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EXP_Prod Systems 24p_A4 23/03/2015 15:03

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350150

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More than

projects on all five continentsthat have allowed ourcustomers to bringhydrocarbons to market

million barrels of oilproduced worldwide fromExpro-installed facilities

years of experiencein the ProductionSystems business

More than

Over

A global leader in fast-track,cost-effective and enhancedproduction solutions.

The production solutions we provide allow our customersto plan the optimal exploitation of their reservoirs.


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Production Systems

Expro has been providing Production Systems since 1983, and isrecognised as a global leader in the provision of fast-trackmodular production facilities, delivered on a lease, operate andmaintain basis for either short-term or long-term projects.

Our experience in providing Early Production Facilities and Production Enhancement packages allows usto assist our customers across the exploration, development and production phases of their wells.

We can design, install, commission and operate Early Production Facilities and Production Enhancementsystems across a range of oilfield developments. Our inventory of equipment facilitates rapid EarlyProduction Facility response and fast-track delivery times.

Our 30-year track record has seen us deliver more than 350 million barrels of oil on behalf of ourcustomers around the world.

We are pleased to offer customers market-leading Early Production and Production Enhancementsolutions through the Expro PTI business, which has provided services to the upstream oil and gasindustry on an international basis for almost 30 years. A strong local focus has helped establish Expro PTIas a market leader across Asia.

We offer a key range of production solutions, including:

■ Early Production Facilities

■ Permanent Production Systems

■ Mobile Offshore Production Units

■ Production Enhancement packages

■ Water handling and treatment plants

■ Seawater injection packages

■ Production testing, including in-line and extended well testing


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Early Production Facilities

Expro is a global market leader in the supply of fast track,modular production facilities; on either a sale or lease,operate and maintain basis.

Early production facilities and fast-track production systems enable Expro’s customers tocreate early cash flow with minimum cash outlay. They also provide real-time productiondata that enables our customers to appraise reservoir performance before installingpermanent facilities.

Our solutions provide our customers with the ability to bring new developments on streamquickly, ahead of permanent facilities being installed, thus offering compelling financial andoperational benefits. In addition, our early production facility solutions can be used for smallreserves that would otherwise not meet acceptable risk criteria or would be uneconomic toproduce with a permanent facility, thereby the EPF in effect becomes the permanent ‘life offield’ solution.

Other benefits include:

■ Through the experience of Expro PTI’s combined team, we have an established track record for delivery of EPF projects in timescales that are unrivalled

■ Our engineering excellence and operational reliability optimises operator productivity, sustaining us as a provider of choice

■ Our EPF solutions are built around modular, prefabricated equipment with reconfiguration flexibility for production optimisation

■ They are operated by experienced personnel, with state-of-the-art control and safety systems, including real-time monitoring and data acquisition services

What we offer


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Mobile Offshore Production Units (MOPU)

Production Enhancement packages

Expro, in conjunction with marine partners, offers two types of MOPUs. A static MOPU, utilising aconverted jack-up drilling rig, or a floating solution (FPSO), utilising a converted oil tanker. Expro typicallyprovides the top-side process package with the marine partner providing the hull for conversion,including the mooring and export umbilical. Expro has considerable experience in integrating thetopsides facility as well as providing operation and maintenance for the life of the contract, therebyproviding time and cost benefits for our customers.

Across the world, production has gone past peak oil. With increasing demand and depleting reserves,every oil company is seeking to maximise production.

In mature oil fields, many wells are no longer producing, ie they are idle or producing little oil, notnecessarily due to depleting reserves, but due to declining reservoir pressure. Continuous efforts are,therefore, needed to ensure the production from these fields is maximised and the optimum amount ofrecoverable oil is extracted from these reservoirs.

Production enhancement is an innovative solution that utilises the well unloading concept, usingstandard well testing equipment. It is unique as it uses existing equipment repackaged as a newsolution.

The well unloading packages handle low pressure production, boosting the oil and gas flow rates andprocessing them for reintroduction into the operator's process plant facilities. Our well unloadingpackages are flexible and mobile, allowing easy re/deployment. A single unloading package can tie inmultiple wells, giving enhanced productivity.

There are distinct advantages of utilising well unloading units. These are:

■ Continued production from a well which would not be able to deliver naturally, increased production equals increased revenues

■ Ability to tie multiple wells into one well unloading unit, no need for multiple downhole electrical submersible pumps

■ Flexibility - can be moved from well to well and platform to platform

■ Cost effective - no need to supply a rig or cranebarge for any installations


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Water handling and treatment plants

Seawater injection packages

Expro water handling and treatment plants meet all global environmental legislation.

We provide for the safe discharge of produced water overboard with oil-in-water levels below regulatorylimits or, alternatively, our water handling and treatment plants can allow for the efficient re-injection ofproduced water back into the reservoir, subject to an injection well being available.

Gas compression and injection packages

As alternatives to gas flaring, Expro can re-compress gas for export, or inject it back in to the reservoirvia a gas injection well.

