J Ray Firsts

J. Ray McDermott “Firsts”

Subsea Tieback Forum 2004

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What Contractor was the “First to Incorporate “SCRAMS” Technology into a Subsea System Design?”

Allegheny Field DevelopmentProduction Facility

Client: British-Borneo Exploration, Inc.

SeaStar TLP Supplier: Atlantia Corporation

Location: Green Canyon Blocks 254, 297 & 298

Water Depth: 3,310 feet

Scope:

EPCI Contract: Installation of the SeaStar® tension leg platform (TLP), including piled foundations, tendons, hull and deck, 5 subsea trees, 2 REM’s 5 x 4” and 2 x 12” SCR with titanium stress joints.

Description:

Five wells, planned among two well centers. Production flows to the SeaStar® mini TLP via individual 4 inch diameter insulated steel catenary risers (SCRs). One well center is situated north-northwest of the platform and the other is to the south-southwest. The well centers are 3,000 feet from the TLP. The TLP contains process equipment and serves as the control center. Two 12 inch SCRs exit the TLP to the north-northwest to export the processed oil and gas.

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Innovation:

Titanium Tapered Stress Joint used for suspending the SCRs at the TLP

High Collapse Resistance (HCR) hoses in a direct hydraulic /electric control umbilical

Two years from design concept to first oil Insulated high pressure 4” flowline SCRs

What Contractor “Developed the Sand-Jack System for Deck-to-Jacket Mating Offshore?”

The Sand-Jack System design was used to install Ras Laffan and QGas in 1998. Development was started in 1996 in a FEED Study for Ras Laffan and began serious development in 1997. In the eighties, JRM used a Crude Sand-Jack System to install three decks for Exxon in Mobile Bay.

What Contractor “Entered into an Exclusive Yard Contract for the Sole Fabrication of 70,000 Tons of Topsides?”

Atlantis Field DevelopmentProduction Facility

Scope/Description:

The Atlantis topsides consist of three modules, the Production and Compression Modules, each weighing about 5,000 tons, and a Generation Module weighing 4,000 tons. Equipment consists of electrical generating equipment and oil and gas processing equipment. The three modules will be installed on a moored semi-submersible hull.

Client: BP

Location: Along the Sigsbee Escarpment in Green Canyon Blocks 699, 700, 742, and 744

Water Depth: 4,400 to 7,100 feet

Innovation:

Atlantis is one of four major BP deepwater projects for the Gulf of Mexico under construction at the company’s Morgan City facility which is under exclusive use for BP.

Holstein Field Development

Client: BP

Location: Green Canyon Blocks 645


Production Facility

Scope/Description:

Holstein will be a 149.25’ diameter SPAR moored by 16 chain, wire and suction pile anchors, supporting a topsides with a total operating weight of approximately 26,445 ST. The topsides will consist of 4 levels with all the production vessels, compressors, generators, and quarters needed for self-sufficient operations. It will have wells for production and water injection and a drilling rig capable of drilling to 25,000 feet. Holstein will also have two steel catenary risers for oil and gas export.

Topside facilities are being fabricated in three major components. The North Module will house the drilling and processing facilities; the South Module will house the quarters and utilities; and the Module Support Frame will house the support structure that will mate the topsides to the spar hull.

Innovation:

Holstein is one of four major BP deepwater projects for the Gulf of Mexico under construction at the company’s Morgan City facility which is under exclusive use for BP.

Topsides under construction

Mad Dog Field DevelopmentProduction Facility

Client: BP

Location: Green Canyon 782


Scope/Description:

Mad Dog will be 16-slot truss spar providing a dry-tree environment for production of oil and gas, as well as provide a host facility for future subsea developments. Production equipment, a drilling rig, and permanent quarters for both drilling and production personnel will be located on the spar.

The Spar will be a single piece structure with a total payload of approximately 18,000 short tons excluding hull storage.

The topsides are designed around a single-lift integrated deck concept with a lift weight of approximately 8,400 short tons.

Innovation:

Mad Dog is one of four major BP deepwater projects for the Gulf of Mexico under construction at the company’s Morgan City facility which is under exclusive use for BP.


