When a drilling rig needs repair, especially in the high-stakes oil and gas sector, every day counts. Downtime for a commercial vessel can translate into massive costs. Understanding this urgency, Mammoet recently assisted Damen Shiprepair in the Netherlands to expedite a critical jack-up leg repair on the Noble Corporation’s drilling rig, Noble Regina Allen, using the Mega Jack 5200 system. This choice ultimately cut down repair time and demonstrated an efficient response to unforeseen challenges.
Initially, Mammoet planned to utilize one of its powerful PTC ring cranes, which would have hoisted the massive 22,000-ton rig directly. However, after reviewing other strategies to streamline the operation, Mammoet shifted course to the Mega Jack 5200 system. This change not only minimized setup time but also aligned with the restricted timeframe in the drydock, which was only available for a short window.
Mammoet’s collaboration with Damen Shiprepair, built on more than 20 years of partnership, played a significant role in the swift execution of this project. Given the complex requirements, Mammoet proposed three distinct methods to Damen and Noble Corporation during a strategy meeting in Houston. Each method was tailored to different scenarios, allowing Mammoet and Damen to adapt quickly depending on availability, equipment, and the physical constraints of the rig.
The first option was straightforward, proposing the use of the Mammoet PTC210 crane positioned quayside to lift the rig leg. The second involved placing a smaller crawler crane directly on the vessel’s deck to complete the repairs. The final option—the one selected—was to lift the entire vessel with Mammoet’s Mega Jack 5200 and perform the repair from underneath. This approach promised faster mobilization and optimal safety, especially with the clock ticking.
René van Lint, Project Manager at Mammoet, explained how they fast-tracked the Mega Jack assembly to fit within the tight timeline, assembling the system in just seven days instead of the usual 15. By doubling their workforce and leveraging Mammoet’s extensive fleet, they managed a seamless setup. Once the dock was prepped and support blocks positioned, the team floated the rig into the drydock, drained it, and lowered it onto the blocks. This prepared the groundwork for lifting the rig 35 meters using the Mega Jack, enabling crews to access and repair the leg from below.
Mammoet arranged six Mega Jack towers, each capable of lifting 5,200 tons, to handle the immense load. Smaller cranes and forklifts assisted in setting up the structure. To fit beneath the rig, the 70-meter leg was cut in half. Mammoet’s self-propelled modular transporters (SPMTs) maneuvered each section into place. Damen Shiprepair completed the weld, reassembling the leg and preparing the rig for service much faster than initially anticipated.
Reflecting on the project, van Lint emphasized the importance of Mammoet’s close relationship with Damen, stating, “Damen are our neighbors, and we have been working with them for a very long time on offshore-related projects. We work together closely, and this was especially evident during this project.”
This collaboration not only enabled quick mobilization but also set a precedent for future large-scale offshore repairs, proving that similar methodologies can achieve high efficiency and reliability.
