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Offshore

Mammoet’s creative engineering delivers safe and efficient operations for the construction and transport of large and heavy structures for the offshore market.

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Offshore

A new era of efficiency

Mammoet’s heavy lifting and transport expertise offers new opportunities for the construction, installation, maintenance and decommissioning of offshore oil and gas facilities around the world.

From its earliest days — when the first oil platforms were little more than wooden piers supporting drills and pumps — the offshore sector has been a driver of innovation and a feeder of economic growth. Securing a cost-effective supply of oil and gas has enabled many countries around the world to develop socially, economically and politically, meeting the energy needs of their populations and leading to greater prosperity.

Heavy lifting and transport services

With a history going back to 1807, Mammoet began about 50 years before the first combustion engine was developed. However, over the decades our heavy lifting and transport services have grown in alignment with the needs of the world’s key industries, and the oil and gas sector has long been a major focus of our engineering expertise. As large-scale, permanent oil platforms and jackets came onto the world stage in the 1970s, Mammoet brought equipment and know-how to the market, enabling the load-out of ever-larger topsides, helping oil companies to vastly expand their offshore capabilities.

 

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Benefitting from efficiency

With fluctuating oil prices due to geo-political events and market forces, each decade has brought new challenges for oil producers. One constant, however, has been the drive for more efficient and cost effective operations. This has led to a trend towards bigger installations, requiring specialist installation techniques. All offshore oil and gas facilities require massive investment. When the oil price is up, high-capacity platforms deliver strong returns. When the price is low, margins are tighter and producers are seeking to benefit from greater efficiencies and economies of scale. Whatever the economic circumstances, the offshore market is continually looking for smarter, safer ways of working to maximize productivity and return on investment. 

Cost-effective construction

Oil and natural gas are a huge part of the global energy picture. However, recent years have seen oil prices constrained, a drive to reduce carbon emissions and increasing competitiveness from renewable energy. This has led to an industry focus on the optimization of all elements of offshore facility construction and operation. Cost-effectiveness, construction efficiency, time to market, productivity, safety and maximizing uptime are all crucial and they can all be enhanced with the right heavy lifting and transport expertise. As the market leader in engineered heavy lifting and transport, Mammoet plays an important role for our customers in realizing efficiencies and optimizing projects to ensure the maximum return on investment.

Efficiency through innovation 

Mammoet has designed new systems to safely load out or decommission the world’s heaviest topsides. We have also helped our clients draft more efficient heavy lift schedules that facilitate the integration of floating production vessels (FPSOs). Across all types of offshore projects our engineers and professionals in the field have a ‘can-do’ approach to every challenge that comes before them. We combine our state-of-the-art fleet of heavy lifting and transport equipment, long experience in the oil and gas sector and engineering expertise. Our aim is always to help customers find innovative, safer and more efficient ways of building, maintaining, repurposing and decommissioning their offshore assets.

 

Better design saves time

By engaging with the heavy lifting experts at Mammoet early in the planning and design phase of an offshore project, safer and more efficient solutions can be identified to save time and money, and enhance safety and quality.

Offshore oil and gas activities require enormous levels of investment, with the latest platforms costing billions of dollars to construct and install. Because of the risks involved in working at sea and with volatile substances, quality, safety and reliable engineering are of the highest importance. Nothing can be left to chance. This is why planning and design is such an important phase of any offshore project.
 
The early involvement of a heavy lifting and transport partner like Mammoet during the planning phase of an offshore project can bring significant benefits throughout construction, transportation and installation operations. Our expertise enables us to identify opportunities to shorten the critical path. We also manage risks that may lead to delays, thus limiting the knock on effects on the project schedule. 
 
In addition, when jackets, modules and platforms are being designed, Mammoet’s heavy lifting experience means we can offer valuable insight into the constructability of these elements. By gaining an in-depth understanding of the structures that will be involved, we can determine the best ways to lift and transport them, and help optimize the fabrication and construction processes.

 

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Heavy lifting experience

In some cases, Mammoet might be able to suggest tweaks to the initial designs that make modules or jackets easier to lift, assemble or transport. These modifications will reduce the project’s critical path so that the facility comes into production sooner, aiding time to market. They will also minimize costs by lowering the equipment and crew requirements.
 
Whenever our customers want to explore new ways of doing things, Mammoet’s natural passion for engineering comes to the fore. Larger platforms, new designs and changing construction techniques create intriguing challenges for us. Mammoet’s team of highly skilled engineers will find new ways of combining our existing heavy lifting and transport equipment to meet these challenges, and we offer bespoke solutions for our customers. Since the 1970s we’ve been supporting fabricators in the oil and gas industry, and many of our innovations are now standard practice in the construction, load-out and installation of platform topsides and jackets.

Improving fabrication techniques

The design of the physical elements of an oil platform, drilling rig or floating production vessel is an important stage of the process. However, planning must also take into account fabrication, load-out and installation operations. Each yard has its own approach to heavy lifting, and Mammoet is able to offer support on a case-by-case basis. We can cover the entire heavy lifting scope during fabrication, with complete oversight of the process, or we can assist in specific areas as required.
 
The load-out of a platform – transferring it from land to water transport – is the riskiest procedure in an offshore project. It’s also where Mammoet’s support is most significant. Our engineers will design the safest and most stable load-out strategy, choosing the most appropriate equipment from our fleet, which includes an array of world-class cranes, jack-up solutions, skidding systems, SPMTs and more.

Smarter offshore installations

The final critical area of planning covers at-sea installation, and here Mammoet offers a range of services. In particular, we can help engineer innovative float-over and jack-up systems that reduce risk and save time and money, for instance by removing the need for heavy-lift vessels.
 
