Design And Construction Of A 5-Kt (5500-St) Facilities Module For Main Pass 299 Sulfur Mine

This paper describes the design, equipment selection and onshore fabrication of the largest facilities module ever installed in a single lift in the Gulf of Mexico. Measuring 35.5 x 70.1 x 21.3 m (110 x 230 x 70 ft), the three operating level structure houses Frasch process sulfur mining equipment and weighed nearly 49 million N (5500 tons) during lift. An operating weight of over 74 million N (8300 st) combines with bridge reactions acting on the in-place module and results in a total operating vertical load on the supporting platform deck of about 107 million N (12,000 tons). A Vierendeel truss structural system was selected for framing the module to allow maximum equipment access and routing flexibility for complex, insulated large diameter process piping. Research and finite element analysis of crimp plate siding behavior in shear was carried out during selection of siding type for the module. An interactive design sequence was carried out that incorporated in-place operational criteria, onshore fabrication considerations, complex process equipment requirements, plus load-out, ocean transport and offshore lift analyses. Project schedule dictated that design, procurement and fabrication be fast-tracked with parallel activities accelerated to the maximum extent possible. Design and construction of this largest and most complex module was done concurrently with 52 other components of the project including jackets, decks, process and living quarters modules as well as two 122 x 22 m (400 x 72 ft) sulfur tankers. Total tonnage of steel structures for the project exceeded 90.7 kt (100,000 st). The 5 kt (5500 st) mining module proved the viability and costeffectiveness of larger modules than commonly used in Gulf of Mexico waters. This technical advance can be matched with economic opportunity for other large-scale offshore installations.