Case Summary

Thunder Cranes, collaborating with New Partner Energy (NPE), was engaged to execute Phase 1 of the replacement project: the safe dismantling and removal of the damaged platform crane boom. Rather than using a costly floating crane barge—which would subject the delicate operation to dynamic sea swells—Thunder Cranes deployed a static, portable-modular crane package directly on the platform deck to ensure maximum stability and control.

Key Project Details

• Location: Offshore Angola (Block 3)

• Application: Platform Crane Replacement / Facilities Engineering

• Key Challenges: Broken crane boom suspended at height, restricted deck space, need for structural deck reinforcements, and transfer of equipment over 200 meters across connected platforms.

• Services Provided: Comprehensive site survey, engineering design, modular rental cranes (TC20 stiff-leg crane and TC05 assist crane), custom rigging, skidding, and rope access support.

• Primary Benefits: Safer static lifting, zero dependence on floating barge cranes, cost-effective execution, and interim lifting capability for ongoing platform operations.

Challenges & Engineered Solutions

• No Functional Crane on PALP2: The primary crane on PALP2 was non-operational. Thunder Cranes offloaded the TC05 and TC20 components onto the adjacent PALP1 platform using PALP1’s working crane. The components were then manually skidded across a 200-meter bridge walkway to reach PALP2.

• Structural Deck Constraints: The target 17 Deck on PALP2 required structural reinforcement to support the TC20 crane’s reaction forces. Specialized welders cut open the deck, added I-beams and spacer pads, and secured the crane base beams using welded dog plates. Handrails were temporarily removed and scaffolding was extended 1 meter outboard to create necessary working space.

• Hazardous Rigging at Height: The damaged boom could not be cut into smaller sections due to hydraulic oil leak hazards. Certified rope access personnel ascended and hung off the TC20 boom, using chain blocks and specialized rigging to safely secure and unbolt the suspended structure.

Steps & Sequence of Work

• Mobilization & Deck Preparation: Offshore mobilization for site preparation, handrail removal, scaffolding installation, and deck reinforcement welding.

• Modular Crane Transfer: Mobilized TC05 and TC20 to PALP1, offloaded using PALP1’s pedestal crane, and skidded all components 200 m across the connecting bridge to PALP2.

• Rig-Up & Testing: Assembled and welded base beams for TC05 and TC20 on 17 Deck. Suspended the TC20 boom over utility lines during assembly before performing rigorous load testing.

• Boom Lowering & Demobilization: The rope access team secured the PALP2 crane boom to the TC20 main block. The boom was unpinned, carefully lowered to the platform’s lower deck, and subsequently backloaded onto a supply vessel.

Outcome

Despite complex rigging requirements, structural modifications, and severe spatial constraints, the entire project timeline—from initial deck preparations to final boom removal—was completed in 67 days. The operation was delivered safely, on schedule, and without incident. In addition to removing the damaged boom, the TC20 modular crane remained on site to perform routine platform lifting duties, ensuring continuous operational productivity until a permanent crane could be installed.