PETRONAS TECHNICAL STANDARDS

Float Over Engineering Design And Installation

PTS 11.03.02
January 2019

© 2019 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Upstream Technical Standards are Company’s internal standards and meant for authorized users only.
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/ manufacturers/ suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the Contractors/
manufacturers/ suppliers to propose other proven or internationally established standards or
practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.
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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 5
1.1 SCOPE ............................................................................................................................ 5
1.2 GLOSSARY OF TERMS..................................................................................................... 5
1.3 SUMMARY OF CHANGES ............................................................................................... 7
2.0 GENERAL REQUIREMENTS ..................................................................................... 8
3.0 OPERATIONAL COMPLIANCES ................................................................................ 9
3.1 CODES AND LEGISLATION .............................................................................................. 9
3.2 IN-FIELD MOORING........................................................................................................ 9
3.3 FLOAT OVER installation ................................................................................................ 9
4.0 DESIGN ENVIRONMENTAL CONDITIONS ............................................................... 11
4.1 PRINCIPLES................................................................................................................... 11
4.2 OPERATIONAL PLANNING & DESIGN ........................................................................... 11
4.3 WORKABILITY ASSESSMENT ........................................................................................ 11
5.0 VESSEL(S) SELECTION CRITERIA ............................................................................ 13
5.1 GENERAL CONSIDERATION .......................................................................................... 13
5.2 VESSEL STABILITY ......................................................................................................... 14
5.3 BARGE OR HTV SELECTION .......................................................................................... 14
6.0 HOST STRUCTURE ................................................................................................ 15
6.1 GENERAL REQUIREMENT ............................................................................................. 15
6.2 SINGLE VESSEL FLOAT OVER ........................................................................................ 15
6.3 DUAL VESSEL FLOAT OVER .......................................................................................... 15
6.4 FREEBOARD, STABILITY AND RESERVE BUOYANCY ..................................................... 16
6.5 DEFLECTIONS / STRESSES DURING (DE)-BALLASTING ................................................. 16
6.6 MOORING OF PRE-INSTALLED FLOATING STRUCTURE................................................ 16
6.7 PRESSURE TESTING OF PRE-INSTALLED FLOATING STRUCTURE ................................. 16
7.0 FLOAT OVER ENGINEERING .................................................................................. 17
7.1 GENERAL ...................................................................................................................... 17
7.2 WEIGHT AND DIMENSIONAL CONTROL ...................................................................... 17
7.3 VESSEL(S) LOAD CONDITIONS ...................................................................................... 19
7.4 STABILITY DURING float over installation.................................................................... 19
7.5 FENDERS AND/OR TETHERS......................................................................................... 20
7.6 MOTIONS AND MATING STAGES ................................................................................. 20
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7.7 DRAFT AND FREEBOARD .............................................................................................. 20

7.8 CLEARANCES ................................................................................................................ 21
7.9 POSITIONING, STATIONKEEPING AND anchoring ........................................................ 21
7.10 DYNAMIC POSITIONING VESSEL .................................................................................. 22
8.0 FLOAT OVER HARDWARE ..................................................................................... 24
8.1 DECK SUPPORT FRAME ................................................................................................ 24
8.2 LEG MATING UNITS, DECK SUPPORT UNITS & DUAL FLOAT OVER SUPPORT UNITS
(MATING & SUPPORT UNITS) ................................................................................................... 24
8.3 SAND APPLICATION ..................................................................................................... 26
9.0 MARINE EQUIPMENT & SPREAD .......................................................................... 27
9.1 PUMPING AND BALLASTING SYSTEM .......................................................................... 27
9.2 INSTALLATION VESSEL(S) SYSTEMS ............................................................................. 27
9.3 ASSIST TUGS AND SUPPORT VESSELS .......................................................................... 28
10.0 FLOAT OVER MONITORING .................................................................................. 29
10.1 LEG MARKING/ACCESS ................................................................................................ 29
10.2 MOTION/CLEARANCE MONITORING ........................................................................... 29
10.3 ENVIRONMENTAL MONITORING ................................................................................. 29
11.0 MARINE OPERATIONS PROCEDURE ...................................................................... 30
11.1 PRINCIPLES................................................................................................................... 30
11.2 WEATHER FORECASTING ............................................................................................. 30
11.3 FLOAT OVER INSTALLATION MANUAL ......................................................................... 30
12.0 BIBLIOGRAPHY .................................................................................................... 31
APPENDIX 1: LOWEST POINT ON TOPSIDE ....................................................................... 32
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1.0 INTRODUCTION

This PETRONAS Technical Standards (PTS) provides the minimum requirements for the
topsides float over engineering design and installation.

In addition to this PTS the requirements of a recognized international Classification Society

and relevant international codes and standards shall be met.

1.1 SCOPE

The scope includes single and dual vessel float over installations for conventional fixed
platforms and floating facilities e.g. semisubmersibles, SPAR and TLP.

The scope does not cover load out and transportation.

1.2 GLOSSARY OF TERMS

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS 00.01.03 for PTS Requirements, General Definition Of Terms, Abbreviations &
Reading Guide.

