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Introduction
26th April, 2013
Title:Design of Jack-up For Extended Well Testing (EWT)/Early Production System (EPS) and Selection of Floating Storage & Offloading (FSO) Vessel for Middle East & India Waters
Group F Presentation
Presenter
2 26th April, 2013 Group F Presentation
Gold Agharese
Group Members:Gold Agharese (Production Engr.)Babajide Ogunsanya (Mech. Engr.)Daniel Boadu (Chemical Engr.)Patrick Omavuezi (Elect. Engr.)Eli Klu (Actuary)Daniel Dore (Elect. Engr.)Wisdom Wakama (Mech. Engr.)Richard Ivanhoe (Chemical Engr.)
Supervisor: Dr. John Preedy
Introduction
26th April, 2013 Group F Presentation
Introduction
Definitions
EWT• To measure the productivity of wells• To Provide data that aids design of full
field development
EPS• To generate early cash flow• To gather more reservoir data of field
• Environmental factors for design considerations.• Modification and upgrading of an existing Jack-up to a mobile offshore production unit.• Appropriate Topside configuration and equipment selection.• Design and selection of suitable Mooring System for both regions.• Selection of a sizable Floating Storage and Offloading (FSO) Vessel for product storage.• Procedures for Transportation, Installation and Decommissioning.• Adopted HSE and SAFETY CASE measures.• Measures for corrosion protection; and• Cost analysis.
Outline
26th April, 20134 Group F Presentation
Environment &
Metocean
Mumbai High & Persian Gulf• Regions of shallow water depth
(90m max.).• Bounded by common water (the
Arabian sea).• Ease of deployment to locations.• Common environmental factors
(Wind, wave, temp., soil stratigraphy and bathymetry.
Suitability of the Regions for Jack-up Deployment
Mum
bai High
Bay
of B
enga
l
26th April, 20135 Group F Presentation
Design DataMumbai High
Climatic Parameter
Minimum
Maximum
Surface Air Temp. (°C )
23 In January(extreme can be 19)
30 in May(extreme can be 33)
Relative Humidity (%) 67 (Feb & Dec.)
75 (July & August)(extreme can be 85)
Average monthly rainfall (mm)
175 mm monthly. July is the wettest period with 710mm of rain and driest 0mm in March.
Visibility (km) 1 20Salinity (°/OO) 30 35
Wind
South-west monsoon in May – Sept.
North-east monsoon in Oct. – April
Occurs during South-west monsoon at 30kmph
Wave North-east monsoon :Maximum wave height is 3mSouth-west monsoon: Maximum can be above 8m. Wave direction is same as wind directions.
Tidal Currents &
Tropical Revolving Storm
Currents: Strong and causes upwelling (Max of 0.5m/s).TRS: Occurs between Monsoons (Oct .– Nov.). Interrupts offshore operations.
Monsoons Tropical Revolving Storm
26th April, 20136 Group F Presentation
Design DataPersian Gulf
Climatic Parameter
Minimum
Maximum
Surface Air Temp. (°C )
17 in Jan. – Feb.(extreme can be 0)
38 in August(extreme can be 50)
Relative Humidity (%)
59 in June(extreme can be 40)
77 in Dec.(extreme can be 90)
Average monthly rainfall (mm)
25mm monthly. Dec. is the wettest period with 710mm of rain and driest 0mm in June – Oct.
Visibility (km) 5 in June – Sept. 8 in June – JulySalinity (°/OO) 37 50
Wind
Winter Shamal in mid Oct. – mid April
Summer Shamal in June – Sept.
Occurs 5 days in April at 22kmph
Wave Winter Shamal: Maximum wave height is 3.5m Winter Shamal: Maximum can be above 5m.
Tidal CurrentsCurrents: Strong and causes upwelling (Max of 1.2m/s).
Tidal Zones Current circulation
26th April, 20137 Group F Presentation
Soil Stratigraphy
& Bathymetry
Persian Gulf• Soil stratigraphy indicates the carbonates occurs in stacked
trapping.• Multiple phases of compressed tectonic layers.• The basin is asymmetric through its Northeast-Southwest sections.• Bathymetry: Densely packed sand inter-layered with Gypsum and
carbonate.
