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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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
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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
OML 125 -ABO Extension project
ABO FPSO ABO FPSO
FPSO conversion an field positioning : 2002/2003 March ( Abo Central)
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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)
OML 125 -ABO Extension project
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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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OML 125 -ABO Extension project
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
OML 125 -ABO Extension project
n
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OML 125 -ABO Extension project
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 – Extension Project -OML 125
ABO 9b –Gasinjector
Release 1_A of Nae3229.41.000.L.DL.FC88001
Field lay-out without bathymetry
Abo Ext
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Abo – Extension Project -OML 125
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Abo – Extension Project -OML 125
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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OML 125 -ABO Extension project
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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.
Abo – Extension Project -OML 125
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Abo – Extension Project -OML 125
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.
Abo – Extension Project -OML 125
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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
Abo – Extension Project -OML 125
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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
OML 125 -ABO Extension project
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
OML 125 -ABO Extension project
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TOPSIDE FACILITIESB. Areas interested in ABO Central Upgrade
MANIFOLD/PORCH AREA (i.e. interconnections between new risers and existing manifolds)
OML 125 -ABO Extension project
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TOPSIDE FACILITIESB. Areas interested in ABO Central Upgrade
• RISERS AND UMBILICAL (AND SUBSEA FOR FACILITIES - i.e.
new risers and umbilical at porch)
OML 125 -ABO Extension project
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TOPSIDE FACILITIESB. 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 centralpkgs shown)
OML 125 -ABO Extension project
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TOPSIDE FACILITIESB. 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 UPSmodification of existing DCS for new topside users)-Cabinet of abo
extension located elsewhere ( Deck ‘C’)
OML 125 -ABO Extension project
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TOPSIDE FACILITIESB. 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 inhibitorsand methanol pump motor skid for new producer
well
OML 125 -ABO Extension project
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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
OML 125 -ABO Extension project
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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.
OML 125 -ABO Extension project
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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)
OML 125 -ABO Extension project
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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)
OML 125 -ABO Extension project
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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
OML 125 -ABO Extension project
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installation contractor sub-orders ( major)
OML 125 -ABO Extension project
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
OML 125 -ABO Extension project
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Abo – Extension Project -OML 125
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
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OML 125 -ABO Extension project
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OML 125 -ABO Extension project
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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)
OML 125 -ABO Extension project
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TOPSIDE FACILITIES-Control system
OML 125 -ABO Extension project
©A
BB -
1Extended architecture
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OML 125 -ABO Extension project
Location Deck “C” where Container will be placed
Internal view Container hosting sub sea
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OML 125 -ABO Extension project
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TOPSIDE FACILITIES- List of commissioned sub-system
Offshore Installation field precommissioning (sample ofsigned hand over document)
OML 125 -ABO Extension project
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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
OML 125 -ABO Extension project