From working with the initial design concepts to improve constructability, through to supporting lifting and transport activities during fabrication, and on to installation, Mammoet’s expertise in the offshore industry offers a range of benefits to our customers. Working with leading fabricators around the world, we know the importance of quality, safety and reliability, while at the same time striving for greater efficiency, lower costs and a shorter timeline.

 

Michel Bunnik

Quality and competitiveness

Mammoet works across a range of major industries, each of which present unique challenges. For the offshore market cost-effectiveness is always important. This has led to ever-increasing scales of offshore structures and facilities. Plus the adoption of modular construction approaches. Operating at these scales brings specific risks and leads our customers to place a strong emphasis on quality, reliability and engineering. To ensure these risks are controlled and managed, to minimize impacts later down the line, it is vital to consult with experienced engineered heavy lifting and transport experts early in the project planning process. 
 
Offshore oil and gas installations cost billions of dollars to develop, so our customers want to be sure that their platforms and jackets are handled in the safest way, using the best engineering solutions available. These state of the art facilities are designed to withstand ocean conditions in some of the most hostile natural environments. Such specialized structures need to be securely maneuvered to their final destination, while safely managing as many risks as possible. 
 
Moving a 20,000-ton platform from land onto a barge presents the highest risk in the entire process chain. Early engagement with Mammoet’s offshore experts offers the best chance for a smooth, efficient execution. Drawing on our engineering expertise we work closely with our customers’ own engineering teams, with marine warranty surveyors and other third-party experts to thoroughly check everything before any operation goes ahead. 

 

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The oil and gas companies and fabricators we work with are adapting their ways of working to maximize efficiency and bring forward time to market in order to improve their competitiveness. This is why offshore constructions are increasingly modular in nature. Mammoet’s global fleet of cranes, SPMTs, skidding and jacking systems are able to tackle the biggest loads, including the ever-growing scale of modules for offshore facilities. In addition to our state-of-the-art fleet, Mammoet’s engineering expertise can optimize operational efficiencies through improved processes. Our solutions are tailor-made to each project, each fabrication yard and each installation. Our alternatives reduce the schedule and bring platforms into production faster, for a much more profitable installation in the long run. 
 
Michel Bunnik has 30 years of experience in the heavy lifting industry. For 11 years he was Mammoet’s Global Sales Director but recently became Commercial Director for the Middle East and Africa.

 

Michel Bunnik

A smooth-running machine

With Mammoet’s end-to-end logistical planning, offshore oil and gas construction and maintenance projects can benefit from the most efficient and safest heavy lifting and transport processes.

Offshore platforms and vessels are complex facilities. Each platform is made up of numerous processing modules geared to that installation’s specific function. Normally they include components that have been carefully designed for the characteristics of the oil coming out of the well, and the pressures involved. The construction and maintenance of each platform often presents a whole series of unique logistical challenges.
 
Heavy lifting and transport expertise is vital to overcoming these challenges for a smooth-running project, which is on time and on budget. A heavy lifting partner like Mammoet can help optimize the assembly of a topside platform or jacket, or the change-out of specific components for maintenance or to improve productivity. With components often coming from several fabricators, the advice offered by a heavy lifting specialist can help improve the logistical chain across the entire project and achieve greater efficiencies along the way.

 

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Preparation is key

Involving a heavy lifting and transport partner like Mammoet early in the process means each move can be engineered for efficiency and the right equipment selected. From the transport of an individual blowout preventer or dynamic positioning thruster through to the load-out of a completely integrated topside assembly, each operation requires thorough planning, taking into account a number of considerations at every stage.
 
For example, if a change-out can be done at sea, the timeline can be shortened but it increases risk and requires specific installation equipment. On the other hand, if a rig can be brought to the quay side, the change-out can be managed with lower costs but there is likely to be more downtime. Consulting with Mammoet as early as possible in the project can help you make these key decisions and choose the right solution.

Global project support

Mammoet’s global reach and quayside premises around the world make it possible for us to mobilize quickly, assemble the required equipment and expertise, and provide a quay for maintenance and assembly work to be carried out if required. With terminals in Schiedam, Westdorpe, Port Freeport and Singapore, as well as relationships with other major ports and terminals around the world, Mammoet offers customers that flexibility.
 
With a dedicated project manager as your point of contact, the logistical process can be planned, taking into account safety, engineering, on-site operations, land-sea transfers, heavy load permitting and more. A route survey is carried out up front, calculating the envelope of each load, anticipating any bottlenecks based on local infrastructure and transport methods, and drawing up contingencies to mitigate risk.

Heavy lifting equipment

Where fabrication and installation are carried out by a yard, Mammoet can offer additional equipment and engineering capacity. In addition to the provision of high-capacity cranes and jacking systems, our specialist engineers will analyze the project and suggest innovative solutions so that jackets can be manufactured faster, parallel fabrication of modules can be planned and executed, and assembly and installation sequences can be optimized to shorten schedules and maximize uptime.
 
Whether it’s the assembly of a platform, decommissioning a facility or maintenance work, time is always of the essence. Downtime cuts into the profitability of the operation, making efficient logistics a crucial facet of the operation. The right heavy lifting and transport partner will help you improve your process, enhance safety, shorten the critical path and keep the project in the black.
 

Richard van Looij

Streamlined multimodal transport

Logistics for offshore projects are time-critical and highly complex. Aligning the delivery of components, modules and complete offshore structures across different modes of transport requires extensive experience and a strong grasp of the significant risks. The key issue for these logistics projects is managing these risks. Surveying the possible routes, determining the right equipment to use and working with the authorities are all essential to ensure a safe, efficient operation. One way to optimize and streamline the logistics approach is to engage one party to deliver an end to end logistics solution, sometimes known as a ‘factory to foundation’ approach.
 