Production testing, including in-lineand extended well testing

Typically, EPFs are installed ahead of permanent production facilities. This early production processprovides customers with the opportunity to gather data to better understand the reservoir behaviourand flow regime. This allows for appropriate equipment selection for the final design of the permanentfacility, thereby avoiding costly mistakes.

We offer seawater treatment and injection packages for reservoir water flooding purposes that meet allrequired global environmental standards.


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Start Tender stage Contractaward

Contractacceptance

Contractreview

& planning

Start paper& electronic

files

Projectdesign

process

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Project Management

Each project is managed by anexperienced Project Manager. The ProjectManager is the customer’s principal point ofcontact during project execution. TheProject Manager assembles the projectexecution team with suitably qualified andexperienced personnel to:

■ Provide the necessary skills to effectivelyundertake the work

■ Set out clear levels of authority and linesof communication

■ Ensure continuity throughout the project

The Project Team prepares and works tothe Project Execution Plan. As workprogresses, regular co-ordination meetingsare held with the customer, the other majorcontractors and the Certifying Authorities.Effective communication between all partiesinvolved in the Project is a key requirement.

This ensures that:

■ All aspects of the work are safely andproperly addressed

■ Risks are identified, assessed andmanagement plans implemented throughthe life of the project

■ The work is then carried out in a safe andproper manner

■ All parties are aware of the objectives andof the work taking place at any point intime

All work is carried out to internationalcodes and standards, making extensiveuse of existing available process packages,including, where appropriate, modified welltesting components. This enables us toprovide facilities at low customer CAPEX,adding value to their oilfield assets.Innovative risk and reward terms can also beused to help realise and align customer,contractor and subcontractor goals.

Engineering & Design

The Engineering team comprises ofexperienced Engineers, Project staffand Operations personnel. Utilisinga range of engineering software,including HYSYS, AutoCAD,FlareSim and MathCAD, theymodel, simulate and develop thesystem design for the project,including:

■ Front End Engineering Design

■ Detailed engineering:

– Process Design

– Mechanical Design

– HazOp/HazID

■ Equipment specification anddesign to the latest internationalstandards and applicable local

■ Procurement:

– New process packages

– Refurbished process packages

■ Optimisation including continuouscritical review in an attempt toexceed customer expectation

Production Management, Operation & Maintenance

Expro is committed to providing the best quality production managementand operations services to our customers.

Expro’s personnel are managed, trained and developed to the standardsrequired by the company and the industry. Equipment is operated andmaintained by a highly trained competent site crew of engineers, operatorsand technicians supported by local and regional bases, and by the company’sresources.

Management of production, operations and maintenance activities is carriedout in accordance with a plan agreed and developed jointly by the Customerand the Project Team. This plan incorporates detailed procedures and regularinspections, performed in accordance with the latest standards, to maximisefacility performance, uptime and minimise LTI’s.

Project execution

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Installation & Commissioning

Operations personnel are utilisedduring the pre-commissioning phasesto gain familiarity of the processequipment. The knowledge gained canthen be used to full effect in order toaccelerate the commissioningschedule.

For the installation phase Expro bases ateam of trained engineers and operationalstaff at the site. In order to avoid commondelays due to lack of site services,clashes with the site contractors,structural obstructions, craneageproblems, etc, this phase is planned indetail, involving both the customer andthe Expro Commissioning Team. A fullinspection of the site is also completedprior to mobilisation of the equipment.

With our experienced team of in-houseoperators and engineers, andmanagement and systems to supportthem, Expro is able to provide ourcustomers with turnkey marine orshore-based systems and services from completion of the well to the pointof sale.


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Track record

Customer benefits

Our premier service portfoliocombined with the expertiseand experience of ProductionSystems enables Expro toprovide an unrivalled overallservice to customers in all partsof the world, with further benefitsrealised via:

■ Credible global industry nameand reputation capable ofmaintaining your licence tooperate

■ Excellent HSE-QA/QC recordand broad understanding oftechnical and commercialissues

■ National and internationalpurchasing with logisticalsupport from our officesaround the world

■ Highly experienced productionteam available immediately forsite specific projects

■ Ability to source or swiftly trainto provide the required skilledoperations personnel withinthe project operationsschedule

■ Continued technical supportservices to addressoperational changes andcontinuous field development

■ HSE expertise and knowledgein the creation of site specificSafety Management Systems

■ Fleet of Existing Equipment

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Procurementprocess

Construction,inspection,assembly

Mobilisation Installation &commissioning

Handover tooperations

Projectclose out& sign-off

End

Expro’s first major production systemwas in 1983 when we provided anEarly Production Facility (EPF) to ThaiShell for their onshore Sirikit field.Based mainly on modified welltesting components, the productionsystem designed, supplied, installed,supervised and operated by Exprohad two 10,000 bbl/day separationtrains with indirect fired heaters,storage tanks and tanker loadinggantries for oil export. Exprodelivered the facilities, whichincluded a camp for the field crew,achieving first oil within 10 months ofcontract award.

