Setting standards in pipelaying and heavy lift

She is one of the largest Ice-classed offshore construction vessels with ultra-deep-water pipe laying and heavy lifting capabilities, and the ability to operate in water depths of more than 2,500m. Increasingly crude oil is drilled from deeper waters in harsher conditions so the advanced technology and expertise that Lewek Constellation carries on board gives the company a marked advantage in the global industry. In addition, having been designed in Singapore and built to high specifications by Triyards SSY Shipyard in Ho Chi Minh City, Vietnam, makes this uniquely Asian vessel an outstanding achievement and especially impressive.

Singapore-based oil and gas subsea services firm Ezra Holdings Limited, founded in 1992, is today a leading offshore contractor and provider of integrated offshore solutions. EMAS is the operating brand of Ezra Holdings offering solutions across a broad spectrum of the support supply chain, over the entire lifecycle of an oilfield. It has now been awarded a major contract by Houston based Vaalco Gabon (Etame). Under the contract, EMAS AMC, the subsea services division of EMAS, is undertaking the expansion of the Etame Marin Field Offshore Gabon in West Africa. The scope of the work includes engineering, procuring, installing and commissioning (EPIC) of rigid pipelines, along with transporting and installing flexible pipelines and two fixed production platforms.

The technical specifications of Lewek Constellation make it suited for this job. The ship is designed to deliver complex projects in a safe, efficient and reliable manner, making it well suited for projects requiring a versatile vessel for a diverse scope of work.

The vessel was completed and delivered in early 2014, and left for Cape Town on 6 June 2014 following a ‘blessing ceremony’ in Singapore. From Cape Town it is scheduled to arrive at Huisman Schiedam mid 2014 for the installation of the 800 tonne multi-lay pipelay tower.

Earlier, in January 2014, a 3,000 tonne offshore mast crane was successfully installed on board the ship by means ofHuisman China’s new 2,400 tonne quayside crane. The quayside crane, also known as the ‘Skyhook’, installed the offshore mast crane within a three day period using only two lifts. The ‘Skyhook’ has two main lifting configurations: a heavy lift configuration, capable of lifting 2,400 tonne at 30m outreach (maximum lifting height of 100m) and an extended reach configuration, capable of placing a 200 tonne load at 90m outreach with a maximum lifting height of 140m. The ‘Skyhook’ enables Huisman China to install, commission and test large pieces of equipment with lower risk.

The Lewek Constellation is equipped for pipe laying of both rigid as well as flex systems through a combined pipelay tower for reel lay and flex lay over a moonpool which measures 19m length x 8m width. The pipelay capacity is 4in to 16in outer diameter for rigid and 4in to 24in outer diameter for Flexible pipes with twin 400 tonne retractable tower tensioners. For storage of the rigid pipes the ship is equipped with four reels, each of 1,200 tonne and also has two carousels, each 1, 250 tonne for storage of flexible pipes below deck with 6m radius chutes for routing. The spooling tower connects to guide the product to the carousel.

Keeping broad-based capabilities is crucial in order to lay pipes and carry out deep-sea contracts in harsher and more varied environments. To this end Lewek Constellation can install pipe in ultra- deep water field developments with allowable top tensions of 800t. The ship’s multi-lay system features pipe deployment capabilities that are claimed to be among the best in the world. These include:

• A&R (abandon & recovery) system: two 600 tonne traction winches, single or tandem use and two 20 tonne storage winches
• Pipe outer diameter: reel lay 4in-16in and flex lay 4in–24in
• Tensioners: two 400tonne (rigid) or two 260 tonne
• Hang-off clamp: (flexible) 900 tonne
• Steel wire rope capacity: 3,800m x 125mm (each winch).

Naturally also, with the enhanced reeling capacity, Lewek Constellation has the extended capability for laying either 64km of 8in pipe, 48km of 10in pipe, 36km of 12in pipe, 24km of 14in pipe, or 16km of 16in pipe

The immediate advantages of this increased capability are that logistical issues associated with reel lay as well as spooling risk can be dramatically reduced, thereby increasing productivity and guaranteeing schedule. Pipelay vessel transit time is reduced considerably as the vessel does not have to return to the spool base to spool pipe. Multiple products can be laid in one trip too. This is advantageous when working in remote locations like the Arctic and other areas with no offshore support services.

Among other capabilities that lend a technical advantage to Lewek Constellation are two Schilling heavy-duty work ROVs and two dedicated ROV moonpools. These ROVs are of the latest type, capable of going 4,000m deep and equipped with data management systems. At the moment Schilling has produced only two such ROVs and Lewek Constellation has both on board.

The DP3dynamic positioning system provides manoeuvrability, ease of position change as required and is not limited by sea-bed obstructions or water depth. The ship is in constant contact via satellite for navigation and communication.

Superior manoeuvring and positioning is a key requirement for heavy pipe laying work and naturally this has been an area of keen focus. On board, Lewek Constellation is assisted by three tunnel thrusters at the bow, and six azimuth thrusters including two retractable thrusters that help auxiliary propulsion for the dynamically positioned ship. The large 3,200dwt vessel is thus capable of making 360°degree manoeuvres rendering it more flexible and stable for pipe-laying

The propulsion system for Lewek Constellation comprises:

• Two 6,000kW stern azimuth thrusters outboard;
• Two 2,000kW stern azimuth thrusters inboard;
• Two x 3,000kW retractable thrusters forward;
• Two 2,700kW tunnel thrusters; and
• One 1,420kW tunnel thruster.

To support the 3,000t crane operation as well as carry four loaded reels and two loaded carousels, the vessel includes pneumatically controlled active heel control as well as anti–rolling and anti–heeling tanks.

Lewek Constellation is outfitted with cabin accommodation for 239 persons; around 50 of which form part of the marine crew. The construction crew comes on board closer to the construction site and the numbers vary for different projects. The ship is equipped with recreation rooms and mess rooms for crew and officers. A gymnasium, hospital, medical room and prayer room are other amenities available on board. The bridge is unusually spacious and luxuriously fitted. The open space is interspersed with a conference table and space for safety briefings and daily meetings. Additionally the ship hosts a general workshop, a ROV workshop, a conference room, 12 offices and three site offices.

High comfort level and notation compliance has been a top consideration for noise, climate and environmental impact. Noise and vibration analysis was carried out to determine acceptable levels in passenger cabins and common spaces. The ship has a green passport and adheres to strict environmental principles. The engines generate lower emission, waste water treatment plants and a waste incinerator are on board. For hydraulic systems that potentially come into contact with sea water, only bio degradable oil is used. Sprinkler systems are fitted and all regulatory requirements are met, with internal audits carried out to ensure workplace safety. The class notation requires set levels of fresh air supply quantity per person, air velocity and relative humidity to be maintained.

PRINCIPAL PARTICULARS: LEWEK CONSTELLATION

Length: 178m
Breadth: 46m,
Draught (max): 10.5m
Gross tonnage: 48,881gt
Deadweight: 32,000dwt
Design speed 12 knots
Fuel oil: 2,000m³
Potable water: 1,600m³
SWB: 33,000m³
Industrial water: 500m³
Deck area: 4,200m² without reels
Accommodation: 239 persons
Crane: 3,000 tonne heavy-lift
Helideck: Suitable for Sikorsky S-92 and the latest S-61N
Class: Ice class with DP3 capability
Year Built: 2013
IMO: 9629756, MMSI: 357428000
Flag; Panama