Multimodal transport operations require coordination with a range of agencies. On water, that may include harbor authorities, agencies, tugboat owners and pilots. On the landside, the right heavy load permits with local road transport authorities must be secured, and arrangements need to be made with rail haulage contractors. Mammoet’s global logistics experts have developed good relationships with key authorities involved and in some places we have standard permits in place. There are many opportunities to gain efficiencies across these operations. When one party is responsible for the complete logistics chain it is possible to create a seamless transport plan.

 

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Taking responsibility for the entire logistical scope of a transport project improves overall efficiency, increases facility uptime, mitigates risk and enhances safety. For example, our end-to-end logistics capabilities were demonstrated when transporting a set of blowout preventers from Houston, Texas, to locations in both South Korea and Singapore. The Mammoet team planned both operations in their entirety for Maersk Drilling. In each instance, we picked up the BOP at the GE premises in Houston, transported it to the dock by road, loaded it out, shipped it to the quay side in the Far East, and lifted the module into place. 
 
Both projects’ engineered heavy lifting and transport activities were taken care of by Mammoet, as well as all the interfaces between land and water transportation. Freeing our customers’ time up to focus on their offshore operations.
 
Richard van Looij is Senior Commercial Manager at Mammoet Europe, and has been helping customers in the offshore sector to plan their projects as efficiently as possible for the last eight years.

 

Richard van Looij

Shortening the schedule and lowering costs

Mammoet’s engineered heavy lifting expertise and equipment help fabricators build modules and integrate oil platform topsides using the quickest, safest and most efficient methods.

Since they first came into mainstream use in the 1970s, platform topsides have been at the heart of offshore oil and gas operations. Once a well has been drilled and risers are in place to carry the oil to the surface, an array of specialist equipment is required to prepare the product for transport. The manufacture and installation of a topside itself, and the modules it will contain, require high levels of investment. Because operators in the sector are always exposed to oil price fluctuations, any efficiency that can be gained during this process boosts margins and provides the business with added stability.

A history of expertise 

Working with a heavy lifting and transport specialist like Mammoet can offer huge benefit to efficiency throughout the design, construction and installation of oil and gas platform topsides. For several decades, the oil and gas industry has developed modular construction techniques to make platform construction safer and more cost-effective. With Mammoet’s long history working alongside oil and gas operators and offshore platform fabricators, we have equipment, expertise and engineering skills perfectly suited to such projects.
 
An oil platform is usually made up of a number of modules across three, four or five decks, supported by a steel framework. Each module is used to carry out a specific function such as drilling, pumping, separation and other pre-transport processing. A blowout preventer (BOP), for instance, is crucial to the safe functioning of the well. Other modules will include crew accommodation and energy generators.

 

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Oil platform efficiency

For optimum construction efficiency, modules are often fabricated at a variety of locations around the world in parallel, and then transported to a dock near the oil field for assembly and integration. When the various decks forming the topside have been pancaked, the platform is floated out for installation and can start producing oil.
 
With Mammoet’s expertise, ways can be found to optimize each lift and transport operation throughout the entire construction sequence for a platform topside. Landside, we have the expertise to lift, load and transport each module, moving it from its point of fabrication to the dock for assembly. Mammoet will provide extensive heavy lifting support in the yard itself to facilitate safe and efficient assembly.

The right load-out method

When the platform is ready to be floated to the rig’s final location, we will engineer a smooth load-out solution based on the weight and design of the topside. For platforms weighing up to 13,000 tons, a configuration of our self-propelled modular transporters (SPMTs) is often the best way to move the payload onto a barge. For heavier weights, and where other designs have been used, skidding systems often provide the most reliable load-out method.
 
At every stage, preventing incidents is of the utmost importance, and Mammoet’s safety procedures meet or exceed those of all the oil and gas operators, fabricators and government bodies we work with. By engaging with Mammoet from early in the design phase of the modules and the platform, we can find ways of optimizing the construction so that lifting and transportation can be carried out in the safest and most efficient way possible. This will reduce construction time, lower costs, and ensure maximum uptime for the platform in the oil field.

 

Ludo Mous

Efficiency and expertise

Working with the offshore industry since the 1970s, Mammoet has built up an unrivalled bank of engineering expertise. We’ve seen topsides grow ever larger in size, and as the market has developed we have continually found ways to deliver efficiency benefits to our clients.
 
Mammoet aims to offer solutions to problems and new ways of doing things. As market leader we have continued to drive innovation in the industry. The oil and gas industry faces major challenges when it comes to reducing time to market and increasing return on investment, innovation in engineering is an important way of improving project efficiency.
 
We have long-term relationships with companies across the oil and gas sector, and we have grown alongside them by providing a service and continually honing our expertise. One of the reasons we developed our self-propelled modular transporters (SPMTs) over 30 years ago was specifically for the transport and load-out of platforms and modules. Today we continue to engineer bespoke solutions for our customers.

 

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The quality of our people is another crucial differentiator that offers important benefits to our clients. The Mammoet training program, alongside our experience in the field, ensures that our crews work at the highest professional standard. Where training for certain equipment is not available externally, we design our own rigorous internal training programs to ensure that our operators have all the skills they need.
 
As a result, our cranes, SPMTs, tension jacks and skidding systems are used in the safest and most efficient ways on every project. With the offshore oil and gas market continuing to face tough challenges, this approach gives us the edge, and in turn it gives our customers the edge. It’s an area you don’t always think about, but it’s where we make a difference.
 