Our first offshore production facilitywas in 1988 when we provided anExtended Well Test (EWT) facility forOccidental’s Birch Field in the UKCS.This utilised modified well testingequipment to enable export ofstabilised crude oil to a shuttle tankermoored one kilometre away. Thefacilities produced at rates of up to12,500 bbl/day over a nine-monthevaluation period.

Furthermore, strong strategicacquisitions have added to Expro'sglobal capabilities and track record.

We can now reference projects goingback as far as the EWT carried outon Chevron's Casablanca Field,offshore Spain, from 1976 to 1978.More recent projects include theInterim Production Facility for ExxonNeftegas' Chayvo project, designedto export 50,000 bbl/day of oil and150 MMscfd of gas; the swampbarge mounted facility to receive50,000 bbl/day of oil and 55 MMscfdof gas at Chevron Nigeria's DibiField; Salamander Energy'sKambuna gas EPF, Sumatra,Indonesia, at 4,000 bbl/daycondensate and 40 MMscfd; and theMOPU/EPFs on NuCoastal SongkhlaField, Thailand, at 30,000 BOPD and20,000 BOPD.

Over the last 30 years, operating insome of the world’s most remoteand hazardous environments, ourfacilities have delivered over 350million bbls of oil for our customersworldwide.


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In order to ensure this goal is achieved, Expro’s Chief Executive hasdefined Health, Safety and Environmental (HSE) requirements for thecompany. These policies are reviewed annually by the Board, and aCSR Report prepared to present details of the group’s performanceworldwide. As part of the Policy and Expectations, the group’s HSEManagement System ensures that a planned and systematicapproach is taken to drive continuous improvement.

Quality Assurance

Our primary objective is to ensure that all services provided for,or on behalf of, Expro safely fulfil their stated contractualrequirements and are provided at the agreed time, every time.

Quality is fundamental to our business success and we are allcommitted to ensuring that we each play our part in ensuringthis objective is achieved. In order to achieve this objective weoperate to a Quality Management System (QMS), maintainedby Production Systems. All personnel have responsibilitiesunder the QMS and are actively encouraged to contribute tothe development and improvement of the system.

Health, safety & environment

Expro’s Health, Safety & Environment policies form part of our CorporateSocial Responsibility (CSR) strategy. This aims to prevent harm to peopleor the environment as a result of our operations, whilst interactingfavourably with local communities.

Policy

Planning &Implementation

Organising

Audit

PerformanceMonitoring &

Review

Group Procedures, Standards & Guidelines

Group Procedures,Standards & Guidelines

Group HSE Manual

Policy – Expectations,Corporate Objectives

and Targets

Region/Business stream HSEQC

ExproHSEQC

HSE policy

■ Provide a safe and healthyworkplace

■ Proactively identify, eliminate orminimise any potential sources ofharm to people or the environmentarising from our activities

■ Ensure our staff and contractors areprovided with the necessaryinformation, instruction, training andsupervision to enable them to workwithout causing or sustaining harm

■ Define objectives and targets forHSE performance for the group

■ Manage and maintain effectivemanagement controls to achieveour HSE objectives

■ Measure and monitor performanceagainst HSE objectives

■ Work towards the continuousimprovement of our HSEperformance


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Early Production – Case studies

Salamander Energy Ltd - Kambuna EPF, Sumatra Indonesia

Project Overview

Expro PTI undertook early in 2009, the complete turnkeysupply of an onshore EPF facility, located at PakalanBrandan, North Sumatra Indonesia. The facility wasdesigned as a complete “stand alone” onshore oil andgas processing facility including Oil and gas Separation,Gas Compression, Gas Dehydration and metering,Condensate stabilization and pumped export via a 20kmpipeline, power utilities, firewater system.

The design production rates for the plant are 40 Mmscf/dand 4000 BCPD respectively.

The project was mobilized within 16 weeks from ourBatam Yard facility, and was installed, ready forproduction within 20 weeks overall from Contract award.

Expro PTI ongoing services include the completeoperational manning for the facility, design and logisticsupport, utilities, maintenance etc.

All elements of the project were completed wholly byExpro PTI staff, other than pressure vessel fabricators forvessel refurbishment work. No other major contractorswere employed on the project.

NuCoastal (Thailand) Ltd - Songkhla “A” and Songkhla “B” MOPU developments

Project Overview

Expro PTI undertook earlier this year,the complete turnkey supply, includingthe supply of the Jack-up Rig 'Soraya'for an offshore MOPU developmenton the Songkhla A oilfield located inthe southern end of the Gulf ofThailand.

The initial project requirements werefor a very rapid mobilization of theMOPU with installed process facilitieswithin a six week period. Theequipment was mobilized out of ourBatam facility and installed on theMOPU within 4 weeks. The MOPUwas then dry towed to location. Theinitial design requirements were for15,000 BOPD and approximately3mmscf/d associated gas. Associatedgas is flared and stabilized crudebeing pumped to an adjacent mooredFSO Tanker. Production commencedfrom the MOPU 8 weeks afterinstructions were received to mobilizethe MOPU. Expro PTI provided fulloperations crew for the MOPU andproduction operations.

