Cutting system is customised for use on pipe-laying vessel

The Saipem 7000 is one of the world's largest semi-submersible crane and pipe-laying vessels, with the capacity to handle the entire range of offshore construction developments worldwide. It can lay pipes in water depths greater than 2000m and has a lifting capacity of over 14,000 tonnes. Owned by world-leading oil and gas industry contractor Saipem, the 198m long Saipem 7000 has now added an ESAB Falcon FXA 3000 cutting system to its comprehensive range of on-board equipment.

Saipem is a long-term customer of the ESAB Group, which was the first-choice supplier when the new cutting system was required. It is primarily to be used for pipe-laying and rig installations. On a short time scale, ESAB Cutting Systems designed and built a cutting system that suited the requirements of this unusual installation.

The Falcon FXA 3000 employs the most appropriate cutting gases and power sources as well as incorporating other specialist modifications. It has a 2.5 x 6.0m cutting area and is equipped with both an automated Cooljet BIE 220A gas cutting torch and an ESP 150 plasma cutting system. The use of acetylene rather than propane is important for safety on board the vessel. A fume extraction table with fan and ducting is also included, together with ESAB Columbus nesting software that provides the Falcon's Vision 51 ESAB CNC controller with the cutting programs.

A Vision 51 CNC controller provides links to Saipem's CAD office as well as connecting to the network onboard so that it can be interrogated by ESAB as part of its customer and product support services. A package of spares and consumables has also been supplied to ensure continuity of operation and to minimise downtime.

Cutting requirements

The Falcon is being used mainly for automated cutting of mild steel 8-100mm thick as well as stainless steel from 5-20mm. Plasma cutting is employed for thicknesses up to 25mm while, for greater thicknesses, oxy-acetylene cutting is used. This dual cutting process capability ensures high-quality cutting for all material thicknesses. The other major benefits of the Falcon in this application are its compact dimensions, easy loading thanks to its low rail on the outboard side, and ease of use. It can also be dismantled and relocated relatively easily.

Full installation drawings were provided to Saipem by ESAB. Normally the pedestals supporting the cutting machine's drive rail are bolted to the floor but, as this was not possible onboard the vessel, ESAB provided drawings of a special mounting plate that was manufactured by Saipem and welded to the deck before the pedestals were bolted to it.

As a global organisation, ESAB Cutting Systems' ability to provide support for the Falcon throughout the world was useful to Saipem. The design of the machine was project managed from the UK, manufacture took place in ESAB's Chinese factory, but it was modified to suit Saipem's requirements in ESAB's German factory before delivery and installation in Spain.

Contact ESAB Cutting Systems for more information about standard and customised Falcon FXA 3000 cutting systems.