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October 2013
IN THIS EDITION
Partnerships that
produce results
Ever deeper, ever colder
The challenges for GustoMSC
CAN DO 20 Kpsi drillship
Home Sweet Home
Brazilian
GustoMSC
Contents
3 Preface
4 Full speed ahead for Brazil's offshore industry
8 Partnerships that produce results
10 Ever deeper, ever colder. The challenges for GustoMSC
12 Qdrill and DSS38E
14 CAN DO 20Kpsi drillship
16 Home Sweet Home
18 "The proof of the pudding is in the eating"
20 ustoMSC Tri-Floater design verified in wave basin
G
22 Recent projects and deliveries
Colophon
GustoMSC Inside is a publication of
GustoMSC B.V.
Total circulation: 4000
This publication is edition 20, October 2013
Edited by: Bahare Boersema and
Monique van der Have
Stijlmeester, Utrecht(NL)
All editorial material is the property of GustoMSC
above mentioned company and may therefore not be
Preface
For more than 10 years, we have been keeping our business relations informed of developments
in the offshore sector and our organization by means of our semi-annual InSide magazine.
Rarely have developments been so rapid as in the past year and our own activities are expanding
equally quickly. In Brazil, for example, now 15 drilling rigs have been contacted based on our licensed
designs, construction of which will be running through to 2019.
In 2011 we proceeded with the integration of Gusto and Marine
Structure Consultants into GustoMSC and moved to another
building. In 2012 our managing director Han Mommaas stepped
down after nearly twenty years at the helm (staying on as
Principle Consultant) and we celebrated our company's 150th
birthday! In November 2012, GustoMSC was spun-off from
SBM Offshore and started operations as an independent
organization. We are now better positioned as independent
designer and supplier of associated equipment. Our subcontractors are a great help and partners in this respect. In recent
months our new internal organization for Finance, IT and HR has
become fully operational.
In the meantime, as the market for mobile offshore units has
grown, so has our market share. Whereas two years ago, when
Gusto and MSC merged, there were 29 GustoMSC designed mobile
offshore units (MOU) under construction, today there are more
than 60; about one quarter of these will be used for oil and gas
drilling offshore Brazil.
This issue of InSide highlights Brazil's growing market and its and
GustoMSCs response to this. Since 2006, a major new oil or gas
province has been discovered and announcements of major oil
field discoveries are commonplace. Developing and operating
these new fields will provide many jobs and serve to stimulate
further economic development. The government of Brazil wants to
ensure that its own people and the Brazilian business community
receive optimum benefit from this situation. The Brazilian
offshore oil and gas industry is developing fast to respond
effectively to the needs of exploitation of huge new reserves.
The immense oil reserves recently discovered off the coast of Brazil are bringing huge investments
into the countrys offshore oil industry. Exploration and production are demanding construction of
dozens of deepwater drilling rigs and production platforms. Knowledge and technological advances
from companies with a rich shipbuilding history will be indispensable for successful development.
Exciting prospects for engineering and design companies such as GustoMSC.
GustoMSC | InSide 20
The scale and pace of progress means some foreign expertise and
technology will be essential. Foreign companies can opt for private
partnership or a Brazilian subsidiary to meet tender criteria. To
facilitate this tendering processes and regulatory frameworks
have been streamlined. Several leading financial institutions have,
in addition, simplified their lending processes specifically to help
overseas investors.
ndustry
Million a day
In spite of these significant technological
and economical challenges, seven years after
discovery this new offshore frontier already has
significant production. In 2013, fields operated
by Petrobras and its partners in pre-salt areas
were at 300,000 barrels per day. By 2017
Petrobras expects to be recovering over
1 million a day.
Pre-salt oil fields
In 2006, Brazils national oil company Petroleo
Brasileiro (Petrobras) discovered the first major
oil reserve in a deep sub-salt reservoir. The Lula
field (until 2010 known as Tupi), is estimated to
hold 5 to 8 billion barrels of oil equivalent (BOE).
The pre-salt frontier is one of the most prolific
offshore oil provinces in the world. Brazilian
National Petroleum Agency (ANP) estimates
pre-salt reserves about 50 billion BOE. Other
specialists believe that these estimates are too
conservative, indicating possible reserves of the
order of 120 billion BOE.
The Pre-Salt layer is a good heat conductor, resulting in lower temperatures than expected in
the reservoirs. Combined with high pressure it raises a new set of technological challenges.
GustoMSC | InSide 20
Oil recovery is expensive and complex as oil is located far from the
coast at extreme depths, and under a heterogeneous and uneven
offshore salt layer. The oil soaked pre-salt rock layer is 5,000 to
6,000 meters below sea level, under a salt layer - which can be up
to 2,000 meters thick - and a post-salt rock layer. The water has
a depth of 1,900 to 2,400 meters. The fields are typically 300 to
350 kilometers from the coast.
