Faculty of Civil and Environmental Engineering of Bandung Institute of Technology April 26, 2010 Tigor Martahan Hutabarat Lead Structure Engineer

  Platform Concept in Offshore Development Faculty of Civil and Environmental Engineering of Bandung Institute of Technology

  April 26, 2010 Tigor Martahan Hutabarat* Lead Structure Engineer

• ) Guest Lecture for Prof. Ricky Tawekal PhD Reference:

  1. Steve Balint, Overview of Deepwater Structures Design, Shell Malaysia, Miri January 2007

  2. Tigor M.H, Subsea Wellhead Foundation, Shell EPA Structure Forum, Miri Nov 2007

  3. N.D.P Barltrop, Floating Structure, a guide for design and analysis Tigor M H GKU ITB Apr 26,10

  1 TOPICS

• Platform Concepts • Field Development • Fixed Offshore Platform • Deep Water Design

  ™ Compliant Tower

  ™ TLP

  ™ SPAR ™ Semi submersible ™

  FPSO

• Riser and Pipeline • Subsea Wellhead

  Tigor M H GKU ITB Apr 26,10

  2 Offshore Development Options Fixed Compliant TLP SPAR FPSO Subsea Platform Tower Completion Dynamic Response of Offshore Platforms

  M x C x K x F & & & = + +

  [ ] { } [ ] { } [ ] { } { }

  Tigor M H GKU ITB Apr 26,10

  3 Development Strategy Field development strategy

• Create sub-surface( reservoir ) models
• Select sub surface development concepts
• Select surface development concepts
• Perform safety evaluation
• Perform economic evaluation

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  4 Our Topics Appraise Select Define Execute Operate FEL-0 FEL-1 FEL-1 FEL-2 FEL-3 _{Identify Appraise Select Optimize Define} Execute Operate

  Phase-2 Phase-1 Phase-3 Phase-4 Phase-5 Generate & Select Identify & Assess Opportunity Develop Preferred Alternative Execute Operate & Evaluate Alternative(s)

  Comm & Appraisal Design Pre-Project Basic Engineering EPSC Operations StartUp

  Pra FEED Konstruksi OPERASI _{Source Rudianto Rimbono, ITB 2010} ‐POD

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  5 Safety Continual Improvement PLAN PERFORM Leadership and Commitment Policy and Strategic Objectives Organization and Resources Risk Evaluation and Management Planning Monitoring and Implementation Audit and Review

IMPROVE MEASURE

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  6 Platform Concept Elements in the oil/gas production process include

• Wellhead

  ¾ Surface/ dry wellhead

  ¾ Subsea wellhead

• Production Manifold • Production Separator • Glycol process to dry gas,
• Gas Compressor • Water injection pumps
• Oil/gas export metering and • Main online pumps.
• Production and Storage

  Tigor M H GKU ITB Apr 26,10

  7 Oil and Gas Production Overview

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  8 Wellhead- Casing Design Conductor Surface Casing

  Production casing Production Tubing

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  9 Block Development Options _MALAYSIA NORTH BELUT _WHP-C DUYONG _{INDONESIA 22" x 10 km 18" x 100 km liquid phase - 12" x 37 km gas phase - 16" x 37 km} CPP _WHP-D

ADGF PLEM HIU

  _{24" x 93 km liquid phase - 12" x 23 km 16" x 0.5 km gas phase - 16" x 23 km SUBSEA KERISI PLEM CPP}

WHP-K BELANAK FPSO/ FSO KERISI

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  10

  11 Tigor M H

  GKU ITB Apr 26,10

  Hub Option 101 Ubah (Block G)

  179 TOTAL Oil (MMbbl) SFR (100%)

  Discovered volumes (incr. to Sabah Gas) ^{Ubah Malikai N} Sabah Gas Fields Malikai N Ubah

  Slide: 1

  Sabah Gas Project – Large Scale Infrastructure Scope

78 Malikai (Block G)

  Kinabalu ^{Erb W est} _{Samarang Sarawak – SabahGas Pipeline 750 MMscf/ d, 530km} ^{Onshore gas plant with condensate export and pipeline gas compression.}

