Abo Oml125

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  • 1. Close-out ABO Extension Project Nigeria -OML 125 Major project milestones Ennio Nitti Engineering Manager Nigerian projects- San Donato Milanese End of March 2008
  • 2. OML 125 -ABO Extension project Field production avg data per year during ABO Ext Phase Green line: produced gas consumed for motive power of FPSO 50 Additional flow rate of ABO 10 .11 (March 2009 trend) approx 18.000 BOPD 40 31,002 33,96 28,8 30 25,147 28,06 26,48 23,83 18,014 20 16,816 10 0 Prod 2005 Prod 2006 Prod 2007 Prod 2008 Expected 2009 March (assuming 50% production yr 2 from start) Crude Avg Production Gas injection trend (1 GI) Note Approx Indication in Barrel Per Day for crude and MillionSCFD per injected or produced gas 2
  • 3. OML 125 -ABO Extension project Location of Nae Block 3
  • 4. OML 125 -ABO Extension project CHARACTERISTICS DATA Past Name / Present GREY WARRIOR / ABO Name FPSO ABO FPSO Built in / Converted in 1976 / 2002 Length overall 280,4 m Breadth 53,6 mVESSEL MAIN DATA Depth 20 m 160.000 Metric Tons Dead weight (approx) Cargo oil tanks 951.658 bbls capacity FPSO conversion an field positioning : 2002/2003 March ( Abo Central) 4
  • 5. OML 125 -ABO Extension projectCurrent Porch Configuration Riser hang-off systems were designed to be located at same FPSO side (even for future expansion) Hang-off of risers in a free hanging configuration from a deck balcony configuration Control Umbilical through I-Tube located on the vessel side (see red line) Total hang-off available systems: 5 + 4 (spares) for risers and 1 + 1 spare for umbilical 5
  • 6. ABO Extension = Schematic Block Diagram of the FPSO Facilities (Receiving manifolds, separation, gas compression, oil handling, water handling) Data regarding actual design envelope for liquid expressed in BPD (Barrel per Day); for gas expressed in Million SCFD Design envelope: Only from Design envelope HP 44 Million SCFD + Second Design envelope: Flare:49 Million 10% = 48,4 Compressor 48,4 Million SCFD SCFD Million SCFD Stage Heating Utility and Relief System Fuel Gas Fuel Gas System for Instrument to Flare Reciprocating Dehydration for Oil Treating Air ( HP, LP) Compressor Glycol Internal Sea Water (3*50% Contactor Process Lift Fire Unit and Fighting capacity ABO Use Central) over Regen within Deluge Package System Three Stages FPSO Design envelope First Stage From 1st Separator: 40000 BPD + Stage 10% (= 44000 BPD) of Separato Gas Handling Via Booster Re- Liquid (Oil+Water) with a r and 2*100 % Cooling for Compressor Injection Overboard Maximum Peak of Water of only Booster Sea Water Water Compressor 9000 BWPD + 44 Million Compressors Filtering Pumps and Oil SCFD of Gas Handling to Wells Well ABO 9 LP Stages Well ABO 10 Design envelope Well ABO 11 Flow lines Inlet Crude Booster: 5,5 and separation Million SCFD + 5,5 Existing ABO manifolds (1st and 2nd Oil Treating Million SCFD Central; Wells 2,3,4 (1st, 2nd Sea Water Stage (i.e Design envelope: Existing ABO Central; Design envelope Degassing stage) Separators, Stabilizing Wells 6,7 Crude Stabilization 9000 BPD interfacing Electrostatic and Abo Central Gas : 40000 BLPD + Subsea Risers Dehydrator) Desalting) Injector Well 5 and 10% (= 44000 BLPD) + 5 Million Umbilicals SCFD Gas Design envelope Test Design envelope Separator :17000 Chemical Hydrocyclons 12000 BOPD+4000 Injection BPD Sea Water BWPD+19000 MSCFD Produced +12000 BPD as Skidded Crude Oil Boosting Water spare Design envelope: Units for Storaging and Treatment 30000 BPD + 10 SEE SLIDE 4 FOR Subsea and within FPSO Pumping Design envelope: %INTERCONNECTION Topsides System 9000 BPD + 2000 SEQUENCE BPD from Chemicals loading Water Overboard Desalting 30PPM Quality (=11000 BPD) + Oil to Export 10% FPSO 6
