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Deepwater completions
Deepwater completions
T
o properly address this wide range of development deeper water will continue as more discoveries are found.
options, ABB has developed a portfolio of deepwater Efficient deepwater development options will be required
hull forms. Three of the more significant elements of for SE Asia.
this portfolio are the Extended Tension Leg Plat- Unlike other harsh environmental regions of the world,
form, Single Column Floater, and semi-submersible. These SE Asia has benign metocean conditions by comparison.
three well-proven hull forms bring tangible benefits to This is the primary enabler for three favourable benefits, 1)
many of Southeast Asia’s deepwater developments as an overall downsizing of the selected deepwater system, 2)
they can be economically adapted to the area’s benign the ability to extend the system into deeper water depths,
metocean conditions and potentially maximise in-coun- and 3) an increased system capacity for larger topsides
try fabrication. payloads. The design efficiencies for deepwater systems
This paper evaluates various development options for a utilised in SE Asia can be high.
water depth of 1,500 m and an average reservoir size of 300
MMboe. All necessary functions including drilling, direct Deepwater challenges
access to wells for workover operations, host to subsea As exploration and development activities move into
tiebacks, processing, injection, etc. are considered. As deeper water, various challenges must be overcome. Al-
deepwater regions of Southeast Asia have little pipeline
though they are not necessarily unique to SE Asia, these
infrastructure, the utilisation of FPSOs will also be ad-
challenges represent barriers to efficient and economic
dressed. Technical and operational considerations for a
development of the deepwater region. Some of the more
budget cost estimate will be presented for the best-for-field
critical deepwater challenges are listed below:
option identified.
◆ The availability of deepwater drilling rigs for well
Introduction intervention will be an important consideration in the
In water depths of approximately 100 m or less, the vast evaluation of wet- vs. dry-tree completions.
offshore region of Southeast Asia (SE Asia) represents a ◆ More detailed site-specific metocean data is necessary
mature oil and gas development area. Existing develop- to assure an adequate design and to help achieve a
ments consist primarily of fixed platforms and Floating higher level of system efficiency.
Production, Storage and Offloading units (FPSOs). Local ◆ In most cases, the area’s benign conditions permit
businesses have developed to provide the majority of tender assisted drilling to achieve reductions in both
services required for this well-established offshore oil and payload and cost. However, all design and operational
gas industry. aspects of drilling tender assist must be thoroughly
The area has experienced recent advances into deepwater investigated. This includes the integrated mooring sys-
with the installation of the West Seno Tension Leg Platform tem, global performance of overall system, drilling
(TLP) in 975 m of water offshore Indonesia. This trend into program, operational up-time, etc.
hull form can permit local construction that will result in a limited to just a few feet in the most severe 100-yr hurricane
reduced project schedule. design conditions.
Complex installation plans requiring the mobilisation of The following sections describe in some detail, ABB’s
large construction vessels and involving long offshore experience with three specific hull forms appropriate
integration and commissioning campaigns can be avoided for application in SE Asia. These are, 1) ETLP, 2) SCF, and
with some hull forms. 3) Semi-submersible. Development history, advantages
Hull forms with well-proven operational performance of the concept and range of application are presented
records will be more reliable. for each.
Although the improved motions of a TLP-type structure A brief review of ABB’s SCF development history and
are more desirable than other floating hull forms for drilling its associated advantages and applications are presented
and production operations, the associated tendon mooring below.
costs in ultra-deep water can be high by comparison. The SCF development history - The Single Column Floater is a
ETLP has proven to be highly effective in extending the compliant, moored Floater. It differs considerably in form
perceived water depth and payload limits of the TLP and from other existing deepwater Floater-type structures
additional development work is currently being carried out because of its shallower draft and extended base. An artist’s
by ABB to further extend the economic water depth and rendering and cut-away views are shown in Figures 4 and
payload range of the ETLP. 5 respectively.
have been proven to water depths of 2,000 m, and designs This figure identifies the range of application for four very
have been developed for water depths up to 2,500 m. The different design environments, i.e., Gulf of Mexico and
use of taut polyester mooring systems has facilitated an offshore Brazil, West Africa and SE Asia. Notice that the
increase in the economic water depth. benign metocean conditions offshore SE Asia permit eco-
Topsides payload – The semi-submersible can handle a nomic extension of the ETLP to deeper water depths and
wide range of payloads, up to 40,000 Mt (BP’s Thunder larger payloads.
