Maderra produced over 200 Electrical design deliverables in support of the Hebron Living Quarters Module permanent electrical systems.  This included system Block Diagrams, Small Power Distribution Drawings, and 600V Circuit Diagrams.

Maderra provided Engineering services and Fabrication support for the construction of the Hebron Flare boom, including:

• Design of steel fabrication jig and concrete support stools to ensure fabrication of the flare boom was accurate and met precision requirements.
• Design of padeyes required for lifting various flare boom components for fabrication purposes.
• Preparation of shop drawings for Fabrication Jig, Loadout and Storage saddles for flare boom, flare boom piping supports, and various supports for electrical equipment.
• Review and approval of Shop drawings for all tubular components of the flare boom structure as well as access platforms.
• Preparation of drawings to aid in placing appropriate coatings on flare boom structure.
• Engineered lift plans for lifting two large segments of flare boom into place for fabrication.
• Preparation of drawings outlining optimum travel path for moving flare boom from fabrication shop to pier for shipment to bull arm site.
• Provided assistance to fabricator in nesting of steel plates, as well as helping with tracking  steel inventories.
• Design of Electrical cable tray, lighting, junction boxes, cable routing and terminations, and ignition system installation details.

Maderra provided technical support to assist with the Electrical Certification process of the COILMS (Crude Oil Level Measurement System) package for the Hebron GBS Project.

Phase I – Structural and Piping Engineering support for the design of the Hibernia Southern Extension (HSE) water injection/stimulation manifold. The manifold is located at a project water depth of 90m in an excavated drill center (EDC). Work was completed to ensure both the pressure containing piping kit, the structural steel frame, and foundation were designed to withstand in-place/operation loads, wave induced current loads, iceberg snag load, and seismic loads. Ceasar piping analysis software and STAAD PRO/STAAD Offshore software were used for the analysis and design.

Phase II – Structural Engineering support for the design of Temporary Guide base (TGB), Permanent Guide base (PGB), and Lower Tree Frame (LTF). These structures function as a part of the subsea tree system for the Hibernia Southern Extension (HSE) project located at a project water depth of 90m. The equipment was placed directly on the excavated drill center (EDC) base and were designed to withstand in-place/operation loads, wave induced current loads, and seismic loads. STAAD PRO and STAAD Offshore software were used for the analysis and design.

This work was completed over several projects and included the definition of System Limits, development of System Boundary drawings, and preparation of Commissioning procedures for turret and mooring systems for the following offshore facilities:  OSX-3 FPSO (Brazil); FSO UOTE (Brazil); HLJOC FPSO (Vietnam); BP Angola FPSO (Angola); Jubilee FPSO (Ghana); and the Pyrenees FPSO (Western Australia).

Maderra provided Structural Engineering support and procedure development for the fabrication and testing of six sub-sea manifolds for Husky Energy’s South White Rose extension.  This support covered shop drawing review, RFI responses to fabrication team, Engineered lifting plans, and modelling of concrete support stools for Factory Acceptance and Site Integration tests.

Fagioli Group had the contract to carry out all the heavy lifts associated with the Hebron Development Project.  Maderra was contracted by Fagioli to provide assistance, peer review, preparation and stamping of Lift Plans, as well as on-site support and partial supervision for approximately 75 heavy lifts for the Bull Arm Site.

These lift plans covered all components for the assembly of the lift elevator (which was used to load the DSM and DES modules onto the finger pier). Also included in the scope were lift plans for upending the flare boom, installing the helideck module, installing the living quarters module, and lifting of various components required to accommodate the arrival of the heavy lift vessels.

The Coral South Project consists of one Floating Liquified Natural Gas (FLNG) vessel and relevant subsea development, to be installed in the Area 4 Offshore Rovuma Basin block on northern Mozambique.  The FLNG incorporates an internal Turret Mooring System (TMS) to allow the vessel to weathervane about the stationary mooring lines, process piping and umbilical connections to the seabed.