  • 7. OML 125 -ABO Extension project Actual design parameters of ABO Topside Facilities FPSODesign Parameter Value / PolicyLife design of existing facilities 10 years (starting from 2002)Oil design flow rate 40000 BOPD + 10 % overdesignMaximum design temperature process side 50 CMaximum design pressure at manifold inlet 21 bargDesign capacity of gas treatment 44 MMscfd + 10% = 48.4 MMscfdGas injection line design 42MMscfd + 10% (total 44 MMscfd at exit of 3rd stage injection compressor when two trains operating in parallel; one in stand by)Maximum gas injection pressure at gas lift line to 250 barg (@ porch)existing ABO_5Gas Strategy Gas reinjection into the ReservoirMaximum water production handling flowrate 9000 BWPD; overboard water quality (Oil in Water) discharged to sea: < 30 ppm 7
  • 8. Abo Extension Project -OML 125 Actual FPSO mooring system and existing flow lines arrangement with indication of the new wells ABO 11c -producer ABO 9b Gas injector ABO 10- producerproposed oordinates wells at sanctioningABO 9B 661919.0 E 631920.0 NABO 10 660343.7 E 631713.1 NABO11C 660653.0 E 632729.0 N Mooring chain number 3 required to be lowered for installation 8
  • 9. OML 125 -ABO Extension project n TOPSIDE EVENTS MAJOR MILESTONES OF ABO EXTENSION 9
  • 10. OML 125 -ABO Extension project Project follow up by subcontractors from project start up till completion The engineering volume of manhours associated with the extension works is as follow: Subsea EPC: manhours (Pm+Eng). Approx: 75000 Topsides-FPSO Vessel: manhours (Pm + Eng):12000 Engineering Follow -up: manhours (13000) Installation contractor: manhours (100000) Note : Documents issued by Install contractor: approx 220 Documents issued by Subsea EPC supplier: approx 500 Documents issued by FPSO owner: app. 150 (new); 330 (revision of exixting one) 10
  • 11. Abo Extension Project -OML 125 Release 1_A of Nae 3229.41.000.L.DL.FC88001 Field lay-out without bathymetry ABO 9b Gas injector Abo Ext 11
  • 12. Abo Extension Project -OML 125 12
  • 13. Abo Extension Project -OML 125 Subsea lines scope of installation. Description Service From To Length (m) RG2 GI riser FPSO ABO-9 950 GI flowline FPSO ABO-9 1976 R10 6 production riser FPSO ABO -10 850 6 production riser FPSO ABO -10 3630 R11 6 production riser FPSO ABO -11 850 6 production riser FPSO ABO -11 3573 F10-11 Pigging loop ABO-10 ABO -11 1286 UM2 Dynamic Umbilical FPSO UTA-UM2 2825 (including riser 745.5 m to TDP UP-10 Infield umbilical UTA-UP10 UTA-UP10 B 1630 A UP-11 Infield umbilical UTA-UP11 UTA-UP11 B 1580 A 13
  • 14. Abo Extension Project -OML 125 Porch area:well connections AFT SIDE FORE SIDE New sequence approved during detailed DECK SIDE engineering Abo Spare New Abo Abo AFT SIDE 11 slot Umbi 9 10 lical Umbilical ABO Central ABO FPSO vessel Existing Water injct (ABO 6 ,7) Existing ABO GI (ABO 5)Existing ABO 2 (Prod) Existing ABO 4 Producer Existing ABO 3 (prod) FORE SIDE 14
  • 15. Abo Extension Project -OML 125 Daisy chain : proposed arrangement of the new production wells. Final configuration as per attached P&I ABO 10 ABO 11 Dinamic Flowline Pig receiving line ABO 11 Production Header Riser to Pig Receiver Pig launcher line ABO 10 Production Header Riser to Pig Launcher 15
  • 16. OML 125 -ABO Extension project 16
  • 17. Abo Extension Project -OML 125 TOPSIDE FACILITIES B. Areas of FPSO deck interested in ABO Central Upgrade1. MANIFOLD/PORCH AREA: i.e. interconnections between new risers and existing manifolds; winch refurbishment2. RACK AREA BETWEEN PROCESS AND INJECTION/BOOSTER COMPRESSOR MODULES: i.e. new line to new gas injector well and associated control ( nearby process equipment module) ;3. RISERS AND UMBILICAL (AND SUBSEA FOR FACILITIES): i.e. new risers and umbilical at porch, complete of greylock, venting and necessary wiring and tubing;4. HPU area/TUTU1 area: installation of new skid packages (i.e. new HPU, new TUTU) for control of subsea equipment on deck as well as new Topside chemical injection unit;5. DCS control room area/Instrument technical room upgrade for the new wells: expansion of the existing subsea control dedicated to the new subsea users; interface with existing UPS; modification of existing DCS for new topside users;6. MCC and Engine room area: new power supply lines to ABO Ext equipment/ instrument;7. FWD Crane Area: tie-ins for methanol and wax inhibitors for new producer well using existing installations or new wax inhibitors and methanol pump motor skid for new producer well.and installation of proper heat radiation shields where required due to higher flare gas flow rates originated from subsea fields ( namely ABO2 field)8. Aft Crane Area: Minor servicing of existing winches for chain slackening. 17