^{24” gas pipeline}

^{Kebabangan Hub Drilling, Processing & Link platforms 750 MMscf/ d, Condensate 20kb/ d WD 130m, 13 wells, Compression Kumunsu East Subsea tieback, W D = 800 m, 5wells Kumunsu East U & UC Subsea tieback, W D = 1100m, 6wells Pipeline 34” Multiphase 34” gas pipeline KBB-SOGT 125km 2x18” 2x18”} _{MLNG SOGT SOGT Condensate slug catchers, gas condensate stabilisation MLNG 25 mtpa, 4 bcf/ d} ^2x18” Sabah Gas Project Scope

  Sabah Gas: Gas custody _{transfer point Sabah Gas: Condensate custody transfer point} ^{KBB Malikai ? ? ? ? Ubah Crest ? Malikai is marginal as a tie-back to KBB Ubah is subeconomic (TLVC highlighted upside potential which is being tested by appraisal well in 2008)} _{Other prospects with Shell interests include Leban (Block G) Northern Area Development plan has been compiled} Malikai Ubah

  Leban _{Kebabangan Hub Gas 750 MMscfpd Oil 80 kbopd} G J

• Reduced CAPEX for (small) tie-back fields
• Pipelay, subsea installation
• Reduced well count (ERD, multi-zone smart wells, open hole smart wells)
• Subsea boosting
• Longer, more challenging tie-backs (50+>Flow assurance management
• Thin Bed Reservoirs • Optimised information from appra>Improved static and dynamic modelling
• Water injection / Gas injection in thin
• Stranded (or sub-economic) Gas • Reservoir imaging below gas chimneys

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  GKU ITB Apr 26,10

  Key Challenges and Needs

  Existing Assets AGX AGX Platform Platform Anoa Anoa Platform Platform Anoa Natuna FPSO Anoa Natuna FPSO West Lobe Platform West Lobe Platform

  Tigor M H GKU ITB Apr 26,10

  13 Project Management Team Project Management Team _{Contractor Client}

_{PMT Base location is in Jakarta}

_{- Internal Interfaces - External Interfaces Interfaces Deputy Contractor Manager Representative Project Manager} Representative/

_ordination

_{- Overall Project Co- Project Control/ Offshore Hook-up & Pre- - Environment - Safety} - Health _{Engineering Procurement Construction Project HSE Project QA/QC Manager Manager - Certification/Classification - Quality Assurance/Control - Project Administration - Project Finance - Planning / Progress - Contract Reporting Administration Installation Com./Com. Mgr Manager *HSE Engineer - Topsides Engineering - Equipment & Material - Jackets *Structure Engineer - Jacket Engineering - Procurement for * Process Engineer Topsides / Jackets *Piping/Mechanical} Manager Manager Manager / Site _{- Fabrication (Topsides / Jackets) - Load Out & Seafastening Fabrication Manager - Topsides - Offshore Commissioning - Offshore Hook-up Supervision - Onshore Pre-commissioning - Overall Commissioning - Offshore Pre-commissioning}
• Cost Control/ Reporting _{Engineer *Electrical/Instrument Engineer - Pipeline Hydro Testing}

  Tigor M H GKU ITB Apr 26,10

  14 Vent Boom Pedestal Crane Helideck TOPSIDE

  Main/ Weather Deck Global Model

  Mezzanine Deck Boat

  Lower Deck Fixed offshore

  Sump deck landing

  Platform

Riser

Jacket/ Substructure

  Conductor Photo

  Pile

  Tigor M H GKU ITB Apr 26,10

  15 Engineering Deliverables

RESPON SI BI LI TY

• SPECIFICATION/ PROCEDURE

  9 Structure Design Criteria

  LEAD / SEN I OR STRUCTURE

  9 Structure Design Brief

  EN GI N EER

  9 Weighing Control Procedure

  CALCULATION NOTE •

  ¾ In Place Analysis ¾ Seismic Analysis ¾ Fatigue Analysis ¾ Load Out Analysis ¾ Transportation Analysis

  SEN I OR STRUCTURE

  ¾ Jacket On Bottom Stability and Mudmat Design EN G.

  STRUCTURE EN G.