Maderra was awarded a contract to develop the Operations and Maintenance Engineering scope for the TMS, which includes:

• Development and ongoing management of critical data sets, including:
  • Master Equipment List (MEL) data.
  • Bill of Materials (BOM).
  • Spare parts interchangeability record (SPIR).
  • Safety Critical Equipment List.
  • Asset Register for Lifting Equipment.
  • Change management and ongoing updates of critical data sets throughout the duration of the contract.
• Reliability and Maintainability:
  • Establish the TMS physical assets for inclusion in RAM Studies.
  • Manage the development of initial RAM analysis and model.
  • Conduct criticality assessment in accordance with Client specifications.
  • Manage the lean and/or full RCM studies, including update of RAM model based on RCM output.
• Maintenance, Inspection and Operations:
  • Develop maintenance plans.
  • Create lubrication schedules.
  • Develop condition monitoring plans.
  • Review regulatory requirements for the operating region, and ensure required inspection activities and frequencies are reflected in all applicable Operations and Maintenance produced documents.
  • conduct a spares analysis and develop all required spares lists including commissioning spares, 2-year operating spares and critical/insurance spares.  Economic evaluation in accordance with Client specifications to be completed for critical/insurance spares.
  • Conduct RBI assessments for all pressure envelopes or provide input to Client for RBI assessments by other system providers.  Corrosion loops as per client specifications to be developed.
  • Conduct a complete review of shutdown/turnaround required maintenance for TMS equipment and identify opportunities to minimize shutdown required activities.  Develop a base scope/duration for the maintenance to be performed.
  • Develop the Asset Register for Lifting Equipment and provide lift plans for critical lifts in accordance with Client specifications.  Maintenance and inspection plans to be developed for all TMS installed lifting equipment.
  • Develop preservation routines for construction/commissioning activities, operational preservation routines as well as longer term/shutdown preservation based upon equipment/fluid degradation modes.
  • Develop Operating Manuals for all TMS equipment and prepare training modules for client.

The MPG Inergen system on the FPSO employed Ansul CV-98 Actuators with Metron Protractors to release the Inergen bottles.  This project included Engineering and design services, materials procurement, and workpack preparation to replace the CV-98 Actuators and Metron Protractors with Ansul HF Actuators.  The work included evaluation of the HF Actuators to ensure compatibility, preparation of Interconnection and Hook-Up Sketches, identification of isolation and/or shutdown requirements; identification of any HSEQ or Certification issues related to the works; and identification of changes to existing Maintenance or Testing procedures.

As a result of cracks observed in the HP Flare piping at two locations in the Flare Tower, Maderra was engaged to determine the stress condition at those two locations to determine if the stress exceeded the requirements of ASME B31.3.  The stress analysis was completed using Caesar II Pipe Stress software.

This project included the Engineering, design, procurement, fabrication services, and preparation of an implementation work package for the Cargo Eductor By-pass modification on the SeaRose FPSO.

Maderra and its partner, Stress Engineering Services Inc., provided engineering support services for the Turret Spring Replacement program for the Terra Nova FPSO. The elastomer springs were used to isolate the main bearing and support ring from the vessel’s deflections and provide an even load distribution on the main bearing.

Maderra was contracted to perform an Arc Flash Study of the electrical systems on the Transocean GFS Grand Banks drilling rig. The scope included an offshore field survey, completion of the arc flash study using ETAP Version 11.1.1, and preparation of a final report to include arc flash results and recommendations to address the identified hazards.

Maderra completed a study on the Flash Gas compressors, and develop FG1 and FG2 bundle specifications to be provided to the compressor OEM for a Flash Gas compressor bundle re-design. The scope of work included modifying the existing Husky HYSYS Plant model and benchmarking against plant data. Feed streams in the model were modified to determine operating conditions for three forecasted production cases which were used to revise the existing process datasheets and to develop Heat and Material Balances.

Maderra was contracted to review all documentation and maintenance history of all batteries and chargers for the SeaRose FPSO. The scope of work included: a comparison of the in-service condition of all batteries and their associated chargers (18 different Manufacturers/Ratings) to ensure that they are configured as per Manufacturer’s recommendations, and suitable for duty; an investigation of battery room environmental conditions (14 spaces), and its effects on battery charger capabilities and battery life; a determination of available upgrades to existing charger systems that could extend battery life; and a review of maintenance records to ensure battery chargers are adequately maintained and where necessary provided updates to existing preventative maintenance routines.

