HEAVY LIFT INSTALLATION STUDY OF OFFSHORE STRUCTURES LI LIANG (MS Eng, NUS) A THESIS SUBMITTED FOR THE DEGREE OF MASTER OF ENGINEERING DEPARTMENT OF CIVIL ENGINEERING NATIOANL UNIVERSITY OF SINGAPORE 2004 HEAVY LIFT INSTALLATION STUDY OF OFFSHORE STRUCTURES LI LIANG (MS Eng, NUS) A THESIS SUBMITTED FOR THE DEGREE OF MASTER OF ENGINEERING DEPARTMENT OF CIVIL ENGINEERING NATIOANL UNIVERSITY OF SINGAPORE ii ACKNOWLEDGMENTS The author would like to express his sincere appreciation to his supervisor Associate Professor Choo Yoo Sang The author is deeply indebted to his most valuable guidance, constructive criticism and kind understanding Appreciation is extended to Associate Professor Richard Liew and Dr Ju Feng for their assistance and encouragement In addition, the author would like to thank the National University of Singapore for offering the opportunity for this research project Finally, the author is grateful to his family, the one he loves, and all his friends, whose encouragement, love and friendship have always been the major motivation for his study TABLE OF CONTENTS CHAPTER 1.1 1.2 1.3 INTRODUCTION Background Objectives and Scope of Present Study Organisation of Thesis CHAPTER 2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.3 REVIEW OF LIFTING DESIGN CRITERIA 10 Review of Various Lifting Criteria Practical Considerations for Standard Rigging Design Sling Design Loads (SDL) Shackle Design Loads Lift Point Design Loads Shackle Sizing Tilt during Lifting COG Shift Factor Summary CHAPTER 3.1 3.2 3.2.1 3.2.2 3.3 3.4 3.4.1 3.4.2 3.4.3 3.5 3.6 HEAVY LIFTING EQUIPMENT AND COMPONENTS 24 Introduction Heavy Lift Cranes Crane Vessel Types Frequently Used Crane Vessels Heavy Lift Shackles Heavy Lift Slings Sling properties Grommets versus Slings Sling and Grommet Properties Lift Points Summary CHAPTER 4.1 4.2 4.2.1 4.2.2 4.2.3 4.3 4.3.1 4.3.2 4.4 4.4.1 4.4.2 4.5 RIGGING THEORY AND FORMULATION 57 Introduction Rigging Sling System with Four Lift Points Using Main or Jib Hook without Spreader Structure Using Main or Jib Hook with Spreader Structure Using Main and Jib Hooks at the Same Time Rigging Sling System with Six Lift Points Using Main or Jib Hook with Spreader Frame Using Main and Jib Hooks without Spreader Structure Rigging Sling System with Eight Lift Points Using Main or Jib Hook with/without Spreader Structure Using Main and Jib Hooks without Spreader Structure Summary i CHAPTER 5.1 5.2 5.3 5.4 JACKET LIFTING 78 Introduction Vertical Lift of Jackets Horizontal Lift of Jackets Summary CHAPTER 6.1 6.2 6.3 6.4 MODULE LIFTING 88 Introduction Vertical Module Lift and Installation Deck Panel Flip-Over Summary CHAPTER 7.1 7.2 7.3 7.4 7.5 7.6 7.7 FPSO STRUCTURE LIFTING 102 Introduction Lift Procedures and Considerations for FPSO Modules Rigging Systems with Multiple Spreader Bars Lifting of Lower Turret Lifting of Gas Recompression Module Lifting of Flare Tower Summary CHAPTER 8.1 8.2 8.3 8.4 8.5 8.6 SPECIAL LIFTING FRAME DESIGN 121 General Discussion Effect of the Shift of the Centre of Gravity Lift Point Forces Padeye Checking Trunnion Checking Summary CHAPTER FINITE ELEMET ANALYSIS FOR LIFTING DESIGN 139 9.1 Introduction 9.2 Finite Element Analysis for Module Lifts 9.2.1 Structural and Material Details 9.2.2 Finite Element Modelling and Analysis 9.2.3 Discussions 9.3 Finite Element Analysis for Lifting Padeye Connection 9.3.1 Structural Details 9.3.2 Loading Cases 9.3.3 Finite Element Modelling 9.3.4 Result Analysis 9.4 Summary CHAPTER 10 CONCLUSIONS AND FUTURE WORKS 170 10.1 Conclusions 10.2 Recommendation for Future Work BIOBLIOGRAPHY 174 APPENDIX A FEM ANALYSIS FOR JACKET UPENDING PADEYE 181 ii Summary Successful lift installations of heavy offshore structures require comprehensive and detailed studies involving many engineering and geometrical constraints including geometric configuration of the structure, its weight and centre of gravity, member strength, rigging details, lifting crane vessel and other construction constraints These constraints need to be resolved efficiently in order to arrive at a cost-effective solution This thesis summarises the results of detailed investigations by the author involving actual offshore engineering projects The thesis first reviews the lift criteria adopted in the offshore industry The key practical considerations for selection of appropriate crane barges, rigging components are discussed The algorithms and formulations for rigging systems with various number of lift points are then presented Practical considerations for module and jacket lifts are investigated For deck panel flip-over operation, the force distribution between two hooks which varies with changing module inclined angle, is calculated consistently Lifting procedures and rigging systems with multiple spreader bars for Floating Production Storage & Offloading (FPSO) modules are also studied Emphasis is given to the design and analysis of lifting unique components to meet the stringent installation requirements The thesis is reports on a versatile spreader frame design which incorporates a combination of padeye and lifting trunnions Detailed finite element modelling and analysis are conducted to analyze the lifting module and padeye connection It is found that finite element analysis can provide important detailed stress distributions and limits for safety verification of lift components iii Nomenclature/Abbreviation A - Cross Sectional Area AISC - American Institute Steel