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Operations engineering

2 | Operations engineering

Oil and Gas at AtkinsSafe and efficient recovery from existing fields and exploiting new fields in difficult environments and uncertain market conditions present our oil and gas industry with many technical and economic challenges.

We have the breadth and depth of expertise, the intellect and the drive to overcome these challenges and help our clients to realise the full potential of their fields and assets. We strive to help improve lives, protect our planet and ensure prosperity through secure and affordable energy.

Working as part of a global community with our clients, industry partners and academia, we are listening, imagining and co-creating the best solutions in offshore engineering, onshore engineering and operations engineering.

Offshore engineering

Onshore engineering

Operations engineering

• Deepwater FPU design and engineering

• Fixed platforms• Subsea engineering• Process and facilities• Safety engineering

• Facilities design and engineering• Midstream LNG• Pipelines• Safety and process specialist

services

• Asset integrity management • Production optimisation • Brownfield projects • Late life management

Operations engineering | 3

Operations engineeringWe’re committed to helping our clients to reduce costs, maximise production, minimise downtime and improve safety and environmental performance in the face of ever-aging infrastructure, ever-changing reservoir performance and economic uncertainty.

Asset integrity management

• Process and facilities, structural, moorings and subsea integrity

• Integrated safety and risk services

• Reliability, availability and maintainability

Production optimisation

• Production efficiency, root cause analysis and debottlenecking

• Subsea flow assurance

Brownfield projects

• Multi-disciplinary assess, concept, FEED engineering and verification

• Global integrity assessment

• Strengthening, Modification and repair

• Safety and risk services• Commissioning support

Late life management

• Late life asset management

• Life extension• De-manning• Decommissioning

Our 800 oil and gas engineers and specialists combine their intellect, imagination and drive to deliver the very best in:


The best engineers

Our teams are made up of experts with deep knowledge of oil and gas structures, brought together over 40 years of acquisition, strategic appointments and investing in our people to retain the best talent.

Collectively our design and operations experience extends back to the late 1970’s with projects in the Gulf of Mexico, North Sea, Australia, Brazil, Middle East, West Africa, Caribbean, South East Asia and the Arctic. Our engineers’ judgment and expertise helps our clients make the most critical of decisions with confidence.

Whole asset, whole lifecycle perspective

Drawing on the broad and deep knowledge of our technical experts worldwide means we can take a whole life perspective and provide the best engineering across all aspects of an asset’s lifecycle; from concept through to decommissioning and abandonment.

ConCePt Help our clients select the economic, efficient

and safe asset to maximise field output

Design Preliminary, FEED and detailed design to meet the safety, budget, program and operational imperatives

DeLivery Supporting classification and regulatory approval,

fabrication, transportation, integration and installation

oPerAtion Establish the right maintenance and integrity management plans that minimise down time and optimise production while maintaining safe operations

extension Help extend asset life and safe, efficient production

DeCommissioning Support the optimum course for decommissioning


INSPECTION & FABRIC MAINTENANCE

CONTRACTORS & CONSTRUCTIONMulti-disc design, Construction, Implementation

Inspection & fabric maintenance

ATKINS OPERATIONS ENGINEERING

OPERATE OPERATEASSESS CONCEPT/SELECT FEED EXECUTE

BROWNFIELD PROJECTS

• Safety studies• Drilling support• Process led multidisciplinary assess & concept design

• Safety studies• Process led multi-disc assess & concept design

• PMC/Owners engineer• Safety studies• Multi-disc design reviews• Niche consulting

• PMC/Owners engineer• Safety studies• Multi-disc design reviews• Niche consulting

• Multi-disc engineering• Framework agreement• Asset integrity management (including structural)• Multi-disc assessment

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ATKINSATKINS

ATKINS

ATKINS

ATKINS

Support to brownfield modifications

Our clients:

• BP• Maersk• Chevron• Woodside• Apache• Saudi Aramco• Centrica• CNR• Talisman• Premier Oil • Shell• SBM• Teekay

Thinking like an operator

Our 40 years supporting operators throughout an asset’s lifecycle means we understand our clients’ goals and can share their vision to balance incremental improvement of production, maintain integrity and assure safety.

It matters to us that assets are future proofed to optimise through-life operation, so we actively ensure lessons learned are fed back into our design and integrity management delivery systems to ensure capital spend is optimised and operational expenditure minimised.