AMAZONAS
Estaleiro BIBI
PAR
Estaleiro RIO MAGUARI
CEAR
Estaleiro INACE
PERNAMBUCO
Estaleiro ATLNTICO SUL
Estaleiro PROMAR
ALAGOAS
EISA Alagoas
BAHIA
EEP Estaleiro Enseada do Paraguau
(ODEBRECHT / OAS / UTC)
ESPRI SAN TO
TO
Estaleiro Jurong Aracruz
SO PAULO
CAMARGO CORRA Naval
Construtora QUEIROZ GA LVO
Navegao SO MIGUEL
RIO TIET (Araatuba)
SETAL Engenharia Construes e Perfuraes
VELLROY Estaleiros do Brasil
WILSON, SONS
SANTA CATARINA
DETROIT Brasil
Estaleiro ITAJA
Estaleiro NAVSHIP
KEPPEL Singmarine Brasil
RIO GRANDE DO SUL
EBR Estaleiros Brasil
RG Estaleiros
QUIP
WILSON, SONS
GustoMSC | InSide 20
RIO DE JANEIRO
BRASFELS
SRD Offshore
Empresa Brasileira de Reparos Navais REN AVE
ENAVAL Engenharia Naval e Offshore
Estaleiro MAU
MAC LAREN OIL Estaleiros
SERNAMAN Servios Navais e Manuteno
STX OSV Niteri
UTC Engenharia
ALIANA Indstria Naval
EISA Estaleiro Ilha
ICN Itagua Construo Naval
IESA leo e Gs
RIO NAVE Servios Navais
Navegao SO MIGUEL
TRIUNFO Operadora
SERMETAL
CASSIN
OSX Construo Naval
DOCKSHORE Navegao e Servios
GustoMSC in Brazil
As part of the initiative to equip Brazilian companies with latest
generation rigs, Petrobras created a program to charter 40 rigs
to Brazilian drilling contractors. The initial 12 rigs were built in
international shipyards, and of these, five were GustoMSC latest
generation deepwater semi-submersibles: the Lone Star and
Norbe VI of TDS2000 design, the Delba III of TDS2500 design
and the Alpha Star and Gold Star of the DSS38 design.
The remaining 28 rigs were chartered by Petrobras to Sete Brasil
to be built at Brazilian shipyards. Of these 15 are GustoMSC
designs being built at three Brazilian shipyards. In the state of
Bahia, Paraguau Shipyard is building six Qdrill drillships. In the
state of Rio Grande do Sul, the Rio Grande Shipyard is building
three Qdrill drillships and in the state of Rio de Janeiro, BrasFels
shipyard is building six semi-submersibles of the DSS38E design.
Over coming years GustoMSCs designs will be well visible in
Brazils offshore world.
Rio Grande do Sul: one shipyard in operation and one under construction.
GustoMSC | InSide 20
Partnerships
that produce results
Fernando Frimm
Located in Maragogipe, Bahia State, the EEP shipyard already has 30% of its construction work concluded
GustoMSC | InSide 20
which will sink offshore wells in the Brazilian pre-salt oil province.
"GustoMSCs knowhow and experience was of paramount
importance for us to have our Basic Design accepted by our
client", says Francisco Dezen, the Drillship Project Director at
EEP. "GustoMSC has worked alongside our team during the
whole process of transferring the basic 3D models to our detail
engineering teams, all the way through seeking and obtaining the
classification society approvals."
Mr. Dezen also points out the robustness of GustoMSCs design
provided EEP with more than usual flexibility to choose equipment
suppliers, which allowed construction to start ahead of schedule.
"Another factor was that the Qdrill is a compact design demanding
less steel to be processed, which positively impacts construction
methods, overall construction schedule and costs," said Dezen.
The Engineering Coordinator at Ecovix, Cassiano Marins de Souza,
emphasizes that the partnership with GustoMSC translated into a
high level of confidence for the company during project execution.
"GustoMSC has offered great technical support and guaranteed
a reliable basic design; its experience and track record, especially
with drillship designs, has been crucial", said Mr. Souza.
"One of the main reasons that allowed us to advance quickly was
the quality of GustoMSCs basic design work", he emphasizes.
Local Content
Ecovix
Ecovix was created in March 2010 as a subsidiary of Engevix Engenharia S/A to construct eight FPSO hulls for Petrobras. To undertake this
contract and indeed other future orders the company acquired a new
shipyard recently built at the Rio Grande Port complex, in the state of
Rio Grande do Sul. In 2011, Ecovix closed an R$ 2.3 billion contract for
the construction of three GustoMSC Qdrill drillships: Cassino,
Curumim and Salinas.
BrasFELS
Francisco Dezen, of EEP: partnership with GustoMSC was of paramount importance for Sete
Brasils approval of the drillship project. Picture Marcus Almeida/Somafoto.