  ¾ Pile Drivability Analysis ¾ Cathodic Protection ¾ Weight Control Report ¾ Material take off- MTO ¾ Deck Local check / Miscellaneous Calculation

  DRAWING •

  ¾ Standard Drawing SEN I OR D ESI GN STRUCTURE EN G. ¾ Main and Secondary framing D ESI GN STRUCTURE EN G. ¾ Detail drawing ¾ PDMS model

  Tigor M H GKU ITB Apr 26,10

  16 Deep Water Development Floating Platform Advantage

• Well testing can be extended and overlap with production to know long term production rate without committing the large risk of field specific platform

  Disadvantage

• Move too much in larger waves so that drilling or production may suspended during storms

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  17 Organization Chart, illustration

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  18 Compliant Tower Main Feature

• Custom design for site specific application
• Single Drilling centre
• Surface completed well
• Integral drilling / work-over facilities
• No oil storage, pipeline, FSU or direct tanker loading
• Tension rigid riser for production
• Flexible or steel catenary for import/export
• Insensitive to topside load
• Long development schedule

  Tigor M H GKU ITB Apr 26,10

  19 TLP- Tension Leg Platform Skid-able Platform Rig

  H&P Lease ≅ 6,000 Tons Hull 4 columns 66.5’ diameter, 166 ‘ high

  Deck & Production Equipmen 200’ centers ≅ 54,700 ton displacement

  245’ x 245’ x 40’ high ≅ 13,500 tons steel 5 separate modules 100 MBOPD 150 MMCFD

≅ 15,000 tons

  Production Risers/Wells 8 wells maximum 4 - 13 5/8” risers Tendons 4 -10 3/4” risers 12 -32” diameter x 1.25”

  2900’ long Direct Tendon/Pile Connection

  ≅ 625 tons each 12 piles 82” diameter x 340’ long URSA- type connectors ≅ 245 tons each

  Tigor M H GKU ITB Apr 26,10

  20

  HULL DESIGN - STRENGTH, GUIDELINES, STANDARDS

  Crane Pedestals Deck Lower

  Chord Upper Chords

  Mooring Connection

  Pontoon – Column (Node) Connection

  Deck Connection Pontoons

  Riser Tigor M H

  Connections GKU ITB Apr 26,10

  21 Appurtenances TLP Main Feature

• Custom design for site specific application
• Single Drilling center
• Surface completed well
• Integral drilling/ work-over facilities
• No Oil Storage, Pipeline, FSU or direct tanker loading
• Tension rigid riser for production
• Flexible or steel catenaries for import/ export
• Sensitive to topside load
• Relatively long development schedule

  Photo

  Tigor M H GKU ITB Apr 26,10

  22 Tendon Tension Components

• the avoidance of wave impacts on the under side of the deck,
• the wave and low frequency horizontal forces and motions,
• the wave and current induced vortices, TLP motions:
• the avoidance of slack tethers,

  DYNAMIC

• the maximum tether

  TENSION PRETENSION TLP offset: = Static Top

  MAXIMUM TENSION MEAN OFFSET Tension = mean offset tension

  TENSION

• dynamic tension
• allowances Bottom Tension MINIMUM TENSION = top tension = mean offset tension
• self weight
• dynamic ten
• allowances

  Tigor M H GKU ITB Apr 26,10

  23 Wave Action

  Tigor M H GKU ITB Apr 26,10

  24

  HULL DESIGN - STRENGTH, GUIDELINES, STANDARDS

  Tigor M H GKU ITB Apr 26,10

  25 HULL DESIGN – Finite Element Model

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  26 SPAR Main Feature

• Custom design for site specific application
• Well Option

  Single Drilling center, surface completed well, integral work-over Remote well completed subsea by specialist vessel

• Export option

  Integral oil storage, export via offshore loading unit No oil storage, pipeline or direct tanker loading

• Tension riser, flexibles or catenary steel riser Flexible or steel catenaries for import/ export
• Medium development schedule

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  27 Spar Photo

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  28 Semi Submersible

• New Built or conversion
• Well Option1 Remote subsea with work over by specialist vessel
• Well Option 2 Wells below with Integral drilling/ work-over facilities
• No storage, pipeline, FSU, direct tanker loading
• Sensitive to topside load
• Flexible riser, large number flexible
• Short to medium development schedule