The first phase of the Songkhla A

project did not include watertreatment equipment as only smallquantities of produced water wereanticipated which were planned to bestripped out at the FSO tanker.

Expro PTI has since received a majorcontract scope expansion whichincludes for an offshore replacementof the current facilities with a 30,000BOPD process

package including water treatment forwell injection, gas treatment for fuelgas usage, Test Separator packageand other system enhancementsincluding upgrades and changes tothe MOPU facilities. This has comewith a contract extension and theconcept to use the Songkhla A MOPU

as a Central Processing Platform(CPP) for the entire field development.

In addition to the work on Songkhla A,Expro PTI has completed mobilizationand installation of a second 20,000BOPD process package which hasbeen installed on a second MOPU(Workships Seafox 6).

Expro PTI has worked closely with thecandidate MOPU supplier and theClassification Society to address allClass issues associated withintegration of the process facilities onthe Vessel. Expro PTI providedinstallation and hook-up supervision ofthe process facilities onto the MOPUwhilst in a Singapore conversionShipyard.

This facility includes oil, gas and waterseparation, flaring, fuel gas treatment,oil, water and gas metering and twophase pumping of well fluids back tothe Songkhla A MOPU.

Expro PTI ongoing services willinclude the complete productionfacilities operational manning for thefacility, design and manpower logisticsupport, maintenance.


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Case studies

■ Fast-track delivery of EPF for Victoria Oil & Gas, Cameroon

■ 20 MMscfd gas / day

■ 600 bcpd

■ Awarded 2011

■ Equipment delivered, installed & commissioned within six months.

■ 24 months operations & maintenance contract

In December 2003, Expro wasselected by Bourbon Offshore tosupply the topsides processfacility for their FPSO, theBourbon Opale. The vessel, beingprovided for a Pemex contract inthe Gulf of Mexico, was designedto produce the well fluids onPemex’s well testing and wellclean-up operations on multiplefields.

The process equipment wasmanufactured in Great Yarmouth,

UK and then transported to theAker Langsten yard in Norway.The topsides process facility wasthen installed at the shipyardlocation.

For this fast-track project, theschedule required the processtopsides to be engineered andfabricated by 20 April 2004 withan anticipated sail out date inearly May 2004 – a total period ofless than 24 calendar weeks fromthe contract award.

Location Offshore Mexico

Type Oil Production Facilityon FPSO

Contract Awarded December 2003

Equipment Mock April 2004 dockside Hook-up UK

Equipment Installation April/May 2004 at yardin Norway

Equipment June 2004

Commissioned

First Production July 2004

Duration of Contract Equipment sale

Design Overall Flowrate 10,000 bpd

Design Oil Flowrate 10,000 bpd

Crude Oil Properties 14 to 43° API

Design Water Flowrate 5,000 bpd

Design Gas Flowrate 26 MMscfd to flare

Number of Wells Multiple fields

Export System Via hull storage tanks

Logbada EPF - Cameroon

Bourbon Opale FPSO Topsides – Pemex, Mexico


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Case studies

Location Niger Delta, Nigeria

Type Floating ProductionFacility for EarlyProduction

Contract Awarded 2 May 2005

Equipment Mock Installed on bargeHook–Up

Equipment Mobilisation December 2006to Site

Equipment Commissioned Mid-2007

First Production Mid-2007

Duration of Contract 2 years LOM






Design Water Injection 100,000 bpd

Number of Wells 2 feed lines fromapprox. 30 wells

Export System Pipeline

Location Onshore SakhalinIsland, Russia

Type Oil & Gas ProductionFacility

Contract Awarded April 2004

Equipment Mock September toHook-up December 2004

Equipment Installation January to July 2005

Equipment May to SeptemberCommissioned 2005

First Production October 2005 (oil),September 2005 (gas)

Duration of Contract 14 months LOM



Crude Oil Properties 39° API


Design Gas Flowrate 150 MMscfd to export

Design Water Injection 5,000 bpd producedwater disposal

Number of Wells 2 (interim production)


IPF – Exxon Neftegas, Chayvo Field, Sakhalin Island

Swamp Queen FPF/EPF – Chevron, Dibi Field, Nigeria

In 2005, Chevron selected Expro tosupply a fast-track, fit-for-purposeEarly Production Facility (EPF) forits Dibi concession in Nigeria. TheEPF is mounted on the SwampQueen barge, operating in blockOML 49, northwest of Chevron’sEscravos terminal in Nigeria.Processing capacity is 60,000bbl/day.

The project was executed on astaged basis, starting with a FEEDstudy to develop the EPFrequirements. This resulted in acontract award for supply of theEPF, including conversion of thebarge into a full Floating ProductionFacility (FPF), with design,procurement & fabrication of theequipment modules, installation on

the barge, commissioning at site,and operation & maintenance fortwo years. Associated offsiteactivities were also carried outincluding design, procurement &fabrication work for pipework andpipe supports, installation of thisequipment, commissioning, andsand pad dredging and installation.