1.2.2 Specific Definition of Terms

No Term Definition

1 A Competent Third (3rd) Party A competent third (3rd) party is a nominated

party with relevant certified expertise and/or
experiences in view of Owner which includes
and not limited to RCS, MWS, vessel surveyor,
etc.

2 Barge Management System BMS: A positioning system installed on float

over or working barge to monitor on real time
all vessel movement using radio telemetry.

3 Deck Support Frame DSF: A structure, which will support the topside
during the load-out and transport operation.
The DSF will transfer the loading from the
topside to the grillage & skid beams (GSB). The
topside will be supported on the deck support
frame and skidded onto the vessel(s) during the
load-out operation. The DSF in combination
with the GSB will provide enough height for the
topside to “float over” the pre-installed
structure during offshore float over installation.
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No Term Definition

4 Deck Support Unit DSU: A “mechanism” for reducing impact loads

between the topside and DSF on the vessel(s).
The DSU will be installed in/on the DSF.

Unit installed on the vessel(s) grillage to support

the structure prior to and during the float over.
It can be designed to either provide a rigid
vertical support and allow horizontal movement
or utilise elastomers to absorb vertical and
horizontal float over installation motions and
forces.

5 Dual float over Support Unit DFSU: A “mechanism” for reducing impact loads
between the topside and DFSF on the DF-
vessel(s). The DFSU will be installed in/on the
DFSF.

6 Host Structure A substructure, pre-installed at site location

where the topsides are targeted to be installed
and mated on to i.e. floating substructure, fixed
jacket, etc.

7 Leg Mating Unit LMU: A mechanism for aligning the topside with
the pre-installed structure and reducing the
impact loads between the topside and pre-
installed structure. A LMU consists of a stabbing
cone supported on modular elastomer shock
cells. The LMU can also be located in the topside
leg or pre-installed structure.

8 Point of "No Return" PNR: The critical point in the overall float over
installation after which the float over
installation cannot be reversed.

The last point in time, or a geographical point

along a route, at which a float over installation
could be aborted and returned to a safe
condition

9 Tug Management System TMS: A system installed on the AHT and the
Installation/ Removal vessel(s) to allow the
accurate placing of the tug and anchors
Table 1.1: Specific Definition of Terms
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1.2.3 Specific Abbreviations

No Abbreviation Definition

1 AHT Anchor Handling Tug

2 DP Dynamic Positioning or Dynamically Positioned

3 FMEA Failure Modes and Effects Analysis

4 HAZID Hazard Identification review.

5 HAZOP Hazard Operability review

6 HTV Heavy Transport Vessel

7 LAT Lowest Astronomical Tide.

8 LRFD Load and Resistance Factor Design.

9 MRU Motion Reference Unit

10 MWS Marine Warranty Surveyor

11 RCS Recognized Classification Society

12 TLP Tension Leg Platform

13 WSD Working Stress Design (effectively the same as

ASD)
Table 1.2: Specific Abbreviations

1.3 SUMMARY OF CHANGES

This PTS 11.03.02 (January 2019) replaces the previous PTS 11.03.02 (April 2015).
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2.0 GENERAL REQUIREMENTS

Reference shall be made to other PTS documents in order to comply with requirements that
are not being addressed in this document.
The float over shall comply with recognized International Classification Society and relevant
international codes and standards.

The principle objectives to be considered in the design of float over engineering and
installation are:

i. To establish a float over engineering and installation design which fulfils the
Owner, Marine Warranty Surveyor and Classification Society requirements to
conduct an efficient installation with full recognition of safety, economy, service
life and environment.

ii. To establish a float over engineering and installation design which covers all
conditions to be accounted for pre-service, in-service and post-service including
extreme environmental condition for all type of float over installation.
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3.0 OPERATIONAL COMPLIANCES

3.1 CODES AND LEGISLATION

All vessels and all of the equipment on-board in-service of the float over installation shall
comply with all local and international marine laws and accompanied with valid certificates
for the entire float over installation/ project duration.

A competent third (3rd) party survey report on the suitability and condition of the proposed
float over vessel, support vessel and all critical equipment forming the Installation Marine
Spread shall be provided including with:

i. Verification of compliance with Owner and RCS requirements.

ii. Verification of compliance with International and Local State rules, legislation and
regulations.

iii. Verification of capability of the vessel(s) to carry out the load out, transportation
and float over installation.

All crew and personnel embarking in the float over installation/ project shall have required
certificates of competencies and satisfy all the requirement of one’s function in the
installation/project.

All crew and personnel embarking in the float over installation/ project shall be fully briefed
and trained on the details of the installation procedures and the operations of all the related
equipment used in the float over installation prior to the departure of the vessel from the
load-out site.

All equipment on-board intended for the usage of the float over installation/ project that
required to be certified shall comply with the requirement of the MWS and/or RCS
accompanied with valid certificates for the entire float over installation/ project duration.

3.2 IN-FIELD MOORING

In-field mooring of the transportation vessel shall be carried out in accordance with Section
7.9 to 7.12 of this document.

