A Case Study - Life Extension of Offshore Bridge Bearings
Abstract Structural bearings of 47 offshore platform-link bridges with average age of 40 years were inspected and recommended for replacements due to their poor condition. Replacement of bridge bearings involves major risk and production interruptions given the structural modifications, and critical piping and E&I disconnections required for safe jacking-lifting activities required during the process. This paper presents the approach adopted to assure the integrity of the bridges and extend their lives without the need to replace the bearings. The approach employed failure mode and effect analysis to identifying and narrowing down areas that need focused efforts while tackling the problem. Scenario based structural assessments were carried out to examine the impact of the level of movement-allowing bearings functionality on the integrity of the bridge and its supporting structures; identify critical locations to be targeted during focused inspections; and establish envelopes for monitoring thermal expansion and contraction of the bridges. Guidelines were developed and implemented for integrated inspection-maintenance and repair campaign, which aimed to tackle corrosion issues and to install movement-monitoring indicators. Indicator seasonal monitoring is employed to establish the functionality of bearings on the long-term. The what-if structural assessments revealed that even in the worst-case scenario (in which the bearing are completely jammed) the option of local strengthening of the bridge and its supporting elements is more attractive than bearing replacement. The integrated inspection-maintenance and repair campaigns revealed that excessive corrosion levels observed from historic visual inspections on external non-critical bearing components (e.g: guide plates, angles, etc.) is not indicative of the condition of the internal load-bearing components (pedestals) which experienced much lower corrosion levels. The seasonal monitoring of bridge movements revealed that the 40+ years old Teflon pads are still functional and allow the bridges expansion and contraction. The developed holistic approach enabled demonstration of the fitness for service of the bearings, and provided means for assuring their long-term performance through monitoring. The results assured safety, integrity and delivered significant cost savings through aversion brownfield modifications, and production loss associated with bridge jacking and bearing replacement operations.