Construction API - American Petroleum Institute CoG - Centre of Gravity CRBL - Calculated Rope Breaking Load CGBL - Calculated Grommet Breaking Load D - Pin Hole Diameter of Padeye DAF - Dynamic Amplification Factors DB - Derrick crane Barge Dh - Pin Diameter of Shackle DNV - Det Norske Veritas E - Modulus of elasticity of Steel Eb - the sling bend efficiency (reduction) factor Et - Efficiency of termination method FEM - Finite Element Method FEA Finite Element Analysis - FPSO - Floating Production Storage and Offloading Fb - Allowable bending stress Ft - Allowable Tensile stress Fy - Material Yield stress Fu - Steel Tensile strength Fv - Allowable shear Stress G - Shear Modulus of elasticity of Steel iv H4 - height of hook block above module (without spreader structure), or height of spreader above module (with spreader) H5 - height of hook block above spreader (with spreader), or, =0 (without spreader) HSE - Health and Safety Executive Ix, Iy - Moment of Inertia Lh - Inside Length of Shackle Li - length of ith sling MBL - Minimum Breaking Load MWS - Marine Warranty Surveyor Rai - ith Cheek plate Radius of Padeye Rm - Main plate Radius of Padeye SACS - Structural Analysis Computer System SDL Sling Design Load - SSCVs - Semi-Submersible Crane Vessels Sx, Sy - Sectional Modulars SWL - Safe Working Load T - Static Sling Load Tci - ith Cheek plate thichness of Padeye Th - Crane Hook Load Tm - Main plate thichness of Padeye Wh - Jaw width of shackle Wh, Lh - the width and length of hook block Wm, Lm, Hm - the width, length and height of module, respectively Wsp, Lsp - width and length of spreader v WLL - Shackle Working Load Limit d - Sling rope diameter fb - Actual bending stress fc - Actual Combined stress fcog - COG shift factor ft - Actual Tensile stress fv - Actual shear Stress xc, yc - location of the centre of gravity of module in local coordinate system θi - angle of sling with respect to the horizontal plane τg - Punching strength vi List of Tables Table 2.1 Lifting Criteria comparison - Single Crane Lift Table 2.2 Lifting Criteria comparison - Double hook Lift Table 2.3 Dynamic Amplification Factors Table 3.1 Some of Heavy Lifting Crane Vessels in the World Table 3.2 Shackle Side Loading Reduction For Screw Pin and Safety Shackles Only Table 4.1 Formulations for rigging configurations with four lift points (using main or jib hook block without spreader) Table 4.2 Formulations for rigging configurations with four lift points (using main or jib hook block with spreader structure) Table 4.3 Formulations for rigging configurations with four lift points (using main and jib hook blocks at the same time ) Table 4.4 Formulations for rigging configurations with six lift points (using main or jib hook block ) Table 4.5 Formulations for rigging configurations with six lift points (using main and jib hook blocks at the same time) Table 4.6 Formulations for the rigging configurations with eight lift points (using main or jib hook block at a time ) Table 4.7 Formulations for rigging configurations with eight lift points (using main and jib hook blocks at the same time ) Table 7.1 Lifting Operation Summary for Laminaria FPSO Table 7.2 Contingency Actions Plan / Procedure Table 7.3 Preparation Check List Table 7.4 Loadout Check List Table 7.5 Installation Check List Table 8.1 Weight and COG data Table 8.2 Total Weight and COG vii BIBLIOGRAPHY • American Petroleum Institute (API) Recommended Practice for Planning, Designing and Constructing Fixed Offshore 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Finite Element Procedures for Contact-Impact Problems, Oxford University Press, Oxford 1993 180 APPENDIX A FEM ANALYSIS FOR JACKET UPENDING PADEYE Additional FFM results for Jacket upending padeye with various loading cases are summarized in this section • Summary of load cases and member forces Table A.1 Member forces coming out from SACS analysis 181 182 • Summary of loading applied to padeye (A.1) Load out (wire-frame view) (B.1) Upending in vertical position (wire-frame view) (C.1) Upending in horizontal position (wire-frame view) (A.2) Load out (solid view) (B.2) Upending in vertical position (solid view) (C.2) Upending in horizontal position (solid view) Figure A.1 Load conditions (to be continued) 183 (D.1) Upending in tilted (D.2) Upending in tilted position (wire-frame view) position (solid view) Figure A.1 Load conditions 184 • Stress distribution of upending padeye (a) 1st- Principal stress (b) Von Mises stress Figure A.2 Stress distribution for the braces of load case A 185 (a) 1st- Principal stress (b) Von Mises stress Figure A.3 Stress distribution for the braces of load case B 186 (a) 1st- Principal stress (b) Von Mises stress Figure A.4 Stress distribution for the braces of load case C 187 (a) 1st- Principal stress (b) Von Mises stress Figure A.5 Stress distribution for the braces of load case D 188 .. .HEAVY LIFT INSTALLATION STUDY OF OFFSHORE STRUCTURES LI LIANG (MS Eng, NUS) A THESIS SUBMITTED FOR THE DEGREE OF MASTER OF ENGINEERING DEPARTMENT OF CIVIL ENGINEERING NATIOANL UNIVERSITY OF. .. may reduce the costs of offshore installation work significantly, especially for large integrated topsides and liftable jacket structures The dynamic aspects of heavy lift installations are to... jackets / modules Without heavy lifting equipment, offshore steel platforms cannot be built effectively For an offshore platform, the issue of final installation of the completed jacket / topside