il Castorone – la più avanzata nave
posatubi al mondo: acquisti e logistica
Paolo Daleffe – Armando Favi
Castorone
concentration of technologies and
efficiency, Castorone is designed for
high productivity pipe laying of large
diameter trunklines in shallow to
ultra-deep water beyond 3,000m
also in extreme environments
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Castorone – comparison of two generations
how the new flagship
Castorone compares in size
with predecessor Castoro Sei
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Castorone – as big as an aircraft carrier
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in the next years many
projects will challenge the
industry with large
dimensions and harsh
environment, including
arctic conditions
Castorone – market drivers
the market of flowlines
and large trunklines is in
espansion especially in
deep water: 25% of
21.000 km planned in
the next 4 years will be
in more than 500m wd
Castorone with his
outstanding productivity meets
the future market requirements
in a vaste range of scenarios,
reducing project schedule and
risks and improving the client’s
economics
Saipem’s target projects: crossings
of Black Sea and Mediterranean,
trunklines and deep water field
developments in Gulf of Mexico, South
Atlantic, Asia Pacific and Russia
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Castorone – unique technical features
 Much higher productivities in S-lay and J-lay modes
(36m pipe strings, 20,000t pipe storage capacity)




25% productivity increase in Nord Stream-type situation
better use of seasonal windows
limited weather standby
lower overall project cost
 Much broader application range with significantly
improved flexibility
 From ultra-deep to shallow waters, also in S-lay, by simply adapting
stinger configuration (advanced control system)
 Advanced weather capabilities
 Fast moving dynamic positioning capability
 On-board switch from S- to J-lay to suit route and depth - one vessel only
for the entire project
 In line installation of large/heavy structures
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Castorone – portfolio of orders
First Projects with Castorone, all in high productivity S-lay mode
Committed until early 2015
Castoro lay barge,
Saipem’s first offshore construction vessel,
a converted oil tanker (1966)
● Walker Ridge Export Pipeline, GoM
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(Chevron)
Max 2,140 m wd
Big Foot Oil Export Lateral Pipeline,
GoM (Enbridge)
Max 2,200 m wd
Keathley Canyon Export Pipeline,
GoM (Williams)
Max 2,100 m wd
Tupi NE - Cabiunas Trunkline,
Brazil (Petrobras)
Max 2,230 m wd
Gas Export Pipeline for Ichthys
LNG Project, Australia (Inpex) 550
miles, 42”, max 275 m wd
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3000 feet water depth
Castorone – Walker Ridge
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high versatility: from
ultra deep waters…
the debut: Walker Ridge
project for Chevron 219 km, 24in, in 2.140
m water depth
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Castorone - Ichthys
…to shallow water,
long distance and
large diameter
in Australia the EPCI contract
with Impex for the 889 km,
42in trunkline in max 275 m
wd from the Ichthys production
platform to the onshore LNG
plant in Darwin
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Castorone – the Italian content
main innovative systems conceived by Saipem
and built in Italy
 Navalimpianti Genoa:
pipe handling and storage systems
 Righini Ravenna:
triple joint prefabrication plant
 Goriziane Villesse (GO): firing line machines – telescopic linkage ramp
 Remacut Rivoli (TO):
tensioners (3 x 250 t) – jacking system
 Remazel Bergamo:
A/R and DMA winches
 Redaelli Milan:
A/R cable
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Castorone
the triple joint
pre-fabrication
plant
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Castorone
the laying
ramp
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Castorone
Purchasing for Materials and Vessel Equipment
 In excess of 600 purchase orders in 16 countries
Italy
Netherlands
Finland
South Korea
China
Germany
Others
Share of value
69%
16%
7%
2%
2%
2%
2%
Share of orders
47%
5%
2%
1%
2%
2%
41%
 The core equipment has been purchased in Italy, involving a
significant effort in research and technology development, by coengineering with key suppliers.
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CASTORONE – Transports management
1. First phase strategy: shipyard YANTAI RAFFLES, China
First phase has been focused on main structural works from keel laying to hull and
main structures fabrication. During this phase transportation has been managed as per
standard Onshore Project freight forwarding philosophy: one Frame Agreement awarded
to one single subcontractor on a competitive basis to cover the whole range of shipments.
2. Second phase strategy: shipyard KEPPEL, Singapore
The Vessel has been towed to Singapore, where the completion of naval shipbuilding
works and equipment outfitting has been carried out.
In order to minimize time & costs, reduce interfaces and mainly improve risk
management, it has been decided to issue a dedicated tender for the transport of main
bulky Items liaising directly with Owners. Notwithstanding this medium and smaller size
equipment have been anyway managed through existing frame agreements:
 shipments by sea of normal cargo and by air have been arranged through general
frame agreements.
 shipments by sea of OS/OW have been arranged through specific Transport
Contracts (BIMCO Gencon 94, Heavycon 2007 and Heavyliftoy 2009) awarded
straight to Ship Owners.
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CASTORONE – OS/OW transport management
Main transports managed through Transport Contract awarded to Owners
1.
Redaelli Steel Wire Ropes
from Trieste port to Singapore
World’s heaviest rope
2. Remacut Stinger Jacking System
from Marghera port to Singapore
dim of pieces up to m 53,35x 4x5,2
3. Remazel DMA Winch
from Trieste port to Singapore
transhipment from barge to Ocean Vessel
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CASTORONE – OS/OW transport management
Main transports managed through Transport Contract awarded to Owners
1. STINGER RAMPS shipment from Rotterdam to Singapore
 about 22.630,00 freight units
 Direct urgent delivery to Singapore
 high level of criticality due to all the issues mainly related to (a) loading
activities at manufacturer premises (b) direct unloading of the ramps from
ocean going vessel to Castorone during her dry dock in Singapore
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CASTORONE – OS/OW transport management
Main transports managed throught closed Transport Contract to Shiponwners
STINGER RAMPS shipment from Rotterdam to Singapore
Loading from manufacturer quay onto barges with floating crane Matador 3
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CASTORONE – OS/OW transport management
Main transports managed throught closed Transport Contract to Shiponwners
STINGER RAMPS shipment from Rotterdam to Singapore
Transhipment to Rotterdam port by barge
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CASTORONE – OS/OW transport management
Main transports managed throught closed Transport Contract to Shiponwners
STINGER RAMPS shipment from Rotterdam to Singapore
Loading from barges onto ocean vessel with floating crane Matador 3
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CASTORONE – OS/OW transport management
Main transports managed throught closed Transport Contract to Shiponwners
STINGER RAMPS shipment from Rotterdam to Singapore
Ready for sailing to Singapore
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Castorone – stinger ramps at arrival in Singapore
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Castorone – stinger ramps at arrival in Singapore
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Castorone – stinger ramps at arrival in Singapore
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Castorone – stinger ramps at arrival in Singapore
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Castorone – stinger ramps at arrival in Singapore
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Castorone
inaugurated in Singapore on september 9, 2012,
will start operations in the GoM in March 2013
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