Abo Oml125

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

28,8

18,01416,816

25,14731,002

26,48 28,0623,83

33,96

0

10

20

30

40

50

Prod 2005 Prod 2006 Prod 2007 Prod 2008 Expected 2009March

(assuming 50%production yr 2

from start)

• Note – Approx Indication in Barrel Per Day for crude and MillionSCFD per injected or produced gas

Crude Avg ProductionGas injection trend (1 GI)

Field production avg data per year during ABO Ext Phase

Additional flow rate of ABO 10 .11 (March 2009 trend) approx 18.000 BOPD

Green line: produced gas consumed for motive power of FPSO

3

OML 125 -ABO Extension project Location of Nae Block

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CHARACTERISTICSCHARACTERISTICS DATADATA

Past Name / Present Name

GREY WARRIOR / ABO FPSO

Built in / Converted in 1976 / 2002

Length overall 280,4 m

Breadth 53,6 m

Depth 20 m

Dead weight 160.000 Metric Tons (approx)

Cargo oil tanks capacity

951.658 bbls

VESS

EL M

AIN

DA

TA


ABO FPSO ABO FPSO

FPSO conversion an field positioning : 2002/2003 March ( Abo Central)

5

Current 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

Total hang-off available systems: 5 + 4 (spares) for risers and 1 + 1 spare for umbilical

Control Umbilical through I-Tube located on the vessel side (see red line)


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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

Flow linesand

manifolds(1st, 2nd

stage) interfacing

Subsea Risersand

Umbilicals

Inlet Crude separation

(1st and 2nd Stage

Separators, ElectrostaticDehydrator)

Oil Treating(i.e

Stabilizingand

Desalting)

Crude Oil Storaging

within FPSO

Gas Handling and 2*100 %

Booster Compressors

Fuel Gas ReciprocatingCompressor

(3*50% capacity ABO Central) over Three Stages

Utility and Instrument

Air

Relief System to Flare

( HP, LP)

ChemicalInjectionSkiddedUnits for

Subsea and Topsides

Well ABO 11

Existing ABO Central; Wells 2,3,4

Existing ABO Central; Wells 6,7

Abo Central Gas Injector Well 5

Well ABO 9

ProducedWater

Treatment

Oil to Export FPSO

Water Overboard30PPM Quality

Sea WaterLift

Sea Water Filtering

Sea Water Degassing

Sea Water Boosting

and PumpingSystem

Re-Injection

Water Pumps

to Wells

Fuel Gas for

InternalProcess

UsewithinFPSO

Via Booster Compressor

DehydrationGlycol

ContactorUnit and Regen

Package

From 1st Stage

Separator

only

HeatingSystem forOil Treating

FireFightingDelugeSystem

LP Stages

Cooling forCompressor

and Oil Handling

Overboard

Chemicals loading

Only fromSecond

CompressorStage

Design envelopeHydrocyclons 12000

BPD+12000 BPD as

spare

Design envelope: 9000 BPD

Design envelope HP Flare:49 Million

SCFD

Design envelopeBooster: 5,5

Million SCFD + 5,5 Million SCFD

Design envelopeCrude Stabilization

: 40000 BLPD + 10% (= 44000

BLPD) + 5 MillionSCFD Gas

Design envelope: 48,4 Million SCFD

Design envelope Test Separator :17000

BOPD+4000 BWPD+19000 MSCFD

Design envelope First Stage Separator: 40000 BPD + 10% (= 44000 BPD) of

Liquid (Oil+Water) with a Maximum Peak of Water of 9000 BWPD + 44 Million

SCFD of Gas

Design envelope: 44 Million SCFD +

10% = 48,4 Million SCFD

Design envelope: 30000 BPD + 10

%Design envelope: 9000 BPD + 2000

BPD fromDesalting

(=11000 BPD) + 10%

SEE SLIDE 4 FOR INTERCONNECTION

SEQUENCE

Well ABO 10

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Actual design parameters of ABO TopsideFacilities FPSO

