ACGJacketsDesignandFabrication

Authors Richard T. Ciezarek, Kellogg Brown and Root Energy and Chemicals; Archie M. Cormack and Allan D. Penman, BP Exploration (Caspian Sea) Ltd; Richard Mackie, BOS Shelf; and Geoff Tate, Kellogg Brown & Root Overseas Operations Ltd. Source Offshore Technology Conference, 5-8 May 2008, Houston, Texas, USA ISBN 978-1-55563-224-3 Copyright 2008. Offshore Technology Conference Discipline 4 Projects, Facilities and Construction Categories 4.7.2 Platform Design 4.10.4 Offshore Construction Management Preview Abstract The ACG field is located in the Azerbaijan sector of the Caspian Sea approximately 130 km east of Baku, in water depths varying between 118m and 176m. As part of the ACG Full Field Development (FFD) (see Figure 1), six barge launched jackets suitable for floatover topsides, plus associated drilling templates and foundation piles were designed and fabricated. Jacket loadout weights varied between 13,200 te and 16,700 te and the total pile weight, for all six structures, was approximately 44,000 te. Each jacket structure supports operating topsides weights of between 18,000 te and 24,000 te. This paper explains the development of jacket design and fabrication capability in Baku. It also highlights the production line approach to the design and fabrication of the jackets and the challenges that were overcome to successfully deliver this part of the ACG FFD project in Azerbaijan. The information will be of interest and value to those who face similar challenges in newly emerging energy markets and need to build up design or fabrication capability in other countries. It may also be helpful to those considering a production line approach to design and fabrication in order to optimise the delivery of major projects. The detailed design for all six jackets was completed in London and Baku between September 2001 and September 2006; this was followed by post design support to both the fabricator and installation contractor. Key drivers for the size, weight and configuration of the jackets, templates and foundation piles are explained in this paper. Construction of the jackets was executed in Baku between March 2002 and May 2007. The execution strategy for this work is explained with details of in-country upgrades of the fabrication yard, training of local personnel, fabrication schedules, specifications of steel, in-country rolling and erection roll up methods. The benefits of a production line of jackets are given in terms of procurement and logistics, re-use of construction and installation aids, lessons