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The Amazing Appomattox Oil Platform: First OilDuration: 11:40Description:Shell's Appomattox, a deep-water oil and gas project, is the largest floating production system Shell has ever built. Take a look behind the scenes as the Appomattox team makes final preparations and then safely and successfully delivers First Oil for Shell’s newest asset in the Gulf of Mexico.[Background Music]Driving, aggressive Sound of Shell music plays in the background[Video]The Amazing Appomattox at night. Illuminated. Massive and magnificent.[Interview]Asim ModiInstallation LeadIt’s like an airplane taking off on a runway. You get to a point and you have to go. And that’s where we are now.[Video]Appomattox has finally reached its home in the Gulf of Mexico, 80 miles off the shore of southern Louisiana. And now we realize what a spectacular feat of construction this platform really is. Four vessels are in the water with a massive crew, ready to prepare Appomattox to drill down into the sea floor.[Narration]Deep in the Gulf of Mexico, a crew of more than 400 spread out over four vessels is in the final, critical stages of connecting the Amazing Appomattox Oil Platform to the oil field beneath the seabed. [Video]From above and to the side, we get a better idea of the complexity and scale of this seven year project. Crew members are everywhere, working on the hull, welding and manning cranes to get Appomattox up and running. [Narration]It’s taken seven years and 15 million man-hours to get the largest oil platform Shell has ever built to the point where it can start production. [Animation]The Amazing Appomattox Oil Platform: First Oil[Narration]This is the story of its Installation and how Appomattox came to draw its ‘first oil.'[Text]Gulf of Mexico{Video]All is quiet in the pre-dawn hours in the Gulf of Mexico. Amin Modi, the Installation Lead aboard Appomattox, is monitoring progress.[NAT SOT](Phone rings) Hello. Asim it’s Gary. Gary, I can see you’re struggling with something. What’s happening? {Video]Asim Modi stares at a screen, nine cameras in all. He's monitoring progress all over the Balder construction vessel. Outside, a massive crane swings into place.[Narration]Engineer Asim Modi is in the middle of a monumental decision. For more than 7 months, he’s been aboard the Balder deepwater construction vessel, overseeing the welding and laying of more than 200-miles of pipeline in the Gulf of Mexico. [Animation]Animation shows the complex web of undersea pipeline, connecting undersea operations to Appomattox.{Video]Crew members stare intently at connecting pipes and monitors. The margin for error is razor thin. [Narration]Whether that pipe successfully hooks up with the nearby Appomattox platform depends on this moment.[Interview]Asim ModiInstallation LeadThe two pipes have to line up so there’s no more than half a millimeter difference between the fit up… For four years we’ve been doing all the engineering design to get to that stage, and it comes down to half a millimeter. It’s kind of astonishing.[NAT SOT]Asim ModiInstallation LeadAnd is it a critical weld or a non-critical weld? It’s a non-critical. [Interview]Sally SimmersInstallation LeadIt’s covered by the ECE so let’s talk to Phil and also Tom.{Video]Modi turns his attention back to the monitors. Welders fill almost every camera angle. The welders' focus and attention to detail are critical. [Interview]Mike DupreSubsea Engineering ManagerEach weld receives a different amount of stress in a different amount of fatigue damage over its life. And so, depending on where it is, the criteria for a good weld is very different.{Video]Sally Simmers, another Installation Lead, watches over Modi's shoulder as he speaker with another crew member. [NAT SOT]Asim ModiInstallation LeadThis is Gary. Gary, this is Asim. Tom was on the line. He verified what I said. He had allowed to go to .75, and so on this occasion, that weld is good to go. Ok, I’ll call the tower and let them know we’re good to go. Cheers, buddy. Thank you.{Video]The welding team down below finishes their work after receiving approval from Modi. From the Balder construction vessel, we see Appomattox in the distance, basking in the sunlight. [Narration]With the go ahead given, the team finish up the final pipe work, preparing for the crucial moment when it will be connected to the Appomattox.[Animation]Animation shows the tree system of pipelines spoking out several thousand feet below the ocean's surface. [NAT SOT]Richard CrichtonSubsea ManagerOne of the dilemmas is with such a large tree system, 200-thousand pounds, how are we actually going to install this safely?