Thunder Horse Field DevelopmentProduction Facility

Client: BP

Location: Mississippi Canyon Block 778/822


Scope/Description:

Thunder Horse facilities for drilling, processing and exporting hydrocarbons will be floating, large and complex, including a PDQ (Production-Drilling-Quarters) semi-submersible. The semi-submersible is currently expected to be moored by 16 chain, wire and suction pile anchors with a weight of approximately 82,543 metric tons. The 185 man quarters will be built into the hull of the semi-submersible.

The topsides consist of three modules – Production, Generator and Compression. The Production and Compression Modules, which are three main deck levels high, each measure approximately 115’ wide x 170’ long x 90’ high and weigh 5,669 tons and 6,130 tons, respectively. The Generator Module, which has two main continuous deck levels, measures approximately 104’ wide x 292’ long x 35’ high and will weigh 7,658 tons.


Innovation:

Thunder Horse is one of four major BP deepwater projects for the Gulf of Mexico under construction at the company’s Morgan City facility which is under exclusive use for BP.

What Contractor installed the “First Pipeline Utilizing the J-Lay Method?”

AugerClient: Shell Offshore, Inc.

Location: Garden Banks 426A

Gulf of Mexico

Water Depth: 2,860 Feet

Scope:

Multi-services contract with J. Ray McDermottbeing responsible for:

Fabrication of deck Offshore mating of Auger hull and deck Installation of lateral mooring system Connection of Auger TLP to lateral mooring system Tendon assembly, installation and TLP tendon

tensioning Installation of 12” Oil & Gas Sales Pipelines

Innovation:

Box girder and node fabrication techniques Float-over mating in open water Tendon assembly and installation Lateral mooring system installation Pipelay utilizing S-Lay and J-Lay techniques

Technology:

World’s first application of J-Lay pipelay technology

Set Gulf of Mexico pipelay water depth records at time of construction

Largest single piece deck fabricated by J. Ray McDermott

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Who became the “First Offshore Platform Fabrication Company to receive ISO 14001 Certification by ABS Quality Evaluations?”

J. Ray McDermott

Morgan City Fab. Yard

December 26, 2001

What Contractor designed and installed the First “In-Line Diverless Pipeline Tie-In Sled?”

Client: British-Borneo Exploration, Inc.SeaStar

Supplier: Atlantia Corporation

Location: Ewing Banks 921, 964, 965Water Depth: 1,690 feet

Scope: Lump Sum contract, plus reimbursable on

certain procured items, with McDermott being responsible for designing, procuring & installing export pipelines, 3 subsea production and 1 water injection well with associated controls, umbilicals and risers. This also includes installation of the SeaStar TLP in 1,690’ of water.

Innovation:

First deepwater project for British-Borneo Two years from concept design to first oil First use of Atlantia SeaStar mini TLP technology First JRM designed and installed steel catenary risers First JRM designed, procured and installed subsea

system in the Gulf of Mexico First deepwater diverless pipeline sidetaps in the Gulf

of Mexico First insulated flexible flowlines in the Gulf of Mexico First coiled tubing access of subsea production

system from surface TLP

Morpeth Field Development

What Contractor designed, fabricated,

and installed the “Only Compliant

Tower Facilities in the World?”

Baldpate Field Development

Description:

The Baldpate site development includes a compliant tower designed for drilling, production and workover operations. Seven wells will be predrilled with a semi-submersible drilling rig and tied-back to the production facility. Eleven additional well slots are provided for future drilling and provisions for future subsea tie-ins were included in the design.

Scope:

JRM Engineering was awarded the design of the compliant tower including foundation piling, drilling & production conductors and tie-back strings

JRM fabrication was awarded the fabrication of the tower base section and foundation piling.

Client: Amerada Hess Corporation

Location: Garden Banks 260Gulf of Mexico


Innovation:

Deepest bottom founded structure designed and erected offshore anywhere

First compliant tower without guylines First articulated compliant tower First compliant tower installed in two sections

offshore•

Drilling and Production Compliant Tower

What Contractor’s Barge “Worked

a Total of 1,284 days without a

Lost Time Accident?”