Ludo Mous is Director of Operations at Mammoet Europe. For over 25 years, he’s been helping clients in the oil and gas sector to assemble and install their platform topsides on time and on budget.

 

Ludo Mous

Smarter methods boost construction efficiency

Mammoet’s expertise in the offshore oil and gas sector means we are able to find new heavy lifting and transport solutions to better facilitate the construction of world-record jackets and compliant towers.

As oil platforms grow ever larger, the jackets that support them have also grown to world-record sizes. Mammoet’s specialist expertise is vital for their construction, transport to the oil field and installation.
 
The majority of offshore oil and gas production takes place on relatively shallow shelf features beneath the ocean, where reserves are easier to access. After exploration has taken place, a topside can be positioned in the field and wells drilled, and extraction can begin — but not before a structure is put in place to support the platform. A jacket or compliant tower needs to be constructed on land, transported to its position above the well site, and then lowered into the water. It will play a vital role supporting a large, heavy and expensive platform through the harshest ocean conditions. As with a topside, a safe, efficient and quick process is essential for the construction, load-out and installation of a jacket or compliant tower.

More efficient construction

Made of steel, up to 600 meters in height, and capable of supporting topside platforms weighing thousands of tons, compliant towers and jackets present considerable construction challenges. A heavy lifting and transport specialist like Mammoet can play an integral role in projects of this nature. The right equipment and teams to operate it are part of the equation. However, your ideal partner in these scopes will also provide engineering advice and suggest construction techniques that shorten the critical path, reduce work at height and improve project efficiency.

 

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A jacket or compliant tower is usually built lying on its side. The process involves the construction of the four sides of the structure side-by-side on the ground. Subsequently, high-capacity cranes lift the panels into position for welding. This process is called the roll-up. Even though the structure is assembled on its side, a good deal of work is done at height, which poses safety risks. It also means that a group of large and costly cranes is used to lift and hold pieces of the steel framework in place for weeks at a time while the welding is completed.

Smarter building methods

When jackets and compliant towers reach a certain size, the deployment of numerous, very large cranes presents high costs, and either they have to be stick built, or alternative methods must be found. Working alongside fabricators, Mammoet has developed a roll-up technique that uses a combination of strand jacks and cranes to lift and pull the side and top panels into place. This speeds up construction, reduces overall crane costs, and makes the process safer for workers in the yard.
 
This method is easier to execute in the construction of a compliant tower, with its straight sides. However, a jacket’s form tapers from the base to the top, meaning each strand jack along the length of the roll-up needs to operate at a slightly different rate to bring the trapezoid-shaped panels into position evenly, and with no deflection or bending. Mammoet’s engineers will tailor the method and equipment used to the scale of the project, overcoming new challenges that arise with new solutions.

Load-out expertise

Once constructed, the jacket or compliant tower needs to be transported from the yard to its final location in the oil field. Its load-out from land onto a barge is the riskiest part of the entire operation. Normally, a jacket is built right on top of a skid track and when complete it is moved directly from quay to the barge. The interface between the pier and the barge is the most critical, because it is here that forces impact the main cords along the length of the structure. Any lateral force impacting the cords could compromise the strength of the jacket, rendering it useless. With vast skidding and ballasting expertise, many decades of load-out experience, and an unrivalled fleet of equipment at our disposal, Mammoet can support, facilitate and execute the load-out of jackets and compliant towers for our customers.
 
Combining a fleet of state-of-the-art equipment with fine-tuned engineering expertise, Mammoet assists fabricators throughout the construction process of jackets and compliant towers. Using methods we have developed helps oil and gas operators reduce the overall construction timeline of an installation, boosts efficiency and enhances overall safety. The result is increased uptime for production platforms, which directly impacts the bottom line.

 

Robert Roest

Continually improving to save customers’ time

For offshore oil and gas operators, it’s a long journey from initial exploration to first oil. Development, fabrication and installation costs are high, and efficiency is critical in order to ensure investors achieve healthy returns. Anything Mammoet can do that reduces the time it takes to get to first oil will help our customers open their revenue stream and begin reducing their finance costs. For an oil platform these can amount to millions of dollars a week in interest alone.
 
Jackets and compliant towers are nothing more than support structures, but they are hundreds of meters long, can weigh over 30,000 tons, and take several months to manufacture. By helping our customers develop smarter ways of fabricating these components, we can reduce crane costs on site but also shorten the critical path, boost overall project efficiency and get them to first oil sooner – a great story for their investors.
 
We have excellent people, excellent equipment and proven methods. But what’s most important is that we have a strong interest in the success of our clients. Our attitude is that we’ve got to make it work for our customers, and we know that they have clients and investors to answer to. So when we identify a problem, we try to solve it, and if we think we can find a better way of doing something, we’ll suggest it and research ways of making it happen.

 

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To achieve that, we look at all the engineering approaches and equipment available to see if we can combine them in new ways. We’ll consider how adding newly developed kit could improve the project, and investigate alternative lifting and transport methods. Wherever possible, our aim is to find ways to upgrade proven concepts at higher capacities or faster working speeds.
 
By optimizing the process — whether it’s the construction of a jacket, the load-out of a platform, or the installation of modules on a floating production vessel — we can maximize safety, increase cost-effectiveness and improve efficiency. What it essentially comes down to is that we help our customers get to first oil quicker.
 
Robert Roest has over 20 years of experience in the heavy lifting and heavy transport industry, and is currently Mammoet’s Special Projects Accounts Manager based in Houston, specializing in offshore.

 

Robert Roest

Raising the bar for efficiency

Working closely with offshore oil and gas operators for many decades, Mammoet is able to develop solutions to facilitate the installation of self-installing platforms safely, efficiently and on schedule.