Indian• Soil Stratigraphy shows large area of shallow multilayered
reservoirs with gas cap and thin sweet zones.• Bathymetry: Dense sand layers with embedded shell fragments.• Clay layers shows trends of increasing strength as the depth
increases.
Area of interest: The Persian Gulf
26th April, 20138 Group F Presentation
Presenter
9 26th April, 2013 Group F Presentation
Babajide Ogunsanya
• Load Response:-• Shear Stress• Overturning Moment
• Loads:-
External Loads
Hydrodynamic Loads
Current induced drag force
Wave Force = Drag Force + Inertia Force
Wave Spectrum AnalysisWindWind induced
drag force
External Loads & Load Responses
26th April, 201310 Group F Presentation
Wave Spectrum Analysis
• Wave spectrum with the Significant Wave Height and Mean Wave Period to define the sea state
• Douglas Sea Scale;• Persian Gulf :- Very Rough• Mumbai High :- High
• JONSWAP wave spectrum approximation best fit observations from both regions
(using approach of Mazaheri and Ghaderi for Persian Gulf and Kumah for Indian Ocean)
26th April, 201311 Group F Presentation
Wave Profile
Mumbai High• The natural frequency of
the structures should be greater than 0.075 Hz
Persian Gulf• The natural frequency of
the structures should be greater than 0.1 Hz
26th April, 201312 Group F Presentation
Jack-up Design Approach
• This design seeks to upgrade and modify an existing unit of, the “baker marine 375 series", jack-up.
• Documents adopting the SNAME and ISO design approach were used.
• Other structural analysis was based on the API requirements.• The design unit was in line with relevant government safety
regulations/standards.
13 Group F Presentation26th April, 2013
Jack-up Leg Design In Jack-up design, twotypes of legs are used. They are;
• Truss legs• Columnar legs
• More stable legs• Adapts to loads and stresses
better Columnar legs
Truss legs
14 Group F Presentation26th April, 2013
Foundation design• The jack-up leg penetrations,
soil bearing capacity of the Indian waters and Persian Gulf with spudcans footing designs was analyzed for use in the foundation design.
• The spudcans can be used on a variety of seabed.
• It is currently the offshore industry standard for jack-
up legs footings.
spudcan
15 Group F Presentation26th April, 2013
Hull DesignThe design entailed the reinforcement of hull using cross-stiffened panel plates.
• The DnV criteria for plate thickness/stiffener sizing was adopted because, it considers fabrication tolerance in plate thickness analysis.
An AutoCAD schematic of a cross-stiffened plate
16 Group F Presentation26th April, 2013
Hull Designcont.
• The hull was refurbished from drilling to production configuration.
An AutoCAD schematic of the Hull
17 Group F Presentation26th April, 2013
Helideck• The deck is made of
aluminum with steel supporting structure for strength purpose.
• The design was verified in line with all relevant regulations.
• Lighting was installed to aid night flights, while design accommodates a variety of helicopter.
18 Group F Presentation26th April, 2013
Presenter
19 26th April, 2013 Group F Presentation
Daniel Boadu
Topside Processing and
UtilitiesDESIGN OBJECTIVES
•Processing plant configuration
•Process requirements
•Equipment Specification
•Well measurement system
20 Group F Presentation26th April, 2013
21
Basic Reservoir DataReservoir Pres. 2000psiReservoir Temp. 100oCGOR (scf/bbl) 300API gravity 28H2S < 3ppmTotal Sulphur Cont. 2.82%wtCO2 0.02%moleRVP, psi 7.8BS&W, %v/v 0.05 Plant Design Basis
Oil handling capacity = 25000bopdAssociated gas = 7.5Mmscfd Effluent Handling capacity= 6250bwpd
Middle-East
Middle-East
Topside Processing and Utilities cont.