J. Ray McDermott

DB-16

What Contractor designed, fabricated,

and installed the “Deepest Tripod

Jacket in the World?”

Cinnamon TripodDeepest Tripod Jacket in the World

Client: Shell Offshore, Inc.

Location: Green Canyon 89A, Gulf of Mexico

Water Depth: 671 Feet

Scope / Description: Risk sharing contract to purchase materials,

fabricate and loadout a tripod jacket with appurtenances, piles and conductors.

Transport & Install tripod jacket (approx. 6,000 s. tons) in 670’ water depth.

Dual Derrick Barge Lift - DB50 & Shearleg 5000 Secure jacket to seafloor with 4 x 84”ø piles (2 @ C1,

1 @ A2 and 1 @ B2); T.O.J. “Dummy Leg” framing to accept a 4-leg deck

(approx. 1,600 s. tons) Designed for Full API Rig (H&P 107) Jacket footprint: 260’ x 260’ x 213’ Skirt piles: 2 @ C1 = 320 s. tons /330’ & 1@ A2 & B2

- 420 s. tons/425’

Innovation:

The Cinnamon jacket is the deepest tripod jacket fabricated and installed to date.

Due to the uncertainties associated with fabrication of a tripod of this size and considering engineering was still in progress, it was decided to handle this project under a risk sharing type of contract. The project was completed on schedule and under budget.

What Contractor designed and

installed the “First ever 15,000 psi

Pipeline in the World?”

Scope: Design, procure, fabricate and install four

subsea pipeline end manifolds Install two 8” rigid flowlines (5 miles ea.)

utilizing S-Lay method Install one - 6” pipeline (1 mile) Pigging and Hydrotesting of installed system First 15K subsea pipeline in the world

Description: DB16 installed two 8” dia. Flowlines

from J-tubes at the “Salsa” platform to subsea pipeline end manifolds using deepwater S-lay method

6” flowline was laid from a wellhead to the pipeline end manifold

Manifold and pipeline end sleds were also installed

Conger Subsea DevelopmentConger Subsea DevelopmentClient: Shell

Location: Garden Banks 172 - 215Gulf of Mexico

Water Depth: 700 to 1,450 Feet


installed the “Deepest and Largest

Diameter PIP project to date (also the

deepest JRM J-Lay to date)?”

Crosby

Client: Shell International Exploration and Production Inc. (SIEP)

Location: Mississippi Canyon 809 to 899Gulf of Mexico

Water Depth: 3,800 - 4,400 Feet

Scope:

Installed dual 8”x12” steel pipe-in-pipe flowlines and Steel Catenary Risers (SCR’s) Approximately 10 miles each from subsea well cluster to Ursa TLP

Installed subsea manifold (200 short tons) in 4,400’ water depth

Installed topside package at Ursa TLP Hand-off SCR’s to Ursa TLP

World’s Deepest Steel Pipe-in-Pipe Flowlines

Technology & Innovation: World’s deepest steel pipe-in-pipe to

date JRM’s deepest pipeline to date JRM’s deepest subsea manifold

installation to date

Description: Dynamic positioned DB-50 and J-lay

system used for installation Flowlines were initiated at subsea well

cluster while drill rig was on station

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What Contractor installed the First

“Man-Made Reef” in Mobil Bay?

J. Ray McDermott

Utilizing Surplus Army Tanks

What Contractor fabricated and installed a platform that received the Award for “Outstanding Civil Engineering Achievement” and was the “World’s Tallest Man-Made Structure?”



Gulf of Mexico


Scope:




Innovation:


Technology:



Largest single piece deck fabricated by J. Ray McDermott

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What Contractor designed, fabricated, installed and commissioned the “Deepest SPAR?”

Location Mississippi Canyon 773, Gulf of Mexico

Water depth 5,610 feetGas rate 110 MMscfd of feed gasOil rate 60 MbpdWater rate 40 MbpdFabricated weight ~6,400 tonsProject drivers Total McDermott supply of

EPCI contract servicesFast-track project schedule & delivery

Engineering Scope: Engineering & procurement management Topsides & mooring system FEED design & detailed

engineering design & hull detailed engineering design Procurement of all topsides & hull marine systems

equipment & mooring system equipment & components

Hull & topsides fabrication support engineering & installation engineering

Dominion Devils Tower Spar

What Contractor designed, fabricated, and installed the “Largest Sulfur Mining Facility Platforms and Bridges in the GOM?”