3.3 FLOAT OVER INSTALLATION

The following considerations shall be complied during the float over installation throughout
the float over operation from stand-off, entry, docking, mating, undocking until exit in order
to safeguard all assets:

i. Lateral impact loads on the host structure not to exceed capacity of the structure
and fendering arrangements.
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ii. No vertical impact loads between deck legs and host structure legs for docking
phase. No vertical impact loads between deck support and integrated deck for
undocking phase.

iii. Limited lateral movement of the vessel relative to the host structure to ensure
alignment of the host structure legs and the deck legs for pre-mating phase.
Limited lateral movement of the vessel relative to the host structure to ensure
alignment of the integrated deck and supports on the vessel for post-mating
phase.

iv. Vertical impact loads on the host structure not to exceed capacity of the host
structure and LMU design for pre-mating phase. Vertical impact loads on the deck
support not to exceed limit loads of the module and DSU design for post-mating
phase.

v. Control over the movement of the vessel in longitudinal and transverse direction
as well as control over the alignment of the vessel.

vi. Sufficient freeboard of the float over installation vessel shall be in accordance to
section 7.7 of this document.

vii. Clearance for the float over installation shall be in accordance to section 7.8 of
this document.
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4.0 DESIGN ENVIRONMENTAL CONDITIONS

4.1 PRINCIPLES

The limiting design criteria and final selection of the limiting design environmental conditions
shall be defined as per the motion of float over vessel with topsides, stationkeeping and
clearance requirement and shall specify the maximum allowable significant swell (if exist),
limiting wind, current, critical tidal range and local sea wave heights and range of spectral
peak periods for head, quartering, and beam seas.

Directional criteria shall be specified with maximum directionality interval of 15o. Collinearity
should be assumed unless location data indicates otherwise.

4.2 OPERATIONAL PLANNING & DESIGN

A Tow Route Study shall be performed by a competent third (3rd) party and documented for
submission to Owner as and when required by the Owner. The report shall consist of 1-year
and 10-year return period of environmental criteria for Extreme/Cyclone and Non-
Extreme/Non-Cyclone. Proposed route shall be the shortest distance by considering the
navigational dangers, safe haven & refuge, piracy activities, towing speed, etc.

Loading and stresses on the topside due to the motion of the float over vessel with topside
during transportation along the proposed tow route shall be assessed in accordance to PTS
11.22.02.

Topside Transportation Fatigue shall be assessed in accordance to PTS 11.22.20 for long period
of transportation exceeding ten (10) days (cumulative).

Float over operation shall be planned and completed within one (1) tidal cycle in a safe
manner to avoid exposure to higher environment condition exceeding limiting criteria.

For areas experiencing more than one (1) tidal cycle within the planned operational duration,
the float over vessel shall be capable to compensate tidal variance. Planned operational
duration shall be subjected to Owner’s approval.

4.3 WORKABILITY ASSESSMENT

A Workability Assessment shall be performed based on the allowable environmental criteria

relative to the local meteorological and oceanographic conditions at float over installation site
to estimate the expected durations for operational phase completion and weather downtime
associated to each phase.

The assessment shall cover twelve (12) months period throughout the planned year to
perform float over installation. The period that gives the highest probability of success for
operational completion shall be considered as selected period.
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Reassessment shall be performed on the float over mating analysis input criteria for any
unsatisfactory on the calculated workability.

The assessment shall also include weather window analysis to obtain the following:

i. An average duration of the weather windows

ii. The number of windows in a given season

iii. Sensitivity to critical operational design conditions and durations

Assessment performed shall be documented and submitted to Owner with approval of MWS/
RCS.
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5.0 VESSEL(S) SELECTION CRITERIA

5.1 GENERAL CONSIDERATION

The topside float over vessel(s) selection shall take into consideration the transported cargo,
float over vessel stability, minimum docking draft, grillage and DSF height and weight with the
vessel(s) beam and depth shall be appropriate for the pre-installed host structure slot.

Proposed candidate vessel shall be evaluated based on the following criteria as minimum:

i. Maximum deadweight sufficient to be operated at largest displacement required

during critical operation for load out, mating and exit stage of Float over

ii. Sufficient tank capacity for ballast operation in acquiring and maintaining
required draft, freeboard and stability during critical operation for load out,
mating and exit stage of Float over. External tank shall not be considered.

iii. Functional and design limits as per approved by RCS and/or statutory regulator
shall not be exceeded where it is deemed to be incapable and not suitable for the
selection

The minimum docking draft shall consider not limited to the following:

i. Lightship weight of float over vessel and COG

ii. Amount of fuel and ballast water with COG

iii. Topside weight with COG

iv. GSB and DSF with COG

v. Additional Deck Equipment

The minimum float over vessel depth shall consider not limited to the following:

i. Minimum Docking Draft and Entry Gap

ii. LMU Compression

iii. Height of LMU stabbing cone

iv. DSU Extension (only if applicable)

v. Minimum freeboard and exit clearance

vi. Tidal Limitation (HAT and LAT effect) throughout load out, docking & undocking
stages
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Any use of special mating concepts i.e. hydraulic jacks/sand jacks and such proprietary system
shall be upon agreement by the Owner. All engineering design and procedures to construct
and operate such system shall be in accordance to Approved International Standards and
submitted to Owner with approval of MWS and RCS.

