SBM Currents April 2013 Magazine
SBM Currents April 2013 Magazine
SBM Currents April 2013 Magazine
Currents
Issue 7 // april 2013
Currents
Issue 7 // april 2013
10
14
Mid-scale FLNG:
a solution for stranded gas fields
16
16
FPSO brasil
18
10
Generation 3 FPSO
On the cover: FPSO Cidade de Anchieta. We want to hear from you: If you have comments about any of the articles in this issue or any ideas for future issues, send them to [email protected]. Currents is issued by the Group Communications Department.
Welcome
18
BRASA
Mid-scale FLNG
14
Bruno Chabas CEO SBM Offshore Welcome to the new issue of Currents - the SBM Offshore magazine. We will share our stories from around the globe from our offices, construction sites and offshore units. Currents will seek to go deeply into key projects or stories about who we are and what we stand for. We are transforming how we work, how we think and act maintaining our commitment to our three values: to work as one, to perform and to shape our own future. In this issue we stay true to our FPSO strategy, we have highlighted some of the recent accomplishments at SBM Offshore - the successful reconversion of the FPSO Cidade de Anchieta, our way forward on the challenging Generation 3 FPSO and how team work is critical for successful FPSO operations. As an extension of our FPSO focus, we see many new market opportunities in the global gas sector and we are working on a viable solution for stranded gas fields with a mid-scale FLNG, which we hope you will enjoy learning about. We remain committed to the countries where we work and we are involved in joint ventures with local companies. Discover our recent activities at the Brasa yard in Brazil as a shining example of this commitment. We hope you will enjoy this seventh issue and please remember there will be many more to come.
CEO of SBM Offshore, Bruno Chabas commented: We are very pleased with the successful start of production on FPSO Cidade de Anchieta for Petrobras as the project has achieved the objectives of minimising stand-by time during the relocation process of a year and half. This substantial investment associated with a major upgrade of the processing equipment of such a complex facility illustrates the bespoke nature of FPSOs and is an excellent example of our leading position in the market.
Rapid conversion
while still producing
The fast-track refurbishment in 2011 and 2012 of the Espadarte FPSO to the Cidade de Anchieta was completed in a record turnaround time of only nine and half months in the Keppel Shipyard in Singapore. SBM Offshore has achieved great success in reducing work schedules on conversions by building additional, required topsides in a yard while the FPSO is still producing offshore - as was the case for the Anchieta. Stein Rasmussen, Vice President Engineering, from SBM Offshore in Houston, said The contract terms were very stringent. The total duration from the departure of the FPSO from Brazilian waters to its return after modifications from Singapore was 435 days; inclusive of the 117 days required for the to and fro tow of the FPSO. Cidade de Anchieta truly demonstrates how an FPSO is a sustainable system. Today, she has the capacity to process 100,000 barrels of oil and 3.5 million m of gas per day and has modified her range for processing crude oil to 28-30 API. In brief, the process facility was upgraded with new modules for gas treatment, water injection, gas turbine generators and flare drums to meet the new field production characteristics. She now has a topside weight of 7,500 tonnes compared to 4,500 tonnes for Espadarte. She also moved to a water depth of 1,221 metres, producing in the Baleia Azul Field offshore Brazil.
First oil was achieved on the 10th of September 2012, within days of her new lease kicking off - an achievement even more significant considering the 37-day turnaround from the FPSOs arrival in Brazilian waters and despite a down time for the weather. The success of the project merited the honour of a visit on board from the CEO of Petrobras, Maria das Graas Foster on November 6th 2012. Having previously produced in the Espadarte field for Petrobras, FPSO Cidade de Anchieta is now under lease to the same company producing in the Baleia Azul Field (also in Brazil) for a period of 18 years, ending in 2030. SBM has collaborated with Petrobras on FPSO projects for over 16 years. For FPSO relocation projects SBM continues to leverage integrated project management teams that tie in the world-class expertise found throughout the global group of SBM companies. By working closely with our clients to assess their future needs, we push the boundaries of technology to meet those needs with pioneering new solutions.