One of the nine mooring legs on the FPSO had incurred separation of the mooring chain from the spider buoy.  Maderra and Stress Engineering Services completed an examination of the failed chain components, carried out failure analysis testing, and root cause analysis.

Maderra and its partner, Stress Engineering Services Inc., provided engineering support services to confirm the root cause of turret spring failure prior to the redesign of replacement springs in order to ensure that the failure mode deficiencies were designed out of the new components.

As part of this analysis, Maderra and Stress designed, procured and fabricated a Turret Spring Instrument Measurement System which included a series of instruments and data acquisition system to measure the movement and loading of the module elastomeric support foundation. The workscope included preparation of installation workpacks, supervision of the offshore installation and system commissioning and start-up, and compilation and reporting of the measurement data at the end of the measurement period.

Maderra and Stress Engineering Services carried out a leak-before-break analysis of the 16-inch super duplex HP1 gas discharge pipe on the Terra Nova FPSO. An inspection of the pipeline near a welded-on trunnion support revealed cracking and leaking. The pipe and support were subsequently removed and sent to SES in Houston for the failure investigation. The objective of the analysis was to determine critical crack sizes and evaluate the likelihood of leak-before-break.

The Cargo Offloading System on the FPSO was equipped with actuated valves which if closed quickly could create a high-pressure surge. A surge analysis was completed by a third party which recommended closing times for the valves.  The Client estimated that emergency shutdown valve 14-ESV-7011 had a closing time of between 30-35 seconds.

Maderra and Stress Engineering Services were contracted to review the third-party study and the piping configuration of the Cargo Offloading system to analyze the transient effects of the shutdown valve closing times to determine if a closing time of 25 seconds was possible for valve 14-ESV-7011 without exceeding the design pressure of the system/piping.

Phase 1:  In partnership with Stress Engineering Services, analyzed studs and shim plates that were recovered from the ocean floor after a failure of the Turret Weathering Lower Bearing Elastomeric Pad on the SeaRose FPSO.

Phase 2:  In partnership with Stress Engineering Services, conducted a follow up analysis on the design of the Turret Lower Bearing Elastomeric Pad on the SeaRose FPSO.

As part of the Regulatory compliance plan to demonstrate the integrity of the SeaRose turret disconnect system, the structural connector has to be opened every 5 years to demonstrate the functionality of the equipment and physical condition of the loaded components.   

During simulated disconnect testing it became obvious that the only means of securing the buoy to the turret was via the chain jacking system.  The chain jack system was incapable of holding the buoy in place for even a short period of time without pressure bleed off. Considering the duration required to complete necessary inspections to the structural connector, the buoy would most likely drop down slightly from its connected position and cause flooding.

Maderra assembled a group of senior engineers to investigate options for holding the buoy in position during testing of the structural connector to ensure safely of personnel, equipment and environment.  This included: a high level strategy session with input from the chain jack OEM; design of a new locking plate mechanism; and preparation of implementation details describing the method, tools, resources and time requirement to receive and install the chain jack lock modification aboard the FPSO; preparation of a dedicated offshore analysis and mechanical handling method statement to ensure activities could be performed safely and efficiently without damage to the modification or existing facilities; and preparation of a step-wise mechanical handling procedure describing the method, equipment, tools and skills needed to complete all mechanical handling aspects of the modification.

Maderra, in partnership with Stress Engineering Services, was contracted to investigate a failure of a breakaway coupling on the FPSO Offloading System.  The investigation included a preliminary review of vendor and design documentation; a detailed visual inspection of the coupling at the Client’s warehouse facility in St. John’s; followed by shipping both sides of the coupling to Stress Engineering’s test facility in Houston, where a metallurgical analysis of the coupling breakaway studs was conducted including a chemical analysis, hardness, and microstructural analysis of the studs.