Mammoet has completed the weighing, jacking and load-out of a 33,000t floating production unit (FPU) for Woodside Energy’s Scarborough project at the Qingdao McDermott Wuchuan (QMW) fabrication yard in China.
The operation utilised Mammoet’s Mega Jack 10000 system, marking its first use on a project of this scale.
Mammoet worked with QMW and project engineers from the early phases, beginning eight years prior, to develop a solution for moving and installing the FPU topsides module and its deck support frame.
Project teams determined that integrating weighing and jacking processes would reduce overall timelines.
The Mega Jack 10000 system, using four towers strategically placed under the load’s strongest points, lifted and weighed the topsides simultaneously.
Eighty load cells, each capable of measuring up to 750t, were incorporated into the system for accurate weight determination and even load distribution.
Engineers manufactured a bespoke load-spreading beam, which was fabricated and attached to the base of the topsides, allowing jacking operations from four points and also supporting construction activities.
Once the system established the final weight of the topsides, the Mega Jack towers elevated the structure to 16m, permitting insertion and connection of the deck support frame (DSF) beneath.
After weight transfer from the towers to the DSF, crews shifted the topsides onto the installation barge in measured increments, utilising eight strand jacks.
Mammoet managed barge ballasting to maintain stability during this transition and loading phase.
The engineering solution involved constructing the topsides near ground level, reducing the amount of lifting equipment required and minimising the reinforced surface area needed for operations.
The integrated beam replaced the need for additional steel in the form of conventional load-spreading beams, streamlining materials and equipment use.
This approach facilitated parallel construction activities and removed the need to wait for the support frame to complete before fabricating the topsides, avoiding work at height and promoting operational efficiency.
Previous planning discussions, dating back to the initial design stages, allowed for project efficiencies by enabling integrated lifting operations and closer ground-level work.
Mammoet’s involvement in the design process ensured the load-out process proceeded according to the planned schedule and specifications for the Scarborough development.