fpso
cIDADE
DE
aNCHIETA
Number of risers 39
Diagram 1 charts the evolution from FPSO VI before her conversion to Espadarte and finally to Cidade de Anchieta Vessel Name Year Client FPSO VI
1985/86 Ashland 12-year lease
Espadarte FPSO
1999/2000 Petrobras 11-year lease inclusive of maintenance, operation & shore base facilities Espadarte fields Campos Basin, Brazil and Marimba Leste June 30th 2000 2000-2011 800m 1,900,000 bbls 100,000 bopd 110,000 bwpd
Field First Oil Project duration Water depth Storage capacity Oil process capacity (barrels oil per day) Water injection Mooring lines Gas handling, export & gas lift CO content H S content Conversion details
Ebughu, Akam and Adanga fields Nigeria February 5th 1986 1986-1998 40m 1,750,000 bbls 80,000 bopd
Tower soft yoke none none none Simple topsides comprising two separation trains of 40,000 bpd each plus associated utility systems
1x4; 2x3 layout mooring lines 87 MMscfd 0.25% none Replacement of original simple topsides with a more complex processing system removal of soft yoke mooring system & replaced with a large internal turret mooring to accommodate the large number of risers rudder steering gear and propeller removed
Capabilities Slots for risers & umbilicals Mooring systems Means of export
N/A Soft yoke mooring system
To process a range of crude oils from 18 - 29 API; offload 1 million barrels in 24 hours 45 Internal turret mooring system designed to accommodate the large number of risers Tandem offload
To process a range of crude oils from 28 - 30 API 39 (currently 34 being used and 5 spare for future development) Internal turret mooring system with polyester mooring ropes Tandem offload
Tandem offload
FPSO VI
Espadarte FPSO
With these two vessels weve launched Generation 3 in the FPSO story and its definitely not business as usual anymore, says Chief Technology Officer Mike Wyllie.
Of course Generation 1 was a long time ago. These were the simple basic units that pioneered the FPSO business. As well as Cadlao, those vessels included FPSO VI (now FPSO Cidade de Anchieta), which served at Nigerias Antan field for 13 years from 1986, and also several other floating storage and offloading units. Around 1999 these gave way to the first examples of the Generation 2 vessels, which more or less represent the SBM fleet today. Over the last 15 years the trend has certainly pushed steadily upwards in topside weight and machinery complexity for the 18 or so projects that this category includes. Those G2 vessels progressed from FPSO Kuito and Espadarte, on through the generic vessels for ExxonMobil in West Africa and a series of FPSOs for Petrobras off Brazil. Typically they support around 100,000 barrels per day of oil production and include conventional systems for gas compression and water injection.
In addition, some have limited facilities for gas processing. At the higher end of the scale their topsides weight approaches the 10,000 tonne mark. Nevertheless, it is clear that the move to Generation 3 is a significant jump beyond even the most recent of these predecessors. What we are seeing now is a real step change, stresses Mike Wyllie. There is a big increase coming in the size of the units were building. The average shaft power of typically up to 100 megawatts for G2 units is being more than doubled for G3 vessels. In its hugely demanding pre-salt development programme, far offshore Brazil, Petrobras aims to exploit vast hydrocarbon reserves that have been obscured deep beneath a mighty blanket of overlying salt until more recent advances in exploration technology have enabled their detection.
What particularly marks out Cidade de Paraty and Cidade de Ilhabela FPSOs as a new league of vessel is the increase in production rate to be handled and the far greater level of sophisticated gas processing and compression technology they will carry. In terms of oil production, Cidade de Paraty is designed to produce 120,000 barrels per day, and Cidade de Ilhabela will go to 150,000 bpd. Added to these impressive throughput capabilities is the need to deal with high volumes of difficult associated gas. The reservoir gas contains a high percentage of carbon dioxide (ranging from 10% to well over 50%) which has to be separated out to allow export of purified natural gas. This contaminant - along with some hydrogen sulphide - and the temperatures and pressures that have to be catered for, mean that materials selection is also a challenge. To filter out the carbon dioxide, a large bank of gas membranes will be used. Once separated, it has to be disposed of by reinjection. This has called for compressors able to pump a CO rich gas at extremely high pressures - up to 550 bar.
