CastorOne and FDS 2: Getting Stronger for Laying Deeper

Abstract Reaching the ultra-deep installation scenarios beyond 2,000m WD means that the new generation of S/J-laying vessels will be capable of applying pipe holding tensions well beyond 500te, which may become twice or three times that value if an unexpected flooding of the pipeline or a wet buckle occurs. To meet the increasing holding tension demand, Saipem adopted two innovative solutions on its new deep-water laying vessels CastorOne and FDS2. The FDS2 J-Lay system has been equipped with new compliant pads. This innovative pad design allows the application of up to 2,000te of holding tension in both normal laying and contingency situations, employing standard friction clamps of relatively small dimensions. In case of a wet buckle or in a contingency flooded pipe scenario, the CastorOne S-Lay vessel has the capability of holding and then abandoning the pipeline in a controlled and safe way by applying a tension of 1,500te through the simultaneous use of the A&R winch, of the three tensioners and of the pipe holding indentation clamp, all rated 750te. Moreover, the CastorOne has been equipped with a next generation articulated stinger capable of being adjusted either in terms of ramp angles and of roller heights in active mode during laying, i.e. with the pipe on top of it. This innovative feature allows to change the stinger configuration in order to suit the different bending radii required when laying in shallow, deep and ultra-deep waters without abandoning the pipeline, therefore saving a considerable amount of time and reducing the risks. These capabilities have been successfully tested in the deep water sea trials that took place before the laying of the Jack St Malo export pipeline. Such innovative technologies and equipment required state-of-the-art control and management software: the Centralized Management System (CMS), the Ramp Management System (RMS) and the Pipe Lay Guidance (PLG) just to mention the most important ones. The ability of the Vessel Management Team (VMT) to remotely control at any moment the instant conditions on the vessel firing line and on the double/triple joint workshop is a unique feature ensuring safe and reliable monitoring of the whole pipe construction cycle onboard. These features make the new CastorOne and the FDS2 unique and distinctive vessels on the pipeline installation market for Steep-S/S/J laying technologies.