EEP Shipyard
GustoMSC | InSide 20
Ever deeper,
Bahare Boersema
"Deeper water and colder water. That is where mobile offshore units designed by us will be
operating in the future. explains Nils van Nood, managing director of GustoMSC since 2012,
sketching the future of GustoMSC's place in the sector. "While we are currently enjoying the fruits
of our success, continuous development will always remain essential."
10
GustoMSC | InSide 20
ever colder
The current jack-up water depth record in the North Sea is with the
West Elara (CJ70) of North Atlantic Drilling at Gullfaks at 135 m.
GustoMSC | InSide 20
11
Brazilian requirements
The Qdrill design was seamlessly tailored to the technical and
functional requirements of the Petrobras pre-salt development
program in order to enable the yards to offer a competitive bid in
the tender.
Compact
The Qdrill may be a compact design, but it maintains flexibility
by adding smart and robust solutions to maximize usable deck
areas, with fixed decks that can be used at all times. The vessels
prime space is dedicated to drilling, and all layout considerations
have the drilling function of the unit as the main priority. The
accommodation is separated from the main sources of noise and
vibration such as the engine room and mud pump room. Also the
layout is in such a manner that the rig floor and derrick are kept
free from smoke and soot particles.
As an option the design supports application of the GustoMSC
patented thruster retrieval system at all thruster locations.
GustoMSC Qdrill drillship for 3,000 meters water depth being built by EEP.
12
GustoMSC | InSide 20
Design
Length
Breadth
Depth
Draft
Displacement
Water depth
Drilling depth
VDL
Power
Thrusters
DSS38E
198.0 m
34.0 m
17.5 m
10 m
57,000 t
3,000 m
10,000 m
Approx. 17,000 t
44 MW
6x 4.5 MW
DSS38E
Displacement
45,000 t
Water depth
The DSS38E design is tailor made to comply with the latest stringent
requirements of Petrobras, and developed as an enhanced version of
the successful DSS38 design, two of which have been in operation
offshore Brazil for some years.
3,000 m
Drilling depth
10,000 m
Accommodation
Dynamic positioning
Thrusters
160 POB
DPS-3
8
GustoMSC | InSide 20
13
Keppel Offshore and Marine Technology Centre (KOMtech) and GustoMSC present a new joint
development design product: the CAN DO 20Kpsi drillship. This new generation drillship targets new
market requirements for 20k well control systems, dual BOP storage, high loading capability and
enhanced functional deck space on an efficient and safe platform.
14
GustoMSC | InSide 20
The 20k wells dictate the required drilling capabilities of the unit. The
casing required will be heavy driving up the hook load, setback
capacity and associated equipment. To cater for increased water depth
capability the structures have been designed to receive heavier riser
tensioners which are well integrated in the design. Mud pumps, mud
pits, two ROVs, cementing unit etc. are integrated in the mud module
which is placed above the main deck, creating a compact drilling plant
with short distances and associated communication lines. On top of
the mud module a flexible deck for third party activities has been
created, and directly below the deck the high capacity sack store is
located with direct access from the aft through a landing platform.
The vessel is designed to create a comfortable and pleasant living
environment for its 220 personnel on board that enhances the level of
functionality with clearly demarcated areas for living spaces,
GustoMSC | InSide 20
15
With offshore oil and gas projects rapidly moving into deeper
waters, the need for top quality accommodation aboard semisubmersible rigs is becoming increasingly important.
The investments pay off in many ways, such as sidestepping hefty
expenses associated with flying technicians and crew members
out. For offshore accommodation, the intention is basically to
offer high quality hotel functions at the highest safety standards
to rig crews. Current offshore accommodation across the existing
fleet consists either of newbuilds or converted units, but most are
old, sometimes exceeding 30 years of age and are no longer in
line with todays rules and regulations.
Floatel Superior
16
GustoMSC | InSide 20
AJ46-360-C
Jack-up hotel
Similar to the floating accommodation units, many jack-up
accommodation units are based on a second life for drilling jackups. Typical jack-up accommodation units can be subdivided into
two groups; units for worldwide operation in depths to 375-400
ft and units for the harsh environments of such as the Norwegian
Continental Shelf.