At this pressure, carbon dioxide is a very dense fluid - almost a liquid - and the challenge of moving it is at the limit of current compressor technology. Recent factory acceptance tests for Paraty achieved the highest pressure ever reached by a centrifugal compressor operating with CO rich gas. The discharge fluid was at the highest density yet handled by such a machine. All of this means that the amount of power needed to drive compressors is much larger than normally experienced on the G2 units of the past, and topsides weight and space needs are going up accordingly. The 23,000 tonnes of topsides to be carried on Ilhabela is by far the largest weve ever designed and constructed, says Mike Wyllie, and its approaching the limits of what is practical on a converted tanker. Weve run out of space to spread the topsides any more, so we can only build upwards, he continues. On some modules we are now up to four operating levels, which makes them heavy, and a challenge to operate and maintain. Clients like Petrobras and one or two others are the drivers towards this generation three of FPSO conversions. A few years ago anything that had 20,000 tonnes of topsides would automatically have been a new, custombuilt vessel, points out Wyllie.
Were happy to keep pushing the limits of what you can do with tanker conversions because thats what we do best and its where our core technology is, says Wyllie. SBMs position in the market is at the top end, with the most challenging projects, so G3 is natural territory for us. As well as building these units, SBM has to be ready to operate them. Since last year SBM has been working closely with its fleet operating company SBM Production Contractors to accelerate preparations, and with its key suppliers who help with the commissioning and early operation of the units. We have to be sure of all our systems and processes, along with the training and competency of our offshore crews, says Wyllie, so that everything is in place and ready for operation of these new units. Things have changed a lot since those early days thirty years ago. At that time the emphasis for the crews was on the marine side. Then G2 brought the start of a transition from marine to process know-how and the topsides crews began to include personnel with offshore production platform experience. Now the present jump to G3 - with its major increase in size of topsides and machinery shaft power - requires another transition and puts the focus ever more on the advanced separation, treatment and compression technologies on deck.
In the ultra-deep waters (around 2,100 metres) and with the very high well pressures of these pre-salt pilot projects for Petrobras, the riser pipes from seabed to surface vessel are also a significantly challenging part of the overall picture. The two new units for Brazil will support a large riser and umbilical count - up to 66 of them. In addition they may carry a mix of riser types: both rigid steel and flexible. Such a large number of risers in ultradeep water definitely adds to the complexity of the projects and is the reason why spread-mooring has been selected here rather than turretmooring. In the past SBM has provided turrets for very high riser counts (notably the Petrobras P53 turret with its 75 slots), and for very high mooring loads (notably the Skarv turret in Norway). It has also connected rigid steel catenary risers to a turret offshore Brazil, at the Espirito Santo FPSO. But a combination of all three of these elements to allow the two current FPSOs to be moored by turret is not yet proven technology. However, SBM is working to develop such a turret and allow future similar vessels to enjoy the benefits that turret mooring brings. For the moment, the challenge of launching Cidade de Paraty and Cidade de Ilhabela into smooth operational life is more than enough to start the company off in this new league of FPSOs.
But now certain clients are recognising that it is possible to put that weight on top of a converted tanker, and to lease it from a contractor, enabling useful cost and schedule advantages to be gained, he says.
23,000 t 10,000 t
G3
1,000 t
G1
G2
Topsides Weight
FPSO Generation 2
Measuring complexity
To formulate its statistics on shaft power, SBM counts all rotating machinery greater than 1 megawatt. This means that where compressors are driven by electric motors, the shaft power at the turbo generator and at the motor-driven compressor are both counted. Total shaft power is a good indicator of topside complexity, and this is the measure that has rocketed for Generation 3 FPSOs. The other indicator of complexity growth in topsides weight of FPSOs over the years - has risen in more linear fashion. However, any more topsides at the record weight of Cidade de Ilhabela will definitely start pushing this line to exponential on the graph. And to cater for whether an FPSO is spread-moored or turret-moored, SBM includes the riser top manifolds in the topsides weight if the unit is spreadmoored. In the turret case it includes the manifold chamber on top, and all the associated valving.