Horse, a production and drilling semi-submersible for
GoM). Design basis and screening
Completions – Typically, the semi-submersible has sup- A representative design basis is defined in this section for
ported wet-tree completions, particularly in deepwater. a typical SE Asia discovery. An applicable screening proc-
The vertical motions of most semi-submersible designs will ess is presented and various development options are
not accommodate dry-tree completions. Import and export evaluated. The most favourable development option is
risers can be either flexible pipe or SCRs. then identified.
Flexibility – Because of its shallow draft and associated Assumed design basis – A representative discovery in SE
ability to be brought back to quayside for topsides modifi- Asia is defined below. Screening of an appropriate devel-
cations, a semi-submersible floating production system is opment architecture, and the conceptual sizing of a candi-
well suited to relocation. date hull form, is established from the following design
The semi-submersible design can be applied to most assumptions:
deepwater applications utilising subsea trees. The design • Reservoir - Estimated 300 MMboe, layered, multiple
allows for quayside integration of the topsides, thereby completions, single drill centre
reducing offshore hook-up and commissioning costs, and • SITP for drilling and production – 500 bar
schedule risks. • Water depth – 1,500 m
• Production throughput –
ETLP and Floater Domain Range Oil and Condensate 50 Mbopd
Resulting from extensive technical and economic studies Water Production 20 Mbwpd
to identify and define the domain range of the ETLP and Gas Production 300 MMscfd
SCF, it has been determined that the optimal best-for- • Riser count – 30 dry-tree production risers, 2 export
project selection of a deepwater hull form is dependent SCRs, and 3 wet-tree tiebacks
upon water depth, topsides payload, design environment • Export considerations – Close proximity to pipeline
and construction methodology. • Metocean conditions are as follows:
Floaters such as the SCF are generally more applicable
for heavier payloads in the deeper water depths. The Waves
improved motions of the ETLP are more desirable for
drilling and production operations. Significant Wave Height, Hs m 3.05
Detailed analysis and evaluation has revealed the most Peak Spectral Period, Tp sec 8.5
economical application of ABB’s ETLP and SCF deepwater
hull forms for the above project-defining parameters. This Wind
is shown graphically in Figure 7.
1 Hour Speed m/sec 21.34
Current
Speed (surface) m/sec 2.13
Speed (30 m depth) m/sec 1.07
Screening process results – Using selection parameters These are, 1) the ETLP’s ability to take best advantage of
discussed in the introduction, and the assumed design SE Asia’s benign metocean conditions, 2) its ability to
basis just mentioned, a conceptual screening process (Phase easily accommodate 30 top tensioned risers, and 3)
I) was performed to identify possible field development fabrication and installation can be performed with local
options. TLP, semi-submersible, Spar and SCF hull forms yards and equipment.
were considered. Although it is a viable option for SE Asia, the SCF scored
A summary of the screening process is presented in table behind the ETLP due to the high riser count. The semi-
format in Figure 12. A brief discussion is provided in each submersible has not yet proven itself to be a suitable
cell regarding the applicability of the subject hull form to platform for the support of dry-trees. The SCF and semi-
the specified design requirement. submersible are both local construction-friendly.
