the full 4 m.
"During the testing of the complete deck raising system, we went above full work
ing load to demonstrate the capacity of the system," says Versabar Project Engin
eer Sid Fabre. "We also went through a sequence of simulated malfunctions and fa
ilure mode testing under load to evaluate the failsafe design and redundancy of
the hydraulic and control system."
All equipment was shipped from Houston to Indonesia using project cargo transpor
tation. This included six 400 HP hydraulic power units weighing 20 tons each, on
e control cabin, and 48 40-ft. shipping containers with a total of 120 rams: 12
rams for the connecting bridges, 48 Stage 1 rams, 48 Stage 2 rams, plus spares.
Extra care and preparation was taken to ensure all cargo and components arrived
safely and on schedule.
Offshore lift
Timas prepared the platforms for the deck raise by installing all of the Versaba
r-provided equipment on the topsides and bridges, cutting and capping the risers
and appurtenances, installing the sleeves and bushings on the deck legs, and in
stalling the initial raising hydraulic rams. Versabar personnel arrived onsite o
n Aug. 2, 2013, to perform offshore installation, hook-up, and commissioning of
the deck raising system, and operation of the raising equipment for the actual l
ift.
The procedure was to be conducted in two phases. In Stage I, the rams would rais
e the platforms 38.5 in. (98 cm) and the leg pins would be inserted. In Stage II
, dual-rod rams would raise the platforms to 106 in. (269 cm). After pinning off
, the Stage II rams would continue to raise the platforms to 159.5 in. (405 cm),
followed by a final leg pinning.
The raising operation began on Sept. 4. All six structures, with a combined weig
ht of approximately 3,300 tons, were simultaneously raised 38.5 in. to complete
Stage I of the lift in 2.25 hours. Fifteen days later, after the Stage I rams we
re removed and Stage II leg extension sleeves and rams were installed, the secon
d phase of the lift took place. Once the structures were lifted to 106 in., the
Stage II intermediate pin was inserted, and then raising continued to the full h
eight of 159.5 in. The legs were then pinned again, providing a full mechanical

lock-off of the deck in the raised position. Stage II was performed in four hour
s, which helped play a part in reaching the LIMA Subsidence Remediation Project
goal of not only raising the decks, but getting the facility back in production
on schedule.
"During the design and testing phases of the project we left no stone unturned,"
says Fabre. "When installing and commissioning a system for an operation this c
ritical, preparation provides the best opportunity for a safe, problem-free oper
ation."
"This raising of three platforms, three bridges, and flare support structures at
once with a synchronized jacking system is a first for PHE ONWJ, Pertamina, Ind
onesia, and probably the world," says Jonly Sinulingga, executive vice president
and general manager for PHE ONW. "The success of this project has given us the
experience and confidence to apply the most advanced technology in our offshore
operations."
The increased air gap provided by the deck raise is expected to grant the LIMA f
low station an additional 12-15 years of use.
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