Freeport McMoRan

Client: Freeport-McMoRan ResourceLocation: Main Pass 299, Gulf of MexicoWater Depth: 212 Feet

Sulphur Mine Project

Description:

Fifteen platforms make up the Freeport-McMoRan Resource Partner’s Main Pass Mine, the largest offshore complex in the Gulf of Mexico. Five of the 6 major platforms are connected via 13 bridges (which span is approximately 1 mile) supported by 9 bridge support platforms.

Six (6) Major Platforms: - 2 Production and Drilling - Pressure Control - Power Plant - Sulphur Storage - Living Quarters/Warehouse

Innovations:

Longest and heaviest offshore bridge: 600 ft. and 2000 s.t.

Thickest and highest strength pile: 60” dia. X 5.0” thick, 100 ksi yield steel

Platforms designed for maximum of 60 ft. vertical subsidence and 30 ft. lateral movement

What Contractor installed the “First Drilling and Production SPAR?”

Genesis Spar

Client: Chevron U.S.A. Inc.

Location: Green Canyon 205A, Gulf of Mexico


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Scope / Description:

Cost reimbursable contract for topsides design, fabrication, topsides equipment, procurement, conceptual riser design services and detailed review, and installation of the spar mooring system, hull, topsides facility and hookup & commissioning services. Production is through buoyancy tensioned risers connected to subsea wellheads with surface intervention and control.

JRM Engineering provided topsides design and equipment procurement.

Mentor provided conceptual riser design services and detailed riser review.

JRM Fabrication provided topsides fabrication. JRM Marine provided installation of the spar mooring

system, hull, topsides facility and hookup & commissioning services

Innovation:


First Drilling and Production Spar in the Gulf of Mexico

What Contractor installed the “First Mid-Line Electrical Connector” for Electric Heated PIP Project?

Habanero

Client: Shell Exploration & Production Company

Location: Garden Banks Blocks 341, 384, 427 & 426 - Gulf of Mexico

Water Depth: 2,000 to 2,860 Feet

Flowline & Steel Catenary Riser Installation

Scope:

Installation contract for the construction of two (2) electrically-heated pipe-in-pipe (PIP) flowlines comprised of 6.625” x 0.719” API 5L X70 SMLS carrier pipe and 10.750” x 0.438” API 5L X70 ERW casing pipe. The 6.625” carrier pipe was insulated with 1.3-inch thick jacketed polyurethane foam.

Flowline construction activities included the installation of two (2) PIP flowline initiation sleds located in 2,000 feet of water using pre-installed suction piles located adjacent to the two (2) subsea wells, and the installation of two (2) 6.625” x 0.844” API 5L X70 SMLS steel catenary risers (SCR’s) located in 2,860 feet of water and insulated with 3.0” of multi-layered Thermotite insulation.

Installation engineering work was performed by JRM Engineering in Houston, TX. All flowline installation activities were performed by the Derrick Barge No. 50 (DB50) utilizing J-Lay installation methods. All welding work was performed by the JRM Vermatt Bug-N-Band Automatic Welding System (JBBS).

Innovation:

Subsea Mid-Line Electrical Connector Assembly For Hydrate Mitigation

Purpose-Built SCR Installation Mast Eliminating Need For Drill Rig Assistance During SCR Pull-In Operations

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What Contractor designed,

fabricated, and installed the “First

Offshore Platform in the GOM?”

Kerr-McGee

Client: Kerr-McGee

Location: Gulf of Mexico

Water Depth: 20 Feet

First Installed Steel Structure in the GOM

Innovations:

In 1947 – our first – McDermott installed in the Gulf of Mexico the first steel structure employing the jacket concept for drilling over water.

What Contractor fabricated the

largest “Single-Piece TLP

Deck” in the GOM History?



