Crane Storage, Mobilization and Installation for Offshore Transporter Vessels

Core was commissioned by Hornbeck Offshore, a leading provider of marine transportation services, to receive, store and install heavy-lift cranes for use on newly constructed offshore supply and installation vessels. This is an ongoing project and required Core’s team to engineer specific solutions for receiving and transporting the cranes to storage as well as moving them dockside for installation.

The first crane was received in January 2015. Each crane weighs approximately 550 tons and has a lifting capacity of 250 tons. We first have to use our heavy-lift capabilities to lift and position Hornbeck’s cranes onto a remote-controlled transporter — specifically, the transporter has 44 lines (set doublewide at two lines by 22 lines), creating an overall bed size of 101 feet by 17.5 feet. Once loaded onto the transporter, the cranes must be moved to storage where they are positioned on custom stands that work in concert with the vertical mobility of the transporter. With the vertical mobility of the transporters, we are able to first jack up and then lower each crane onto the stand for storage.

As of April 2017, Core has received two of Hornbeck’s new vessels for crane installation. When each vessel is received, our team loads the crane back onto the transporter, which is then brought dockside for vessel installation. This primarily involves lifting, placing and welding each crane on the vessel’s pedestal. Once complete, Hornbeck is able to deploy these offshore supply and installation vessels for subsea installation work and for use in supplying offshore oil and gas installations.

Decommissioning of Hero Demolition’s Safe Britannia

In July 2016, Hero Demolition Corporation hired Core for our deepwater port facility as well as operational capacity to execute a project involving their accommodation semisubmersible, the Safe Britannia. They docked the rig at our private port facility to remove and scrap the underwater thrusters, lowering the overall weight of the rig for total decommissioning at another facility with shallower water depth.

The Safe Britannia had an overall underwater depth of 40 feet, nine of which were made up of the thrusters. Core first procured specialized underwater welding services to remove the anchor guards from the thrusters, which were then scrapped. The thrusters were later removed from the rig, unloaded and stored at Core until a buyer was found. Core’s team for this project included welders, riggers, crane operators and other staff to plan and execute the work.

Receiving and Long-Term Storage of Equipment for Subsea 7

Subsea 7 is a seabed-to-surface engineering, construction and services contractor for the offshore energy industry. In 2006, Subsea 7 contracted with Core for long-term shore-based services as well as storage, maintenance and mobilization of project equipment. In March 2016, Subsea 7 needed support to prepare the FMOG Holstein for three oilfield projects in the Gulf of Mexico.

Core received 13 large reels from Subsea 7, weighing between 150 and 250 tons, and stored them dockside while assisting with hydraulic and installation testing on the reels before their deployment to the Gulf. After storing and preserving the reels, Core assisted in mobilization and loading of the equipment onto installation vessels to support each of Subsea 7’s projects.

Refurbishment of Technip’s Flagship Vessel — The Deep Blue

Technip is a global leader in oil and gas projects, technologies, systems and services. Technip partnered with Core to prep its flagship vessel, The Deep Blue, for refurbishment in July 2016. The Deep Blue is one of the most advanced pipelay and construction vessels in the subsea industry. As part of refurbishment, the Deep Blue required specialized care and support to deconstruct certain equipment and perform maintenance and repairs.

This vessel has an aligner wheel, for coiling and uncoiling pipe and umbilicals, installed approximately 300 feet above its top deck. Core’s experienced staff were contracted to plan and execute the removal of this aligner wheel and its attachments for refurbishment. To accomplish this, we reconfigured our Heavy-Lift Manitowoc Crane. What made this lift especially unique was the need to lift the wheel vertically but place it horizontally onshore. Because of the complexity of this project, it took nearly two days, two cranes and about 15 people to complete.

Once deconstructed and offloaded to our facility, our team then assisted in metal refurbishment, welding on the aligner wheel as well as maintenance/repair to the bearings and other wheel internals, and blasting and repainting of the entire wheel. In conjunction with this work, we also removed lattice frames and several other pieces of equipment for refurbishment. While this work was being conducted, the ship was sent for full refurbishment at a shipyard. Once all work was complete, Core reinstalled and reconfigured the aligner wheel and other equipment onto the Deep Blue.

Mobilization of Heerema’s New DCV Aegir

In March 2014, Core served as a shore base for Hereema Marine Contractors and their newest vessel — the deepwater construction vessel (DCV) Aegir. This was the Aegir’s first port call in the U.S. on its maiden voyage from the Netherlands. It was designed for use on complex oil and gas infrastructure and pipeline projects in ultra-deep water. Core’s team supported demobilization and storage of heavy reels and other project equipment.