FPSO Generation 1
Mid-scale FLNG:
The development is well timed to take advantage of the strong growth in natural gas demand that is expected during the coming decades. In its World Energy Outlook 2012 the International Energy Agency forecasts that gas demand will rise from 3.3 trillion cubic metres (tcm) in 2010 to 5.0 tcm in 2035, an increase of 50%. Industry estimates suggest that there are over 2,000 trillion cubic feet (Tcf) of proven undeveloped offshore gas reserves in the world today. Many of these reserves, however, are considered stranded i.e. the fields are too far
further potential projects are likely to be announced in North and South America, Africa and the Middle East. This new market will be a good complement to SBMs already strong position in the oil FPSO business. SBM has extensive experience in designing, building and operating FPSOs and is now drawing on this experience to develop its FLNG concept. Commenting on SBMs strategy Bruno Chabas, CEO SBM Offshore said: Our core position is for midscale FLNG (1.52 mtpa) conversion.
schedule. With such a conversion, the process facilities along with the storage and crew living quarters are located on deck. This novel topside layout is achieved by joining together two LNG tankers. This twin hull concept allows adequate space for the process facilities with the necessary space between sections of equipment to satisfy safety requirements, while providing sufficient LNG storage capacity. SBM has performed generic pre-FEED work, together with Linde Engineering, a strong and reliable LNG topsides partner, to cater for a wide range of potential reservoir compositions and environmental conditions, which can then be easily optimised for specific fields. For the mid-scale FLNG concept, a pre-cooled dual nitrogen expansion process without natural gas liquid (NGL) recovery has been selected, providing an optimum balance between efficiency, simplicity, robustness and safety. Avoiding the use of mixed refrigerants on the topside and the introduction of several innovative features achieves an efficiency level approaching that of the single mixed refrigerant (SMR) process. This design provides a highly economic solution for mid-scale applications.
from shore to be considered economic. This, combined with the increasing permitting challenges of building onshore terminals, will drive the market for FLNG. Kees Willemse Director of Proposals & Technology Development from Schiedam office, said: With the increasing global demand for gas we expect there will be a strong market for FLNG vessels. FLNG has the potential to make a significant impact on the global LNG market over the coming decade. According to energy analysts, Infield Systems, capital expenditure (Capex) on FLNG and offshore regasification markets will increase significantly over the period to 2018. In the short to medium term, the majority of planned FLNG projects are concentrated in Australia and South East Asia. However,
Willemse added: This size is suitable for the 700-plus stranded gas fields between 0.5 TCF and 2 TCF and is also a good fit with SBMs current FPSO product line, in terms of project scale, risk and investment. Many of the technologies and capabilities that SBM has in-house are applicable to the FLNG concept. For example, the same turret mooring systems used for FPSOs can be used for FLNG. Notably, SBM is providing the turret for the first new build FLNG project a very large-scale project that is currently under construction for Shell. Although building a new facility is possible, SBMs innovative option is to convert LNG tankers into FLNG facilities in much the same way as has been successfully achieved for oil FPSOs. The advantage of this concept includes lower costs and a shorter
SBMs design will continue to be validated, not only in terms of economics but also for operability. Some wind tunnel testing has been performed to verify the effect of topside design on the loading of the vessel. The next step is to make a scale model of the vessel for testing in a tank. This testing will provide SBM with the further information needed to confidently offer the concept to potential clients. Willemse summed up: The concept is at a sufficiently advanced stage of design whereby SBM can accept specific details of the potential field for example wave and wind conditions and gas composition in order to tailor an optimum FLNG design to the exact needs of the client.
