Fpso Revamp for a Marginal Field Ea-spe

7/28/2019 Fpso Revamp for a Marginal Field Ea-spe

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Offering solutions 2 value

FPSO Revamp for a Marginal Field

WAOil

&

Gas

Facilities

Group,

August

2012

F.Piasentin


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Introduction

S2VprovidesstrategicadvicetoOil&GasClientsDeliversolutionsthataddvaluebyadoptingaholisticapproach

ReviewofprojectsallowsS2VtoidentifyinsightsandtransferknowledgetoourClients

FPSO Revamp for a Marginal Field 2


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What is an FPSO?

FloatingProductionStorageandOffloadingunit

+ Processesoil,

gas

and

water

+ Equippedwithproductionfacilitiesofvarying

complexity

+ Maybenewbuildorconversion

+ Maybespreadorturretmoored

Turret may be disconnectable



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Key FPSO Components


Moorings

Risers

Turretand

fluid/control

transfer

swivel

Processand

Utilities

Storageand

Marine

Utilities

Accommodation,

CCR,Helideck

Offloading

Facilities

5


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Why an FPSO?

+ Selfcontainedfacilities

+ Overcomeslimitations

of

afixed

structure

+ Operateswithoutexportliquidspipelinenetwork

+ Relocatable/Reusable

+ Relativelyinsensitivetoadditionalpayload

+ Canbenewbuiltorconvertedfromexistingtanker



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FPSO Concept Features

+ AdditionalmarineequipmentincreasesOPEX

+ Modulartopside

facilities

+ Turretsystemscanconstrainexpansion

+ Nodrillingfacilities

+ Requiressubseawellsandfacilities



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FPSO Complexity


RegionalChallenges(metoceanandregulatory)

Facilityproductioncapacity

200k+

BOPD

Injection

/export;

water&

gas

10k

BOPD

nogas

WestAfrica SEAsia Brazil Australasia GoM NorthSea

Purposebuilthighspecvessel

withcomplexhighthroughput

processequipment

Purposebuilthighspecvessel

withcomplexhighthroughput

processequipment

Simplelowcost/lowtech

tankerconversions &lifeextension

Simplelowcost/lowtech

tankerconversions &lifeextension

8


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Why are FPSOs so important

+ Technologyofchoicefordeepwater oildevelopments

+ Economicsolution

for

exploitation

of

marginal

fields

andspreadreservoirs

+ Conceptalsoapplicableforgasproduction(FLNG)

+ Fastexecution

schedule

+ Leasepossibility reducedupfrontCAPEX



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FPSO market in 2011

SouthAmerica

21%

WestAfrica

25%NorthSea

15%

SEAsia

23%

Australasia

11%

Other

5%

WorldwideDistributionofFPSOVessels


Conversions

62%

Newbuilds

38%

Contractor

Owned

57%

Operator

Owned

43%

Source:OffshoreMag. Worldwide

SurveyofFPSOUnits,August2011

Totalof158producingvessels:

10


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PROJECT OVERVIEWFPSOCaseStudy



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FPSO Project Framing

+ MaxOilProduction40,000BOPD

+ Subseafield

layout

composed

of

3wells

+ LocationAustralasia,~350mwaterdepth

+ Processingoftheincomingfluids:OilSeparationand

Stabilisation,Gas

Dehydration

and

Compression

+ Useoftheprocessgasforfuelandgaslift

+ Crude

storage

+ Exportmeteringfacilities

+ Offloadingtoatandemmooredshuttletanker



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FPSO Key Specs and Field Layout

+ ConversionofanexistingFPSOvessel

+ Tankerbuilt

1996

(operated

on

two

previous

fields)

+ 105,000DWTtanker,240mlength,doublehull

+ Internalfixedturret

+ Mooring:3x2wirelines

+ Drivenanchorpiles

+ Hullstorage

500,000

bbls

+ 3+3Production&GasLiftRisers

+ 1ControlUmbilical&Infields


Well 1 Well 2 Well 3

Risers

Umbilical

& Infields

13


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Project Drivers

+ Schedule StrategicProject

+ Marginalfield

requires

managed

budget

to

ensure

economicsaremet

+ Ensureexecutionandoperationalsafety

+ MeetLocal

Content

Requirements



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Execution Timeline

+ PreliminaryFDP May2009

+ FPSOContract

Award

December

2009

+ FDPApproval February2010

+ StartofConstructionActivities May2010

+ Endofmooringinstallation March2011

+ Sailaway June2011

+ FPSOMooring

Hook

up

July

2011

+ SubseaHookupcompletion October2011

+ Startup October2011


30months

15


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SCOPE OF WORKFPSOCaseStudy



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FPSO Execution Works Overview

EPCLeasedContractincluding:

+ Repair&

Life

Extension

(RLE)

+ Conversionworks

+ Mooringsystemdesign,supplyandinstallation

+ Hookup,CommissioningandStartup

+ OperationsandMaintenance



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RLE Scope

+ Predictoverhaulingscopeandrisks

+ Inputfrom

maintenance

database

and

operations

+ AdditionalWorksInstructions(AWI)hadtobeissued

FPSO Revamp for a Marginal FieldFPSO Revamp for a Marginal Field 18

0%

10%

20%30%

40%

50%

60%

RLE Conversion AWI

40%

60%

25%YardM

an

hours

OriginalContract AdditionalScope


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RLEMain Activities


RLE AWI

Mainbearingexchange

Swivelde

stack,

seal

change

out,reinstatementandtestSwivelreactivation

Preparationofturretdeckhouse

GasCompressorsoverhaulMachiningofGas

Compressorheads

Valvesinspection

and

overhaul/replacement

ExtraValves

overhaul

scope:

PRVs,ESDV,BDV

MarineandTopsidesBoiler

Repairs

Pressurevessels

inspection/upgrade

Inspection

and

modification

chainstopper

Electricmotorsoverhaul

CoatingFPSOTanks

Swiveldestack


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Conversion Scope

Turret

SideImpact

GasDehy.