The Aegir was at port for two weeks while Core provided assistance for remote operated vessels as well as welding. This particular vessel can be configured to support various types of projects, such as laying umbilicals and collecting umbilicals. Our team provided support for demobilizing equipment that was not necessary for the Aegir’s next assignment using our heavy-lift capabilities and supported configuration of the vessel once that equipment was offloaded and stored.

Core is equipped with the facilities and space to store equipment, long-term or short-term, while providing preservation and maintenance. The Aegir redocked in fall 2014 after deployment to the Gulf of Mexico. Core assisted Heerema in reloading the stored equipment back onto the vessel.  

The Aegir will be returning to Core’s private port facility in 2017.

Scrap Steel Storage and Handling

AIA Recycling is a South-Korean company that recycles the steel byproduct of manufacturing in two automobile plants located in the Southeast U.S. This is new steel that can be repurposed and fed back into the manufacturing process. AIA compresses this scrap steel into bundles weighing about a ½ metric ton each. They approached Core to devise a solution for stockpiling this scrap and loading 40,000-50,000 tons at a time onto vessels for shipping back to South Korea.

To effectively and efficiently handle this type of product, we engineered 10 specialized loading pans to facilitate loading using the ship’s cranes, with all four cranes operating simultaneously. These pans are 24-feet in length and curved on the inside to properly handle the bundled steel. These pans are similar to skip pans, but we needed to devise a safe way to operate the pans with the ship’s cranes that only had one hoist line (which is not conducive for dumping traditional skip pans that require a two-line system).

The solution was to create a self-unhooking mechanism so that when the spreader bar picks up the pan and sets it down in the vessel, it is able to release on one end, allowing the scrap to be dumped as the pan is lifted back out of the vessel. This solution was a game changer because it allowed maximum productivity with all four cranes dumping pans at once. We are capable of loading vessels with 40,000-50,000 tons of scrap steel within a week using this method.

Woodchip Handling for Yildiz Entegre

Since March 2016, Core has provided ongoing cargo handling support to Yildiz Entegre USA, a global leader in the manufacturing of forestry products. Yildiz was seeking to source pine woodchips in the Southeast for use in making medium density fiberboard, and after finding that supply, they needed to engineer an efficient and economical means of shipping that supply to Turkey, their homebase.

Our facility is one of the leading woodchip handling operations in the world based on storage capacity and vessel loading speed. We are equipped to receive woodchips by both barge and truck. For this particular project, we receive woodchips five days per week at up to 100 trucks per day, or approximately 2,800 short tons, which are dumped and conveyed into stockpiles on storage pads. Our shiploader has the longest jet slinger ever built to distribute chips in vessel holds in order to achieve the best compaction factor. Employing these methods for receiving, storing and loading, we are able to facilitate shipping of several hundred thousand metric tons of woodchips per year for Yildiz. Our facility is currently equipped to handle in excess of 2 million tons per year.  

Yildiz dispatches a ship to Theodore Industrial Port approximately once a month to be loaded. We load approximately 44,000 metric tons each ship loading. Our facility has an automated system whereby we push the woodchips into chain reclaimers that then transfer the chips onto belt conveyors. These conveyors then transport the woodchips to a traveling shiploader that delivers the chips into the vessel holds.

Hornbeck Offshore

In April 2016, the Core team brought the second of four MacGregor cranes associated with the Hornbeck MacGregor Crane Project out of long-term, off-berth storage. The crane was moved to the dock using 44 lines of self-propelled modular transporters (SPMTs). Core’s heavy-lift crane was used to load and install the 550-ton crane onto the Woodland HOS, one of Hornbeck’s newly built offshore service vessels.

Yildiz Entegre USA Inc.

In March 2016, Core used its newly refurbished wood chip facility to transfer 44,000 metric tons of wood chips onto the Andalucia. The wood chips were then carried to an overseas medium density fiberboard manufacturing facility.

AIA Recycling

In March 2016, Core loaded approximately 50,000 metric tons of scrap metal onto the vessel Scarabe to be shipped to Korea. This shipload of scrap was part of an ongoing project with a Greenville based recycling company and two of the largest motor vehicle manufacturing companies in the world. Core supplied all of the equipment and personnel necessary to successfully complete the job.