Delivering as true partners

We work hard to earn and retain our clients’ trust and stand by them when faced with increasing complexity or even adversity. We want to sit side by side with our clients, listening, sharing knowledge, leaning in to challenges and delivering what we say we will. We function in complete independence of contractors and operators, so our sole interest is to provide top quality engineering to solve the task at hand.

Whether engaged as one multidisciplinary delivery team for a brownfield project or embedded as a specialist team for operational support, we work together with our clients and partners to bring different disciplines closer together and ease the managing of multiple suppliers.

Thinking like an operatorWe know our clients; we’ve been working together for 40 years; we understand their goals and can share their vision.


“Maximum safety, cost reduction and production improvements are in our DNA.”

Anywhere in the world

OTHER ATKINS OFFICES•

• ATKINS’ ENERGY OFFICES: United Kingdom and Europe: Aberdeen, Bristol, Derby, Epsom, Esbjerg, Glasgow, Leeds, London, Rotherham, Warrington, Whitehaven North America: Calgary, Charlotte, Houston, Trinidad & Tobago Middle East: Abu Dhabi, Sharjah, UAe; Al Kobar, saudi Arabia Asia Pacific: Perth

Asset integrity & late life management of offshore oil & gas assets North Sea

Mars B Gulf of Mexico, US

Claymore life extension North Sea

Designing offshore oil & gas structures Gulf of Mexico, US

Safety and risk services to Fort Hills oil sands facilities Fort Hills, Canada

HAZOP & enhancing safety Frade FPSO, Chevron, Brazil

Offshore personnel risk assessment (OPRA) Gulf of Mexico, US

Reducing cost of offshore wind farms DONG Energy, UK

Solan field development Premier Oil, North Sea

Valhall redevelopment BP, North Sea

Tension leg platform design ExxonMobil, West Africa

Structural integrity management for onshore & offshore platforms BP, Trinidad & Tobago

Offshore floating wind platform design WindFloat, Portugal


Our engineers work together across our international network of technical hubs in the UK, Middle East, North America and Asia Pacific regions. This means that wherever in the world a project needs to be delivered, our clients benefit from our ability to quickly mobilise a team of industry-leading experts and dedicated local contacts.

We support projects from our hubs, close to our client’s base or through a remote team co-located with our client. Our worldwide presence means we understand the unique characteristics of each region for planning, designing, transporting and installing offshore and onshore projects.

Asset integrity & late life management of offshore oil & gas assets North Sea

Making floating LNG as safe as possible Prelude, Shell, Australia

Khafji Field Offshore, Saudi Arabia

First LNG receiving terminal Singapore LNG Corporation

Qatar A-South Offshore, Qatar

New build LNG Poland

Reducing cost of offshore wind farms DONG Energy, UK

Asset integrity for oil & gas assets ENI, Australia

Flow assurance & systems engineering Ichthys (Darwin), INPEX, Australia

Tension leg platform design ExxonMobil, West Africa

Tangguh LNG Indonesia

Safe life extension of critical oil & gas infrastructure ADMA-OPCO, UAE

TC Pipeline Routing Study Caspian Sea to Turkey

Shah Deniz Caspian Sea


Zakum West Super Complex © ADMA OPCO

Asset integrity management We deliver an extensive range of integrity management services spanning all types of fixed, floating, subsea and onshore facilities, which includes approximately 50% of UK North Sea assets plus many more assets globally.

We routinely manage interfaces with regulators and verification bodies and have experience of integrity management of pressure systems, including Fitness for Service assessments of corrosion and crack-like defects using both screening assessments and advanced 3D finite element analysis of defects.

ProCess AnD fACiLities, strUCtUrAL, moorings AnD sUBseA integrity

Talisman North Sea integrity management framework We currently deliver integrity management services to all 13 UK North Sea Assets removing all anomaly management and 10,000 man hours safety critical backlog.

BP Trinidad, offshore and onshore We have worked with BP Trinidad & Tobago (BPTT) on the structural integrity management (SIM) on all their Caribbean offshore platforms for the last four consecutive years. We also provided SIM and hurricane assessments for BPTT’s onshore facilities.

