“IMPROVING PRODUCTIVITY, TIME MANAGEMENT & CONTROL OF

WELDING COSTS IN FABRICATION OF OFFSHORE OIL & GAS PROCESS

AND WELL HEAD PLATFORMS”

Hitesh Bhanushali1a, Adil Bhathena 2a , Hiral Patel3a ,

Hardeep Singh4a, Mrunal Prajapati5a, Pratik Gandhi6a

1 hitesh.bhanushali@larsentoubro.com (9687643126), 2 adil.bhathena@larsentoubro.com

(9879113170), 3 patel.hiral@larsentoubro.com (9879113185),
4 hardeep.singh@larsentoubro.com (9879113238), 5 mrunal.prajapati@larsentoubro.com
(898006543), 6 pratik.gandhi@larsentouro.com (9924171790)

a L&T Hydrocarbon, MFF- Hazira, Surat-Gujarat

ABSTRACT:

As Welding is one of the Core manufacturing processes in Fabrication of Offshore Process

and Wellhead Platforms for oil and gas, it is critical to look for ways and means which will
help improve overall product quality, improve productivity, reduce cycle time & cut down
on overall cost. On an approximate scale, the contribution of deposited weld metal towards
the total weight of module or platform generally accounts to 2.0 - 2.5%. The percentage of
weld metal deposited directly resembles the welding cost. Selecting the right process,
effective control & automation for a given application, optimized joint design / redesign of
Weldments, can decrease the required amount of filler metal, will help achieve results when
planned for maximum efficiency. This is a step forward to reduce costly reworks / repairs
and average cost of the consumables. Bearing this in mind, L&T-Modular Fabrication
Facility in Oil & Gas Upstream Business has developed innovative methods to control
Welding cost. The special measures taken for cost reduction includes Verification
constructability at design stage, proactive Planning of process automation, implementing
Ceramic backing for direct open root welding, Optimizing Groove Designs, use of semi-
automatic Processes, Skill enhancement training to welders & welding operators,
Standardizing Good Engg. Practices providing Welding Aids, IT development, support for
process data entry, system control & documentation. Effective adaptation of above
mentioned methods over last six years has resulted in increase in “First Time Acceptance”
in NDT of welds by 56.25%, weld metal deposition using automated methods has increased
by 18% and Deposition rate per welder has increased from 3.8 kg per shift to 5.5 kg per shift.

Keywords: Productivity, Optimizing, Automation, Standardizing

  DETAILS OF THE CONTRIBUTION MADE

The Structure of Multi Million Projects is designed to produce million barrels of Oil
which ignites lives of Human-beings. The Design, Manufacturing and Installation of these
structures is the biggest challenge and requires remarkable team efforts. L&T MFF is one of
the leading players in South East Asia for manufacturing of offshore modules. Welding is
the core manufacturing process used in fabrication of these offshore structures.

To cut down on the overall project fabrication cost, some of the welding variables
can be optimized. The aim is not only to minimize the overall cost but also to enhance the
overall final product quality. Welding variables are tactically maneuvered to Increase
process efficiency, optimizing cycle time and thereby reducing overall cost without
compromising with final product quality.

For any given application, some processes are more economical than others. This
paper presents some of the initiatives taken by L&T Modular Fabrication Facility for
improving productivity, managing time & control of welding costs.

1. Implementation of Mechanized SAW (Submerged Arc Welding) in Pad-Eye and

Lifting Trunnion Assemblies

One of the most critical assemblies of Off-shore Jackets are Lifting Trunnion and Lifting
Pad-eye. These assemblies are structural member which is used for lifting Jackets for
installation at Offshore and hence has to be capable of taking complete load of the
structure.

Fig 1: Ceramic Backing for Double-Bevel Groove Joint

A lifting trunnion assembly typically consists of Main shear plate, Mitre Tubular and
Ring stiffener. Shear plates are welded to Main Leg of Jacket with double bevel groove
welds. Mitre tubular are welded with each other by 90 Deg by SAW.

A lifting pad-eye assembly typically consists of Main plate, Cheek plate and Shear
plate. Thicknesses of these plates typically vary from 50–120 mm and their welding
involves huge amount of Weld Metal.

Conventionally, these joints were welded using SMAW process. To decrease cycle
time and maximize cost savings, indigenous setup was developed to employ SAW
process in place of SMAW process
 Table 1: Cost Savings by using SAW with Ceramic Baking - BH Jacket (08 Nos.)

