World’s First Fast-Track Integration of Vessels with Spread Mooring System for LNG Operations

Executive Summary Drydocks World was awarded the CONGO LNG conversion project, TANGO FLNG and EXCALIBUR FSU in February 2023. A pioneering project based on the integration of two vessels using a spread mooring system, designed and patented by Exmar. This design permits combined assets to liquify, store and offload LNG, besides increasing LNG production by at least 15% above the original capacity and in this instance the modified process was designed to achieve approximately 1 billion m3 per annum. This worlds-first venture required fast-track execution involving Drydocks World engineering, fabrication, installation and commissioning of 12 steel mooring foundation structures of 4000T, associated equipment, piping and electrical systems, all within 5 months. Due to the critical nature of the project and the stringent requirements to ensure that the planned upgrades were suitable for the long deployment on site, the procurement team worked relentlessly to secure class certified cryogenic and exotic materials. These materials were extensively tested for compatibility at a Drydocks World certified laboratory. With concurrent projects ongoing in the shipyard and parallel engineering being implemented on multiple projects being executed simultaneously, Drydocks World took a strategic approach by optimizing workforce efficiency and deployed additional resources, peaking at 2000 personnel per day, while also maintaining the highest level of quality and safety standards. The utilization and management of twelve different fabricators to deliver structural blocks and assist with the final assembly at the shipyard ensured that there was no compromise on project delivery. The utilization of drydocks World 2000T floating crane for heavy lift operations aided in maintaining the delivery timeline. The use of various in-house portable and precision machining equipment like in-situ line boring machines, milling machines and flange facers provided the necessary flexibility to sequence activities onsite. During the upgrade, the yard optimized timelines by pre-rigging offshore mooring chains and polyester hawsers at its Mina Rashid facility, a task not originally considered in the initial scope of work and traditionally performed offshore. Dedicated dockings and life extension activities were carried out on both vessels to ensure a 20-year extension. Remarkably, this project was successfully completed on time with approximately 2.5 million manhours, zero Lost Time Incidents (LTI) and setting a new benchmark in fast-track conversions. This unique project sets a new milestone and standard for clean energy solutions in maritime and energy sector and underscores an unwavering commitment to shaping a cleaner, more sustainable energy landscape globally.