Time, cost and revenue are three of the most important factors that can make or break an offshore oil and gas sector installation project. While revenue levels are largely dependent on the market prices of oil and gas, and are therefore beyond the control of individual producers in the sector, time and cost are aspects that can be managed. Working with an experienced heavy lifting and transport specialist like Mammoet opens up new possibilities for the efficient construction and installation of oil and gas equipment that can shorten timelines, reduce costs and improve safety.
 
The use of a self-installing platform is an approach that delivers several efficiency benefits to companies in the oil and gas sector. Rather than constructing a jacket and a topside platform separately, and carrying out load-out and installation operations for each of them, self-installing platforms are integrated floating units. Their legs are lowered through the deck to the seabed in a manner similar to a drilling rig, replacing the need for a jacket or compliant tower for support. When the legs have stabilized, the platform is raised above the level of the waves and the installation can go into production.

 

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One reason for selecting a self-installing platform is the reduced construction requirement. By eliminating the need to produce a separate support structure, a significant amount of construction time can be saved, which reduces risk and improves overall project efficiency. With modular construction techniques facilitating the parallel fabrication of the platform, modules and legs, and with a heavy lifting and transport partner helping coordinate the integration process, this approach can offer the right solution when a quick turnaround is vital.
 
A second area where self-installing platforms bring real benefits to operators is in the installation phase. Without the need for an operation to load-out, transport and install a jacket structure, project risks can be significantly reduced and safety enhanced. Transporting the finished platform to its final location is normally as straightforward as floating it from the port to the oil field.
 
One of the most challenging phases of the installation is the lowering of the legs. When they begin to touch the seabed, the force of the waves may move the platform and its legs up and down and laterally, making it difficult to lock in at the correct position. However, Mammoet’s experience and specialized, tensioned strand-jack technique can be used to simultaneously lower and stabilize the legs and raise the platform above the waves. The result is operations that can be carried out smoothly, efficiently and without incident in a wider weather window.
 
Developments in the design of self-raising platforms may even lead to nimbler solutions for oil and gas operators. The self-installing platforms of the future might be able to jack their legs up when a deposit is depleted in order to begin production in another location, or for simpler and safer decommissioning. Mammoet’s expertise and experience means we are ideally positioned to facilitate such operations. This could open the way for companies to extract smaller deposits where they exist in shallower waters more cost-effectively, removing the upfront investment burden involved in building a brand-new platform and jacket.

 

Dennis Polak

Innovative techniques for more efficient installation

Offshore operators and owners need to carry out new installations or upgrade facilities in the field quickly to maximize uptime and productivity. They are also continually seeking new reserves, some of which may be in remote or challenging environments. Under these circumstances, project efficiency is always key to ensure the economic viability of a project. One route to greater efficiency is through economies of scale — this has meant larger platforms and larger jackets. Mammoet has responded by developing equipment and engineering solutions to meet the challenges of size and scale and the need to deploy facilities in hazardous locations. 
 
Project efficiency and safety can be improved through modular construction techniques. Working with our customers, and based on our experience, Mammoet has developed existing lifting, transporting and installation techniques to support our customers’ modular construction approaches. Our equipment innovation and development delivers safer, faster and more cost-effective solutions. One example of this is techniques for ‘self-installing’ offshore platforms.

 

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Self-installing platforms are a fast and efficient way of building and installing an offshore oil or gas platform. They are built completely in dry dock to be floated out to sea. As the topside doesn’t need a jacket to stand on, the complex construction, load-out and installation of such an item is not necessary. These platforms have legs that are lowered into the sea, and Mammoet’s engineers have perfected a tensioned strand-jack technique to both lower the legs to the seabed safely, and then lift the topside to its production height.
 
This approach reduces project complexity, cost and risk, and shortens the critical path. Across the oil and gas sector, we find solutions for our clients that put to use our extensive global pool of equipment, and when we need to innovate, that is what we do. Mammoet improves efficiency, maximizes uptime and ultimately helps customers get to first oil more quickly — which is a big advantage considering the level of investment involved.
 
Dennis Polak is Team Leader for Project Engineering at Mammoet. With 20 years of experience in special equipment, project management and engineering, Dennis helps clients in the oil and gas sector find better heavy lifting solutions.

 

Dennis Polak

Shipshape for deep-sea production

Floating production vessels offer an efficient alternative for deep-sea oil and gas operations, but their integration presents a range of heavy lifting challenges.

Mammoet’s heavy lifting and transport expertise in the offshore sector make us the ideal partner on projects where modules are integrated into floating production vessels for the oil and gas industry.
 
The extraction of deep-sea oil and gas deposits presents a whole range of engineering, safety and production challenges for energy companies around the world. Floating platforms using both tethering and dynamic positioning systems to hold their locations above wells that can be over 2,000 meters below the surface are one solution. Another is to convert oil tanker hulls to create floating production storage output (FPSO) and floating liquefied natural gas (FLNG) vessels. In certain ocean conditions, a ship’s hull copes better with the wave dynamics and positioning challenges than the square-shaped semi-submersible format of floating oil platforms.
 
Typically, a floating production vessel is created by converting a stripped-down oil tanker hull through the installation of between 15 and 20 modules, which carry out the same functions as those on a traditional platform topside — separating the oil from water and sand, and splitting the gas content. These modules need to be compact for a smaller deck footprint, but powerful enough to deal with the high pressures involved in deep ocean production. They are often very heavy objects. An engineered heavy lifting and transport company like Mammoet is an invaluable partner in any project that aims to integrate offshore modules into an FPSO.