The FPF is a complete self-contained unit with 36-manaccommodation module andhelideck. Processed crude isexported via flowlines to theEscravos terminal, with the gasutilised as fuel or being flared.Produced water is disposed of byre-injection.

First oil was achieved in mid-2007.

In March 2004, Expro was selectedby Exxon Neftegas Limited (ENL) tosupply, build, install, commissionand operate a 50,000 bbl/day, 150MMscfd Interim Production Facility(IPF) for the Chayvo Field in fareastern Russia. The IPF wasprovided on a lease, operate andmaintain basis.The contract was based on a 14-month period of operation andwould run until completion of thepermanent Onshore ProductionFacility (OPF) on Sakhalin I, due inSeptember 2006.Expro’s track record in deliveringsuch projects on schedule was thekey in this award. Even so, theproject was particularly challengingdue to the combination of remotelocation and harsh environmentalconditions at site. This requireddetailed logistics managementinvolving shipment by road, rail and sea.

Project management, engineeringand procurement for the projectwere co-ordinated out of Expro’sHouston office. This wasconvenient for ENL’s project teamand cold weather equipmentvendors in the USA and Canada.Certification, licensing and permittingfor the production facility werecritical for this project, and were ajoint effort between Expro, ENL andthe Russian certification authorities.The IPF was mechanically completeand first oil delivered by the end ofJuly 2005. Operation andmaintenance was carried out byExpro using locally recruitedpersonnel and expatriatesupervisors. All personnel weretrained and certified according toRussian regulatory requirements.Expro subsequently received a letterof commendation from ENL inrecognition of the excellent jobperformed on this project.


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Case studies

Location Offshore UK

Type Oil Production Facilityon MOPU

Contract Awarded September 2002

Equipment Mock May to June 2003Hook-up

Equipment Installation June to September2003

Equipment September 2003Commissioned

First Production 27 September 2003

Duration of Contract 2 years



Crude Oil Properties 39° API



Number of Wells 4 (phase 1)

Export System Shuttle tankers

production MOPU allowed Shell to achieveproduction earlier than would otherwise havebeen possible. Uptimes in excess of 98%were maintained throughout the life of theproject, whilst the crew also achieved twoyears operations without a Lost Time Injury.

Location Offshore Iran

Type MOPU

Contract Awarded June 2000

Equipment Mock August to SeptemberHook-up 2001

Equipment Installation July to September2001 on ESP-1 MOPU

Equipment CommencedCommissioned 13 October 2001

First Production 14 November 2001





Design Water Flowrate N/A


Design Water Injection 60,000 bpd

Number of Wells 4 (early productionphase)

Export System FSU

Rowan Gorilla VII MOPU Topsides – Tuscan Energy, Ardmore Field, UK

The project was awarded inSeptember 2002 to supply thetopsides process facility forredevelopment of the Ardmore field,UKCS, on a lease, operate andmaintain basis. The contract wasbased on a two-year period ofoperation. The topside facility wasplaced on the Rowan Gorilla VII jack-upas a mobile offshore production anddrilling unit.

Completed in early June 2003, thefacility was shipped to McNultyOffshore’s yard for installation on theRowan jack-up before the rig departedfor the field.

First oil was achieved ahead ofschedule on 27 September 2003, withwell fluid production rates of up to

22,000 bbls/d. Expro’s process facilitythen stabilised and conditioned thisproduced crude on the jack-up MOPU.By using two mooring buoys Tuscanwas able to maintain productionthroughout the shuttling operations.

Tuscan Energy’s CEO recognisedExpro’s and the other contractors’efforts on the project by saying: “We’vegiven them a lot of responsibility,access to (financial) upside in theproject and, to a man, they haveperformed.”

“Achieving production again from thisfield is a tremendous boost for theNorth Sea and is an indication of whatis still possible in this area throughinnovative thinking and utilisation of thelatest available technologies.”

ESP 1 MOPU EPF – Shell, Soroosh Field, Iran

Shell Exploration BV was selectedby the National Iranian Oil Company(NIOC) to develop the Soroosh andNowrooz oil fields, lying in around30-40 m water depth, located 120km offshore Iran.

In June 2000, Expro SwireProduction Limited was contractedto supply and operate an earlyproduction facility which wasrequired ahead of permanentfacilities on the field. Scope includedthe supply, installation and operationof a Mobile Offshore Production Unit(MOPU) alongside the field’s newproduction jacket at Soroosh. Thefacility was required for a period of20 months before installation of thepermanent field infrastructure, andhad the capacity to produce up to amaximum of 100,000 bbl/day.

The ex-Mansal ‘Muna’ MOPU wasacquired, renamed ‘ESP 1’ andmobilised to Dubai for conversion.The vessel was recertified andmachinery zero houred.