5.2 VESSEL STABILITY

The topsides float over vessel(s) shall satisfy intact and damage stability criteria for all phase
of float over installation including load-out, transportation and float over installation and
meet all Flag state stability requirements.

No green water effect shall take place at any point of the float over installation.

Adequate stability and motion characteristics at all stages of the float over installation are
required for the vessel(s).

5.3 BARGE OR HTV SELECTION

For long distance dry towing from construction to float over installation site, vessel(s) with
better sailing capabilities should be considered to avoid storms and adverse weather
conditions.

Vessel(s) with larger main deck strength should be considered for heavy cargo support
purposes taking into consideration of stresses and bending moment due to wave induced and
still water.
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6.0 HOST STRUCTURE

6.1 GENERAL REQUIREMENT

A global and local strength analysis shall be performed for the host structure with variety of
loading conditions during the docking and mating operations and documented to
demonstrate adequate strength capacity of the host structure to withstand such loading with
consideration of accidental loadings. The assessment for fixed structure shall be in accordance
to PTS 11.22.02.

Any effects of non-uniform load distribution during the mating operation shall be calculated,
documented and reported to the notice of Owner and MWS.

Design dimension of pre-installed host structure shall be in accordance to Section 6.2 and 6.3
of this document and appropriately sized in providing sufficient side clearance including
consideration on fabrication tolerance of all associated component to fit the float over vessel
for entry and exit.

Dimensional survey and control to ascertain the actual dimension shall be carried out in
accordance to Section 7.2 of this document.

6.2 SINGLE VESSEL FLOAT OVER

The pre-installed host structure design dimension shall define minimum slot width and level
of horizontal bracing for single vessel(s) float over.

The minimum pre-installed host structure slot shall take into consideration:

i. The width of transportation vessel.

ii. 2x clearance between sway fender and vessel(s); typically, between 100-150 mm.

iii. 2x sway fender width; typically, between 1000-1500 mm.

6.3 DUAL VESSEL FLOAT OVER

The pre-installed host structure design dimension shall define minimum topside outrigger
length and minimum clearance between pre-installed structure and DF-vessel(s) for dual
vessel(s) float over.

The minimum topside outrigger length shall take into consideration:

i. The width of pre-installed structure.

ii. 2x clearance between sway fender and DF-vessel(s); typically, between 100-150
mm.

iii. 2x sway fender width; typically between 1000-1500 mm.

iv. 2x half of the selected DF-vessel(s) width in combination with possible DF-
vessel(s) eccentric loading.
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6.4 FREEBOARD, STABILITY AND RESERVE BUOYANCY

A floating host structure shall satisfy intact and damage stability criteria with adequate reserve
buoyancy for the float over installation.

Float over design from docking to undocking phase shall avoid the floating host structure to
be ballasted exceeding maximum allowable draft and/or fully submerged. Unless otherwise
approve by RCS and MWS the duration of the floating host structure at such position shall be
minimized as possible.

Response of the floating host such as pitch, roll and heave shall be demonstrated to be
negligible under the design float over installation condition. Otherwise, additional freeboard
will be required with acceptance of MWS and RCS.

The floating host structure shall be capable to be deballast to achieve as minimum as follows:
i. Required freeboard for damage stability

ii. Float-on/Float-off within planned weather window.

6.5 DEFLECTIONS / STRESSES DURING (DE)-BALLASTING

The deflection and additional stresses due to the resultant result of (de)-ballasting of the pre-
installed floating host structure shall be incorporated in the design of the floating host
structure and ensured that the deflections of the floating host structure are within reasonable
limits for the capture radius of the LMU.

6.6 MOORING OF PRE-INSTALLED FLOATING STRUCTURE

Pre-installed floating host structure with station keeping shall be safely moored prior to the
float over installation.

6.7 PRESSURE TESTING OF PRE-INSTALLED FLOATING STRUCTURE

As a minimum the floating structure should be tested according to RCS requirements. In

addition, it is recommended to execute a (partial) pressure test of the floating structure which
represents the maximum float over draft.
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7.0 FLOAT OVER ENGINEERING

7.1 GENERAL

All engineering design, calculations and analyses associated to the float over installation,
systems and components shall be performed as per required and in accordance to Approved
International Standards and submitted to the Owner with acceptance and approval of RCS
and/or MWS.

7.2 WEIGHT AND DIMENSIONAL CONTROL

A maximum design weight of the structure shall be defined and established with basis in
satisfaction to Owner and used for the float over installation analysis and calculation and shall
not exceed for the float over installation. Weight monitoring shall be in accordance to PTS
11.22.02 correlative to specific design stages.

Dimensional control drawings and report shall be submitted to Owner for the pre-installed
structure at leg top level and the topside at leg bottom level. All structure dimensions shall be
ensured to meet the final dimension restraints specified.

The topside leg final cut-off shall be based on the final survey results after the installation of
pre-installed structure with acceptance of MWS and approval of Owner.

A float over mating tolerance procedure with all possible remedial measures shall be
submitted to Owner with approval of MWS.