 

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Reducing risk, improving efficiency

Early involvement is vital to minimize risk, save time and enhance overall safety. Mammoet’s engineers can help with the planning process in a number of ways. First, suggestions can be given on the design of the modules so that they can be transported from the yard to the quay, and lifted onto the vessel safely and efficiently. Secondly, with an understanding of all the lifting required across the entire scope of the project, Mammoet’s logistical expertise means that vital moves and lifts can be sequenced for optimum efficiency. This includes carrying out the operation with as few movements of the ship itself as possible, taking into account the need to load modules to both port and starboard sides. Thirdly, the layout of the yard during fabrication can be planned so that cranes and other equipment can be optimally positioned, and so that moves of components don’t interfere with other construction processes.

Heavy transport expertise

Some of the components required for an FPSO or FLNG normally come from external fabricators. Mammoet’s global experience in heavy transport means we are ready to support the load-out, transport by land and water, and unloading of modules from fabricators around the world. Mammoet can also carry out heavy transport within the yard using equipment such as self-propelled mobile transporters (SPMTs) and skidding systems.
 
Throughout the integration of an FPSO or FLNG, Mammoet’s engineers and equipment operators will look for ways to innovate, saving time and ensuring the safe load-out of each component. Our range of fast and flexible equipment, and crews who are familiar with the workings of a busy offshore fabrication yard, mean that we are ready to adapt to changes of plan that may occur.

Optimum SHEQ

Mammoet is a heavy lifting and transport partner that supports the health, safety, environmental and social commitments of our customers in the oil and gas sector. Safety is our number one priority during every project we undertake, and we look to engage with and contribute to local communities wherever our customers carry out their operations.
 
As the oil and gas industry seeks to improve productivity, every day spent at the quay is a day of lost production. With the right heavy lifting and transport partner involved, operations can be solidly planned, production schedules brought forward, and load-outs handled as efficiently as possible. This helps put FPSOs into production sooner rather than later, and improves the bottom line.
 

Akira Koga

Flexible, fast and efficient

The integration of a FPSO is an incredibly complex task. Our customers have different needs and face different challenges with each FPSO integration. When a unique situation arises, we can combine different types of equipment, or design bespoke solutions, so that the job gets done on time and in the most efficient way. 
 
The equipment is important, but what really makes a difference is our ability to innovate and engineer alternative methods to save time and boost overall productivity. We identify the challenges behind different construction scenarios in the yard, verify the installation sequence to ensure efficiency, and help our customers mitigate risk that might arise in the heavy lifting and transport scope.
 
We have carried out several FPSO integrations in Brazil in recent years, including the 17,000-ton lift of a topside onto a submersible hull, setting a world record at the time and demonstrating the heavy lifting expertise we have developed. Mammoet is able to bring a range of state-of-the-art equipment including cranes, jacking, skidding and transport solutions to the yard for any integration project. This hardware, alongside the knowledge and skills Mammoet brings to a project, can shave days or weeks off the schedule.

 

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For a recent project in Brazil, we built an adjustable linking plate using a hydraulic bar, which meant we could adjust the rigging for different types and weights of modules without having to dismantle it and set it up again for each lift. This equipment reduced the rigging component of the timeline from two or three days down to just one, for each important lift. This delivered significant time gains across the entire critical path for the project.
 
Akira Koga is Sales Director at Mammoet Latin America, based in São Paulo, Brazil. A qualified marine architect, for the last 12 years he’s helped clients in the oil and gas sector complete their projects using heavy lifting and transport services.

 

Akira Koga

Drilling down on cost and maximizing uptime

With Mammoet as your heavy lifting and transport experts, you can ensure that the installation of drilling modules is carried out quickly, safely and efficiently, providing maximum uptime for your investment.

Drillships, drilling rigs and the drilling modules on offshore platforms all play a crucial role in the offshore oil and gas sector. They facilitate the exploration and development of new oil fields, enable the drilling of initial wells, and provide the equipment for deeper and more extensive boring, which enables production platforms to reach their full potential.
 
With oil prices constantly changing, it’s vital that the operators of drilling rigs are able to launch and maintain their vessels as efficiently as possible to insulate margins. Whenever a drillship or drilling rig is inactive, it means that no revenue is coming in. With the high running costs these vessels face, any downtime eats into the bottom line. Meanwhile, if a drill tower or any related equipment on a topside platform is out of commission, it could hinder production and lead to lower productivity. Ultimately, the bottom line will take the hit.

 

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Solutions for drilling vessels

With the early engagement of a heavy lifting and transport partner like Mammoet, optimum solutions can be found for the fabrication, upgrading, maintenance and emergency repair of drilling vessels and drilling equipment. Mammoet’s extensive heavy transport and logistical experience includes the on-time delivery of large and heavy drilling components from manufacturers’ premises to quayside yards, or directly to vessels at sea, across the globe.
 
The engineering expertise Mammoet brings means that innovative solutions can be found that shorten the critical path of projects such as the repair, replacement or extension of drilling rig legs. In some situations, we can find ways of carrying out the work without requiring the time and expense of bringing a drilling vessel into a dry dock for upgrading. If newer, longer legs and new spud cans can be installed using a strand jack system rather than by carrying out the work on land, costs and schedules can be reduced, and the vessel can be back in the oil field carrying out assignments far sooner than a dry dock would allow.

Heavy lifting, parallel working

By combining engineering expertise and an unrivalled palette of heavy lifting and transport equipment, Mammoet finds ways to help customers carry out work in parallel. For instance, by providing a large crane on the dock rather than a smaller one on the deck of a drilling vessel, extensions to the legs can be carried out at the same time as other vital maintenance and inspection work on the deck, directly reducing downtime for the rig.
 
