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Paolo Daleffe – Armando Favi
il Castorone – la più avanzata nave posatubi al mondo: acquisti e logistica
Titolo presentazione luogo presentazione 2
Castorone
concentration of technologies and
efficiency, Castorone is designed for
high productivity pipe laying of large
diameter trunklines in shallow to
ultra-deep water beyond 3,000m
also in extreme environments
Titolo presentazione luogo presentazione 3
Castorone – comparison of two generations
how the new flagship
Castorone compares in size
with predecessor Castoro Sei
Titolo presentazione luogo presentazione 5
Castorone – market drivers
the market of flowlines and large trunklines is in espansion especially in deep water: 25% of 21.000 km planned in
the next 4 years will be in more than 500m wd
in the next years many projects will challenge the
industry with large dimensions and harsh environment, including
arctic conditions
Saipem’s target projects: crossings of Black Sea and Mediterranean, trunklines and deep water field
developments in Gulf of Mexico, South Atlantic, Asia Pacific and Russia
Castorone with his outstanding productivity meets the future market requirements in a vaste range of scenarios, reducing project schedule and risks and improving the client’s
economics
Titolo presentazione luogo presentazione 6
Castorone – unique technical features
Much higher productivities in S-lay and J-lay modes (36m pipe strings, 20,000t pipe storage capacity) 25% productivity increase in Nord Stream-type situation
better use of seasonal windows
limited weather standby
lower overall project cost
Much broader application range with significantly improved flexibility From ultra-deep to shallow waters, also in S-lay, by simply adapting
stinger configuration (advanced control system)
Advanced weather capabilities
Fast moving dynamic positioning capability
On-board switch from S- to J-lay to suit route and depth - one vessel only for the entire project
In line installation of large/heavy structures
Titolo presentazione luogo presentazione 7
Castorone – portfolio of orders
Castoro lay barge,
Saipem’s first offshore construction vessel,
a converted oil tanker (1966) ● Walker Ridge Export Pipeline, GoM
(Chevron)
Max 2,140 m wd
● Big Foot Oil Export Lateral Pipeline,
GoM (Enbridge)
Max 2,200 m wd
● Keathley Canyon Export Pipeline,
GoM (Williams)
Max 2,100 m wd
● Tupi NE - Cabiunas Trunkline,
Brazil (Petrobras)
Max 2,230 m wd
● Gas Export Pipeline for Ichthys
LNG Project, Australia (Inpex) 550
miles, 42”, max 275 m wd
First Projects with Castorone, all in high productivity S-lay mode
Committed until early 2015
Titolo presentazione luogo presentazione 8
Castorone – Walker Ridge
the debut: Walker Ridge project for Chevron -
219 km, 24in, in 2.140 m water depth
3000 feet w
ate
r depth
high versatility: from
ultra deep waters…
Titolo presentazione luogo presentazione 9
Castorone - Ichthys
in Australia the EPCI contract with Impex for the 889 km, 42in trunkline in max 275 m
wd from the Ichthys production platform to the onshore LNG
plant in Darwin
…to shallow water,
long distance and
large diameter
Titolo presentazione luogo presentazione 10
Castorone – the Italian content
main innovative systems conceived by Saipem and built in Italy
Navalimpianti Genoa: pipe handling and storage systems
Righini Ravenna: triple joint prefabrication plant
Goriziane Villesse (GO): firing line machines – telescopic linkage ramp
Remacut Rivoli (TO): tensioners (3 x 250 t) – jacking system
Remazel Bergamo: A/R and DMA winches
Redaelli Milan: A/R cable
Titolo presentazione luogo presentazione 13
Castorone
Share of value Share of orders
Italy 69% 47%
Netherlands 16% 5%
Finland 7% 2%
South Korea 2% 1%
China 2% 2%
Germany 2% 2%
Others 2% 41%
Purchasing for Materials and Vessel Equipment
In excess of 600 purchase orders in 16 countries
The core equipment has been purchased in Italy, involving a
significant effort in research and technology development, by co-
engineering with key suppliers.
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CASTORONE – Transports management
1. First phase strategy: shipyard YANTAI RAFFLES, China
First phase has been focused on main structural works from keel laying to hull and main structures fabrication. During this phase transportation has been managed as per standard Onshore Project freight forwarding philosophy: one Frame Agreement awarded to one single subcontractor on a competitive basis to cover the whole range of shipments.
2. Second phase strategy: shipyard KEPPEL, Singapore
The Vessel has been towed to Singapore, where the completion of naval shipbuilding works and equipment outfitting has been carried out.
In order to minimize time & costs, reduce interfaces and mainly improve risk management, it has been decided to issue a dedicated tender for the transport of main bulky Items liaising directly with Owners. Notwithstanding this medium and smaller size equipment have been anyway managed through existing frame agreements:
shipments by sea of normal cargo and by air have been arranged through general frame agreements.
shipments by sea of OS/OW have been arranged through specific Transport Contracts (BIMCO Gencon 94, Heavycon 2007 and Heavyliftoy 2009) awarded straight to Ship Owners.
14
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CASTORONE – OS/OW transport management
Main transports managed through Transport Contract awarded to Owners
1. Redaelli Steel Wire Ropes
from Trieste port to Singapore
World’s heaviest rope
2. Remacut Stinger Jacking System
from Marghera port to Singapore
dim of pieces up to m 53,35x 4x5,2
3. Remazel DMA Winch
from Trieste port to Singapore
transhipment from barge to Ocean Vessel
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CASTORONE – OS/OW transport management
Main transports managed through Transport Contract awarded to Owners
1. STINGER RAMPS shipment from Rotterdam to Singapore
about 22.630,00 freight units
Direct urgent delivery to Singapore
high level of criticality due to all the issues mainly related to (a) loading
activities at manufacturer premises (b) direct unloading of the ramps from
ocean going vessel to Castorone during her dry dock in Singapore
16
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CASTORONE – OS/OW transport management
Main transports managed throught closed Transport Contract to Shiponwners
STINGER RAMPS shipment from Rotterdam to Singapore
Loading from manufacturer quay onto barges with floating crane Matador 3
17
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CASTORONE – OS/OW transport management
Main transports managed throught closed Transport Contract to Shiponwners
STINGER RAMPS shipment from Rotterdam to Singapore
Transhipment to Rotterdam port by barge
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Titolo presentazione luogo presentazione
CASTORONE – OS/OW transport management
Main transports managed throught closed Transport Contract to Shiponwners
STINGER RAMPS shipment from Rotterdam to Singapore
Loading from barges onto ocean vessel with floating crane Matador 3
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CASTORONE – OS/OW transport management
Main transports managed throught closed Transport Contract to Shiponwners
STINGER RAMPS shipment from Rotterdam to Singapore
Ready for sailing to Singapore
20
Titolo presentazione luogo presentazione 26
Castorone
inaugurated in Singapore on september 9, 2012,
will start operations in the GoM in March 2013