A dimensional survey of the topside prior to load-out and the pre-installed host structure
dimensional survey for both prior to load-out and post installation shall be performed to
confirmed the verticality and alignment of the LMU with the legs of the pre-installed host
structure. Any miss alignment of the mating legs shall be rectified with approval of RCS/MWS.

The diagonal distance between the centres of any two mating legs and structure shall not
exceed the tolerance of ±12mm.

The dimensional survey results during the pre-installed structure fabrication and after
installation shall be used as the reference. The elevation tolerance of the mating legs and
stabbing cones shall not be more than ±10mm.
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Figure 7.1: Left view, tolerance between mating legs (horizontal);

Right view, elevation tolerance

Pre-installed structure dimensional survey shall be performed by an independent survey crew

after the fabrication of pre-installed structure and after the pre-installed structure installation.
Following dimensions shall be surveyed as a minimum:

i. Distance between the centreline of the receivers on top of the pre-installed

structure legs

ii. Elevations of the top and bottom of the receptors of the pre-installed structure

iii. Centreline alignment of the pre-installed structure legs in both rows

iv. Distances between the sway and surge fenders with respect to the centrelines of
the pre-installed structure legs

v. Elevations of the bottom and top of the sway and surge fenders

vi. Orientation and incline angle of the pre-installed structure legs

A dimensional survey shall be performed for the location of the topside on the vessel(s) and
principal dimensions shall be noted. In addition, the following dimensions shall be measured:

i. The distance between the outer extremes of the vessel(s) to the centreline of the
mating legs.

ii. The distance between the surge fender and the nearest set of legs in the
longitudinal direction.
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Figure 7.2: Dimensional Survey

7.3 VESSEL(S) LOAD CONDITIONS

The entry operation shall be analyzed with a minimum of three (3) positions as per follows:

i. The stern of the vessel(s) passing the first row of the pre-installed host structure
slot.

ii. The stern of the vessel(s) passing the second row of the pre-installed host
structure slot.

iii. The vessel(s) in final mating position with the engagement of surge fenders
against pre-installed host structure column and/or mating lines connected to the
pre-installed host structure.

The vessel(s) loading condition for each stage of docking, mating, load-transfer and undocking
operation shall be defined, determined and analyzed in accordance to Approved International
Standard with minimum of five (5) transitional phases of load transfer and separation gap.

The exit operation shall be the reverse operation of the entry operation except that the
topside is removed and the vessel(s) is at deeper draft with increased ballast. A minimum of
three (3) steps, similar to the entry operation, shall be included in the analysis.

7.4 STABILITY DURING FLOAT OVER INSTALLATION

Vessel(s) stability shall be demonstrated to be adequate throughout the float over installation.
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7.5 FENDERS AND/OR TETHERS

Suitable fendering system shall be required for all float over installation to reduce the stress
in host structure and vessel(s) in the event of contact. During the mating operations, the float
over vessel may be held in positions by tether.

Use of tether shall be subjected to strength check assessment of host structure in accordance
to Section 6.1 of this document.

Fendering system can only be exempted for design of float over installation utilizing vessel(s)
with DP as the primary method of vessel(s) station keeping provided with the analysis of global
and local capacity of the host structure for accidental impact scenarios and risk assessments
with acceptance and approval of RCS and/or MWS.

Testing shall be performed covering the full range of conditions (e.g. forces, displacements)
anticipated for the float over installation to demonstrate and verify the engineering properties
(strength, stiffness, damping, hysteresis, elastomeric creep) of all the components and
systems for mating.

The test shall be performed by RCS certified service provider and witnessed by RCS and Owner.

7.6 MOTIONS AND MATING STAGES

Float over mating analyses shall be performed taking into account vessel load condition in
section 7.3 of this document, demonstrated and submitted to Owner with approval of MWS
and/or RCS prior to sail-away and to confirm the motion and impact loading to the pre-
installed structure and the topside during every step of float over installation are acceptable.

DP capability assessment shall be provided to Owner for DP float over installation.

Model testing shall be performed only upon Owner request to verify the float over mating
analyses.

7.7 DRAFT AND FREEBOARD

Float over design shall define the maximum draft of the float over installation vessel(s) during
float over installation and shall not exceed the maximum load line draft without RCS
exemption.

The minimum vessel(s) freeboard shall comply with Approved International Standards and
shall not be less than 1 m at all phases of the float over installation.

A minimum of 1 m vertical clearance to any downflooding point or exposed equipment at risk

shall be provided considering the maximum wave height and motions.
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7.8 CLEARANCES

Topside shall be designed in principle to ensure safe entry and exit of float over operation
avoiding any clash between structures.

A minimum vertical clearance of 1 m from the transportation vessel keel to the highest point
/ horizontal braces in the pre-installed host structure shall be complied under all conditions
at all phases of the float over installation considering the maximum motion of float over vessel
with topsides and possible trim.

A minimum vertical clearance of 300 mm from the lowest point of the topside shall clear the
highest point on the pre-installed host structure while the float over vessel is being docked
for entry and shall also clear the highest point of any equipment or DSF/DSU on the float over
vessel while it is being undocked for exit considering the maximum motion of float over vessel
with topsides and possible trim

A Deck Support Frame (DSF) shall be designed with height sufficiently to provide minimum of
1 m vertical static clearance for both respective entry and exit stage of Float over.