  • 18. Abo Extension Project -OML 125 FPSO arrangement- Areas interested by modifications affected areas: Crane area DCS Rack area MCC (compressor ) area Flare area Manifold area Exist HPU -TUTU and main winch Porch areaABO FPSO 18
  • 19. OML 125 - ABO Extension project Offshore Installation Topsides works in support of Vetco Control topside installations (1) Major works recap Description Scope Notes ABS certification of subsea HPU, TUTU and Control Topside items container Upgrade of Container design to Fireproofing with meet safety ABS requirements Chartek 7 to ABS due to deck C installation requirements Transformer installation to suit available on-board power supply Engineering and (440 V /3 phase) to the power Material supply supply rating of the container (220 V monophaseNote (1) = Whole installation process completed safely with 0 LTI 19
  • 20. Abo Extension Project -OML 125Engineeringdeveloped by FPSO vessel owner in support of their EPC (1/1) -P&I s of new elaboration/ rework: - Chemical injection system methanol and wax inhibitor units servicing the new TUTU, supplied by VETCO and Instrument air, Nitrogen, closed drain , sea water cooling - new manifold area P&I scheme in order to show new the pig launcher( x-234) and receiver (x-235) - Reissue new P&Is pig launcher-receiver equipment/ instrumentation as well as show piping connections with inhibitors lines - Manage tie-ins on existing schemes - Provide support for SIMPOP-HAZID-HAZOP - Activation of MTO of piping valves and in line material -General arrangement drawings (Layouts and Piping): -elevation and plan drawings at porch area and manifold area -New plot plan drawing(s) of the new pumps and relevant installation -Installation drawing(s) of the new TUTU Installation drawing of the New HPU -plot plan of FPSO areas where new technical room of the new ECS Cabinets has to be installed. Wire connections to ITR existing in order to ensure DCS-ESD and subsea datalogging continuity. 20
  • 21. Abo Extension Project -OML 125 TOPSIDE FACILITIES Engineering developed by FPSO vessel owner 2/2 Specification /BoQ-MTO New duty specifications of new equipment,piping, instrumentation and electric HW supply, including Chocke valves, SDV and miscellanea. Provide BoQ and isometric drawings for piping and valves Instrumentation and control ( Cause effect ) documents: Provide instrumentation list with settings and main design data Revision of the EDS/PSD diagram Review of the UPS connectiona Revision of the Juncion box connection diagrams Interfaces with I/0 of new subsea Implementation of new video pages for existing DCS Electrical distribution drawing: New wiring from diatribution 440 V/3ph engine switchgear room associated ones to feed new HPU ,TUTU,ECS panels by VETCO Revise diagrams and terminals for miscellanea ( instrumentation feed) Provide BoQ of cabling of new supply for different cable design specification Update / procure cable ways when required 21