Group F Presentation26th April, 2013
22
Basic Reservoir DataReservoir Pres. 157 kg/cm2
Reservoir Temp. 115oCGOR (m3/m3) 37API gravity 39.52H2S 12ppmTotal Sulphur Cont. 0.25%wtCO2 10.33 %moleRVP, psia 10BS&W, %v/v 0.2
Plant Design BasisOil handling capacity = 25000bopdAssociated gas = 5.19Mmscfd Effluent Handling capacity = 15000bwpd
India
India
Topside Processing and Utilities cont.
Group F Presentation26th April, 2013
• A single train facility (1x100%) plant configuration was selected
• Fluid Packages: PR, Glycol and Amine
Topside Processing Overview
23 Group F Presentation26th April, 2013
Fluid Phase and Hydrate Analysis
with HYSYS
India Fluid Phase envelope
Middle-East Fluid Phase envelope
INDIAReservoir condition(154bar,115C) Single PhaseArrival Cond.(10bar, 60oC) Multi phase Hydrate range - 6oC-9oC
MIDDLE-EASTReservoir Condition (137bar,100C) Single PhaseArrival Cond.(28.6bar, 60oC) Multi phaseHydrate range 6oC-20oC
24 Group F Presentation26th April, 2013
• Throughput, GOR and Component Analysis• Middle-East - 3-stage flash stabilisation unit• India - 2-stage flash stabilisation unit
Oil Processing
with HYSYS
25 Group F Presentation26th April, 2013
Sweetening, Dehydration, and Final Compression Processes with HYSYS
Glycol Dehydration – By absorption, 99.8wt% pure TEG is used to remove water still entrained.
Final Compression – Compresses gas finally to 175bar.
Amine Sweetening – H2S, Mercaptan and CO2 removal using aqueous Diethanolamine (DEA) of 34.45wt% Soln Strength.
26 Group F Presentation26th April, 2013
Well Measurement
System
• Each of the wells will be connected to a multiphase flow measurement system (MPFMS) for metering of all fluid phases (oil, liquid and gas) during production.
• Effluents (flared gas and produced water) from production system will also be metered.
• Other internally used fluids (fuel gas, make up water for amine sweetening and continuous purging) during production will also be metered.
• Design, testing and operation of all forms of metering must comply with applicable guidelines and regulations
27 Group F Presentation26th April, 2013
Topside Utilities
• Power Generation System
• Process Pipework
• Gas Flaring System
• Seawater and Sewage Treatment
• Others: Cooling, Heating, Chemical Injection, fuel, VOC Recovery System.
28 Group F Presentation26th April, 2013
•Gas powered turbine generator, configured with a single redundancy diesel/gas generator to produce 12MW of electricity.
•The unit comprises of 2 generators, UPS battery backup for critical emergency, a change-over station, transformer unit, control and distribution units.
•Generators uses produced gas as fuel.
•Generated electricity is used to power the rig system, topside processing units, pumps (ESPs), control module, accommodation, etc.
Power Generation
System
29 Group F Presentation26th April, 2013
Presenter
30 26th April, 2013 Group F Presentation
Patrick Omavuezi
In-Field Floating Storage OffloadingVessel
The purpose of deploying an FSO vessel for Jack-Up Extended Well Testing (EWT)/Early Production Systems is to store and export oil from Persian Gulf and Mumbai high oil fields’ at a flow rate of 25,000 barrels per day for a 3 year period. FSO ‘Endeavour’ was selected
31 Group F Presentation26th April, 2013
FSO Machinery andUtilities
• Cargo Handling System• Accommodation and Central Control Room• Pumping and Metering Systems• Inert Gas and Venting Systems• Ballast Systems and Cargo Heating Systems• Tandem Offloading and Shuttle Tankers
32 26th April, 2013 Group F Presentation
FSO Selection Justifications
• FSO has provision for storing off specification crude while in seabed system it is absent.
• FSO’s segregated tanks’ prevent oil spill and scouring.
• An FSO is not affected by the seabed uncertainty which may not permit deployment .
• In an FSO concept there are less production equipment and component on the Jack-Up Platform while a seabed storage system may have congested topside platform.