The work Mammoet carries out on exploration drillships, drilling rigs and platform-based drilling equipment helps operators in the oil and gas sector on two main fronts. Firstly, working with a heavy lifting and transport expert is a cost-effective way of bringing greater versatility to the vessels — newer, more efficient components can be installed to enhance productivity, while bigger, stronger and longer legs on a drilling rig, for instance, give it access to deposits that lie under deeper and more turbulent waters. But the second area is even more crucial from a business perspective. By optimizing fabrication and maintenance processes, we shorten the critical path on projects, which ultimately maximizes uptime for these vessels. Productivity is improved, revenue streams are maintained and the ledger stays in the black.
 

Erik Kroes

Analyze, innovate, execute

Offshore drilling systems installation, upgrades or maintenance projects often have extensive heavy lifting and transport requirements. Mammoet’s main goal is to offer a complete and failsafe engineering system for these projects. We look at the scenarios, consider the fallback options, and have the right contingencies in place in order to safely and cost-effectively carry out the operation.
 
At Mammoet we align our thinking with that of our customer at an early stage in the project. Gaining a better understanding of the requirements and concerns of our customers, we aim to find the right solutions and to minimize the timeline and cost impact wherever we can in an operation. Analyzing the construction and installation methods, we can optimize the project – determining which equipment and techniques to deploy, and where we need to innovate for a safe, efficient and successful operation.
 
Where exploration and drilling vessels are concerned, an important part of the operation is to consider how we can minimize our impact after the installation or maintenance has been carried out. By looking at the logistical chain beyond completion, we can ensure that our equipment is removed quickly, safely and efficiently so that our customer’s regular activities can resume as soon as possible.

 

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At Mammoet, we have an innate drive to find the optimal solution. Lifting and transporting modules for the offshore oil and gas industry is where we have developed our insight and expertise. By taking the whole picture into account during any project we work on, we are able to present ways of reducing costs and shortening timelines, as well as ensuring a more efficient, safer execution.
 
Erik Kroes is Managing Director of Mammoet Netherlands. For the last decade, he has helped customers across a range of industrial sectors to find the right solutions for their heavy lifting and transport projects.

 

Erik Kroes

Keeping your offshore assets productive

Newer, safer and more sustainable modules help to extend the life of an offshore platform, improving productivity, volume or product quality.

The boom in offshore oil and gas platforms began in the 1970s and Mammoet has been developing heavy lifting solutions for partners throughout the industry since those early days. With many older installations still in production, there is a continuing requirement for the maintenance, renewal and updating of the range of components found on oil and gas platforms. Over the years, Mammoet has continually innovated, finding new ways of using our equipment and expertise to help offshore operators achieve greater efficiencies. During this time, we have built up a considerable bank of engineering knowledge in the sector.

Maximizing offshore assets

There is a whole range of different scenarios in which Mammoet supports offshore oil and gas companies, and their fabrication contractors, with maintenance activities. Improving environmental regulations sometimes means that modules and equipment used in oil and gas production need to be changed out, and replaced with newer, safer and more sustainable units. In other cases, replacement of components on working oil platforms can lead to improvements in efficiency, productivity, volume or the quality of the product. When an oilfield is depleted, there may be the option to redeploy a platform or its components, with certain modifications, at a new location. Adaptation of equipment in this way helps to fully utilize existing assets in an efficient way.

 

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Heavy lifting support

Whatever the driver behind the operation, a heavy lifting and transport partner like Mammoet can be a valuable ally in the battle to maximize efficiency and shorten the timeline, without compromising on quality or safety. Mammoet can manage the logistics involved in moving components such as new dynamic positioning thrusters or blowout preventer (BOP) units from the manufacturer’s site to a fabrication yard or dry dock, or to the platform itself for installation. We have supplied heavy lifting expertise to projects converting topside platforms from production to accommodation units, and handled the transport and load-out of fully assembled drilling modules to help our customers achieve a shorter timeline, which ultimately helps maximize productivity.

Adapting to new conditions

Where drilling rigs require longer or more stable legs in order to be more versatile, Mammoet has found innovative solutions on a case-by-case basis. To extend the legs of a drilling rig, a very large quayside crane rather than a smaller crane on the deck of the rig means that the leg extensions can be carried out in parallel with other maintenance work, saving our client time. In other cases, a rig’s legs and spudcans can be replaced without the need to go into a dry dock, again shortening the schedule, improving uptime and lowering costs. And sometimes, when a big crane might seem like the right answer, Mammoet can offer quicker, leaner solutions. For instance, if a rig’s BOP carrier needs to be changed, it may be possible to lower it with strand jacks and skid it onto the quay side rather than using a large crane. This eliminates the mobilization period required for a crane from the timeline for a faster change-out.
 
Equally, when problems arise on an oil and gas platform and repairs and maintenance work need to be done quickly, Mammoet is ready to respond. With a global presence, and the world’s largest fleet of fully maintained and reliable heavy lifting equipment, we can help you bring facilities back online safely and efficiently, minimizing downtime and helping maximize productivity.
 

Darren Watson

Minimizing unproductive time

Offshore oil and gas companies are focused on being as lean and efficient as possible. To ensure productivity is maximized on their facilities it is essential to limit the time spent out of action for maintenance and adaptation work.
 
Mammoet helps clients design their maintenance and adaptation projects to be as swift and efficient as possible, returning the facility to productivity as soon as possible. Early engagement in a project is important, when we are involved with our clients at the planning and design phase we have the greatest opportunity for realizing efficiencies. We investigate the heavy lifting and transport scope of the project to identify opportunities for optimization of the build or installation philosophy, the approach to the load-out, and other operational areas.
 