Modifications included a waterinjection facility capable of 50,000bbl/day, as well as processupgrades to handle the Soroosh wellfluids. This work was complete inunder 32 weeks.

Flexibility in Expro’s approach meanta number of important design andengineering changes could be madewithout affecting the schedule.Additional workscope includedaddition of a 500 tonne powergeneration module, complete witheight 1MW Aggreko dieselgenerators and 11 kV high voltageswitchgear, to meet therequirements of a revised ESPdesign. A temporary wellhead deckwas also procured, fabricated andinstalled at location to allow thewellheads to be supported from theESP 1 until installation of thepermanent deck four months later.

As a result, Expro’s fast-track,marine-based, turnkey ESP 1


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Case studies

Kodeco Energy Ltd. - Poleng Field MOPU, Offshore Indonesia

Expro PTI provided a 30,000 BOPD Oil ProductionFacility, which was installed on the jack-up platform,'Taurus'. We were contracted on a 'life-of-field' basis.The facilities were contracted for a period of 12 years.

This project was undertaken on a turnkey basis, and wewere responsible for conceptual design, equipmentpreparation, equipment installation, commissioning andstart-up. Process Design - 30,000 BOPD, 3,000BWPD, 10 MMSCFD Gas.

Thai Shell - Nang Nuan Offshore Early Production System

In association with Swire PacificOffshore, Expro PTI were contractedfor the turnkey supply of a FloatingProduction Unit (FPU), including alloperations (marine, process andwellhead) and including maintenanceof the field facilities and shuttletanker management for cyclicproduction from the Thai Shell NangNuan Offshore field.

The project which wascommissioned in 1993 completed inAugust 1997.

Process System

■ Production Separator; 3-phase horizontal, 42” OD x 10' S/S,1,440 psi WP

■ Test Separator; 3-phase horizontal”, 36” OD x 9' S/S, 285 psi WP

■ HP Knockout Drum; 75” OD x 12' 6” S/S, 100 psi WP

■ LP Knockout Drum; 75” OD x 12' 6” S/S, 100 psi WP

■ Fuel Gas Scrubber; 30” OD x 7'6”, S/S, 100 psi WP

■ Settling Vessel; 36', 100 psi WP

■ Second Stage Separator; 66” OD x 12'6”, 100 psi WP

■ Stabilizing Vessel; 66” OD x 12'6”, 100 psi WP

■ Stabilizing Reboiler; 15.032 mmbtu/hr

■ Reboiler / Exchanger; 7.42 mmbtu/hr

■ Heat Exchanger / Production Cooler; 11.384 mmbtu/hr

■ Cool Water Pump; 2,500 GPM

■ Flare Boom; 60ft long, HP and LP Flare tips

■ Production Pump; 10,000 bpd capacity @ 150 psig WP

■ Sump Pump

Supply Boat

■ 5 point spread mooring x 3” chain legs with embedment anchors Moored

■ Equipped with full Fi-Fi systems and auxiliaries to support the process plant including:

- 200'x 6” ID Coflexip Production Hose

- 6” ANSI 600 Gall Thompson marine breakaway coupling

Process Design

■ Wellhead Platform, 12,000 BOPD, 250 BWPD, 5 MMSCFD Gas. Wellstream coolerpackage

■ Extreme flowing conditions (400 ppm H2S, 40% CO2 and 130 degC FWHT).

■ Flowline; 7” flowline assembly c/w adjustable choke and instrumentation

■ QCDC; Quick disconnect at flowline riser MSL

■ Wellhead control system

Process System

■ Inlet Manifold; 4”, 600# RF

■ Production Separator; 3-phase horizontal, 54” ID x 10' T/F, 275 psi WP

■ Flare KO Drum; 3-phase horizontal”, 36” OD x 12' 6” S/S, 600 psi WP

■ Heat Exchanger; 8.0mm btu/hr, 1,440 psi WP c/w twin fan assisted air cooler

■ Crude Oil transfer Pump; Twin 8,000 bpd @120 psig WP

■ Flare KO Drum; 42” OD x 10' T/T, 1,440 psi WP

■ Flare Booms; 2 x 6” gas flare line, 55 ft long

Export System

■ Shuttle Tanker; 40,000 DWT shuttle tanker with full IG blanketing and cargo heating

■ Export Manifold; 6”

■ Marine Hose; 150m x 6” Dunlop Selflote Hose

■ Breakaway Coupling; 6” ANSI 150# Gall Thompson Marine Breakaway Coupling


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Case studies

Project Overview

■ The facilities included an advancedautomated control system that used stateof the art R.F. frequency, level and pointtransmitters integrated into an AllenBradley programmable controller (P.L.C.)for process measurement and control.User friendly access to the controlsystem was achieved via a graphic userinterface (GUI) DMAC.. Major processitems were displayed on HMI units withreal time display of pressure, temperatureand flows, both oil and gas, given in bothgraphical and analogue display.

■ The system was commissioned inOctober 1993 and remained onsite untilthe end of December 1996.