Lowest point of the topside shall be defined based on the topside design elevation considering
the lowest deck beam with associated attachments and outfitting below the deck i.e. piping
and flanges etc. in relative to the mating level (lower / higher) and pre-installed host structure
highest elevation with/out any protruded elements within the exclusion zone as illustrated
and highlighted in Appendix I

Side clearances shall be in accordance to Section 6.2 and 6.3 of this document.

7.9 POSITIONING, STATIONKEEPING AND ANCHORING

Detailed maneuvering and positioning system shall be submitted to the MWS and Owner for
approval prior commencement of float over installation activities.

Anchors shall not be set in the vicinity of existing pipelines or structures and shall comply to
PCSB Towing, Mooring and Anchor Handling Guideline Doc No: S04 012 Rev 0, 4/2012 and
shall not be less than 200m in radial distance.
At no time shall an anchor wire and/or mooring lines come in contact with any existing
facilities at any point of the float over installation.
No mooring to Owner assets shall be allowed without prior approval from Owner.

The safety factor specified in API RP 2SK shall be used for the mating mooring line design.

Pre-tensioning shall be performed for all mooring lines to maximum operating loads and shall
be held at minimum of fifteen (15) minutes to verify the holding capacity of the anchors,
winches and mooring lines.
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A test procedure shall be submitted Owner for review and approval prior to the test. Owner
shall be informed on the test schedule provided with the assistance to the Owner’s
representative if deemed necessary. The test report shall be submitted to the Owner after
completion of the test.

All deployed anchors and mooring lines shall not be left on the seabed upon completion of
float over installation.

7.10 DYNAMIC POSITIONING VESSEL

In the event that the float over vessel(s) is a HTV with dynamic positioning capability, a
minimum of DP Class 2 category shall be required with consideration on the use of DP in place
of vessel(s) moorings, subject to review of station keeping analyses and DP operating
procedures. The FMEA analysis for the DP system shall be submitted for review to Owner and
MWS.

Portable Outboard DP may be fitted to the float over installation vessel for the use of float
over subjected to Owner’s approval.

A DP capability assessment shall be made for the vessel(s) and topside taking into
consideration the design environmental conditions. The DP capability assessment should
consider the vessel(s)'s DP capability for the worst case failure condition and show that the
vessel(s) is able to complete the float over installation with the reduced capability, or to abort
if prior to the point of no return.

Results of the DP capability assessment shall be taken into account in the weather windows
analysis.

Annual DP trials should be up to date, documented and submitted to Owner for review.

DP system shall be verified for DP Class compliance and installation suitability prior to load
out. DP systems shall be tested once again at site with Owner and MWS representatives for
acceptance. The DP float over vessel may require a minimum or emergency mooring lines (if
any) depending on the Float over installation engineering performed by Contractor.

Full satisfactory documented DP trials shall be completed before the load-out of the structure.
These trials shall demonstrate:

i. Float over installation in the intact and post failure configurations.

ii. A group redundancy test as a minimum.

iii. Positioning in the intact and post worst case failure configurations with the
reference systems chosen for the float over installation.
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Any tests that cannot be completed prior to load-out shall be completed prior to the
commencement of the float over installation.

Field arrival trials shall be completed on location in actual conditions before the float over
installation.
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8.0 FLOAT OVER HARDWARE

8.1 DECK SUPPORT FRAME

The Deck Support Frame (DSFs) shall be designed to integrate with Deck Support Unit (DSUs)
which shall allow the DSU to be installed and fully compressed prior to installation of sea-
fastening.

DSF shall provide a minimum float over height/clearance for the selected vessel(s) with the
designed draft of the vessel(s). The elastomer pad compression and expansion, the tides and
the vessel heave motion shall be considered in the clearance checks.

8.2 LEG MATING UNITS, DECK SUPPORT UNITS & DUAL FLOAT OVER SUPPORT UNITS (MATING
& SUPPORT UNITS)

Leg Mating Units (LMUs) or Dual Float Over Support Units (DFSUs) shall be designed, tested,
supplied along with stabbing cone and elastomer shock cell and comply with Approved
International Standards.

The stabbing cone shall be designed to ensure the mating interface is aligned under specified
motion amplitudes with dimension tolerance compatible with the receiving cone.

LMUs as-built dimensions shall be provided for pile cut-off adjustments to ensure the LMUs
final top elevations are within design elevation tolerance of ±3mm.

The design of the LMU shall be such that any hot work activities between topside/preinstalled
structure and LMUs will not be detrimental to elastomers.

Specification of design, fabrication, testing of the Mating & Support Units (MSUs) shall be
submitted to the Owner for approval.

MSUs installation procedure shall be developed and submitted to Owner with approval of RCS
prior to installation.

The allowable stresses for rolled steel sections and steel plates shall be in accordance with
basic allowable stresses specified in API RP2A-WSD and AISC. One-third increase in allowable
stresses shall be allowed for transportation and mating with dynamic forces.

Allowable Von Mises stress, as calculated from FEA, for transportation and mating with
dynamic forces shall be limited to 90% of material yield strength.