[Animation]Animation takes us through the extensive subsea operational system. From above, the asset resembles a massive spider. [Narration]Design engineers are working with a subsea system that’s almost double the size of any other Shell has previously used. The team needs to lower the asset, roughly the weight of a space shuttle, 7 thousand 4-hundred feet to the seabed, and land it on a target less than half an inch wide.[NAT SOT]Richard CrichtonSubsea ManagerSo there's not a lot of room for error and we've got some very sensitive components which we have to make sure mate correctly from the tree into the top of that well.{Video]A large onboard crane moves into position as they lower an ROV into the water. With the ROV now submerged, the operator goes to work, positioning the ROV using a large bank of monitors. The operator controls the ROV with a joystick, a delicate maneuver. The pressure of completing the operation correctly is written all over the operator's face. On the seabed, the funnel system connects perfectly.[Narration]To set the sub-sea tree in place a giant crane and ROV are used. The team guides the tree a mile-and-a-half down in a complicated procedure that takes about 24 hours to complete. Once the tree nears the target, the ROV operators move from monitoring to full engagement, making sure the tree doesn’t go astray and land in the mud on the seabed. With laser-like precision they land it perfectly on the narrow target that’s less than half an inch wide. The tree’s funnel system then self-adjusts to ensure all parts lock together.[Interview]Mike DupreSubsea Engineering ManagerIt was a pretty amazing feat but I have a great team; specialists of all kinds who are able to do amazing things.{Video]Skimming along the ocean's surface, we approach Appomattox. From above, we see the platform and surrounding vessels prepare to do the delicate dance of the "riser transfer."[Narration]With the subsea systems in place, it’s time for the Balder to hand the final pipeline over to the Appomattox. The process is called a ‘riser transfer’ and it requires four vessels to perform complex movements, in perfect synchronicity, on the water.[Interview]Noah SmithwickProject EngineerThe transfer is dramatic. It’s a really heavy load being transferred from one vessel to the host.?[Animation]Animation shows the "riser transfer," an undersea hand-off from the Balder construction vessel to Appomattox. [Interview]Noah SmithwickProject EngineerWe pay our chain out so the Bylgia can recover the chain. The Bylgia and Balder both connect the chain to the riser. Then basically they lower the riser into the water until we take the load.?{Video]On the surface, we now see the size of the Balder construction vessel as it moves closer to Appomattox. Control room crews share information across walkies and phones.[Narration]The Balder, which rivals the size of the Appomattox, comes within a few feet of the platform. So, the control rooms on all sides stay in constant communication, making sure the vessels don’t come in contact. {Video]Michelle Brunkenhoefer, a Control Room Operator, eyes several monitors to keep the Balder from colliding with Appomattox. [Interview]Michelle BrunkenhoeferControl Room OperatorThe most critical point is that you have to make sure the facility is positioned in the right direction that the vessels need in order to place the riser into the basket.[Interview]Paul HattyVersabar OperatorIf you miss one step, if you have a lot of weight on it and one of the chocks doesn’t close properly, well then you have a potential problem that everything can take off on you.?{Video]Appomattox sits just a few yards away from Balder. Spotters aboard each vessel communicate constantly to position and re-position, visually and verbally. [Interview]Noah SmithwickProject EngineerThings can clash so we constantly have people spotting to we make sure we don’t have any steel touching.?{Video]A heavy chain is visible on the surface, while in the control rooms, all eyes are on the monitors. [Interview]Sally SimmersInstallation LeadThis is the point where most of the interfaces we’ve been working as a team for the last few years all come together.?[NAT SOT]A steel cable snaps.{Video]Below the surface, we see what the entire team has been waiting for-- the pipeline. [Narration]A steel cable is cut, allowing the pipeline that will bring up the oil to be connected to the Appomattox. [Interview]Paul HattyVersabar OperatorWe’re all stop. [NAT SOT]All right guys, good job. Risers in the basket. Ok fellas. Nice. Good job, Paul. Stephen. Way to go, Stephen.[Interview]Michelle BrunkenhoeferControl Room OperatorWhen you can safely get it in the basket and there’s no incidents and the day is done. It’s a good feeling.