Ampolex Australia - Wandoo 'A' Development

A comprehensive 16,000 BPD EarlyProduction Process System installedonto the Ampolex jack-up rig 'HakuryuVII' in Dampier, Western Australia, in late1993. This system was later modified toprocess up to 28,000 BFPD. Thefacilities were initially installed tocomplete a 120 day EWT phasefollowed by EPF operations if provedcommercial.

Production Testers Australia managed allthird party contractors involved in thedesign of the completely new processfacilities, built under strict quality control

to the Clients fully detailed specification requirements.

This system was based on 3 stage separation train and included,separators, electrostatic coalescer, steam generation plant, plate heatexchanger and shell and tube exchangers in a complex and efficientheating system for the problematic 19 deg API crude.

Water processing was based on use of corrugated plate interceptor and agas flotation units in series. The water disposal system was designed tohandle 5,000 BPD. This was later upgraded to 12,000 BPD. Water wasdisposed directly to the ocean at less than 15 mg/l specification.

Strict environmental quality specifications were met and exceeded.

Maersk Oil Qatar - Al Shaheen MOPU, Qatar

Project Overview

In conjunction with our joint venturepartners, Swire Pacific Offshore,Swire Production Testers (SPT) wasawarded a contract by Maersk OilQatar AS. The contract was for theprovision of a jack-up production unit(MOPU) installed at the Al Shaheen Clocation, Block 5 offshore Qatar.

The facility used the refurbished exdrilling unit Cliffs Drilling No.10 whichwas chartered to SPT by Cliffs DrillingInc. The facilities provided had adesign throughput capacity of 60,000bopd\100MMscfd gas. The MOPU

operated with an uptime in excess of99.5%.

On behalf of SPT, we designed thefacility at our Perth office, andundertook the entire projectmanagement phase includingprocurement, facility construction and

installation, hook-up, commissioningand operation.

The complete facility was hooked upand commissioned June 1997 onlyseven months after the contractaward was issued by Maersk.

SPT leased and operated the facilityfor Maersk on a turnkey basis. ExproPTI had a subcontract with SPT forthe provision of all productionpersonnel to the project.

We were responsible for senior levelmanagement of the contract and allproduction operations under thecontract.


17

Case studies

The Swamp Queen was firstcommissioned for ShellPetroleum DevelopmentCompany (SPDC) in 1995 whenan ex-Santa Fe drilling bargewas converted by Expro into a20,000 bbl/day floatingproduction facility for the TunuField.

Two years later SPDCcommissioned an upgrade to thefacility to produce 50,000 bbl/day.The new topsides equipment wasinstalled on the Swamp Queenwith contractaward to first oilwithin 17 weeks,includingaccomplishing theretrofit in a record14-day shut downperiod.

The facility was originally stationedon the Tunu field, but was re-deployed (by Expro) to theOgbotobo Field in 1997. After fiveyears of production for SPDC inthe Niger Delta, the SwampQueen FPF was shut down in2001 and cold stacked in PortHarcourt until beingdecommissioned in 2002. The50,000 bbl/day topsides wereremoved and returned to Europeready to be utilised on anotherproduction facility.

Swamp Queen EPF – Shell, Tunu/Ogbotobo Fields, Nigeria

In 1995 Agip awarded a contractto Expro for the supply of anEarly Production Facility (EPF) aspart of the Zinnia project,onshore Tunisia.

The EPF was required to treat wellfluids from up to two wells,separating andprocessing the fluids tomeet the requiredexport specifications forgas, exported bypipeline, and crude oil,exported by roadtanker.The EPF was providedon a full turnkey basisto the client, including

design, engineering, installation ofthe equipment, commissioning,start-up and operation by Expropersonnel. At the end of the lease,operate and maintenance (LOM)contract, Agip exercised theiroption to purchase the facility.

EPF – Agip, Zinnia Field, Tunisia

Location Onshore Tunisia

Type Oil and GasProduction Facility

Contract Awarded 1995

Equipment Mobilisation to Site 4 Months after award

First Production 8 Months after award

Duration of Contract Turnkey LOM + saleoption

Design Oil Flowrate 285 bpd

Design Gas Flowrate 7 MMscfd

Number of Wells 2

Export System Gas by pipeline/oil byroad tankers

Location South Forcados,

Niger Delta

Type Floating Production

Facility, Swamp

Location

Contract Awarded April 1995 (Extended

November 1996)

Equipment Mobilisation

to Site September 1995

Equipment September 1995Commissioned

First Production October 1995 &

November 1997




Crude Oil Properties 20˚ API


Number of Wells 7



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Production enhancement – Case studies

■ Chevron originally identified a number of candidate wells thatwere unable to flow through the production facilities due to lowwell flowing pressures.

■ By installation of bespoke packages of equipment, includingmulti-well manifolds, separation equipment and high volume /pressure pumps, Expro PTI was able to flow multiple wells intosingle unloading packages allowing produced oil to be pumpedback into the production line at normal line pressure.