  Tigor M H GKU ITB Apr 26,10

  29 Semi Submersible

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  30

  FPSO- Floating Production Storage Offshore

  MAIN FEATURE

• New build or tanker conversion
• Remote wells, normally completed subsea
• Drilling/ work-over required special vessel
• Integral Oil Storage and offloading

  Flexible riser

• Insensitive to topside load
• Short development schedule

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  31 FPSO- Turret

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  32

  FPSO- Internal Turret

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  33 STRUCTURE- DESIGN PROCESS

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  34 FPSO- Discipline Dream Ships

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  35 Design of Floaters – Naval Architectural Principles Archimedes Principal “The upward force on a submerged body in a fluid is equal to the weight of the fluid displaced by the volume of the body”

  Buoyancy Force = rho*g*V

  Tigor M H GKU ITB Apr 26,10

  36 Design of Floaters – Naval Architectural Principles

6 Degrees of Freedom

• Surge (along x)
• Sway (along y)
• Heave (along z)
• Pitch (about x)
• Roll (about y)
• Yaw (about z)

  Tigor M H GKU ITB Apr 26,10

  37 Design of Floaters – Naval Architectural Principles Stability

  K K

  Righting Moment

  B is the center of gravity of the volume of Metacentric height (GM) is water that the hull has displaced. a characteristic that G is the center of gravity of the vessel itself. determines vessel stability.

  M is the intersection of the centerline and

  line of buoyancy

  A floating or K is the keel point submerged body is stable if GM>0

  Tigor M H GKU ITB Apr 26,10

  38 Design of Floaters – Naval Architectural Principles Heeling and Righting Curves _st

1 Intercept

  Moment _nd

  2 Intercept Stable Equilibrium Unstable Equilibrium

  A Wind Heeling Moment (HM) Righting Moment (RM)

  B C

  Heel angle

  Range of Stability Down flooding Angle

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  39 Bonga Model Test at Texas A&M

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  40

DEEP WATER DESIGN

  41 Tigor M H

  GKU ITB Apr 26,10

  Functional Requirements for Floaters Environment – wind, wave and currents Topsides payload requirements, including drilling

  Riser connections Foundation Integrity Appurtenances (external & internal)

DEEP WATER DESIGN

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  GKU ITB Apr 26,10

  Design Spiral

  Mooring and Foundation Design

  Arrangements Hydrostatic

  Compartments Hydrodynamics

  (including Model Tests) Structural Design

  Configuration Proportions

  Weight estimate Functional Requirements

  Contract Strategy

DEEP WATER DESIGN

  43 Tigor M H

  GKU ITB Apr 26,10

  Global Performance Analysis ENVIRONMENT Wind, Waves & Current

  ¾ “operating storms” ¾ “design storm” ¾ “survival event” RISERS

  ¾ loads to TLP ¾ angles, strokes LATERAL MOORING SYSTEM ¾ configuration

  ¾ tensions TENDON TENSIONS ¾ pretension ¾ maximum (strength) ¾ minimum (unlatch) ¾ UNDERDECK WAVE

  CLEARANCE (“Air Gap”) ¾ SUBSIDENCE RELATED ISSUES ¾ tendon components / fatigue life

  ¾ riser components / fatigue life ¾ deck loading and strength ¾ hull loading and strength

• Potential equipment height limitations
• Limitation of gravity systems caused by inadequate deck height
• Maximum use of lightweight equipment
• Shared utilities with drilling and hill systems
• Loads generated by horizontal, vertical, and rotational movements of TLP during fabrication, tow out, mooring, and operations.
• Damping liquid movement and stabilize process levels • Drain system influence on buoyancy and CG.
• TLP hydrodynamics impact
• Riser connection locations
• Regulatory requirements
• Cool flowing temperatures and possible hydrate formation due to extreme water depth • Potential souring of reservoir due to water injection.
• Large power consumption associated with gas compression, product pumping and water injection.