Gas reinjection into the ReservoirGas Strategy

9000 BWPD; overboard water quality (Oil in Water) discharged to sea: < 30 ppm

Maximum water production handling flowrate

250 barg (@ porch)Maximum gas injection pressure at gas lift line toexisting ABO_5

42MMscfd + 10% (total 44 MMscfd at exit of 3rd stage injection compressor when two trains operating in parallel; one in stand by)

Gas injection line design

44 MMscfd + 10% = 48.4 MMscfdDesign capacity of gas treatment

21 bargMaximum design pressure at manifold inlet

50 °CMaximum design temperature process side

40000 BOPD + 10 % overdesignOil design flow rate

10 years (starting from 2002)Life design of existing facilities

Value / PolicyDesign Parameter

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Abo – Extension Project -OML 125

ABO 11c -producer

ABO 9b –Gas injector

ABO 10- producer

Actual FPSO mooring system and existing flow lines arrangementwith indication of the new wells

proposed oordinates wells at sanctioning

632729.0 N660653.0 EABO11C631713.1 N660343.7 EABO 10631920.0 N661919.0 EABO 9B

Mooring chain number 3 required to be lowered forinstallation

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TOPSIDE EVENTS MAJOR MILESTONES OF ABO EXTENSION


n

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The engineering “volume” of manhours associated with the extension works isas follow:

Subsea EPC: manhours (Pm+Eng). Approx: 75000Topsides-FPSO Vessel: manhours (Pm + Eng):12000

Engineering Follow -up: manhours (13000)Installation contractor: manhours (100000)

Project follow up by subcontractors from project start up till completion

Note : Documents issued by Install contractor: approx 220Documents issued by Subsea EPC supplier: approx 500Documents issued by FPSO owner: app. 150 (new); 330

(revision of exixting one)

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ABO 9b –Gasinjector

Release 1_A of Nae3229.41.000.L.DL.FC88001

Field lay-out without bathymetry

Abo Ext

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Subsea lines scope of installation.

1580UTA-UP11 BUTA-UP11 A

Infield umbilicalUP-11

1630UTA-UP10 BUTA-UP10 A

Infield umbilicalUP-10

2825UTA-UM2FPSODynamic Umbilical(including riser 745.5 m to TDP

UM2

1286ABO -11ABO-10Pigging loopF10-11

3573ABO -11FPSO6” production riser

850ABO -11FPSO6” production riserR11

3630ABO -10FPSO6” production riser

850ABO -10FPSO6” production riserR10

1976ABO-9FPSOGI flowline

950ABO-9FPSOGI riserRG2

Length (m)ToFromServiceDescription

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Abo – Extension Project -OML 125Porch area:well connections

FORE SIDE

AFT SIDE

AFT SIDE

FORE SIDE

DECK SIDE

Existing ABO 2 (Prod)

Existing ABO GI (ABO 5)

Umbilical ABO Central

Existing ABO 4 ProducerExisting ABO 3 (prod)

Existing Water injct(ABO 6 ,7)

ABO FPSO vessel

Abo 10

Abo 9

New Umbilical

Spareslot

Abo 11

New sequence approved during detailedengineering

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Abo – Extension Project -OML 125Daisy chain : proposed arrangement of the new production wells.

ABO 11

ABO 10

Final configuration as per attached P&I

Dinamic Flowline

Pig launcher lineABO 10 – Production Header Riser to Pig Launcher

Pig receiving lineABO 11 – Production Header Riser to Pig Receiver

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TOPSIDE FACILITIESB. Areas of FPSO deck interested in ABO Central Upgrade

1. MANIFOLD/PORCH AREA:• i.e. interconnections between new risers and existing manifolds; winch refurbishment

2. 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 wiringand 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 withexisting 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 originatedfrom subsea fields ( namely ABO2 field)

8. Aft Crane Area:• Minor servicing of existing winches for chain slackening.


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Porch area

Manifold area

Exist HPU -TUTU and main winch

Crane areaRack area

(compressor )DCS MCC area

ABO FPSO

affected areas:

– FPSO arrangement- Areas interested bymodifications

Flare area

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Offshore Installation –Topsides works in support of Vetco Control topside installations (1)

Major works recap

Fireproofing withChartek 7 to ABS requirements

Upgrade of Container design tomeet safety ABS requirementsdue to deck “C” installation

Engineering and Material supply

Transformer installation to suitavailable on-board power supply(440 V /3 phase) to the power supply rating of the container (220 V monophase

HPU, TUTU and Control container

ABS certification of subseaTopside items

NotesScopeDescription

OML 125 - ABO Extension project

Note (1) = Whole installation process completed safely with “0” LTI

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Engineeringdeveloped 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 servicingthe new TUTU, supplied by VETCO and Instrument air, Nitrogen, closeddrain , sea water cooling

-new manifold area P&I scheme in order to show new the piglauncher( x-234) and receiver (x-235)

-Reissue new P&Is pig launcher-receiver equipment/ instrumentationas 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 relevantinstallation-Installation drawing(s) of the new TUTUInstallation 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.


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TOPSIDE FACILITIESEngineering developed by FPSO vessel owner “2/2”

Specification /BoQ-MTONew 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 dataRevision of the EDS/PSD diagramReview of the UPS connectionaRevision of the Juncion box connection diagramsInterfaces with I/0 of new subseaImplementation of new video pages for existing DCS

Electrical distribution drawing:New wiring from diatribution 440 V/3ph engine switchgear room associated ones tofeed new HPU ,TUTU,ECS panels by VETCORevise diagrams and terminals for miscellanea ( instrumentation feed)Provide BoQ of cabling of new supply for different cable design specificationUpdate / procure cable ways when required


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Offshore Installation –Topsides works in support of Flow line installation (1)

Major works recap

Leak testing and tubingrouting for venting of connection

Greylock fittings of flow lines

ABS certifiedAbo 9 injection; 10, and 11 production pipelines statisfactorily tested at 270 bar and 240 bar respectively

ABS supervised

Mooring analysis and procurement of new parts (chain links) for slackening of chain number 3 and additional works/ personnel to achieve the installationTechnip schedule

Support to safely dewaterand diesel fill new flowlines

Support for precommissioning flow lines

Additional certification for deck winch (22t) and tugger winch (5t)

Load re-testing and ABS recertification, (includingpulling wire)

Main FPSO winch (75t design capacity)

Cleaning bellmouth and fixing / installing new umbilicals

Diving squad in support of installation

NotesScopeDescription


Note (1) = Whole installation process completed safely with “0” LTI

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TOPSIDE FACILITIESB. 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 9

Abo 10Rack Xssing Foreside-Aft side


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MANIFOLD/PORCH AREA (i.e. interconnections between new risers and existing manifolds)


25


• RISERS AND UMBILICAL (AND SUBSEA FOR FACILITIES - i.e.

new risers and umbilical at porch)


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HPU area/TUTU1 area -installation of new skid packages (i.e. new HPU, new TUTU)

for control of subsea equipment on deck ( Abo centralpkgs shown)


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DCS control room area/Instrument technical room ‘B’ (expansion of the existing subsea control dedicated to the new subsea users; interface

with existing UPSmodification of existing DCS for new topside users)-Cabinet of abo

extension located elsewhere ( Deck ‘C’)


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FWD Crane Area -tie-ins for methanol and wax inhibitors for new producer

well using existing installations or new wax inhibitorsand methanol pump motor skid for new producer

well


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TOPSIDE FACILITIES

Engineering/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,testingline) 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


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TOPSIDE FACILITIES

Engineering/Procurement Activities (2/2)

Revise all relevant existing drawings, safety plans, P&ID's, 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, SupportDocumentation 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.