ADMA-OPCO Abu Dhabi, offshore structures We’ve worked with offshore operator

ADMA-OPCO to optimise mitigation designs to withstand additional operational placement of loads of existing assets. We also provided SIM assessments for a variety of structures including Quantitative Structural Assessment of Well Head Towers (WHTs) to establish a robust integrity management system for the company’s fleet of offshore structures, building structural models to enable detailed in-place and progressive collapse analyses. This in addition to Advanced Structural Analysis of Barge-Type Structures, which form the central platforms of ADMA OPCO’s offshore processing facilities.

FUKA and Vesterled life extension We employed FMECA software to consider all failure modes and root causes, extending the life of the twin 32” gas trunklines, commissioned in 1977 considerably.


integrAteD sAfety AnD risk serviCes

Offshore personnel risk assessment (OPRA), Gulf of Mexico We developed a common safety risk philosophy for all the operating BP assets in the Gulf of Mexico. This included conducting safety risk and consequence modelling to establish a consistent risk profile for each asset.

Well integrity on offshore production installations Our client has a number of wells on its production platforms which have experienced sustained casing pressure, to a greater or lesser degree. We were asked to further develop the in-house risk model to help make it more representative, robust and transparent in quantifying the associated risk from credible hazards. A user guide and supporting manual was developed

by the Atkins team and enabled the client to move forward with greater confidence with what had been a problematic issue for some time. Feedback was highly positive with a senior client representative stating that Atkins had undertaken “one of the best bits of technical work I have ever seen…the quality and the format of the report was exceptional.”

reLiABiLity, AvAiLABiLity AnD mAintAinABiLity

Improvements in the operational availability and maintenance cost reduction of aging assets are becoming increasingly important to our clients.

The Al Shaheen Oil Field is a production oil and gas field off the North East coast of Qatar, operated by Maersk Oil Qatar AS. In 2014, Atkins successfully completed the maintenance strategy review of water injection equipment

installed on production platforms in Locations A and B, aiming to increase the overall field production performance.

All services can be most effectively achieved if integrated under a single process – lifecycle management. Our commitment to improving integrity management techniques is demonstrated by our Cause-Oriented Inspection System (COINS) JIP, which applies root cause analysis to all failure modes to develop a more focused and effective integrity risk assessment approach.

INTEGRITY CYCLE

exeCUte DAtA

evALUAtionstrAtegy

The Integrity Cycle which is common for the Asset Integrity of all disciplines


However, where such modifications are required, the emphasis is on minimising their extent wherever possible. The service includes engineers seconded to client offices in day-to-day operations support roles, offshore-based support and study teams based in Atkins offices.

Experience has been gained over more than 30 offshore commissioning support projects, ranging from small remedial scopes to FPSO redeployment. Our service is typically provided by engineers who understand the topsides process and safety systems as well as subsea.

ProDUCtion root CAUse AnALysis AnD DeBottLeneCking

Ichthys LNG, onshore and offshore Appointed by INPEX in April 2011, we’re providing flow assurance engineering as well as ad hoc process engineering services for the Front-End Engineering and Design (FEED) phase of the Ichthys Field. The Ichthys Field expects to deliver 8.4 million tonnes of LNG and 1.6 million tonnes of liquefied petroleum gas (LPG) per annum, as well as 100,000 barrels of condensate per day at peak.

The scale of the project has seen Atkins deal with a wide range of issues, including hydraulic analysis, thermal analysis and hydrate management. Detailed analysis has also been completed on the complex tasks of well clean-up, initial well start-up, pipeline

blow-down, initial onshore LNG plant start-up and on-going pigging for flowlines and pipeline systems.

We also prepared system operating philosophies, operating envelopes, pigging philosophies and operating manuals for the entire Pluto Icthys subsea production system.

Foinaven facility debottlenecking - North Sea We conducted a comprehensive debottlenecking study for BP using our MeasCap software tool. MeasCap allowed the client to see the trade off between equipment cost vs oil production rates, and determine where the step changes in required investment would be.

Production optimisation We have extensive experience in troubleshooting and debottlenecking process plant and specifying solutions to problems. We review and investigate opportunities and problems with all unit operations and overall systems installed offshore. Our focus is always on providing a solution that does not require physical plant intervention for modification.

