A new, light-weight modular living quarters module, designed for offshore platforms, uses structural sandwich panels constructed by vacuum bonding aluminum to a polyvinyl chloride ("Divinycell") structural core.
This manufacturing process has been used successfully in the marine industry, oil and gas pipeline installations, and refrigerated containers, according to manufacturer Total Building Systems Inc. (TBS).
TBS constructed the 85-man quarters package for Sundowner Offshore Services. The package and a drilling rig will be shipped to a platform offshore Trinidad later this year, where it will be put into service under a contract with British Gas plc.
The unit contains 16 modular buildings each 10 x 10 x 40 ft. These weigh 145,000 lb. The steel quarters support structure weighs 140,000 lb, totaling 285,000 lb for the entire structure. In comparison, a conventional steel design with 16 units weighs 480,000 lb with the steel quarters support structure weighing 140,000. That is a total of 620,000 lb.
The aluminum/Divinycell modules are strong, durable, and noise absorbing. If burning, fires self-extinguish once the source of the flame is removed, according to TBS. The modules can easily be taken apart and relocated to other platforms.
The finished weight of this building design, compared to that of a conventional design, allows an operator the flexibility to use an existing rig or platform crane for the installation. TBS says the buildings are stackable up to three high, for easy addition of more quarters. The helideck can be designed to be an integral part of the roof and to accommodate various helicopter sizes, including a Bell 212 or Sikorsky 76.
The buildings comply with American Petroleum Institute (API) design guidelines for offshore living quarters and meet specified safety factors. API requires offshore living quarters to withstand hurricane force winds of 166 mph, and this building is rated for 180 mph wind loads.
The building's end frames (two required per building) are fabricated of formed 316-in. carbon
steel. The angle frames are seal welded and equipped with ISO (International Shipping Organization) connectors at the top corners. These ISO connectors serve as the top lifting devices and as the mechanical connection for multiple stacked buildings.
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