Elastomer shock cells shall be of multi-element elastomeric disks bonded to steel plates, top
and bottom. All bonds should be chemical bonds formed during the vulcanization process.

Elastomer shock cells shall meet the following requirements:

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i. Target Deflection: The target deflection tolerance shall be specified in the detailed
float over analysis stage for the project. However, the deflection should generally
be within ±10 mm of the target deflection at the static design load. This target is
the most critical functional parameter requiring coordinated deflection between
the legs to limit topside structural stress during the mating phase.

ii. Compression Stress Limit: The maximum allowable static compression stress on
the MSUs elastomer components should not exceed 35 MPa. Compressive stress
is calculated as the static design load over the minimum cross sectional area of
the elastomer components of the MSUs.

iii. Elastomer Tolerances: Elastomer components shall be manufactured in

accordance with ASTM D4014 except as follows:
a) Tolerances on thickness of internal laminate shall be ± 2% with an angular
tolerance of 1 degree.
b) With reference to ASTM D4014-03 Section 8.1.3.3, knit, flow, and other
surface marks shall also be the basis for rejection of a part.

Common practice is to account for stress relaxation such that for example the DSUs carry 25%
of the topside and the DSF carries 75% on the day of float over.

For DSUs design utilizing modular shock cell elements, consideration should be given to
adjustments of elastomer pads stiffness to meet the requirements of COG shifting of the
topside based on the final weighing operation.

The fabrication dimensions of steel components for DSU and LMU shall not exceed the
tolerance as per below:

Parameters Tolerances

Machined Components ± 1 mm

Rolled Cans (Length) ± 3 mm

Outer Diameter ± 2 mm

Circumference ± 12 mm

Roundness

For thickness ≤ 50.88 mm Diameter x 1% ≤ 6 mm

For thickness > 50.88 mm Thickness/8

Table 8.1: Dimension Tolerances for Steel Components

A test procedure shall be developed and submitted to the Owner for approval prior to the
test.
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The LMUs, DSUs and DFSUs full scale pad stack assemblies shall undergo load and function
tests as part of a Factory Acceptance Test (FAT) in accordance to the test procedure.

The FAT shall include, as a minimum:

i. Load test of full assembly of elastomer pads to 100% of the specified maximum
vertical design load.

ii. Five (5) cycle load deflection test of the full-scale pad stack assemblies, where the
load and deflection will be continuously recorded and used to generate the
stiffness curve for each assembly.

A written notice to the appointed RCS and Owner shall be provided prior to all tests. Owner
and RCS shall have the right, but not obligation, to witness all tests. The test results shall be
submitted to Owner with approval of RCS.

8.3 SAND APPLICATION

Use of sand material as part of the material in the Float Over Hardware i.e. sand jack, sand
tray, etc. shall follow the following minimum properties requirement:

i. Water Content: The sand must be dry and demonstrated to be sufficiently able to
flow out from the sand discharge hole without any restriction. In-situ test shall be
carried out witnessed by Owner and MWS prior to insertion.

ii. Sand Particles: Sand grade should be fine to medium sand with maximum particle
size not greater than 2mm

iii. Grading Requirement:

a) 1.0 mm < D15 < 1.4 mm
b) 1.2 mm < D50 < 1.6 mm
c) 1.4 mm < D85 < 1.8 mm

Where D15, D50, D85 are sizes of sand grain comprising 15%, 50%, and 85% of a sample of the
material, by mass, when tested and analyzed by dry sieving.

The sand application hardware shall be designed and analyzed based on its properties and
capability to received maximum vertical load / impact load associated to its functions.

Sand hole for discharge shall be designed with sufficient numbers and sizes to achieve
flowrate of sand required and avoid blockage from compressed sand.
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9.0 MARINE EQUIPMENT & SPREAD

9.1 PUMPING AND BALLASTING SYSTEM

Ballast procedures, calculations and sequences for both float over installation vessel(s) and
floating host structure shall be developed and consider float over clearances, keel clearances,
load transfer, tidal range, expected timing and freeboard, residual ballast water, tidal
compensations, weight compensations etc.

Ballast operation shall be design with adequate pumping capacity required to achieve the total
amount of ballast water in corresponding to the targeted final draft for vessel exit within
planned operational duration while maintaining vessel stability in accordance to Section 4.2
of this document.

A risk assessment on potential ballasting errors shall be performed and recorded with
acceptance of MWS and/or RCS.

Ballast system shall be provided with fully integrated and centralized control, monitoring and
auto tank gauging system. External portable ballast pumps and generator during float over
shall not be considered to avoid impact on ballasting plan due to manual operating, unless the
control and monitoring can be integrated to existing control unit.

Ballast pump and pumping system shall have adequate pumping capacity in providing
sufficient flowrate for critical ballast operation during load out and mating operation as
minimum in accordance to PTS 19.30.03.

The ballast system with sufficient pumping capacity considering failure of any one primary
pump or power source capable to maintain the required pumping rates shall be provided.

All pumps and system shall be tested and proven to be operational fit prior to transportation
and verification of pump capacity from MWS and/or RCS representatives are required.

