subsea: dalla r&s alla realizzazione di mega-impianti in

Subsea: dalla R&S alla realizzazione di mega-impianti in acque profonde

Giulio FaticaOffshore Engineering Manager, SAIPEM sa

Milan, 7 Febbraio 2014

Subsea: dalla R&S alla realizzazione di mega-impianti in acque profonde18 December 2013

Subsea Technology

The ensemble of all technical solutions aimed at transferringOil & Gas-extraction-related fluids from/to subsea reservoirsto/from surface facilities.

Subsea Field Development (or SURF)

The ensemble of all technical solutions aimed at transferringOil&Gas-extraction-related fluids from/to subsea wellsto/from surface facilities.

More and more associated to Deepwater developments.

The Subsea, few definitions …


Subsea Field Development – What…


SURF

SubseaUmbilicalsRisersFlowlines


SubseaUmbilicalsRisersFlowlines

Umbilicals RisersSCR, SLOR, BOHR…Flowlines Manifolds

PLEM, PLET…Offloadingsystems

Mooringsystems

SubseaProcessing

In reality constituted by several different

Components(sub-products)


Subsea Field Development


Subsea Field Development – The Main Systems

Subseaensures and controls the

connection with the reservoir

Subseaensures and controls the

connection with the reservoir



Umbilicalsensure controls and power to the subsea equipment

Umbilicalsensure controls and power to the subsea equipment



Flowlinesconvey the fluids at seabed

Flowlinesconvey the fluids at seabed



Risersconnect the seabed to the

surface

Risersconnect the seabed to the

surface


Risers

FPSO

OffloadingTerminal

Production Loop Flowlines

Water Injection Flowlines Gas Export Line

(to shore)

OffloadingTanker

Drill CentersUmbilicals

Umbilicals

Mooring System

A typical case (deepwater): Egina Field


Subsea / Deepwater Golden Triangle Subsea / Deepwater Golden Triangle

Gulf of Mexico Gulf of Mexico

West of Africa West of Africa

Offshore Brazil Offshore Brazil

Subsea Field Development – Where…

With some newcomers:East of Africa, Asia, Australia…

With some newcomers:East of Africa, Asia, Australia…


EngineeringProcurementConstructionInstallation



Mooringsystems

SubseaProcessing

The most frequent Contractual

scheme in SFD


TYPICAL CONTRACT: LUMP SUM EPCI or «EXTENDED T&I»

THE CONTRACTOR IS FULLY RESPONSIBLE OF THE DEVELOPMENT

SFD IS AN ENGINEERING INTENSITIVE PRODUCT

TYPICAL PROJECT DURATION BETWEEN 30 TO 50 MONTHS, WITHOFTEN AN INSTALLATION CONSTRAINT RELATED TO FPSO ARRIVAL (byothers)

IN TENDERING PHASE CLIENT PREFERENCE IS FOR A FUNCTIONALAPPROACH. BASIC DOES NOT EXIST, BID IS ON FEED (when available)OR SIMPLY ON CLIENT FUNCTIONAL SPECIFICATION. THE CONTRACTORDEVELOPS A COMPLETE & AUTONUMOUS SOLUTION FOR THEDEVELOPMENT

IN CERTAIN AREA LOCAL CONTENT IS A STRONG LOCAL REQUIREMENTNOT EASY TO BE SATISFIED FOR COMPELX ENGINEERING TASKS

Subsea Field Development – The Main Drivers


SFD: Development of Components

In order to get to a feasible and effective solutions in line withClient expectation each Components of a SFD development(flowline, riser, umbilical, …) undergoes to an R&D phase,partially before and partially during the Project Execution.

The SURF CONTRACTOR is the main actor of this developmentbeing in charge of the overall configuration of eachcomponents, with the aim of getting the most competitivesolution.

The CONTRACTOR own the whole responsibility of the finaldelivery of the Subsea Field Development.

Subsea Field Development – How…



The Riser Systems


17

Steel Catenaryand

Steel Lazy Wave Riser

Akpo (TOTAL, Nigeria 2009)

Sapinoa Norte (PETROBRAS, Brazil ongoing)

Subsea Field Development – The Riser Systems


18

Buoyancy TankSingle Hybrid Riser (SHR)

Top Assembly

Bottom Assembly

Foundation

Riser Section

Riser Base Jumper

Conventional SHR

Suction Pile



Large Track Record for SHRs

Kizomba A, B and Satellites (EXXON, Angola from 2004 to 2012)USAN (TOTAL, Nigeria, 2012)Egina (Total, Nigeria, ongoing)Sapinoa (PETROBRAS, Brazil, ongoing)



20

Bundle Hybrid Riser Tower (BHOR)



21

Riser Towers Track Record

Girassol (ELF, Angola 2001)Rosa (TOTAL, Angola, 2007)




The Flowline System


Wet Insulated Flowline

Akpo (TOTAL, Nigeria), Kizomba A, B and Satellites (EXXON, Angola), P55 (PETROBRAS, Brazil, ongoing), Sapinoa (PETROBRAS, Brazil, ongoing)

Subsea Field Development – The Flowline Systems


Pipe in Pipe

Kizomba A, B and Satellites (EXXON, Angola from 2004 to 2012)