Gulf of Mexico


Scope:




Innovation:


Technology:



Largest single piece deck fabricated by J. Ray McDermott of 26,000 Short Tons in 1994

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What Contractor designed the

First Buoyed “Lazy-Wave” SCR?

King Kong / Yosemite Field DevelopmentClient: Mariner Energy, Inc.Host Facility: AGIP Petroleum, Inc.

Location: Green Canyon Blocks 254, 472, 473 & 572Water Depth: 3,400 feet

Scope:

Engineering & PMT: Performed the detailed design of 2 x 5” flowlines 2-miles each, 2 x 7” flowlines 15-miles each and 2 x 6” buoyed steel catenary risers. Prepared all specifications and request for proposal documents for procurement and installation of the flowline & riser system.

Technology:

API RP 1111 Limit State Design of flowlines and pipelines First Buoyed Steel Catenary Risers First use of CRP, Inc. Uraduct® on an Umbilical Crossing in the

Gulf of Mexico Insulated VIV Strakes on SCRs Titanium Stress Joints on the SCRs Titanium SCR Stress Joints

Mariner KKY SCR (with 900' Buoyancy modules 1500' from Strakes) Total Static Stress Distribution (with 7500 psi Internal Pressure)

0.00

5000.00

10000.00

15000.00

20000.00

25000.00

30000.00

35000.00

40000.00

0 500 1000 1500 2000 2500 3000 3500 4000

Arc Distance From The Top of The SCR (ft)

Stat

ic S

tres

s (p

si)

Stress Joint Strake Bare pipe Buoyant Sagbend

Buoyed Region

Straked Region


installed the First “Pipe-in-Pipe

Pipeline Utilizing the J-Lay Method?”

Macaroni Flowlines/Steel Catenary Risers

Client: Shell Deepwater DevelopmentLocation: Garden Banks 602 to 426

Gulf of MexicoWater Depth: 2,970 to 3,670 Feet

Scope:

Installation of two pipe-in-pipe (PIP) flowlines (6 x .719” X-65 Carrier pipe w/10 x .469” X-52 Jacket pipe) from GB602 (subsea Sled) to GB426 (SCR).

Description:

Each line (approx. 11.8 miles ea.) was initiated with a Sled pull-in assisted by a drill rig mounted winch. Both lines terminated at Shell’s Auger TLP with a SCR. The SCRs were pulled into their final position utilizing the TLP’s Drill Derrick.

Technology:

JRM’s DB50 and (enhanced) J-Lay was utilized. The JRM J-Lay system and pipeline abandonment and recovery (A&R) system were upgraded to perform the work.

Innovations:

JRM developed an internal weld cooling device, which significantly reduced the weld cycle times (~20%) - (JRM applied Floatec between the Carrier and Jacket.) The application worked very well and there was controllable shrinkage.

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What Contractor installed the “First

Water Injection Riser” in the GOM?

Client: AGIP Petroleum

Host: Morpeth TLP

Location: Ewing Banks 921, 964, 965


Scope:

To manage project on behalf of AGIP, carrying out detail design and overseeing equipment refurbishment.

To provide offshore installation support

Innovation:

Fast track well conversion from water injector (WI) to producer

Reuse of original WI, stab and hinge over (SHO) connector

Reuse of modified existing pigging loop Reuse of WI tree, modified for production

Morpeth Producing WellConversion of Water Injection Well to a Producing Well

What Contractor installed the “Dual

Infield Flowlines in a Single Lay

Pass?”

Tahoe

Client: Shell Oil CompanyLocation: Viosca Knoll 783, Main Pass 252

Gulf of MexicoWater Depth: 275 feet to 1500 feet

Scope/Description:

Pipe Length was 12 miles each Project consisted of dual 4” flowlines from

an existing well to an existing platform Recover previously laid flexible pipe tails Rigid pipe welded to the two flexible pipe

sections Two lines laid from separate reels

simultaneously

Innovations:

Use of project stinger designed and built by JRM

What Contractor installed the First

“Atlantia SeaStar® Mini-TLP?”






Innovation:






What Contractor installed the “First

Truss - SPAR?”