Ichthys LNG, INPEX


BP’s Shah Deniz platform, Caspian sea

sUBseA fLow AssUrAnCe

Shah Deniz debottlenecking study The overall objective of the dynamic simulation study was to assess the controllability and operability of the process at off-design and higher gas throughput rates and also examine the extent of transient excursions during upset scenarios. We modelled the full process facility in Aspen Hysys and performed the dynamic runs in order to validate the flare loads during the higher gas throughput rates. The flare system was sized to handle a maximum flowrate of 900 MMscfd during operational demand and 970 MMscfd during emergency demand. Atkins identified key debottleneck areas limiting the operability at higher throughputs and also necessary modifications to mitigate the bottlenecks.

Gryphon FPSO recovery project Following an incident in severe weather, four anchor chains failed and significant damage was sustained to the subsea infrastructure. Atkins prepared procedures to ensure that the subsea wells were isolated and could be disconnected, and that flowlines were hydrocarbon freed and filled to minimise any potential release upon disconnection from the FPSO. Atkins’ personnel supervised the implementation of the procedures offshore to ensure that the workscopes ran smoothly and all requirements were met.

Production efficiency improvement (confidential client) Our client achieved significant increase in overall asset production efficiency through revision to operator’s maintenance strategies, which enabled

reduced downtime and losses associated with major equipment.

Landline pump stations optimisation study BP asked us to determine the optimum plan for investment in an important UK landline, taking into consideration CAPEX/OPEX associated with decommissioning or upgrade/replacement of pump stations and equipment. Based on the studies conducted, we determined that by replacing VSDs at one key pump station, would result in a potential commercial benefit of ~ £7M over the following 5 year period.


We provide an extensive range of multi-disciplinary engineering services in support of asset brownfield project design; ranging from additional/changed production requirements and meeting new regulatory requirements to the removal/installation of new plant equipment and advanced structural analysis to accommodate changed topsides configurations.

mULti-DisCiPLinAry Assess, ConCePt, feeD engineering AnD verifiCAtion

Ross/Blake field life extension project – process and utilities study Atkins identified key upgrades / improvements required to Ross / Blake facilities in order to deliver high uptimes and meet the required performance specifications for the remaining field life. We provided clear rational for improvement options with a FEED scope for each system studied.

BP Unity tie-in study culzean condensate development We undertook concept-select and Pre-FEED design for the tie-back of the Culzean condensate export pipeline to BP Unity platform. The subsea (riser) and multi-discipline engineering was carried out by one integrated team.

gLoBAL integrity Assessments

BP Andrew Area Development (AAD) In Spring 2011, the AAD project was in the final stages of detailed design when the existing topsides joints were discovered to be insufficient to support the new facilities due to be installed in 2012.

The joints were heavily loaded by the pre-AAD topside loads and it was not possible to strengthen to maintain the steel in the elastic range at the

factored loads. Atkins used plastic design criteria to ensure strains in the steel were acceptable if the joints were strengthened prior to installation of the AAD facilities.

We’ve validated proposed strengthening details that were initially shown to be inadequate and to show that other strengthening was not required.

strengthening moDifiCAtion AnD rePAir

We have undertaken more than 250 SMR projects worldwide. Our deep understanding has led, together with a number of Joint Industry Projects (JIPs), to a considerable body of experience and our input into codified guidance. Core activities are:

• Clamp technology – mechanical, grouted, neoprene lined

• Welding – dry and wet• Weld improvement – toe grinding,

profile grinding, hammer peening• Other techniques, including remedial

grinding, composites, member removal, bolting

sAfety AnD risk serviCes

BP North Sea life extension projects Atkins provided key safety support to both BP Magnus and ETAP platforms life extension projects. These projects were focussed on executing an extensive remediation programme for each platform with a large additional offshore workforce accommodated on a bridge linked flotel. Atkins assessment work identified measures to improve platform safety during this critical project and provided assurance that the platforms could continue to operate whilst the flotel was on station and remediation work taking place. This resulted in significant savings for the operator.

Reliability and production efficiency improvement Our reliability programmes have concentrated on supporting the optimisation of day-to-day operations on BP North Sea installations, with specific focus on improving operating efficiencies. Reliability and production simulation models were used to assist in the prioritisation of remedial plant activity and current/future work programs, such that an installation’s vulnerability to potential production related threats will be significantly reduced.

