Straight on the heels of successfully fabricating and supplying pipe line end terminals (PLET) for Shell’s Ursa/Princess waterflood project, Bayou Welding Works (BWW), a subsidiary of The Bayou Companies Inc. (TBC), was awarded a contract to fabricate 14 additional PLETs for Shell’s Perdido development. The Perdido PLETs are installed in nearly 10,000 ft of water, making them some of the deepest in the world.
The Ursa/Princess project saw the first use of the technology of another Bayou Companies subsidiary, Commercial Coating Services International (CCSI). CCSI’s internal fusion bond epoxy (FBE) InnerGard™ coating improves the flow of water, oil and natural gas by creating a smooth, defect-free surface. The company constructed a new coating plant specifically to apply internal FBE for the Ursa/Princess water injection lines. This new facility also was used to internally coat the flowlines and pipelines supplied to the Perdido project.
The first load out of PLETs and other flowline and pipelines were completed on schedule while the second load out was completed ahead of schedule with no lost-time incidents. Among the welds and coating provided by TBC were double joint welding to combine two 40 ft joints prior to coating operations, FBE coating, triple layer polyethylene (TLPE) coating to provide abrasion and corrosion protection for pipes contacting the seabed, glass syntactic polyurethane (GSPU) coating of line pipe, forging production welding of end pieces for installation and forging collar coating.
The steel catenary risers were counter bored at the end of each pipe to provide a smooth ID. A total of 1,108 joints of 10-in. and 16-in. pipe were counter-bored for a total of 2,216 bores.
Full array of services
The Bayou Companies was established in 1942 as a one-man, one-welding truck operation and has grown to provide welding and coating services to the some of the largest offshore oil and gas production projects in the world. Today, the company provides a full array of welding and coating services, including pipe multi-jointing, pipe-in-pipe fabrication and insertion, and steel catenary riser, flowline welding and flow assurance insulation products.
The company has provided fusion bond epoxy coatings for more than 40 years and today operates multiple FBE operations locations in Louisiana, Texas, California and Canada. The facilities can handle pipe diameters from 2-in. to 60-in. and up to 80 ft in length. TBC provides ID coating services for a smooth, defect-free surface at facilities in Louisiana, Texas and Canada, and can accommodate 2-in. to 48-in. diameter pipe in varying lengths. CCSI, which provided its InnerGard ID FBE coating, operates facilities in Louisiana, Texas and California.
|Perdido PLET sled S-2 and a double-jointed flowline with FBE and GSPU coating loaded to barge.|
In addition to providing PLETs, PLEMS, manifolds and jumpers, BWW also offers new offshore platform fabrication, production packages, living quarters and heliports. The company’s onshore fabrication facilities include a waterfront capable of handling up to a 100 ft x 400 ft barge, 10,000 sq ft of covered storage area, and 90 ft x 150 ft and 50 ft x 150 ft fabrication shops equipped with overhead cranes. Bayou Companies’ port of Iberia facility offers more than 280 acres of storage and access to the Intracoastal Waterway and the Gulf of Mexico with 6,000 linear ft of waterfront. The facility also features a 250 ton and 70 ton crawler cranes, a 70 ton cherry picker and the capacity to load more than 20 89 ft flat railcars within the facility.
The Bayou Companies strives to continually improve workplace safety and operations in order to provide quality products and services in an environmentally friendly manner. The company’s Quality Management System is in accordance with the requirements of ISO 9001:2008, ISO 14001:2004 and OSHAS 18001:1999.
The PLETs for Perdido being loaded to barge at Bayou’s waterfront facility.
It is The Bayou Companies’ extensive experience and expertise and its commitment to quality products and services that has resulted in large and small oil and natural gas companies around the world to choose the company for their pipeline and flowline welding and coating requirements.
The Bayou Companies, Inc.
5200 Curtis Lane
New Iberia, LA 70560
Tel: 1.800.619.4807 or 337.369.3761