Client: Kerr-McGee (op.), Ocean Energy &Enterprise Oil

Location: Nansen - E. Breaks 602 Boomvang - E. Breaks 643

Gulf of MexicoWater Depth: Nansen - 3,678 feet

Boomvang - 3,453 feet

Scope/Description: Contract type: Lump sum Mentor is providing engineering, procurement and

project management Each facility utilizes production from wells completed

beneath the spar and tied back through Top Tensioned Risers (TTR) and “dry” wellheads and trees. Additionally, tie-ins will be incorporated from subsea satellite wells

Mentor’s scope includes nine (9) top tensioned production risers and associated equipment for Nansen and five (5) top tensioned production risers and associated equipment for Boomvang.

Design work for SCR’s was performed to assess the impact on hull/truss design with regard to loads.

Innovation/Technology: 9 5/8” single casing riser design Single pieces, multi-chamber buoyancy cans Space saving surface wellhead Ten (10) foot space-out adjustment in addition to

riser pups Internal tieback adapter to subsea wellhead & stress

joint designed for 350 ft. nominal drilling offset Tensioning monitoring for each top tensioned riser Provision for “through the keel” tie-in of future

import or export flowlines or pipelines up to 12”

Nansen and BoomvangDouble Spar Development


installed the First “HIPPS (High

Integrity Pipeline Protection System?”

Shell Expro - Kingfisher Field Development

Clients: Shell Expro formerly Enterprise OilLocation: Central North Sea, Blocks 16/8a &

16/8cWater Depth: 360 feet

Description:

The Kingfisher prospect, located to the east of the Miller and Brae fields, comprises two reservoirs, Heather and Brae. The host platform for the tie-back is Marathon’s Brae “B”, approximately 5 miles away. Well fluids co-mingle in a subsea manifold before entering two ten inch pipelines which operate in multi-phase flow back to the platform.

Scope:

J. Ray McDermott’s success in Shell’s design competition led to the award of this EPCI contract to develop the Kingfisher prospect as a subsea tie-back. JRM was responsible for design through to commissioning of all components, from the downstream flange of the subsea well guide bases to the top of the test and production risers on the host platform.

The project was managed by an integrated Project Management Team composed of Shell and JRM personnel. It was executed under an alliance agreement with risk and performance targets for schedule, capital and operating costs and system availability.

What Contractor designed the first

“Insulated Flexible Catenary Riser” in

the GOM?






Innovation:






What Contractor Designed, Built, and Patented the First “Laser Tracking System” for Pulse Gas Metal Arc Welding (GMAW-P) Process?

AWS Welding System (JAWS)

Pulsed Arc (PGMAW) process offers improved penetration and reduces the potential for incomplete sidewall fusion

Less weld spatter reduces porosity and increases deposition efficiency

Six welding torches at each station provide exceptional production

Programmed welding parameters eliminate operator adjustments

Easily maintained, reliable, with very little equipment downtime

For use with 20” - 48” pipe in S-Lay mode

Track record in excess of 2.500 KM Lay rates 30” up to 4.0 KM/day (329

joints) Lay rates 24” up to 5.2 KM/day (424

joints)

What Contractor developed the

“First Commercial Subsea

Development West of Shetland?”

BP – Foinaven Development

Client: BP

Location: 190km West of ShetlandUK Sector

Water Depth: 400 to 600m

Scope / Description: Alliance contract, with McDermott responsible for

project management, design, engineering, procurement and installation of total subsea system (trees, flowlines, risers, etc.) as well as design, procurement and supervision of hook-up & commissioning of the 95,000 bopd topsides and turret.

Innovation: 1st Commercial Development in the

hostile Atlantic Frontier Open management and mutual

business goals, e.g. subsea alliance involving all major suppliers, shared risks and rewards

Fast track schedule, 3.5 years from discovery to first oil

Parallel engineering, field appraisal and design work carried out simultaneously

Petrojarl IV FPSO & Subsea System

What Contractor has “Worldwide In-House Capabilities for the Design, Fabrication, Installation, and Commissioning of Platforms, Topsides, SPARS, and Subsea Field Developments going back over 58 years?”

J. Ray McDermott

1946 - 2004

J Ray Firsts

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