Transporting large pre-fabricated modules to a remote, hostile and storm-ravaged environment is difficult and not without risk. For this reason, centrifugal pumps were chosen to play a key role in making the delivery a success. Here's how they did it.
Foss Maritime Company (Seattle, WA), a marine services firm specializing in worldwide marine transportation and logistics, successfully delivered 36 pre-fabricated modules that were part of a multi-year sealift of specialized structure and components needed to construct an oil production facility at a remote project site in the Russian Far East.
This extremely remote oil production site is located near Chayvo Bay on the northeast tip of Sakhalin Island. Located north of the Japanese island of Hokkaido, Sakhalin is separated from Russian mainland by the Tartar Strait. The project was safely completed ahead of schedule despite complex logistical requirements and many environmental challenges such as ice, harsh storms and sea conditions.
This project involved the delivery of 36 large, prefabricated, modular structures fabricated in Ulsan, South Korea for construction of a facility that is used to separate oil and gas, and to stabilize it for further shipment by pipeline. The transport of the 36 prefabricated modules was required to support the oil and gas development field.
A number of Foss tugs were used to transport the 280-ft long x 45-ft wide x 85-ft tall modules, each weighing up to 1,800 tons. This required complex logistics, in addition to combating environmental challenges that included dangerous sea conditions, ice, and typhoons. For these reasons, Foss worked in conjunction with pump manufacturer Pioneer Pump, Inc. to assist a major international oil company with this construction project.
With strict requirements presented, pump engineers designed and manufactured a custom, portable centrifugal pump package to meet the rugged requirements of this job. A special low profile trailer was designed to accommodate the onboard storage requirements for the vessel carrying the pumps.
The project required six pumps initially, each capable of pumping 3,250-gpm with a 20-ft suction lift. The 8-in model chosen has a maximum flow capability of 5,400-gpm and maximum head of 210-ft. The trailer mounted unit capabilities exceeded expectations and assisted in completing the job efficiently.
Captain Herb Gazeley, the maritime operations manager, reported that his company was very impressed with the function and durability of the pumps. He related that in the middle of the first season of the project, one of the pumps started banging during a critical part of the application. The pump had to keep running for approximately another 15 to 20 minutes until it could be shut down without hindering the project. After inspecting the unit to find out what was causing the clanging and banging, an 18-in piece of metal debris was found lodged in the impeller of the pump.
The debris was sucked into the suction of the pump and then lodged in the impeller. The debris was removed and the pump was put back into service. It continued to run satisfactorily for the remainder of the season. After the first season concluded, the pumps were inspected to find everything to be in excellent mechanical condition.
The oil consortium was so pleased with the pump performance that six more identical units were purchased for the second season, to be used in other aspects of this project. With the help of the maritime and pump companies, the project was completed safely, ahead of schedule, on budget and with all materials delivered in good condition.
Pumps & Systems, March 2007