We have also developed simulation models for Andrew, Bruce, Clair, Harding, Magnus, Foinaven, and ETAP which includes production input from Mungo / Monan, Machar, Marnock, Mirren / Madoes. Each model is constructed to include the throughlife performance of production and utility equipment/systems, safety systems, and throughlife reservoir profile(s).

Fort Hills, Canada By using advanced process and flare simulations, explosion modeling and surface mapping of pressure loads, we were able to rationalise the original design and safety scenarios to match the actual needs of the facility.

Commissioning sUPPort

Maersk DSV 365 subsea commissioning support We were contracted by Maersk to support all subsea project implementations in the UK North Sea Sector in conjunction with DSV contractor (Bibby Offshore) in 2014.

Brownfield projects Our intimate asset knowledge combined with our depth of operational experience and access to the best engineering talent means we can tackle the most complex and challenging of projects with confidence. With any brownfield project the hidden costs are not in the new equipment but in the impact on the existing process, its maintenance, structural and safety systems. Utilising Atkins’ knowledge during the assess and concept phases ensures the right option is selected and cost overruns are avoided.


Explosion modelling


Life extension

North Rankin A We were approached by the client to give a second opinion on the cost for life extension on North Rankin A. Through a refined phased assessment approach and reliability-based assessments, Atkins applied USFOS to demonstrate that the structure had significantly higher capacity than initially thought. We also

used an Abaqus global model to further refine the assessment, bringing the cost to the client down to less than 10% of their first estimation.

Compression upgrade for Claymore Described as “a benchmark for future brownfield projects,” Atkins assessed the impact of the new 1700 tonne compression module on the existing structure. The addition of the new

module allows the platforms life to be extended to 2035 by providing the necessary pressure increases to the reservoir.

De-mAnning

Atkins works closely with all the major operators to determine the de-manning requirements for critical storms affecting aging assets that now have issues.

Late life management Increasingly, the operating lives of offshore infrastructure need to be extended significantly beyond the original design life. To cover the increased focus needed on asset integrity, production optimisation and brownfield projects, we’ve developed methodologies and techniques to safely manage and upgrade aging assets portfolio, ultimately through to decommissioning. The effectiveness of our versatile approach to late life management has been extensively demonstrated on numerous facilities.

Image left and centre: USFOS pushover concluded in significant savings to our client

Image right: Original linear assessment approach

• Late life asset management • De-manning

• Life extension • Decommissioning


low resolution

image

DeCommissioning

We have been actively involved in the decommissioning of offshore facilities in the UKCS and Gulf of Mexico since the 1990s. We have experience at all stages of the decommissioning timeline for fixed, floating and subsea installation, providing the level of technical and costing expertise relevant to the stage in the asset life span. We have delivered concept studies through detailed design to assistance whilst decommissioning is underway. Activities typically include:

• Decommissioning strategy - methodology statements, philosophy, feasibility studies, optioneering, execution plans

• Programme scheduling and cost estimation - critical path identification, event sequencing (including COP, well plugging and abandonment), resource allocation, benchmarking

• Qualitative assessment - advanced structural analysis, safety engineering, weight assessment, independent verification, design, hydrocarbon freeing/flushing procedures, comparative analysis

• Offshore supervision during removal, inspection services and execution support

Camelot East Jacket, North Sea We engineered the reuse of the Camelot East facility which was installed in 1990 and removed in 2011 at the end of the field life. We completed detailed inspection requirements for reuse, and

analysed and engineered the required modifications for installation in 2006.

Eugene Island 322, Gulf of Mexico We were responsible for the decommissioning assessment of the EI 322 complex, which was damaged by Hurricane Lili. We undertook ultimate strength analysis to establish toppling loads and other key decommissioning requirements.

Maersk Gryphon, North Sea When the Gryphon FPSO catastrophically drifted off station due to severe weather in 2011, Atkins was called upon to support Maersk in making the affected area safe and to manage the large scale recovery program. We provided rapid response by mobilising a task team of skilled offshore engineers equipped with Atkins’ decommissioning procedures to manage the risks associated with removing the inventory from the entire subsea network, installing barriers to prevent hydrocarbon release from stranded wells and performing all construction work associated with recovering un-salvageable assets.