9.2 INSTALLATION VESSEL(S) SYSTEMS

Float over installation vessel(s) system which are deemed critical including power supply and
lighting shall be provided and shown to be adequate as per specified in Approved International
Standards.

To prevent interference between the CP systems electrical linkage should be avoided by use
of non-conductive tethers. If this is not feasible then the linkage should be arranged to be as
resistive as possible to minimize the interference current. To prevent stray currents from
welding and other electrical processes the return path from the equipment must be by
electrical return cable to the power supply to avoid the return current flowing through the
seawater between structures/vessels.
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9.3 ASSIST TUGS AND SUPPORT VESSELS

Assistant tugs of an AHT or equivalent capable of controlling and moving the vessel(s) loaded
with the topside in the field shall be provided as when required and shall comply with
Approved International Standards.

Required bollard shall be calculated and proved to be sufficient for pre-installation and testing
of anchors in accordance to Approved International Standards and submitted to Owner.

AHT shall be equipped a Tug Management System (TMS) to assist in monitoring and allow for
accurate positioning.

Support vessels additionally can be required for mating operation assistance shall be highly
maneuverable with steerable propulsion system and equipped with rubber fenders on the tug
bow and winches with minimum pull capability of 20mT at speed of 10-28 m/min. The winches
shall be located on both bow and stern.

All assist tugs and support vessel(s) are to be screen suitably for the float over installation and
surveyed with acceptance of appointed MWS.

Detailed specification of the selected docking assisting tug(s) and AHTs shall be submitted to
Owner for approval prior to mobilization of the tugs.
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10.0 FLOAT OVER MONITORING

10.1 LEG MARKING/ACCESS

Leg marking/access shall contain at least the following:

i. Longitudinal alignment marking at the centreline of all topside legs.

ii. Centreline markings on the pre-installed host structure legs shall be clearly visible
and floodlit.

iii. Vertical alignment markings.

iv. Provide visual monitoring of waves and tides level markings on the pre-installed
host structure.

10.2 MOTION/CLEARANCE MONITORING

A motion monitoring system shall be provided accuracy of the measurement system for
transitional displacement of the topside legs shall be in the range of ±20 mm.

Motion Reference Unit (MRU) shall be used to monitor critical factors for the float over
installation.

Vessel(s) shall be equipped with Barge Management System (BMS) at minimum to assist in
monitoring and allow for accurate positioning.

The system shall be calibrated and tested to the satisfaction of MWS and/or RCS prior to sail
away to float over installation site.

10.3 ENVIRONMENTAL MONITORING

The environmental conditions monitoring shall require as minimum but not limited to as
follows:

i. Wind speed with direction

ii. Wave and swell height with period

iii. Current speed with direction

iv. Tidal height against time

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11.0 MARINE OPERATIONS PROCEDURE

11.1 PRINCIPLES

All marine operations shall be carried in accordance to the approved procedures and with
approval of MWS.

Marine operation procedure shall clearly define and include as minimum as follows:

i. Interfaces between Contractor for separate scope of Marine Operation (including

Load Out, Transportation, Float Over and Float Off)

ii. Detailed step by step procedures with contingency

iii. Allowable environmental criteria and operational limit

iv. Docking procedure with consideration of the tide cycle

v. Identification of stopwork criteria and critical “point of no return”

vi. Training requirement on the float over installation procedure for the installation
crew and installation equipment operator

vii. Float over installation vessel(s) detailed running stationkeeping procedure

inclusive of AHT and assist tugs

A readiness meeting shall be conducted prior to the start of float over installation, attended
by all involved parties including Owner, MWS and RCS as required.

11.2 WEATHER FORECASTING

A weather forecast provided only from recognized International Weather Forecasting service
provider shall be used with six (6) hours interval forecasts starting at forty-eight (48) hours
prior to arrival at site and three (3) hours interval forecasts upon arrival at site continuously
until completion of installation.

11.3 FLOAT OVER INSTALLATION MANUAL

A comprehensive Float Over Installation Manual shall be written to identify all aspects of the
float over installation in detail, cover all likely contingencies and specify exactly how the float
over will be conducted with minimum required information as per specified in Approved
International Standards.

Document shall be submitted to Owner with approval of appointed MWS and/or RCS prior to
sail-away.
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12.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:

PETRONAS STANDARDS
Index to PTS PTS 00.00.01
Requirements, General Definition of Terms, Abbreviations & Reading PTS 00.01.03
Guide

INTERNATIONAL STANDARDS
Specification for Structural Steel Buildings, Allowable Stress Design AISC
and Plastic Design

Specification for Structural Steel Buildings AISC

Design and Analysis of Stationkeeping Systems for Floating Structures API RP 2SK

Recommended Practice for Planning, Designing and Constructing API RP2A-WSD

Fixed Offshore Platforms – Working Stress Design

Standard Specification for Plain and Steel-Laminated Elastomeric ASTM D4014

Bearings for Bridges
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APPENDIX 1: LOWEST POINT ON TOPSIDE

1 2

1 Lowest Point at Mating Level (Tip of LMU)

2 Lowest Point at Lowest Deck (Low Point of Outfittings / Attachments Below Deck Beam)