33 Group F Presentation26th April, 2013
FSO Selection Justifications
cont.
• The complexity in equipment and components required for fabricating, installing and operating a seabed storage system is more than that of an FSO deployment.
• An FSO can be easily disconnected to operate in a
separate location while a seabed storage system is fixed thereby less mobile.
• The FSO vessel will provide performance data during the
period for making investment decision and future design
34 Group F Presentation26th April, 2013
FSO Size and Offloading Operations
DIMENSIONS DATA
Length overallLength between perpendiculars Beam moulded Scantling Draft Depth on Deck Deadweight Operating Draft Oil Storage Capacity Slop Tanks Diesel oil Maximum Accommodation
157.5m110.7m28.0m13.013.0m15.5m65,000DWT3,800 cu m540,000 2,350 cum 53,000 cu m60 persons
35 Group F Presentation26th April, 2013
Presenter
36 26th April, 2013 Group F Presentation
Eli Klu
• Cost Effective• FSO vessel withstand Loads with NO interruption in
operations• Hydrodynamic Loads• Wind Loads • And Loads from the mooring system itself
• Design Standards: API 2SK, 2005, IACS Req. 1993/Rev.5, 2009, GL Noble Denton Mooring Guidelines 0032/ND, 2010
Aims of Mooring Design for The Persian Gulf & IndianWaters
37 Group F Presentation26th April, 2013
Major Mooring Challenges
• Wave loads over entire mooring system and risers in
shallow water
• High wave height especially Mumbai High (Hs = 8m)
• Water depth influences catenary risers design thus
mooring design
• Water depth influences choice FSO vessel capacity thus
mooring design
38 Group F Presentation26th April, 2013
• Mooring Designs Considered: turret mooring, Soft Yoke Mooring, Fixed Arm Catenary Anchor Leg Mooring (CALM), and Single Anchor Leg Mooring
• Selected Design: Fixed Arm CALM Mooring (turret buoy);• Withstands wave height as high as 8m• Deployable in water depth of 30m to 150m• Easily installed - pre installation• Requires minimum FSO vessel modification• Ballast to maintain restoring force• Relatively Cost effective
Mooring Design Selection
39 Group F Presentation26th April, 2013
Mooring Line Selection
• Options: Chain Line, Wire Line and • Studless Link Chain Mooring line
(R4s);• Chain weight provide damping
force• Not damaged by abrasion with
seafloor• Studless link don’t suffer crevices
corrosion, weld decay due to poor stud welds
40 Group F Presentation26th April, 2013
OrcaFlex Analysis
Compared chain weight
and minimum breaking
load with result of valid
simulationComparing Drag Force and Submerged chain weight (= 0.1875 d2 in N/m)
Submerge Weight (N) for a 110m chain line
FSO Hydrodynamic Drag Force approx. (N)
FSO Wind Drag Force approx. (N)
Mumbai High Persian Gulf Mumbai High Persian Gulf186,140.9 7,021.90 11,364.60 876,365.40 238,150.40
41 Group F Presentation26th April, 2013
OrcaFlex Analysis
MUMBAI HIGHComparing line tension, minimum breaking load (= 0.0304 d2(44-0.08d)
In kN) and proof load (= 0.0213 d2(44-0.08d) In kN)Line Line Tension (kN)
(Orcaflex Result) Design Safety Factor (Intact)
Net Line Tension (kN)(Orcaflex Result)
Minimum Breaking Load (kN) (95 cm Diameter Studless link)
Proof Load (kN) (95 cm Dia. Studless link)End A End B End A End B
ML1 32.6 280.9 2 65.1 561.7 9,986.7 6,997.3ML2 29.2 33.7 2 58.4 67.4 9,986.7 6,997.3ML3 2,775.9 2,992.1 2 5,551.8 5,984.3 9,986.7 6,997.3ML4 29.8 34.8 2 59.6 69.9 9,986.7 6,997.3ML5 1,747.9 1685.1 2 3,495.8 3,370.1 9,986.7 6,997.3ML6 33.0 34.23 2 65.9 68.5 9,986.7 6,997.3
42 Group F Presentation26th April, 2013
OrcaFlex AnalysisPERSIAN GULF
Comparing line tension, minimum breaking load (= 0.0304 d2(44-0.08d)In kN) and proof load (= 0.0213 d2(44-0.08d) In kN)