We provided 24 hour offshore support in a project management role acting as client representative to drive schedule commitments while ensuring safe working and environmental compliance at all times. We also tracked the change to asset, providing status updates on a daily basis to onshore management and produced close out documentation and deconstruction P&IDs for the field. The success of this campaign

led to our heavy involvement in the re-commissioning of the Gryphon FPSO and new subsea infrastructure two years later.

BP Amoco NW Hutton NW Hutton was the first major North Sea installation to be physically removed. We provided both pre-decommissioning and real time analysis support to monitor the stability of the jacket during the cutting and removal operation. The largest jacket section removed weighed 2,250 tonnes, from a complete jacket weight of 17,500 tonnes.

Excalibur Pieter Schelte (now Pioneering Spirit), North Sea In addition to current methods of decommissioning, we have also been involved in the development of vessels which may be used in future deconstruction. The vessel will have the capacity to remove and install topsides up to 48,000 tonnes and jackets up to 25,000 tonnes in a single lift operation

Shell Brent Flare and Spar Anchor Blocks In August 2005 Shell recovered the Brent Flare and SPAR Anchor Block structures from the Brent Field. Atkins carried out various studies to determine the possibility of re-use of the structures. The anchor blocks were identified as having real residual civil engineering value and were taken to Norway to be used in the construction of a new smarter decommissioning quay.

Excalibur Pieter Schelte (now Pioneering Spirit), North Sea (credit Frans Berkelaar)


Committed to sharing industry learning we have been involved in numerous Joint Industry Projects (JIPs) and hold regular lectures that brings industry experts together and encourage pan industry collaboration.

During the last two decades, we have concluded the following seven relevant JIPs:

JIP Cause-Oriented Inspection System (COINS) Our commitment to improving integrity management techniques is demonstrated by our Cause-Oriented Inspection System (COINS) JIP, which applies root cause analysis to all failure modes to develop a more focussed and effective integrity risk assessment approach.

JIP Strengthening, Modification and Repair A design manual has been created covering all strengthening, modification and repair techniques for offshore platforms, delivering new and more robust design procedures for strengthening and repair techniques.

Enriching industry learningWe believe that collaboration between operators and suppliers is one of the keys to addressing the cost challenges faced by the industry. It is in our mutual interests to ensure that money is spent most effectively, operations are streamlined safely, production is improved and field life extended to maximise economic recovery.

JIP SAFEBUCK: Finite element analyis of lateral buckle in soft seabed

JIP Carbon Fibre Reinforced Composites This four-phase JIP has involved over 500 tests and has led to the creation of a design manual for the strengthening of offshore structural components using carbon fibre composites.

JIP Neoprene-lined Clamps Some 20 ‘slip’ tests conducted on neoprene-lined clamps under various conditions of bolt load and member surface condition. The tests confirmed earlier indications that the slip capacity is not as high as was generally believed. New robust guidance was formulated based on the test data.

The ownership of the technologies developed in the above JIPs resides with Atkins. These technologies are available to any study work carried out by Atkins on behalf of our clients.

JIP Grouted Joints This JIP involved in excess of 150 structural tests, leading to a design manual for the strength, local joint flexibility, SCF and fatigue life design of grouted joints utilising standard API grouts.

JIP Diverless Repairs Full scale underwater demonstration trials were conducted in this JIP of the diverless implementation of grouted repair systems using ROV intervention only. The trials were fully successful and led to the development of installation aids and procedures for diverless implementation.

SAFEBUCK JIP The SAFEBUCK JIP developed methodologies to deliver a safe and effective pipeline design that permits lateral buckling that takes into account the associated pipeline walking phenomena. The design guideline has been utilised on many major projects around the globe.


Image credits

© BP (page 04,13) © Shell (page 5)

© ADMA OPCO (page 10) © INPEX (Ichthys LNG) (page 12)

© Frans Berkelaar (photo credit Excalibur Pieter Schelte / Pioneering Spirit, page 17)


The Atkins logo, ‘Carbon Critical Design’ and the strapline ‘Plan Design Enable’ are trademarks of Atkins Ltd. © Atkins Ltd except where stated otherwise.

www.atkinsglobal.com/oilandgas

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ATKINS Operations engineering A4/media/Files/A/Atkins-Corporate/group/... · Mars B Gulf of Mexico, US laymore life extension North Sea Designing offshore oil gas structures Gulf