It was the perfect gift for Petrobras back on 7th December 2002 when FPSO Brasil achieved first oil just before the holidays. Ten years later she continues to pump the black gold at a rate of 35,000 bbls oil per day and plans to reach 60,000 bbls by June 2013 when a new well is added. With an uptime of 99.5%, this is quite an achievement married with the fact that she has achieved a decade in operation without any LTI (Lost Time Incidents).These high performance and safety milestones clearly demonstrate a cohesive team at work onboard and onshore. Paul Whittle, Onshore Technical Manager for SBMs Brazilian sevenstrong fleet hits the nail on the head when he comments on what matters to our clients A unit of happiness is a barrel of oil. This is the goal for the tight ship team of 95 persons on board Brasil as well as a dedicated onshore team. FPSO Brasil is moored on the Roncador field, which lies in deep water (1,360 metres) offshore Brazil in the Campos Basin. The vessel was originally a VLCC oil tanker, the T/T Moscliff; whose equipment
SBM Offshore / Currents 16
was partially replaced or refurbished to meet the FPSO design life during the lease with Petrobras, which has extension options. The client is opting for a three-year extension to prolong the current lease due to finish in December 2013. To assess potential modifications required a review of the vessel, which started in February 2013. The review report will recommend what and how alterations and repairs will take place. Often the yard work for example the upgrading of topsides can be done while the FPSO continues to operate offshore, until the actual refitting onto the vessel takes place. The options are presented to the client who in discussion with SBM will come to a decision on the best way forward.
Tom Tayne (left) OIM on FPSO Brasil Paul Whittle: Technical Manager in Maca
Isabele Reginato:
Safety Officer
Tom Tayne, one of the two OIMs assigned to FPSO Brasil, says The principal part of my job is overseeing the daily work routine and liaising with the client on a daily basis. We then communicate to shorebase keeping them up to date on the running of the vessel with any issues arising. Contact with the shore base manager is indispensable; I rely on him and the General Manager to ensure that logistics run smoothly and that all instructions are implemented, as well as staying on top of all offshore activities, including those conducted by third parties. He adds Often crews are a multinational mix, which further underlines the importance of communication in order to work together as a team and get the job done. Being a close knit family per se, communication, whether in English or Portuguese, is essential and it is really important that we recognise good team work. A pat on the back goes a long way to support the team spirit. Tom Tayne emphasises the importance of input from the client. A close collaboration between the SBM team and our client Petrobras ensures that a high level of productivity is consistently maintained. The clients representative is called a fiscal and they are involved on a daily basis with operations and regularly request for movements of choke setting on wells and chemical usage. While the OIM is the focal point of contact offshore for the client, the Operations Manager is the direct link with the client onshore. Antoine Kovacs who fills this latter function is based in the Maca office. He explains Onshore we have a weekly contractual meeting with the client, the aims of which are first to verify that SBM is remedying any problems - which could include maintenance of equipment after breakdown, local regulations compliance or personnel issues. Secondly, to line up the information and events related to production/process which could include gas flaring impact or water injection loss.Everything is registered in the meeting minutes and serves as a log, which is important to ensure clarity between SBM and the client.
Financial penalties in the industry for reduced or loss of oil and gas production and water injection can be severe. Antoine adds There is a personal relationship between the key management at Petrobras and SBM, who work together to help mitigate such fines.
HSSE
Thankfully, nowadays in the industry safety is king. It is the first message that greets workers onboard. The safety briefing is immediately after embarkation and the message is ubiquitous on all vessels. At times the challenge is to change peoples attitude - the crew must want to work safely. This is a matter of time and the head of department and safety officer are there to set a good example. On all FPSOs any incidents are recorded onto the SBM system called SIRS, which monitors and identifies the root cause for analysis. Safety Officer Isabele Reginato says In order to reinforce safety issues, I use the many resources available. I find that encouraging crew interaction boosts thinking about safety practices. I randomly choose an employee to observe a worker in action. Afterwards, the employee compares the actions with the requirements of the Permit to Work (PTW). It is a good opportunity to highlight safe behavior or to reflect upon ways for improvements. The final step is to write the STOP CARD.