Line Line Tension (kN)(Orcaflex Result)
Design Safety Factor (Intact)
Net Line Tension (kN)(Orcaflex Result)
Minimum Breaking Load (kN) (95 cm Diameter Studless link)
Proof Load (kN) (95 cm Dia. Studless link)End A End B End A End B
ML1 32.6 280.9 2 65.1 561.7 9,986.7 6,997.3ML2 29.2 33.7 2 58.4 67.4 9,986.7 6,997.3ML3 2,775.9 2,992.1 2 5,551.8 5,984.3 9,986.7 6,997.3ML4 29.8 34.8 2 59.6 69.9 9,986.7 6,997.3ML5 1,747.9 1685.1 2 3,495.8 3,370.1 9,986.7 6,997.3ML6 33.0 34.23 2 65.9 68.5 9,986.7 6,997.3
43 Group F Presentation26th April, 2013
Presenter
44 26th April, 2013 Group F Presentation
Daniel Dore
Jack-up Installation and
Decommissioning
45
WET TOW• Cheaper.• High vessel availability.• Weather limitations.•Suitable for short distances; below 1000km.
•Within the Persian Gulf/Mumbai High.
DRY TOW• Expensive.• Limited vessel availability.•Safest means of transportation.•Suitable for long distances.•Persian Gulf - Mumbai High.
Transportation Modes
Group F Presentation26th April, 2013
Transportation & Distance
Route Approximate distance (Km)
Transportation method
Within West Indian field
500 Wet tow
Within East Indian field
500 Wet tow
Within the Persian Gulf
500 Wet tow
East India –West India
5000 Dry tow
East India – Persian Gulf
7500 Dry tow
West India –Persian Gulf
2500 Dry tow
46 Group F Presentation
The distance is an important factor that can determine the choice of transportation in most cases.
26th April, 2013
Transportation Considerations
• Size• Tow distance• Weather conditions• Vessel availability• Vessel-sharing opportunity
47 Group F Presentation26th April, 2013
Preloading and Punch-through risk consideration
Causes• Existing footprints.• Hard clay crust over softer soils, decreasing with depth.• Sand over soft clay strata.• Firm clay with sand or silt pockets.
48 Group F Presentation26th April, 2013
Preloading and Punch-through risk consideration cont.
Methods of preloading• Preloading sequentially.• Preloading above water (with air gap).• Preloading in water (without air gap).
49 Group F Presentation26th April, 2013
Decommissioning Plan
Jack Up• Jacking system is reactivated.• Equipment in the legs are disconnected from the deck.• Buoyancy chambers filled with air.• Lower the deck into the water to generate sufficient pull.• Jack Legs.• Towed to the yard for continued decommissioning or
refurbishing.
50 Group F Presentation26th April, 2013
Decommissioning Plan cont.
FSO• Disconnect in-field pipeline system.• Disconnect Moorings.• Sail to shipyard.
51 Group F Presentation26th April, 2013
Presenter
52 26th April, 2013 Group F Presentation
Wisdom Wakama
Safety Considerations
• Safety consideration in jack-up installation & decommissioning.
• Safety consideration for jack-up design
53 Group F Presentation26th April, 2013
Safety consideration in jack-up installation & decommissioning
Facility : Jack up
General Hazard Category
Specific Hazard Causes Consequences Safe
Guards Action Actionee Remarks
Installation and Decommissioning
Hazard
Jack up Leg Punch Through
Risk
Excessive penetration of one foot/ unbalance
leg penetration
over turning/ collapse of Jack
up
Sequential Preloading
or Preloading
at limited air gap
Jetting out legs
Installation & Decommisionin
g team
Environmental Hazard Scouring
Wave and current effect
around spud can
over turning/ collapse of Jack
up
Efficient Penetration or Concrete
Mattress
Refilling with soil
Installation & Decommissioni
ng team
Hazard Management
26th April, 201354 Group F Presentation
Penetration Monitoring Devices
Cone penetration test and data acquisition device.