  • 22. OML 125 -ABO Extension project Offshore Installation Topsides works in support of Flow line installation (1) Major works recap Description Scope Notes Load re-testing and ABS Additional certification for deck winch (22t) and Main FPSO winch (75t design capacity) recertification, (including tugger winch (5t) pulling wire) Leak testing and tubing Greylock fittings of flow lines routing for venting of connection Abo 9 injection; 10, and 11 production pipelines statisfactorily tested at 270 bar ABS certified and 240 bar respectively Mooring analysis and procurement of new parts (chain links) for slackening of chain number 3 and additional works/ ABS supervised personnel to achieve the installation Technip schedule Support for precommissioning flow Support to safely dewater lines and diesel fill new flowlines Cleaning bellmouth and Diving squad in support of installation fixing / installing new umbilicalsNote (1) = Whole installation process completed safely with 0 LTI 22
  • 23. OML 125 -ABO Extension project TOPSIDE FACILITIES B. Areas interested in ABO Central Upgrade RACK AREA BETWEEN PROCESS AND INJECTION/BOOSTER COMPRESSOR MODULES (i.e. new line to new gas injector well ABO 9 ) Abo 10 Rack Xssing Foreside-Aft side Abo 9 23
  • 24. OML 125 -ABO Extension project TOPSIDE FACILITIES B. Areas interested in ABO Central Upgrade MANIFOLD/PORCH AREA (i.e. interconnections between new risers and existing manifolds) 24
  • 25. OML 125 -ABO Extension project TOPSIDE FACILITIES B. Areas interested in ABO Central Upgrade RISERS AND UMBILICAL (AND SUBSEA FOR FACILITIES - i.e. new risers and umbilical at porch) 25
  • 26. OML 125 -ABO Extension project TOPSIDE FACILITIES B. Areas interested in ABO Central Upgrade HPU area/TUTU1 area - installation of new skid packages (i.e. new HPU, new TUTU) for control of subsea equipment on deck ( Abo central pkgs shown) 26
  • 27. OML 125 -ABO Extension project TOPSIDE FACILITIES B. Areas interested in ABO Central Upgrade DCS control room area/Instrument technical room B (expansion of the existing subsea control dedicated to the new subsea users; interface with existing UPS modification of existing DCS for new topside users)-Cabinet of abo extension located elsewhere ( Deck C) 27
  • 28. OML 125 -ABO Extension project TOPSIDE FACILITIES B. Areas interested in ABO Central Upgrade FWD Crane Area - tie-ins for methanol and wax inhibitors for new producer well using existing installations or new wax inhibitors and methanol pump motor skid for new producer well 28
  • 29. OML 125 -ABO Extension project TOPSIDE FACILITIESEngineering/Procurement Activities by FPSO vessel owner (1/2) Project Management throughout the project; Site visit by designer to verify the design /installation if required, including surveys for subsea- installation contractor and precommissioning of flow lines ; Design, engineering, procure, install and hydraulic testing of new piping pertaining to production header tie-ins and gas injection header tie-ins, using local content labor; Prepare piping isometrics for piping pre-fabrication with the aim of minimizing hotwork and shutdown requirements; Shut down minimized in march 2008 for manifold line tie-ins ( HP,LP,Header,testing line) Procurement of piping, valves, control valves, shutdown valves, instrumentation systems, cables, tubing, cable trays and etc. as required to tie-in the new wells from the riser porch dummy spool; Support and assist Company in refurbishing mooring line ( required for chain slackening #3) as well as maintain and service existing hydraulic winches for umbilical and flowlines installation 29
  • 30. OML 125 -ABO Extension project TOPSIDE FACILITIESEngineering/Procurement Activities (2/2) Revise all relevant existing drawings, safety plans, P&IDs, cause and effect, vessel general arrangement, instrument drawings etc to incorporate the new modifications; Develop modifications to the process control system to reflect the new equipment; Obtain Class approvals as required to implement the changes; obtain permits, license and authority approvals (Support Documentation for approval of Nigerian authorities, Support Documentation for approval of ABS); Perform HAZOPS, HAZIDS for the construction and operations phases; Develop Job Cards and Procedures for the offshore installation as well as implement installation details in Office Project for all the installation activities ( Prosafe scope and interface scope) ; Logistics, Coordination of shipments and Offshore Construction works in cooperation with Nae; Revise Operating Manuals to suit the modifications; Monitor punch lists after First oil. As-built all drawings preparation and final documentation affected by the change. 30