{Video]Over the shoulder of a crew member aboard the Balder, we see Appomattox in the distance, aglow from the setting sun. [Narration]With installation complete, it’s now time to attempt to bring up oil from the subsea reservoir to the Appomattox for the first time. {Video]An overcast day from the ship's cockpit, as we look below at the drilling operation.[Interview]John HeideDeepwater Proteus Ship MasterWe’re just southeast of the Mississippi about 100 miles offshore. The depth of water is 74-hundred feet and we’re drilling to a good 4-point-5 miles down.[Video]The main rotary table torques as crew members observe. A lone crew member peers out over the Gulf of Mexico expanse, as waves crest and fall.[Narration]Working at these depths is a complicated and time-consuming procedure. [Interview]Garry JordanBusiness Opportunity ManagerYou’re working over a mile and a half beneath the sea so you can’t reach out and touch things. [Video]Garry Jordan works modeling software on his computer as crew members operate heavy equipment in the open ocean. [Interview]Garry JordanBusiness Opportunity ManagerAnd then you put a reservoir that’s 25-thousand feet below sea level, everything has to be done by logs and visualizations and remote operated vehicles. [Video]Aboard the deck of the 781-foot long ultra-deepwater drillship, Deepwater Proteus, we see the months of prep work on the wells themselves. [Narration]While the Appomattox platform was being constructed, prep work was started on the wells getting them ready for the day when the first oil would flow. [Video]The early morning sun cracks through the drilling structure aboard the Deepwater Proteus as crew members monitor the remote drilling process.[Interview]Olayinka AdeleyeWells Operations ManagerWe kinda did things in phases. We just finished VX2 which is the third well, so we really have three wells in the ground now. [NAT SOT]Weather approaching[Video]The open ocean begins to churn and the wind picks up. The windsock sits stiff in the breeze. Inside, a monitor shows a NOAA weather warning of an approaching storm. [Narration]But just as things are looking good to go there’s some bad news. A storm moves in which could make striking first oil a lot more complicated.[NAT SOT]Thunder and lightning approach.[Video]The storm strikes suddenly and violently. Wind and rain rip thru the topside of Appomattox. Sheets of water batter the exterior. [Interview]Marno De JongProject ManagerWeather can be very challenging in the offshore industry. That does have a propensity to work things that are normally safe, less safe. [Video]Inside the cockpit, crew members monitor the very latest reports, including approaching cells.[Interview]John HeideDeepwater Proteus Ship MasterWe get weather throughout the day. We get various status sources that report to us about what to expect from weather.[Video]Monitors in the cockpit show direction and distance of the storm, which is relayed to the computer, allowing it to adjust the platform and operate continuously.[Narration]This information is fed into a computer which uses global positioning from satellites rather than anchoring to maintain the vessel’s position. [Interview]Chelsea RiceDynamic Positioning OperatorWe have six thrusters and six engines and those automatically change their position and thrusting force to keep us in a really tight watch circle. It’s actually more precise than anchoring.[NAT SOT]The storm tapers off.[Video]Time lapse footage shows the storm clearing topside. Crew members continue their work without missing a beat.[Narration]After hours of being battered by the storm, it begins to subside. The crew’s calm heads pay off and everything is kept stable until the storm passes. [Video]Crew members review operations plans while others patrol the deck, load and maintain heavy equipment. [Interview]Luke SpinuzzaWells EngineerEverybody responded really well. We all jumped up, and ran into the bridge, got on the phone with the drill floor. Everybody did exactly what they were supposed to do.[Video]Appomattox sits majestically atop the Gulf. Time lapse footage shows the storm clearing out, leading to a picture perfect day.[Narration]With the storm over, the work continues to achieve Appomattox’s first oil.[Interview]John HeideDeepwater Proteus Ship MasterThe Appomattox is just about ready for us to take the oil from the wells and now working those to completion.[NAT SOT]Helicopter comes in for a landing.[Video]We hear a Sikorsky helicopter coming in for a landing atop the helideck. Elsewhere, crew members topside prepare for first oil. Inside, all eyes are on the monitors. [Narration]As the moment of first oil draws near, the excitement begins to mount on the Appomattox.