Mammoet has extensive experience supporting the offshore industry to safely and cost-effectively adapt, extend and maintain their valuable assets to maximize their working life. In recent years, projects have been getting bigger and bigger. The weights of modules and topsides we are transporting, jacking up and loading in and out are increasing all the time. We’ve developed and invested in equipment and new approaches to take on these projects. Mammoet can facilitate jacking, skidding and float-over processes for updating, expanding and maintaining a range of offshore assets.

 

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We work with our customers on their maintenance or upgrade methodology to identify ways in which we can improve operational efficiency. For example by suggesting alternative engineering approaches and optimizing utilization of our heavy lifting and transport equipment. In some situations, we are able to suggest a number of alternatives. This approach contributes to the overall aim of any maintenance or upgrade project, which is to improve efficiency and guarantee maximum uptime of offshore assets.
 
Darren Watson is Sales Manager of Mammoet UK. Since 2009, he has worked with major fabricators of offshore oil and gas installations, helping them find bespoke solutions to their heavy lifting and transport requirements.

 

Darren Watson

When it’s time to remove a platform

A safe and efficient decommissioning process is essential whenever an offshore oil platform comes to the end of its working life, or needs to be moved to a new location.

The depletion of wells, aging equipment, oil price fluctuation, the move to a more diverse energy mix — there are many reasons why offshore assets are being decommissioned. Over the next few decades, it is estimated that up to 500 topsides will be removed from the North Sea alone, and a similar trend is expected in the other main offshore regions including the Gulf of Mexico, the Persian Gulf, the Far East and Southeast Asia.
 
The decommissioning or relocation of an offshore oil and gas platform or drilling rig is a complex and expensive process. Many parameters are considered during the planning of such an operation. The wells must be safely capped, and hazardous materials need to be removed and safely disposed of to avoid contaminating the environment. If there are piles and jackets, they might remain in situ to reef over, or they might need to be raised and removed. Undersea steel pipelines will be brought up for recycling. Then there’s the platform or rig itself. Usually its structure will be a key determining factor in the decommissioning or relocation approach taken.

 

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Essential heavy lifting

One thing is certain. When an oil platform or drilling rig is decommissioned, heavy lifting will be on the project’s critical path and is pivotal to the project’s overall success. That’s why having an experienced heavy lifting expert like Mammoet on board from early in the planning phase is so important. From the first engineering calculations right through to the landside demolition of the topside and its modules, Mammoet will help find ways of making the process faster, safer and more efficient. Because many decommissioning projects will rely on both taxpayer and oil company funding, maximum project efficiency is vital.
 
Often, the conventional method of decommissioning or relocating a fixed topside would involve transporting a mobile crane to the platform to lift heavy modules or cargo containers from the deck onto transport vessels. Although this approach can still be taken, today’s high-capacity heavy lift ships usually make it safer and more cost-effective to lift the entire platform from its jacket onto a barge, which will take it to its new location, or to the quay side. Once at the dock, it can be lifted, skidded or rolled ashore on a self-propelled mobile transporter (SPMT), and then dismantled in the yard.

The right equipment

Working with our customer and other partners involved in the decommissioning or relocation, Mammoet can offer advice, expertise and equipment across the project. The grillage that the cargo will rest upon during the barge journey needs to be carefully designed in order to safely accommodate the load, taking into account its weight and center of gravity — but also, crucially, the means by which it will be moved from the deck onto dry land. Mammoet designs grillage structures as well as computer-controlled ballasting systems so that the barge’s deck is at the right height during load-out at sea and load-in at the port. We can also provide the jacks, cranes, skidding system or SPMTs required to move the topside from the barge onto the quay, and engineer this critical part of the process.

Innovative engineering

Sometimes, the design of the platform means that Mammoet’s engineers are able to come up with innovative new ways of lowering it onto the barge. A strand jack solution, for instance, would remove the need for a heavy lift ship, saving time and direct costs on the project. The platform can then be barged ashore for decommissioning, or moved to a new location and jacked up onto its legs to resume production at another well.
 
Every offshore decommissioning or relocation project comes with its own unique challenges, but that’s what excites us at Mammoet. With each operation, our aim is to understand our customer’s needs, and then to plan and execute a project that saves time and money, while protecting people and assets.

 

Tom Rutgrink

Making a difference in decommissioning

From the beginning of an offshore decommissioning or relocation project, the most important thing for Mammoet is to understand our clients and their key concerns. Then it’s up to us to identify the optimal technical solutions.
 
Our engineers identify the critical points in the process where heavy lifting and transport expertise and equipment can be used to unlock smarter, safer or more efficient methods. Using our hardware and knowledge they optimize the lifting and transport scopes. They will also innovate and spot opportunities to reduce costs, reduce risk and reduce the schedule.
 
We have the most extensive, most modern and best maintained heavy lifting and transport fleet in the world. But the equipment is not the whole story. Our highly trained and very experienced professionals focus on developing techniques for the offshore industry that enable our customers to do things in new ways. We’ve learned from both offshore and onshore projects over the years, bringing the benefits to all our customers.

 

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One example is our use of strand jacks to install and remove oil platforms. Strand jacks are typically used in onshore construction to draw structural elements into position. However, with certain platform designs they can be used to lower a platform down to sea level for barging, and to raise its legs for removal. We have also developed techniques for the safe removal of end of life platforms for disposal. Our optimized approach to the decommissioning of the 24,000-ton Brent Delta platform was a record-breaking operation that safely and smoothly brought the topside onto dryland for dismantling and recycling.
 
For the last eight years, Tom Rutgrink has worked across a range of offshore projects, helping clients realize their goals efficiently. He is currently Sales Director for Mammoet Europe.

 

Tom Rutgrink

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