  • 31. OML 125 -ABO Extension project TOPSIDE FACILITIESOffshore Installation (1/3) Mobilise construction crews to offshore for installation of mechanical, electrical, controls and instrument scope of work; Transport all equipment, tools, and materials to offshore; Install all valves, instruments, tubing, piping and cabling to connect the new equipment; Modify the process control system (DCS) to include the new wells (field instrumentation); Preserve the system ready for riser pull-in (final dummy spool -if required- and one section of pipe to be left intact for later removal during riser pull-in should these activities not be combined; Obtain ABS Class Supervision during key installation phases 31
  • 32. OML 125 -ABO Extension project TOPSIDE FACILITIES Offshore Installation (2/3) Subsea Control System Interface activities: - Coordinate with Subsea Contractor regarding supply and installation of hydraulic tubing from the HPU/TUTU to the riser porch JB according NAS 6 quality standard; - Supply, install and test hydraulic tubing as required to suit the new well control requirements; - Cabling and hook up tubing for subsea controls, terminating in new junction box at riser porch; - Mobilise specialists for process system software changes and perform site modifications for the subsea control system interface. - Keep under control POB during crucial installation phase ( off-shore) 32
  • 33. OML 125 -ABO Extension project Offshore Installation Topsides (3/3) Key Parameters (internal evaluation based on FPSO vessel owner final numbers for 2+1 wells) Installation Description Installation Manhours Parameters Piping and Ancillaries (1) 30.000 kg Indicative data from OIM: Packaged Equipment (2) 10000 13000 20.000 kg Cable/Cableways 3000 m 4500 (Power and Control) NOTES (1) It includes approx 8000 Kg of valves and light steelwork for support; (2) it includes 2 off pigs, 1TUTU,1HPU, 1 control cabinet 1 Chemical injection skid 33
  • 34. OML 125 -ABO Extension project installation contractor sub-orders ( major)Description Scope CompanyFlexible pipe and ancillary equipment (Hang off Material, shop production, FlexiFrance (France)collar, Bend stiffner and Bend stiffner spacer) shop testingAnodes for flowlines Material, production, shop Impalloy (UK) testingInsulation Covers Material, production, shop Bardot (France) testingPrecommisioning Service (FPSO and Installation Detail Engineering and BJ (UK)Vessel) Offshore rental equipment - labour for commissioning activitiesSteel Bend Restrictor Material, shop production, Asturfeito (Spain) shop testingSurvey Service Detail Engineering, DOF (UK) offshore personnel, labour and ancillary tools / equipmentTurning points Material, shop fabrication, COMETRA (France) testing AMS (Nigeria)*Umbilical Tether Base & Tether Material, fabrication, COMETRA (France) testingNOTE : (*) Spare itemsNote (1) = Whole installation process completed safely with 0 LTI. - main subcontractors list forABO Extension. (Installation of all items managed by Installation contractor) 34 Technip