SMAW SAW
Total Weld metal [kg] 364 364
Cost of Consumable /Kg [INR] 75275 63882
Manpower Cost 93184 25480
Man Days 101 20
Electricity Cost [INR] 23805 10920
Total Savings INR 91,982

2.Use of Mechanized Submerged Arc Welding Processes:

2.1 Submerged Arc Welding for Cheek Plates in Lifting assemblies

A lifting pad-eye assembly typically consists of Main plate, Cheek plate and Shear
plate. These plates are welded to each other using circumferential fillet welds.
Thicknesses of these plates typically vary from 50–120 mm and their welding involves
huge amount of Weld Metal.
Conventionally, these circumferential fillet joints were welded using SMAW
process. To decrease cycle time and maximize cost savings, indigenous setup was
developed to employ SAW process in place of SMAW process.

Fig 2: SAW Set-Up & Welded Assembly (Pad Eye)

Table 2: Comparison of SMAW and SAW Process for Cheek Plate Welding

SMAW SAW
Total Weld metal [kg] 192 192
Cost of Consumable /Kg [INR] 39706 33696
Manpower Cost 49152 13440
Man Days 54 11
Electricity Cost [INR] 12557 5760
Total Savings INR 48,519
2.2 Submerged Arc Welding for Miter Joints in Lifting assemblies

In BH Jacket fabrication 4Nos. of 90ᵒ Mitre

Assemblies welded using SAW Process with
designed in-house fixture attachments to
Implement Automation & Improve productivity

Fig 3: SAW Set-Up for Mitre Joints

2.3 Submerged Arc Welding for Conductor Guides, Riser Clamps and Stiffener
Joints

2.3.1 SAW for Conductor Guide

Conductor guide assembly for conductors of an offshore well platform having a
jacket with an interior pile for extending from a sea bed to above a water level which is
over the sea bed. In BH Jacket fabrication of Conductors Guide Joints welded using SAW
Process with designed in-house fixture attachments.

2.3.2 SAW for Riser Clamp and Ring Stiffener Joints

Riser clamp is used by mechanical building trades to support vertical runs of piping
at each level of jacket. The devices are
placed around the pipe and integral
fasteners are then tightened to clamp them

onto the pipe. Riser Clamps Joints welded using SAW Process. Total 4Nos. Ring Stiffener
to Flange joints welded using SAW
 Fig 4: SAW Set-Up for Conductor Guide

Fig 5: SAW Set-Up for Riser Clamps and Ring Stiffener Joints

Table 4: Comparison of SMAW and SAW Process (Mitre joints, Conductor Guide,
Ring Stiffener and Riser Clamp joints welding)

SMAW SAW
Total Weld metal [kg] 1092 1092
Cost of Consumable /Kg [INR] 225825 191646
Manpower Cost 279552 76440
Man Days 303 61
Electricity Cost [INR] 71416 31760
Total Savings INR 2,75,947

2.4 Using SAW for Upending Pad-eye Ring Plate Joints

In BH Jacket fabrication 12 Nos. Joints of upending pad eye ring plate welding was carried
out with using in house turn table positioner.

Fig 5: SAW Set-Up for Upending Pad-eye Ring Joints

Table 5: Comparison of SMAW and SAW Process (Upending Pad-eye Ring Plates)

SMAW SAW
Total Weld metal [kg] 117 117
Cost of Consumable /Kg [INR] 24196 20533
 Manpower Cost 29952 8190
Man Days 33 7
Electricity Cost [INR] 7652 3510
Total Savings INR 29,567
2.4 Using SAW for Shear Key Welding from ID side of skirt sleeves

In BH Jacket Sher Keys (Square bars) welded using SAW on the inner surface of skirt leg.
Increases sliding resistance between Skirt leg and Skirts piles. Transfers load from platform
jacket to piles. Total 232Nos. Sher Keys joints welded by SAW.

Fig 6: Shear Keys welded by Using SAW

Table 5: Comparison of SMAW and SAW Process (Shear Keys Welding)

SMAW SAW
Total Weld metal [kg] 1126 1126
Cost of Consumable /Kg [INR] 232856 197613
Manpower Cost 288256 78820
Man Days 312 63
Electricity Cost [INR] 73640 33780
Total Savings INR 2,84,539

Savings for BH Jacket (BDP): - 7.30 INR Lacs

Saving for N23 Jacket (MHNRD-III Project) : 5.00 INR lacs

 Standardizing Good Engineering Practices

1) Monthly Consumable wastage analysis & control:

2) Welding sequencing:
3) Attending Weld repairs:
4) Best Welder awards for enhancing workmen motivation:
5) Regular Tool Box Talks:

 SUMMARY

To remain in business and achieve sustainability, it is inevitable for any company today
to remain alert and keep upgrading on technologies and human resource. In the continuous
endeavor to set benchmark, MFF-H has tried to upgrade itself on technology front by
adopting better Welding Processes, better documentation system, standardizing Good
practices, etc. With the same we have been able to remain live in market and present very
tough competition to our global counterparts.

This kind of journey never ends and hence we have ongoing developments in pipeline
(viz. complete change-over to FCAW GS Process, SAW in 2G position, etc.)