Anti-silt/punch connector floater.
55 Group F Presentation26th April, 2013
Bow – Tie Diagram
26th April, 201356 Group F Presentation
Jack up Design Safety Considerations
• Efficient topside layout to move hazard away from the temporary refuge
• Process Area is High risk
• Accommodation (TR) is low risk
• Utility area reduces possible impact from process area to TR
26th April, 201357 Group F Presentation
Other Jack-up Topside Design Safety Measures
•Temporal Refuge (TR) with ballast wall
•Helideck made of steel support structure extended as cantilever to reduce of impact with TR
•Water deluge at vital areas especially the topside processing units
26th April, 201358 Group F Presentation
Safety Regulations
Safety Regulation are in line with:• SOLA- International convention for the safety of life.• SOLA-Requirements for A60 fire protection
standard(SOLAS 2002). • Act 1974-Health and safety at work place etc.
26th April, 201359 Group F Presentation
Presenter
60 26th April, 2013 Group F Presentation
Richard Ivanhoe
Corrosion
Environment Conditions • Micro-organisms• Salinity• Temperature • Pressure
• Reservoir Characteristics• H2S• CO2
Types of Corrosion• Crevices corrosion• Stress corrosion
cracking• Galvanic • Water line corrosion• Pitting corrosion
26th April, 2013 Group F Presentation61
Corrosion Protection
Types of Protection• Coating
• Fusion bond epoxies (FBE) • Two and three layers FBE and extruded polyurethane
(to reduce corrosion and impart of fire)• Coal tar enamels have been used to protect offshore
facilities
• Cathodic protection• Sacrificial Anode (Aluminium – Zinc - Indium)
26th April, 2013 Group F Presentation62
Corrosion Inspection & Monitoring
• Inspection
• Routine general visual Inspection by a remotely
operated vehicle (ROV) after the first year
• Use of Non-destructive testing such as ultra sonic
survey to inspect wall thickness
• Monitoring
• Use of corrosion coupon26th April, 2013 Group F Presentation63
Costing
Cost of Calm Buoy
Mooring Chains & Clamps
Design Cost of Jack-Up and EWT/EPS
Calm Buoy & Mooring
Cost of Jack up
Cost of acquisition
Cost of modification
Cost of Topside
Cost of Utility equipments
Cost of processing equipments
FSO
Cost of Lease
Miscellaneous
26th April, 2013 Group F Presentation64
DESIGN COST (PERSIAN GULF & INDIAN)
FACILITY Persian GulfCOST $M
IndiaCOST $M
Jack up acquisition 135 135
Jack up modification 30 30
Topside 154.42 145.28
FSO 26 26
Calm Buoy & Mooring 20 20
Total 365.42 356.28
26th April, 2013 Group F Presentation65
COST COMPARISION BETWEEN REGIONS
38%
8%
41%
7% 6%
OVERALL PROJECT COST BREAKDOWN
Jack up acquisition Jack up conversionTopside FSOCalm Bouy & Mooring
Jack
up ac
quisi
tion
Jack
up co
nvers
ion
Topsid
e FSO
Calm B
ouy &
Moo
ring
0
20
40
60
80
100
120
140
160
180
INDIAMIDDLE EAST
26th April, 2013 Group F Presentation66
Conclusion
PAY BACK PERIODCAPEX YEAR 0 YEAR 1Cost of oil per year ($M) 0 812.1
Design cost ($M) (365.42) 0
Installation cost ($M) (18.271) 0
Miscellaneous(10% -$M) (38.37)
OPEX ($M) 0 (324.84)
(422.06) 70.20
This study addressed the design and deployment of a jack-up and Floating Storage and Offloading vessel for extended well test/early production system in the Middle East and Indian waters in a cost effective and excellent safety system.
26th April, 2013 Group F Presentation67
68 26th April, 2013 Group F Presentation
Thank You