  • 35. OML 125 -ABO Extension project Major subcontractor packages for Topsides FPSO works Description Scope Company Mooring equipment for chain Material (air shipped) and Noble Denton Singapore number 3 slackening labour Overhaul and refurbish 75,25,5 Laad cell monitoring, Mc-Gregor Plinsol tonn winches service parts and labour Singapore Personnel assistance during Labour in support of Noble Denton- Mc hook-up phase operations by Technip Gregor Labour, tools and tool HP Tubing and Chemical tubing service container to on board of vessel up to Hulliburton Nigeria perform NAS 6 quality Umbilical plate flushing Labor and logistic to clean Diving and divers equipment bellmouth and install / fix Ken-dive Nigeria new umbilical Small bore spare valves for Material supply Alton piping works Material (air shipped) and Flare radiation shields Thermolimitec engineering Material supply for continuty of installation Dummy fittings Dormen long between piping and flowlines Prefabricated piping (above 2) Material supply, support for all pipework from porch area during installation, field Amber resources Nigeria back to manifold an Pigs welding Xray testing ABS Singapore and ABS supervision/ approval Process review connected offices 35
  • 36. Abo Extension Project -OML 125 Estimated subsea contractor delivery schedule (only Items interfacing topsides ) Final delivery for installation : trees between February 2008 and April 2008 Topside control End of June 2008 36
  • 37. OML 125 -ABO Extension project-Installation of FPSOmodification 37
  • 38. OML 125 -ABO Extension project 38
  • 39. OML 125 -ABO Extension project 39
  • 40. OML 125 -ABO Extension project The scope of supply for Integrated Control and Safety System modifications included but was not limited to following: Design, Engineering, Procurement, Programming, Configuration, Software, Graphics, Logics, Fabrication, Assembly, Testing and Commissioning, Preparation for Shipment, packing and supply of System hardware with cabinets, I/O Modules, and Controllers for the modification of existing control system at offshore (on the FPSO). Integrated Control and Safety System (ICSS) consisted of : Process Control System (PCS) Process Shutdown System (PSD) Emergency Shutdown & Fire and Gas System (ESD/F&G) Specifically : Updating the existing configuration and configuring additional I/O Modules, Spare Channels and Marshalling Termination Configuration and integration with new ECS system HPU system supplied by Vetco with existing PCS. Modification to existing graphics and build new graphics. Upgrading of the redundant controllers for 6MB Capacity. Supply of IS barrier for intrinsically safe signals. Review existing M-NET capabilities for additional nodes and its adequacy. Configuration of existing Tag server database for new I/Os and its adequacy. Configuration of existing Historian Server database for new I/Os. 4-mation Configuration Software Configuration and testing (on-shore-offshore) Configuration of alarm functions for existing inputs-3 Nos FAT,SAT & Commissioning assistance. Update Clients comments at site. RS485/RS 232 serial link connectors and required network adaptors. Engineer site deputation for installation, testing and commissioning at ABO FPSO. Packing and Shipment. Tagging and labelling. Supply of special tools. Documentation. 40
  • 41. OML 125 -ABO Extension project ITEM 5.1 -TOPSIDE FACILITIES-modification of overall subsea control system to be integrated with ABO central ( Using Multi drop communication system protocol) 41
  • 42. OML 125 -ABO Extension project TOPSIDE FACILITIES-Control system ABB - 1 Extended architecture 42
  • 43. OML 125 -ABO Extension project Location Deck C where Container will be placed Internal view Container hosting sub sea 43
  • 44. OML 125 -ABO Extension project 44
  • 45. OML 125 -ABO Extension project Offshore Installation field precommissioning (sample of signed hand over document) TOPSIDE FACILITIES- List of commissioned sub-system 45
  • 46. OML 125 -ABO Extension project FIELD START-UP EFFECTIVE DATES OF ABO EXTENSION Wells start-up dates of ABO COMBINED PROFILE (CENTRAL + ABO EXTENSION) : Wells Date ABO 11 (P1) 14 February 2009 ABO 10 (P2) 15 February 2009 ABO 9 (GI) 20 February 2009 Test of production : mid 2009 46
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Close-out ABO Extension Project Nigeria -OML 125 Major project milestones – Ennio Nitti – Engineering Manager Nigerian projects- San Donato Milanese – End of March 2008
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