We are currently customizing our innovative Chain type Stinger Handling system concept for three different companies on three different continents. The compact system improves both the vessel design and pipe-lay operations, and as acknowledgment on April 16^th 2013, the equipment has won the bi-annual IRO Innovation Prize. At award acceptance Arjan Boezeman said: “We are delighted to receive the industry’s recognition for one of our innovative equipment packages.”

IRO stands for the Association of Dutch Suppliers in the Oil and Gas Industry. On their IRO Oil & Gas Innovation Event in April, four pre-selected companies presented their innovations and competed for the IRO Innovation Prize.

Two distinct developments can be observed in today’s offshore construction market: Firstly, exploration and production in deeper waters will continue to push boundaries of existing technologies, and innovative solutions will be required to enable construction at increased water depths. Secondly, the operators are increasingly striving to optimize of D the utilisation of existing or smaller assets with smart equipment to perform at better cost.

Deepwater infield pipelines are forecast to grow at a yearly pace more than 15% between 2012 and 2017. Pipelines are typically installed by using techniques called J-Lay or S-lay. Traditionally S-lay was used in shallower waters and J-lay for deeper waters. However, since S-lay provides some distinct advantage over J-lay in relation to the optimisation of the pipe-joining process, the market demanded to further develop S-lay equipment to install pipelines at deeper waters.

The deeper waters require the stinger and its handling system to be capable to operate at higher loads. Most offshore construction vessels, so called derrick lay vessels, used for the installation of sub-sea pipelines have both pipe-lay and heavy-lift functionalities.

Traditionally the stinger handling system comprises winches with wires and sheaves, which, by the increasing load is reaching its practical limits in relation to the available deck space with the presence of the offshore crane. Another disadvantage and operational cost often forgotten is that wires need to be frequently exchanged, imposing both cost and downtime for (de-)reeving. For most heavy lift operations, the stinger will be removed and to avoid time demanding (de-)reeving of the cables typically an A-frame is added to the Stinger Handling configuration. Aside from the investment for such frame, an A-frame imposes an obstruction to the so called firing line for objects that may need to be supported from the vessel into the water.

The market demand and operational disadvantages of the existing solutions has led to the development of the Chain type Stinger Handling System by Ulstein Idea Equipment Solutions. The system is very compact and characterized further by its small footprint, leaving space for most lifting operations. The system comprises hydraulic driven chain pull units, using only proven technologies and components. For large heavy lift operations the units, including the chain, can be quickly removed by simply removing some pin connections and some connections at the manifold. By its nature this system does not contain costly consumables nor does it require a heavy and costly A-frame, optimising the investment of the equipment. As the main pulling system comprises large capacity cylinders, the system can be easily upgraded with a functionality to avoid slack chain due to stinger uplift, using components already present.

The customized Pile Gripper Frames from Ulstein Idea Equipment Solutions is soon to be installed on board two jack-up platforms for use in wind farm installations.

We get a great deal of satisfaction when developing unique concepts and convincing our client to select this as their preferred solution, but it doesn’t come for free: always think one step ahead and each report or drawing has to spark their interest.

A seed was planted 8 months ago, when the Pile Gripper Frame (PGF) existed only on paper; developing into more and more optimized equipment with every brainstorm session; becoming a more and more customized design with every meeting with the customer.
Incremental innovations
The PGF’s will be used for the installation of mono-pile foundations at the West of Duddon Sands Wind farm project, offshore UK. In this project our client is using a new generation jack-up platform with increased cargo, crane and deck space capacity, which allows them to take both foundations and transition pieces on board in each logistical cycle. In order to match the installation sequence the PGF’s are foldable, which enables our client to install and grout the transition piece on top of the foundation after it is installed, optimizing the utilization of the ships’ capacity. Although we have used some similar principles in other designs, the unique combination of functionalities that are combined in this design make these PGF’s quite innovative.

Last year, late summer major engineering efforts were made to meet the deadline for the production start date of the PGF’s. Under the leadership of Gilbert Rezette, Director of Engineering and Operations, who acted as project manager himself during this phase, our engineers have worked at a fast pace under demanding time tables to the requirements and expectations of the customer with regards to safety and operability.

These days the project manager Ton Klitsie and one of our construction supervisors, Erik van de Braak, are spending their light hours, with the continued active involvement of Gilbert, on the assembly quay to monitor the construction and final assembly works of the PGF’s.

Ton says ” This project has proven to be a challenge to keep the focus of the client, UIES project management and major subcontractors aligned on quality, delivery time, budget and safety during construction.”

The Pacific Orca and the Sea Installer – state of the art jack-up platforms, pregnant with potential – will be expecting the (twin) Pile Gripper Frames 9 months after we signed this EPC contract, at the end of March.

By using basic laws of mechanical equilibrium, Ulstein Idea Equipment Solutions’ proprietary design ‘Simplicity Improves Safety’ (SIS) upend frame provides increased safety during pile upending operations by ensuring a balanced support and full control of the pile throughout the entire upending cycle, eliminating the risk of uncontrolled lateral forces (side lead) on the crane. Its improved geometric design, which is based on the proven “Saddle and Hook” upending technology, will also avoid the support cables to become slack and therefore prevent resulting shock loads.

“Ulstein Idea is proud to have been awarded the contract to supply this innovative equipment, as it is our passion and ambition to develop and supply equipment that enhances the operation and safety of work performed offshore.” says Arjan Boezeman, Director of Concepts and Sales. “This design eliminates the risks introduced in particular when upending large diameter piles using traditional slender pile upending methods. We are convinced that this design will set a new standard for safe upending of large diameter piles.”

The products will be delivered in Rostock in the summer of 2013 for final installation and commissioning on3to the ‘Goliath’ Jack-up Platform that will be used for the installation of the foundations for the Baltic 2 Offshore Wind farm in the Baltic Sea, offshore Germany.