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TOPSIDE FACILITIES

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

Offshore Installation (1/3)


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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)

TOPSIDE FACILITIES

Offshore Installation (2/3)


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Offshore Installation –Topsides (3/3)

Key Parameters (internalevaluation based on FPSO vessel owner final

numbers for 2+1 wells)

45003000 mCable/Cableways(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

20.000 kgPackaged Equipment (2)

Indicative data fromOIM:10000 – 13000

30.000 kgPiping and Ancillaries (1)

Installation ManhoursInstallationParametersDescription


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installation contractor sub-orders ( major)


Note (1) = Whole installation process completed safely with “0” LTI. - main subcontractors list for ABO Extension. (Installation of all items managed by Installation contractor)

NOTE : (*) Spare items

COMETRA (France)Material, fabrication, testing

Umbilical Tether Base & Tether

COMETRA (France)AMS (Nigeria)*

Material, shop fabrication, testing

Turning points

DOF (UK)Detail Engineering, offshore personnel, labour and ancillary tools / equipment

Survey Service

Asturfeito (Spain)Material, shop production, shop testing

Steel Bend Restrictor

BJ (UK)Detail Engineering and Offshore rental equipment - labour for commissioning activities

Precommisioning Service (FPSO and Installation Vessel)

Bardot (France)Material, production, shop testing

Insulation Covers

Impalloy (UK)Material, production, shop testing

Anodes for flowlines

FlexiFrance (France)Material, shop production, shop testing

Flexible pipe and ancillary equipment (Hang off collar, Bend stiffner and Bend stiffner spacer)

CompanyScopeDescription

Technip

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Major subcontractor packages for Topsides FPSO works

ABS Singapore and connected officesProcess reviewABS supervision/ approval

Ken-dive NigeriaLabor and logistic to cleanbellmouth and install / fix

new umbilicalDiving and divers equipment

Hulliburton Nigeria

Labour, tools and tool –service container to

perform NAS 6 qualityflushing

HP Tubing and Chemical tubingon board of vessel up toUmbilical plate

Noble Denton- Mc Gregor

Labour in support of operations by Technip

Personnel assistance duringhook-up phase

Mc-Gregor PlinsolSingapore

Laad cell monitoring, service parts and labour

Overhaul and refurbish 75,25,5 tonn winches

Noble Denton SingaporeMaterial (air shipped) and labour

Mooring equipment for chainnumber 3 slackening

ThermolimitecMaterial (air shipped) and engineeringFlare radiation shields

AltonMaterial supplySmall bore spare valves forpiping works

Dormen long

Material supply forcontinuty of installation

between piping and flowlines

Dummy fittings

Amber resources Nigeria Material supply, supportduring installation, field

welding Xray testing

Prefabricated piping (above 2”) for all pipework from porch area back to manifold an Pigs

CompanyScopeDescription


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Estimated subsea contractor delivery schedule (only Itemsinterfacing topsides )

Final delivery forinstallation : treesbetween February2008 and April 2008

Topside control End of June 2008

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OML 125 -ABO Extension project-Installation of FPSO modification

38


39


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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/O’s and its adequacy.• Configuration of existing Historian Server database for new I/O’s.• 4-mation Configuration• Software Configuration and testing (on-shore-offshore)• Configuration of alarm functions for existing inputs-3 Nos• FAT,SAT & Commissioning assistance.• Update Client’s 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.

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ITEM 5.1 -TOPSIDE FACILITIES-modification of overall subsea control system to be integrated with ABO central ( Using Multi drop communication system protocol)


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TOPSIDE FACILITIES-Control system


©A

BB -

1Extended architecture

43


Location Deck “C” where Container will be placed

Internal view Container hosting sub sea

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TOPSIDE FACILITIES- List of commissioned sub-system

Offshore Installation field precommissioning (sample ofsigned hand over document)


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FIELD START-UP EFFECTIVE DATES OF ABO EXTENSIONWells start-up dates of ABO COMBINED PROFILE (CENTRAL + ABO EXTENSION) :

Test of production : mid 2009

20° February 2009ABO 9 (GI)

15° February 2009ABO 10 (P2)

14° February 2009ABO 11 (P1)

DateWells


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