The major advantages of jack-up units are the improved
operability and significantly competitive operating costs. Where
floating units are dependent on environmental conditions, leading
to a limited 10-15% uptime in North Sea winters, elevated jackups offer 100% uptime. Together with CBI-MMEER, GustoMSC
has developed the accommodation jack-up AJ46-360-C, based
on the proven concept of the CJ series. The AJ46-360-C has
been designed to operate in 375 ft water depth. The unit can
GustoMSC | InSide 20
17
45
16
160
40
14
140
12
120
10
100
80
60
40
20
35
30
5
GW
GW
GW
GW
25
20
3
15
10
1
0
Annual
Cumulative
18
2011
1.0
3.9
2012
1.4
5.3
2013
2.8
8.1
GustoMSC | InSide 20
2014
2.9
10.9
2015
3.1
14.0
2016
3.4
17.4
2017
4.1
21.6
2018
5.1
26.7
2019
6.4
33.1
2020
6.9
40.0
Annual
Cumulative
2021
7.8
47.7
2022
8.5
56.2
2023
9.1
65.5
2024
9.6
75.6
2025
10.5
86.5
2026
11.5
98.1
2027
12.4
110.4
2028
13.0
123.2
2029
13.2
136.4
2030
13.7
150.0
Further proof?
Having started work in September 2012, the Seajacks
Zaratan installed the last of 80 mono-piles in April this
year. This NG-5500C carried out installation at the
Meerwind Offshore Park at a rapid pace, installing three
monopiles in just under a day and a half.
In relatively short succession, Fred. Olsen Windcarrier took delivery of the Brave Tern and Bold Tern, both
GustoMSC NG-9000C designs. The first job for the Brave
Tern was installing met-masts at Dogger Bank and wind
turbines on the BARD Offshore 1. The Bold Terns first job
was installing turbines at the German Riffgat Windfarm,
loading up to eight complete Siemens 3.6 MW turbine sets
per trip.
The record installation times achieved by these new WTIJack-up vessels is clear evidence that the new generation
GustoMSC designs are contributing to the reduction of
installation costs for Offshore Wind Farms. Besides the
well-balanced design, the overall CAPEX of the NG-9000C
series shows that size is not the only consideration; using
the right tool for the right job is just as important.
Other recent deliveries include the JB-118, a SEA-3250
design for Jack-Up Barge BV, and BAM / Clough Australia
have taken delivery from COSCO Shipyards of the IB-914,
a new SEA-1250 design.
GustoMSC | InSide 20
19
GustoMSC Tri-Floater
design verified in wave basin
Fons Huijs
Floating offshore wind turbines could well open up deep water areas for offshore wind power
generation. GustoMSC has designed a semi-submersible wind turbine support structure:
the Tri-Floater with a design that has recently been further optimized and verified with advanced
simulations and model tests. They confirm some impressive claims.
Artists impression of the GustoMSC Tri-Floater equipped with a 5MW wind turbine
20
GustoMSC | InSide 20
The 1:50 scale model of the GustoMSC Tri-Floater tested in gusted wind and
irregular waves by MARIN
Because of the relevance of the control system, MARIN constructed a model scale wind turbine, including an active blade pitch
mechanism, which was coupled to the ECN control algorithm during
the model tests. This enabled GustoMSC to assess the performance
of the Tri-Floater including its control system which had never
previously been included in the testing of floating wind turbines.
Rotor diameter
Hub height above SWL
5.0 MW
126 m
90 m
Radius to columndimensions
Tri-Floater main centre
Column diameter
36.0 m
Draft
13.2 m
12.0 m
Displacement
3,630 t
8.0 m
GustoMSC | InSide 20
21
Brave Tern
Sea Installer
Bold Tern
Seajacks Zaratan
Seafox 7
JB-118
N O RT H S E A
Maersk Innovator
Maersk Resolute
Maersk Gallant
NORTH SEA
In operation
BRAZIL
Delivery: 2013
22
GustoMSC | InSide 19
Delivery: 2014
Delivery: 2014-2015
Delivery: 2015
Delivery: 2015
CHINA
Seajacks Scylla
GustoMSC design: NG-14000X
Builder: Samsung Heavy Industries
Delivery: 2013-2015
Delivery: 2016-2017
Delivery: 2015
Delivery: 2014
Delivery: 2014
KO R E A
MI D D L E EA ST
CHINA
SIN GA P O R E
2 units
GustoMSC design: CJ46
Builder: CMHI
Delivery: 2015
Delivery: 2014
Delivery: 2015
Delivery: 2015
T.B.N. 1 & 2
GustoMSC design: CJ46
Builder: DDW-PaxOcean
Delivery: 2015
Delivery: 2016
Delivery: 2015
Delivery: 2015
Delivery: 2015
Delivery: 2014-2015
Delivery: 2016
GustoMSC | InSide 19
23
GustoMSC B.V.
P.O. Box 687, 3100 AR Schiedam
Karel Doormanweg 25
oil and gas market as well as for the offshore construction market,
3115 JD Schiedam
The Netherlands
Telefax +31 (0) 10 28 83 001
Marketing@GustoMSC.com
provides class approved basic designs and supplies associated equipment e.g.
jacking, fixation and X-Y skidding systems and offshore cranes.
GustoMSC Houston
Marketing@GustoMSC.com
www.GustoMSC.com