■ Expro PTI supports each well unloading package in the field witha full crew of operators and supervisors, providing 24 houroperational coverage and maintenance support.

■ The initial contract commenced in 2004 and is currently firmthrough to 2014.

Main Components

■ Production manifold for multiple wells

■ Safety valve / ESD system

■ Vertical Separator

■ Surge Tank

■ High pressure re-injection pump

■ Generators/ air compressors

■ Gas Compression

■ Water Treatment

Optional Components

■ Sand management

Chevron Well Unloading Spread

■ PTI's operations team delivers packagesto Chevron in timeframes no other serviceprovider can match, typically within 12 - 16weeks.

■ Well flow enhanced, resulting insignificantly improved economics for theclient.

■ Typical platforms have shown increases inproduction varying from 700 bopd up to5000 bopd. Introducing gas compression,reduces gas venting and retains gasproduction in the range 0.5 - 2.0 MM scfd.

■ If produced gas is used for gas lift, thiscan enhance the production still further foreven more wells on the same platforms.

Benefits to Chevron

Well Unloading For Chevron On Various Fields Throughout Thailand


19

Case studies

■ Well Unloading Unit with GasCompression

■ Chevron Benchamas Field

■ Gulf of Thailand

■ 2005 - 2010

Petronas Carigali

In July 2008, Petronas Carigali (PCSB) commissioned a pilot projectfor production enhancement for some of their low pressure wells onseveral of their fields in Malaysia. Expro PTI were awarded a contract,in conjunction with Uzma Engineering and Sigma Setia, to providetheir well unloading unit (WUU) to the Dulang D platform. This projectran for a six-month period and proved very successful in achievingincreased production from four wells on the platform in excess of1,000 Bbls per day of Oil. A second WUU package was awardedand mobilised for the Bayan D platform in October 2008 and has

been continuouslyproducing since thatdate at a rate in excessof 1300 Bbls/day of oil.

An additional WUU package was mobilised in March 2010 on Bayan Bplatform and is currently continuing in production around 900 Bbls/day ofoil from 4 wells.

PCSB have identified several other candidate platforms for the WUUservices and have recently awarded a further contract for the Tinggiplatform which is due to be mobilised in December 2010.

Chevron Thailand

This is the fastest fast-track project that

we have undertaken globally that has been

completed on time and under budget.

Major customer regarding Expro project in the Niger Delta ’’


20

Case studies

Arthit Field

Sirikit Oilfield Thailand

■ Well Clean Up Package

■ Arthit Field

■ PTTEP


■ 2006-2009

■ Package Design

■ 10,000 Bbls/day

■ 40 mmscft/day

■ Portable well test unit

■ Water Treatment Package

■ Reinjection Facility

■ PTTEP

■ Sirikit Oilfield Thailand

■ 2006-2008

° 13,000 Bbls/day water

° 1,500 psi

° 1,500 BOPB


21

■ Early Production Facility

■ MOPU – PTI Seafox

■ Songkhla Field

■ NuCoastal Energy


■ 2009-2010

■ 15,000 Bbls/day

■ 10 mmscft/day

■ Water Reinjection

Expro PTI Seafox MOPU

Songkhla Field - Soraya


■ MOPU - Soraya

■ Songkhla Field

■ NuCoastal Energy


■ 2008-2010

■ 30,000 Bbls/day

■ 10 mmscft/day water

■ 20,000 Bbls/day injection

Case studies


22

Kambuna Field

Chevron Thailand

■ Seawater Injection Package

■ Chevron Thailand

■ 5,000 Bbls/day

■ 2,000 psi

■ Submersible Pumps

■ Cartridge Filters c/o Chevron

■ 1996 – 2010

Case studies


■ PTI Indonesia

■ Kambuna Field

■ Salamander Energy

■ North Sumatra - Indonesia

■ 2008-2010

■ 40 mmscft/day gas

■ 4,000 BCPD


23

Expro’s mission is well flow management. We provide servicesand products that measure, improve, control and process flowfrom high-value oil and gas wells, from exploration and appraisalthrough to mature field production optimisation and enhancement.

With a specific focus on offshore, deepwater and othertechnically challenging environments, we provide a range ofmission critical services across three key areas:

■ Well Test & Appraisal Services

■ Subsea, Completion & Intervention Services

■ Production Services

Our vision is to be the market leader in well flow management,using the industry’s best people, to deliver the highest standards ofsafety, quality and personalised customer service.

We provide a range of solutions including:

■ Exploration & Appraisal Testing

■ Subsea Safety Systems

■ Drilling & Completion

■ Flowback & Clean-up

■ Production

■ Well Integrity & Intervention

Expro’s 40+ years of experience and innovation empowers thecompany to offer tailor-made solutions for customers across theenergy sector. With over 5,400 employees in over 50 countries,Expro offers a truly global service solution.


Contact us:

Peter Cook, Business Development [email protected]

Tony Walker, Business Development [email protected]

Keith Palmer, President [email protected]

Or visit www.exprogroup.com


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