BoosterGasCo.

MeOH Skid

MeteringUnit

Offloading

ICSUpgrade

FPSO Revamp for a Marginal FieldFPSO Revamp for a Marginal Field


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Main Conversion Items


GasDehy.

BoosterGasCompressor

MeOH Skid

Bearing

Exchange

MeteringSkid

21


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Dry-dock Activities


SpiderUpgrade

Dry

dock

blocks

JtubesInstallation

Side

Impact

Protection

22

Dockingsequence


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Mooring Installation

+ Campaign#1(MooringInstallation)

+ Campaign#2

(FPSO

Hook

up)

+ Reducerisksrelatedtodelays



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Main Technical Challenges


Challenge Action

Additional

RLE

scope

FirstyardmonthtocompleteRLEsurveys

Additionalscope

to

external

Contractors

LongLeadItemsProcurementMaximizedequipmentmodularization

Aggressiveexpeditingcampaign

MigrationofthenewICSsystemFullICSscopecontractedtoaspecialist

Broadpre

testing

campaign

GasCompressorsrefurbishmentand

commissioning

EarlyinvolvementofVendor

OverhaulingworksatVendorsHQ

SwivelleakageSplitscope

Swivelde

stacked

involving

Vendor

Drydockheight EarlyYardinvolvement5.2m blocks


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HSE and Quality Assurance

JointeffortbetweenOperatorandContractor

+ SystematicHSE

and

QA

Audits

+ HAZIDsandHAZOPsheldthroughouttheexecution

involvingallstakeholders

+ Monitorcompliance

to

HSE

requirements

in

yard

+ SIMOPSworkshopheldpriortoinstallationphase

+ Neverputschedulerequirementsaheadofsafety

Whatwasachieved

+ 1millionmanhoursover14monthswithzeroLTIs



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CONTRACTING STRATEGYFPSOCaseStudy



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+ ProjectManagementbasedonPackagebreakdown

+ EachPackage

related

to

aspecific

contract

/budget

+ Packageswithindependentteams

+ CriticalityofInterfacemanagement

+ Defineclearscopesandbatterylimits

Whythisapproach?

+ Selectbest

Contractors/Prices

+ MorecontroltotheOperator

+ Differentexecutionphasing

Packaged Project Approach



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Fast-Track Contracting Structure


ProjectManagement

Turret&Mooring

Hull&Topsides

Flowlines

SubseaEquipment

FPSOInstallation

Concept

Definition

DetailDesign

Procurement

Construction

Hook

up

Comm.

Start

up

Operations

Operator

Operator

FPSOContractor

SubseaContractor

FlowlinesContractor

FPSOContractor

Operator

Operator

28

ITT/Tender LumpSum+LDsuponNoticeMechanism

FixedDayRate+

Reimbursable

Services


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Operators FPSO Package Team


FPSO

Package

Team

Developcontractual

technicalspecs

Tenderreview

ContractManagement

DetailDesignreview

Constructionsupervision

Logisticsexpediting

MonitorContractorsperformance

AssistinterfaceswithotherPackages&Contractors

Offshoresupport

Handovertooperations


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LESSONS LEARNEDConclusions



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Lessons Learned - Negatives

+ UnexpectedadditionalRLEworks Hardtomonitor

onschedule

(fragmented

scope

+knock

on

effects)

+ YardcontractheldbyContractor Operatorhadno

contractualleveragetoincreaseresources

+ PipingFabrication

/Construction

performance

+ PooryardqualityrequiredincreasedContractor

supervision

+ Managementof

Reservoir

/Operations

input

Sourceofthemaindesignvariations



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Lessons Learned - Positives

+ Conversionimpliesbalancebetweenscope

complianceand

schedule

Flexibility

+ Technicaldocumentationfinalizedduringtender

phase(+tailoring) AvoidVariationsandDelays

+ Applyno

change

policy

Freeze

Design

+ ClosereviewoftheContractor NoTurnkey /over

relianceonEPCContractor

+ Contractstructure

with

Operating

fees

energises

Contractorsperformance

+ StronginteractionwithGovernmentalAuthorityFPSO Revamp for a Marginal Field 32


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Lessons Learned - Positives

+ ClearroledivisionbetweenOperatorandContractor

+ SingleContract

for

the

FPSO

+ InterfaceManagementbasedondirectinformation

exchangebetweenContractors

+ Maximizefacilities

modularization

+ ICSintensepretestingminimizedintegrationissues

+ Outsourceadditionalscopenottooverloadyard

+ OnshorecommissioningonFPSOContractor



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QUESTIONS?Any


Documents

Fpso Revamp for a Marginal Field Ea-spe