[Interview]Marno De JongProject ManagerAs you move towards the last bits and pieces, everybody starts realizing that you’re close to the end game.[Interview]Allison HallockOffshore EngineerSo much work has been done over the past several years. A lot of steps have gone into play from preparation for first oil.[Video]We follow Allison Hallock through the maze of machinery aboard the Deepwater Proteus, as another crew member rappels from above and another monitors gauges.[Interview]Kevin BurnsOperations SupervisorWe’re getting so close to the end. And everybody’s amped up and everybody’s, you know, ready.[Video]Shell team members stare intently at monitors, awaiting news from Appomattox. The tension is palpable and visible.[Narration]The Shell team are spread across Texas and Louisiana. They wait patiently for news that oil has finally reached the platform. [Interview]Marno De JongProject ManagerPart of the team was in the New Orleans office and of course a very important part of the team was offshore actually making it happen. [Video]Appomattox project members monitor a cluster of data screens, including one connecting the onshore and offshore teams.[NAT SOT]Come in Joe. I'm going to start up engine 27-52. Copy that. Go ahead.Alright, roger that. I'm gonna start increasing pressure. Temperature is rising. (beep) Looks like the well is flowing.(Applause)Good job![Video]Inside the control room as the Appomattox project team begins well operations. Applause breaks out and handshakes all around as the well opens. We look back at the work that went into making this project a reality.[Narration]Seven years since the Appomattox project first began and taking more than 15 million man-hours, the oil is finally flowing. It’s an emotional moment for everyone involved. [Video]Handshakes and huge smiles all around.[Interview]Allison HallockOffshore EngineerThe well opened. They said the well is flowing. [Video]An engineer tests the quality of the flow from the well.[Interview]Allison HallockOffshore EngineerEverything worked well topsides. We had really stable flow which is exciting.[Video]A long line of project team and crew members cheer loudly as news of the well opening spreads. [Interview]Tim FrankOperations ManagerReaction was both relief on one hand and a feeling of immense responsibility on the other. [Video]Crew members shake hands, high-five and embrace across the vessels and onshore.[Interview]Allison HallockOffshore EngineerThere was a lot of handshakes, high fives. Some hugs, maybe some tears. [Text]Rick Tallant, VP Production GoMCongratulations to the Appomattox team. After four long years, first oil. Done safely. Well done everybody. Fantastic job.[Audio: Speaker]Congratulations to the Appomattox team. After four long years, first oil. Done safely. Well done everybody. Fantastic job.[Audio](Applause)[Interview]Marno De JongProject ManagerPeople were dancing in the corridors, jumping with joy because Appomattox had started up. [Interview]Todd CoulonOffshore Installation ManagerYou don’t get too many opportunities like this in your career, to bring on a facility in this magnitude. I get goosebumps just talking about it because I’m so proud. [Video]Todd Coulon stands and smiles with pride, after four years of hard work is realized. We see Appomattox in full operation from above.[Narration]It’s an immense accomplishment for everyone who’s helped design, construct, install and operate the Appomattox. [Interview]Marno De JongProject ManagerIt’s been an enormous team achievement but this is not the end. There’s a duty now to take care of this asset for the next 40 years. [Video]Allison Hallock takes in the view along a catwalk aboard Appomattox, then we look back at the hull construction team in Geoje, South Korea.[Interview]Tim FrankOperations ManagerPersonally, I’m very humbled to be a part of this project. It’s exciting, but it’s also one of the most humbling things I’ve ever done. [Video]Appomattox, from plans to fruition, involving thousands of people and endless hours of work, now sits in all its glory in the Gulf of Mexico. Kelly Bowen, the Fabrication & Integration Lead can only smile at some of his handiwork.[Interview]Garry JordanBusiness Opportunity Manager I’m proud to be a part of this team. You sit back and reflect and go "wow, what a journey."[Video]A drone captures the entire crew waving from high atop the helideck as we close on Appomattox silhouetted by the afternoon sun.[Close]Close card with pecten and mnemonic.[Narration]Subscribe to Shell’s YouTube channel to see more on the Amazing Appomattox Oil Platform and other technology and engineering films from Shell. ................
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