Subsea Field Development – The Flowline Systems



The Subsea System


Manifold North SDA North

Manifold South Piping Skid

Manifold South Cover

Manifold North and SDA Suction Piles

Manifold South Foundation

Subsea Field Development – The Subsea Systems

Sequoia, WDDM (Burullus O.C., Egypt), Block 17 PLEM (TOTAL, Angola)


LONGER AND DEEPER

INCREASED COMPLEXITY AND FUNCTIONALITY OFSUBSEA PRODUCTION & GATHERING SYSTEMS

ROTATING EQUIPMENT & HIGH POWER INSTALLED ONSEABED

INTERVENTION & OPEX-DRIVEN DESIGN &QUALIFICATION OF “ACTIVE” EQUIPMENT

EXISTING RISER & FLOWLINE TECHNOLOGIESCHALLENGED BY WATER DEPTH, DYNAMICS ANDEXTREME OPERATING CONDITIONS

Subsea Field Development – Technological Trends


Deeper Water Depths

Longer Tie-Backs

King

Ceiba

Tyrihans

OreganoPluto

Chinook

Mutineer / Exeter

Rosa

Penguin A-EMachar

Ladybug

Habanero

Aspen

Macaroni EuropaLianzi

Mica

Madison

Plutao

Perdido (Tobago)

BC-10

Pazflor

NaKika

Marshall

Saturno

Venus Marte

Cascade

0

500

1000

1500

2000

2500

3000

0 10 20 30 40 50 60 70 80 90 100

Tie-Back Length (km)

Wat

er D

epth

(m

)

Conventional technologiesSubsea Multiphase BoostingActive Heating of FlowlinesSubsea Separation System

Liwan

Saipnhoa

Subsea Field Development – Technological Trends


Subsea Field Development – A Glipse of the Future

Today…Today…


Subsea Field Development – A Glipse of the Future

Tomorrow…Tomorrow…Riser Systems for Ultradeepwater

Riser Systems for Ultradeepwater

Subsea Processing(separation, compression, water

treatment & re-injection,…)

Subsea Processing(separation, compression, water

treatment & re-injection,…)

Flowline System for long tie-back

(insulation, heat tracing,…)

Flowline System for long tie-back

(insulation, heat tracing,…)


SAIPEM® Multipipe Separator: the Future is not so far…


SAIPEM Spoolsep: the Future is not so far…




Mooringsystems

SubseaProcessing

A SFD Project requires

• a wide, strong & integrated organization

• dedicated construction and installation assets


2012-09a

Saipem SA (Paris, France)Saipem SpA (Fano, Italy)Saipem UK (London, UK)

SCNL (Lagos, Nigeria)DWET (Luanda, Angola)Saipem do Brasil (Rio de Janeiro, Brazil)

SCNL (Port Harcourt, Nigeria)Petromar (Soyo, Angola)Petromar (Ambriz, Angola)Boscongo (Pointe-Noire,Congo)

Intermare Sarda (Italy)Karimun (Indonesia)

Saipem FDSSaipem FDS2Saipem 3000SB 230S 355Normand CutterBar ProtectorCastoro OttoCastoro DueCastoro SeiSaipem 7000Castoro 7CastoroneSemac 1

Project Management, Engineering & Procurement

ConstructionYards (Fabrication)

InstallationVessels

(*) In bold the resources more deeply involved in Subsea Field Development Projects

Subsea Field Development – SAIPEM Main Assets for SFD


Houston

Rio

Paris Fano

Cairo

LagosSFD Centers of Competence

SFD Local Teams Luanda

Singapore

Project Offices

London

Subsea Field Development – The Main Sites


2012-09a

Saipem FDSMulti-purpose Installation Vessel

Pipelay vessel (J-lay) up to 22”,quad joints Lifting capacity: 600 t213 bedsDP Class 3

Saipem FDS2Ultra Deepwater Installation Vessel

Pipelay vessel (J-lay) 1,500 T tension capacity*, quad joints AHC crane 1000 T @ 400 mWD,2 capstan winches 750T & 500 T325 persons on boardDP class 3

(*) max. 36”, max. 3000 mWD, 2,000T holding capacity for flooded cases

Subsea Field Development – The Offshore Fleet


2012-09a

Saipem 3000Heavy Lift Vessel

Umbilical layingLifting capacity 2,200 tSubsea structure installation195 bedsDP Class 3

Length: 162 m / 532 ftWidth: 38 m / 125 ftUmbilical layingSikorsky S-61 N



2012-09a

CastoroneDP3 Pipelay Vessel up to 60” triple joints – 330m long / 39m width

3 x 250 t tensioners, 750 t A&R winch, 120m hinged stingerPossibility to install J-Lay towerDesigned for arctic area operations: ICE class Baltic rules, ABS700 beds

Singapore – September 2012



2012-09a

Castoro 6Semisubmersible Pipelay Vessel

Pipelay (S-lay) up to 60”3 x 110 t Tensioners330 beds

Saipem 7000Semisubmersible Heavy Lift Vessel

14,000 t Pipelay (J-lay) up to 32”DP Class 3

Castoro 7Semisubmersible

Pipelay Vessel


Thank you.

subsea: dalla r&s alla realizzazione di mega-impianti in

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