  44 Tigor M H

  GKU ITB Apr 26,10

  Facilities Design Considerations

  Riser System

• Production riser
• Export and import riser

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  45 Platform Export Riser and Pipeline

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  46 Riser Type

• Rigid: Usually steel, nominally vertical, top tensioned pipes
• Flexible: usually steel polymer composite pipes hung in a simple or S shape catenary
• Metal catenary riser ; steel or possibly titanium pipe hung in catenary

  Tigor M H GKU ITB Apr 26,10

  47 Deep Water Free Standing hybrid riser SLOR=Single Line Offset riser COR=Concentric Offset Riser

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  48 Deep Water Free Standing hybrid riser

  Seabed Tigor M H GKU ITB Apr 26,10

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• Custom design for site specific

  Sub sea tie back to existing facilities

  application

• Multiple drilling centre
• Remote subsea well
• Well work over by specialist vessel
• Integral drilling/ work-over facilities
• No Oil Storage, oil/gas exported from host platform
• Hydraulic performance of long flowlines key design issue
• Topside load capacity/ullage determined by host platform
• Short development schedule

  Malikai seabed features

  Tigor M H GKU ITB Apr 26,10

  50 Sub sea tie back to existing facilities _{Flowlines • 2 x 16” CRA wet gas flowlines (design • 650 MMscf/day total capacity so ~150 MMscf/d • Concrete weight coated • 24” Dry gas pipeline Pipeline spare (if operating pressure increased to 204 bara) • Onshore operation of offshore} Onshore Gas Plant _{• Potential component of condensate • 300 ppm Methanol • 1000 ppm H2S • Support systems up to 500 MMscf/d • 2x 450 MMscf/d trains platform from Q2 2004 offtake scheme to Tabangao} rate of 550 MMscf/d per flowline) _{• Electro hydraulic subsea control Subsea Manifold • 2 slots planned for Camago, 2 for Malampaya, 1 • 10 slot, 2-header manifold (5 slots used) "spare" • Scope for additional control umbilical to • Scope for 3rd wet gas flowline (2021?) Malampaya/Camago Platform • Continuous MeOH injection, MeOH coalescers • 2 x 100% gas export compression • 30 yr design life (20-22 yr GSPA's) • 4,500 bbl/d aqueous phase • 32,800 bbl/d condensate • 500 MMscf/d at OGP outlet conditions (conditioned gas)}

_{• Supports for Spare risers (3rd Flowline, Camago, SC-38) & J-tubes}

Malikai seabed features _{• Horizontal Xmas tree • 4 Additional development wells (2009/2010) • 7” production tubing, max rates 200 MMscf/d (erosional velocity constrained) • 5 Development wells • Future methanol injection control skid Wells • Future compression re-wheeling • 30-70 degree deviation • Cased and perforated (crestal interval 120-200 ’ or m? along hole) • Tie-in porch for 3rd umbilical • Tie-in porch for 3rd flowline • 2 x control umbilicals}

_{• Future additional facilities for depletion compression (fuel, water,}

_{• Future depletion compression • Designed for load and space for all above} (3 x SSIV, 3 x Control Umbilicals) _air)

  Tigor M H GKU ITB Apr 26,10

  51 Seabed Relief Slump scars Gumusut Malikai Point source Morongo Ubah Tarangan Pinitukidan 20 km Malikai seabed features Rendered 3D image of the NW Borneo Slope

  Tigor M H GKU ITB Apr 26,10

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  Subsea Architecture Subsea Package

• Subsea wellhead, trees, PFB
• Subsea Control Module •Electro-Control hydraulic Umbilical BUTA=Bullnose umbilical termination assembly SUTU= Subsea umbilical termination unit TUTU= topside umbilical termination unit

  Tigor M H GKU ITB Apr 26,10

  53 Subsea Umbilicals Function WP (Psia)

  2 HP Super Duplex tube 7,500

  2 LP Super Duplex tube 3,000

  1 MeOH Super Duplex tube 5,000 1 spare Super Duplex tube 7500

  2

  2 COP 10mm screen pair All are pre filled with transaqua

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  54 Lateral subsea Tree ROV Panel

  Production Choke Valve Subsea Control Module

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  55 Subsea Installation

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  56 Thanks Question ?

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