Castoro 12

Laying process and general dataLaying process and general data

eni.com PREPARED BY: C12 FIELD ENGINEERS

CASTORO 12 – PIPE LAY VESSEL

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CASTORO 12 – PIPE LAY VESSEL

SWS

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CASTORO 12 – GENERAL LAYOUTLINE UP

35t PEDESTAL CRANE

PIPE STACKING AREA

LINE UP ROLLERS No. 1 AND 2

PIPE PIPEPIPE LOWERING CRADLE

PIPE LONGITUDINAL CONVEYOR

TRANSVERSAL CONVEYOR

TENSIONER

STINGERABANDON & RECOVERY WINCH

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WINCH

FIRING LINE WORK STATIONS

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FIRING LINE

The firing line will consist of the following major components:

• Four fixed height pipe supports R1, R2, R3 and R4• Variable height track support R5, R7• Tensioner + additional support (R_T)• Roller support R8 and R9• Vertical rollers V1 and V2 (mounted respectively on track support R7 and 

rollers support R8)• Firing line working stations

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FIRING LINE STATIONS FUNCTION

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CASTORO 12 – ACTIVITIES PERFORMED ON BOARD

The activities to be performed onboard Castoro-12 are:• Pipe joint storage and handling• Welding preparations (bevelling, pre-heating & line-up)• Firing line welding (3 stations)• Firing line welding (3 stations)• NDT and Welding Repair (1 station)• Field Joint Coating(3 stations)• Initiation, normal pipe laying, lay down & contingency

operations`operations

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LOADING OF PIPES INTO THE PIPE LOWERING CRADLE

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MOVING OF PIPES INTO LONGITUDINAL CONVEYOR

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GRINDING OF PIPE SIDE BEFORE WELDING

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BEVELING OF PIPES

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PIPES ALIGNMENT

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PIPES WELDING

PIPE WELDINGAll welding shall be performed as per approved WPS/Welding Book and by qualified welders.The pre‐heating of the welding area of each joint, as specified on approved WPS/Welding Book, will becompleted prior to clamping The temperature will be measured using Digital Pyrometer or Tempilsticcompleted prior to clamping. The temperature will be measured using Digital Pyrometer or Tempilsticbefore to confirm WPS requirement. The root and Hot pass will be completed at the 1st station internalline‐up clamp will be removed after completion of the required passes with reference to the approvedWPS. The remaining subsequent passes will be carried at the 2nd or 3rd welding stations.

NDT OPERATIONNDT examination will be performed in station no. 4 as per approved procedure

WELD REPAIRIn case of defects out of acceptance criteria, the repair will be carried out at Station No.4 or No. 5, inaccordance with approved repair welding procedure and weld repair analysis.In case that the weld repair will be longer than admissible limit identified by weld repair analysis, therepair can be split in two independent sections, each one within admissible limit and shall be performedin different time (one subsequent the other). This will assure the safe condition during groove repairexcavation. The repair is allowed to be performed one time only, no second repair to be allowed.If the repair results is not successful, the pipe joints until the defective weld will be cut and removed fromthe firing line while C12 is back laying, then both cut pipe ends shall be re‐beveled and the laying process

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repeated.

ILUC

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IPW

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WELDING 1ST STATION – ROOT & HOT PASS

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WELDING 2nd STATION

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WELDING 3rd STATION

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NDT-RX

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SAND BLASTING

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PHASE 11 – SAND BLASTING APPARATUS

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PRE-HEATING AND EPOXY APPLICATION

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STINGER SYSTEM - PICTURES

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STINGER SYSTEM – OVERVIEW

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PALFINGER CRANE

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PIPE LAY DOWN – CASTORO 12 MAIN NORMAL LAYING CONFIGURATION

Scope of Work:PULLING OF 28’’ EXPORT OIL LINE PIPE STRING IN TRANSITION ZONE FROM KP40.5 TO KP50.5

Transition Zone is identified as a zone, b t KP40 5 d KP52 9 hbetween KP40.5 and KP52.9, where water depth varies from approximately 1m to 0m. Due to the limitation of barge draft, the C12 cannot install pipeline in

t d th l th 1 6 b

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water depth lower than 1.6m by conventional S-lay method.

TRENCH

Prior to start installation works trench was excavated by dredging subcontractor  up to the required design depth from KP40.5 to KP50.5 for burial requirement.

After shore‐pull completion the pipeline will be backfilled by dredging subcontractor in order to guarantee a burial depth of 1.0m TOP from KP40.5 to KP50.5. 

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HOLD BACK SYSTEM

The hold‐back cable composed of several wire rope sections with different diameters (38 mm, 52 mm and 56 mm) will be pre‐laid in trench which is connected to an hold‐back system. y

7sections of Ø38mm cable

10 sections of Ø52mm cable

26 sections of Ø56mm cable

The hold back cable anchors system consists of 2x2 piles of a suitable capacity

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The hold‐back cable anchors system consists of 2x2 piles of a suitable capacity 

PIPE STRING PULLING - INITIATION

• CASTORO 12 moored at KP40.5 • STORIONE 2 comes close to stinger (approx.12m)• STORIONE 2 connects the hold-back cable to Skagit Winch pilot cable at her bowg p• STORIONE 2 connected to pipe pulling head via load cell at her stern

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STORIONE 2 PULLING PONTOON

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STORIONE 2 PULLING PONTOON

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FLOATERS

3.25 T FLOATER

Over 760 floaters equipped with quick release system will be installed on the pipe string.

9 5T FLOATER9.5T FLOATER

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FLOATERS

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LIFTERS

Lifters are dedicated floating platforms with 20T load capacity equipped with motorized winch and chain blocks utilized to hoist

the pipe

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STRING FABRICATION AND PULLING

The string fabrication and pulling operation will consist of the following activities:will consist of the following activities:

• Set-up of C12• Fabrication of string• Installation of floaters• Pulling of stringPulling of string• Support during pulling operation

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PULLING OF STRING

• The pipeline will be pulled only when welding, NDTand FJC of a pipe joint is completed in the FL andinstallation of the floater, if required, is completedover the stinger

• During string pulling operation the essentialparameters will be controlled to ensure that the stringis not subject to excessive stress or deflection outsidethe specified limits: rollers reaction, stinger angle,Tensioner tension, Winch pulling force, Barge draftTensioner tension, Winch pulling force, Barge draftand trim, Barge positioning, String Configuration.

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TERMINATION OF PULLING

• Once the weld joint between the pulling head and thepipeline has reached the intended location at approx. KP50.5,the pipe string will be abandoned on the trench bottom bythe pipe string will be abandoned on the trench bottom byremoving the floaters after that the alignment of the pipestring has been properly checked.

• 300m of pipeline must be laid from C12 stinger (about 25floaters to be removed) to ensure a sufficient pipe stabilityb f th t t f C12 l l i tibefore the start of C12 normal laying operation.

• Pipeline alignment will be checked prior of removing thefl t St i b h d l t ll b f l ifloaters. String can be pushed laterally before releasingfloaters by work boat to make sure the installation tolerancesare respected.

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