fdesign & modification of ewt/eps jack-upinal presentation

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


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


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


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


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


Presenter


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


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)


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


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


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


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


Hull Designcont.

• The hull was refurbished from drilling to production configuration.

An AutoCAD schematic of the Hull


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.


Presenter


Daniel Boadu

Topside Processing and

UtilitiesDESIGN OBJECTIVES

•Processing plant configuration

•Process requirements

•Equipment Specification

•Well measurement system


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.


• A single train facility (1x100%) plant configuration was selected

• Fluid Packages: PR, Glycol and Amine

Topside Processing Overview


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


• Throughput, GOR and Component Analysis• Middle-East - 3-stage flash stabilisation unit• India - 2-stage flash stabilisation unit

Oil Processing

with HYSYS


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.


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


Topside Utilities

• Power Generation System

• Process Pipework

• Gas Flaring System

• Seawater and Sewage Treatment

• Others: Cooling, Heating, Chemical Injection, fuel, VOC Recovery System.


•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


Presenter


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


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


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.


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


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


Presenter


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


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


• 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


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


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


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


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


Presenter


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


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


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.


Preloading and Punch-through risk consideration cont.

Methods of preloading• Preloading sequentially.• Preloading above water (with air gap).• Preloading in water (without air gap).


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.


Decommissioning Plan cont.

FSO• Disconnect in-field pipeline system.• Disconnect Moorings.• Sail to shipyard.


Presenter


Wisdom Wakama

Safety Considerations

• Safety consideration in jack-up installation & decommissioning.

• Safety consideration for jack-up design


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


Penetration Monitoring Devices

Cone penetration test and data acquisition device.

Anti-silt/punch connector floater.


Bow – Tie Diagram


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


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


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.


Presenter


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)


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


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


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


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.



Thank You