A scoring system (not necessarily valid for all deepwater
applications) is used to identify the best overall hull form Observations related to the major areas of interest for a
solution for this example. Specific parameters of the re- SE Asia deepwater development are:
quirements are weighted in order to identify critical aspects Water depth, payload and metocean – All four of the hull
of the design and delivery for SE Asia. The scores shown in form concepts are considered to be capable of supporting
each cell reflect a variety of evaluation parameters includ- an estimated 20,000 Mt of topsides payload at a water
ing maturity of the technology, system performance, cost, depth of 1,500 m. The tendon system of the TLP will have
risk, etc. The totals at the bottom of the table represent the a higher CAPEX cost than the spread mooring system of a
overall scoring of the hull forms to all weighted design Floater which is likely to be a polyester taut design. The
requirements. area’s benign wind and wave conditions favour all of the
In this example, the ETLP scored well against the other concepts. However, the moderately high current will be
deepwater hull form options for three primary reasons. an issue for the Spar due to the length of its hull.
Delivery Options
Following engineering, the high-level logistics for
platform delivery are shown in sequence in Figure 14.
Details regarding fabrication of the ETLP hull and deck,
and deck-hull integration are outlined below. Com-
ments relating to local construction of the ETLP are
found at the end of this section.
ETLP Hull – Due to its compact form, fabrication of the
ETLP hull can be tailored to suit a number of construc-
tion methods depending upon the capabilities and
strengths of a given Fabricator. For example, ABB has
demonstrated that land-based fabrication at quayside
can be equally as efficient as drydock fabrication.
For either of these methods, hull fabrication is a very
systematic and disciplined process, and one that is fully
integrated with engineering. The fabrication sequence
begins with sub-assemblies, which form blocks, which
in turn form super-blocks. Super-blocks are the largest of
the hull components and are lifted into the drydock or
rolled into the land-based erection area. The super-
blocks are pre-outfitted to the maximum extent with
equipment, piping, pipe supports, penetrations, cable
trays, ladders, stairs, etc. Due to parallel design-fabri-
cation activities, pre-outfitting is often limited by engi-
neering supply of drawings. Painting is the last activity
prior to final lifting of the super-block into place within
the structure.
It is desirable for all sub-assemblies and blocks to be
fabricated in a covered shop area. These components
are then moved to a staging area adjacent to the drydock
or erection area where the super-blocks are completed.
For the Kizomba ‘A’ ETLP hull, a total of 24 super-blocks
were used. Because of this efficient procedure, complete
erection of the ETLP in the drydock was performed in
only six weeks. A photograph of the Kizomba ‘A’ ETLP
hull in drydock (Daewoo Shipbuilding and Marine Engi-
neering - Korea) is shown in Figure 15. A photograph
showing land-based fabrication (Belleli - Italy) of the
Auger TLP hull is shown in Figure 16.
Upon leaving the drydock, the ETLP hull is moved to
a nearby quayside location where final mechanical
completion and pre-commissioning activities are per-
formed. Systems entirely contained in the hull are fully
commissioned. The hull is then readied for transport.
Figure 17 shows the float-on operation of the Kizomba
‘A’ ETLP hull.
If the hull is fabricated at a quayside land-based location,
all final mechanical completion and pre-commissioning
activities are performed prior to direct skid-out onto the
transportation vessel.
Once in place on the transport vessel and secured,
the ETLP hull is then transported to the deck-hull
integration site.
Acknowledgements
The authors would like to thank Edward Huang and Rajiv
Aggarwal for their technical contributions to this paper.
Summary The authors would also like to thank Steve Pywell, Jason
The development of deepwater fields in Southeast Asia is Nunn and Gardiner Henderson for their local area knowl-
generally complex requiring the installation of several edge and commercial contributions. Many special thanks
major elements for a successful development. Among to Frank Steinhauer for his graphical contributions and to
these are subsea infrastructure, dry-tree unit, and if so ABB for its generous support of deepwater technology
determined, FPSO and export shuttle tankers. development.
For the assumed deepwater application in SE Asia, the
ETLP was identified as the most appropriate dry-tree References
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ENQUIRY NUMBER: 10-01
Asia. The ETLP can carry 1.44 Mt of topsides payload