In recognition of outstanding project delivery performance in terms of health, Safety, Security and environment (hSSe), quality, cost and schedule, the estaleiro Brasa yard team in Brazil was honoured earlier this year with the SBM Offshore Focus award for project performance. the tribute is the rst of more to come as clients in Brazil are acknowledging the yards importance in bringing their projects to fruition and the media is holding up the yard as an example of sustainability.
Through a joint venture with Naval Ventures Corp, the pioneering yard has proven to be an excellent example of commitment to sustainability with SBM Offshore leaving its ethical and ecological imprint on every step of the yards development and going far beyond the legal requirements imposed by Brazilian law. Globally, the project entailed the development of new fabrication yard facilities dedicated to complex FPSOs for the Brazilian market. Specifi cally, the plan for the 65,000m2 yard was to have the capacity to assemble Topsides modules goals that were realised. The added challenge was to build the yard while adhering to SBMs ecological programme, which is dedicated to preserving the fragile ecological surroundings.
SBM Offshore / Currents 18
Situated on the island of Ilha do Conceio within the environmentally sensitive Guanabara Bay, SBM Offshore felt strongly about carefully conserving this heritage whilst at the same time providing a thriving workplace that offers jobs to the local community. In particular, this latter point would help SBM Offshore meet the obligations imposed by the Brazilian government on international companies to source at least 65% local content for all projects in the country. General Manager Rio offi ce, Philippe Levy, underscores the importance of SBMs expansion by way of the yard For local content projects the basis for the future is that all complex and heavy modules will have to be built in Brazil. The yards construction was achieved within a very tight schedule and its completion allowed the assembly of FPSO Cidade de Ilhabela modules to start on time in July 2012. Ilhabela will be leased to Petrobras and is set to become SBMs biggest FPSO, once she is completed in September 2014. Ilhabela will leave China at the end of July and is expected to arrive at the Brasa yard towards the end of September. Jos Miranda Formigli Filho, Petrobras Exploration and Production Director says I believe that SBM Offshore brings the expertise to the local market and more than that can also bring the mind-set to deliver what is contracted. SBM and Brasa will really contribute to the development of local capacity for
With the help of volunteers 140 seedlings were planted in a nature reserve at the Municipality of Niteroi City Park, to environmentally compensate for the removal of vegetation at the yard. The exercise helped promote environmental awareness. The trees progress will be monitored annually by the eco-volunteers.
Philippe Levy says The location of the yard in Guanabara Bay is unique and convenient - situated just across the Niteroi Bridge. It has the space, which allows the freedom to engineer how best to build modules. With the help of local partners it can accommodate more than two projects at a time. In addition, the four-story offi ce building is perfect as we can have all the project teams together. Underlining the key role in the future of SBM in Brazil, Christophe Rousseau, Yard Operations Manager says Ten modules and 11,200 tonnes for a new yard is a big challenge but we know that we have all the cards in our hands. We know we are better able to control projects than if we had to go to other yards and we are not always their priority. Here we control everything.
Originally home to an old abandoned yard, work included demolition of the redundant facilities with an estimated 40 tonnes of construction waste being donated to other companies for re-use. in addition, waste soil sampling and analysis were conducted to ensure that the soil was not contaminated. the yards environmental programme also includes:
Assessment and monitoring of ground water pollution Installation of a rainwater drainage system, a compact station for sanitary effluent treatment, an oil and water separator box for a car wash, a waste central and containment gutters for buildings Milling of wood and plant material, which was incorporated into compost windrows for organic fertilizer production. A week-long event Cleaning Guanabara Bay
An educational program with local communities and schools for the 2013 World environmental Week in June (including a celebration for International environment Day, with activities and games to raise awareness) A workshop on an energy saving solution for the yard publication of an environmental booklet on waste reduction and segregation