low cost field development using hybrid risers - 2h offshore · 2020. 5. 21. · between 1986-1999...
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
1
Low Cost Field Development using Hybrid Risers
Prahlad Enuganti Technical Manager
2H Offshore Engineering Ltd., Aberdeen
Learn more at www.2hoffshore.com
OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Typical Field Development Options
Fixed Structure Shallow Water Platform Wells
Floating Production Storage and Offloading (FPSO’s)
Flexible Catenary Risers (FCRs) Modified Steel Catenary Risers (SCRs) Free Standing Hybrid Risers (FSHRs)
Other Floating Production Facilities (Semi-submersibles & Spars)
FCRs SCRs Top Tensioned Risers (TTRs)
Tension Legged Platform (TLP)
TTRs SCRs
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Learn more at www.2hoffshore.com
OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Proposed Alternatives
Current drilling rig market is oversaturated – Purchase at low cost compared to new build FPU Free Standing Hybrid risers are installed from the MODUs
Option A
MODU repurposed as FPU to be either minimal or full processing facility Fluid processed at MODU before export to shallow water facility Any future drilling, intervention can be done by a different MODU
Option B
MODU used for pre-drilling wells, FSHR installation Production fluids offloaded to FPSO MODU remains at field to drill future wells, install future risers, intervene on existing wells Solution for fields that would otherwise need a substantial production and drilling host (PDQ)
Long lead-time and expensive TLP/FPU can be avoided Heavy construction vessel can be avoided
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Free Standing Hybrid Risers –
Key Components
Buoyancy
Tank
Buoyancy
Tank
Connection
Upper Riser
Assembly
Steel
Linepipe(s)
Flexible
Jumper(s) to
Vessel
Lower
Riser
Assembly Base
Spool(s)
Foundation
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Free Standing Hybrid Riser Advantages
Design decouples riser from vessel 1st order motions Not highly sensitive to environmental loading Good fatigue performance (F class weld offshore)
Low vessel payload
Pre-installable ahead of production host vessel
Flow assurance flexibility
Large insulation thicknesses Pipe-in-Pipe Can use corrosion resistant alloy lined pipe
Installation flexibility pre or post laying of subsea flowlines and pipelines
Lower the cost ($60MM to $25MM per installed riser) by installing from
the MODU drilling on the field
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
FSHRs – To Date
Type Field Status Owner/Field
Operator Yr.
Installed Region
Water Depth Vessel
(ft) (m)
Bu
nd
le
Green Canyon 29/Garden Banks 388
De-commissioned Placid Oil Company/Ensearch
1988/1994 GoM 1,529/2,096 466/639 Semi-Submersible
Girassol Operating Total Elf 2001 Angola 4,430 1,350 Spread Moored FPSO
Rosa Operating Total Elf 2007 Angola 4,430 1,350 Spread Moored FPSO
BP Greater Plutonio Operating BP 2007 Angola 4,300 1,311 Spread Moored FPSO
Sin
gle
Lin
e Kizomba A & B Operating Exxon 2004/2005 Angola 3,330 to 4,200 1,006 to 1,280
Spread Moored FPSO
Block 31 NE Operating BP 2012 Angola 6,890 2,100 Turret Moored FPSO
P-52 Operating Petrobras 2007 Campos Basin 5,906 1,800 Semi-Submersible
Macondo De-commissioned BP 2010 GoM 5,000 1,515 DP FPSO
Cascade/Chinook Operating Petrobras 2010 GoM 8,531 2,600 Turret Moored FPSO
Block 32 Construction phase Total TBC Angola 4675 - 6315 1425 - 1925 Turret Moored FPSO
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Potential Applications
Deep water field developments
Remote locations
Marginal fields
But really, can be considered for most applications!
7
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Worldwide Rig Count (Ref: IHS)
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Option A – MODU Repurposed as FPU
Convert a drilling semi to a production host to reduce CAPEX
Improve schedule to first oil
Use FSHRs from subsea wells for production/injection and a FSHR for export
Learn more at www.2hoffshore.com
OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Vessel Field Startup Region Water Depth (m)
Argyll FPU Argyll Oil Field 1975 UK North Sea 150Buchan A Buchan oil field 1981 UK North Sea 160P-09 Corvina Oil Field 1983 Brazil 230P-15 Pirauna 1983 Brazil 243
P-12 Linguado / Badejo Oil Field 1984 Brazil 100
P-21 Badejo / Salema Oil Fields
1984 Brazil 112
Deepsea Pioneer FPU Argyll & Duncan Oil Fields 1984 UK North Sea 150
P-22 Morela 1986 Brazil 114P-07 Bicudo Oil Field 1988 Brazil 207Veslefrikk B Veslefrikk Oil Field 1989 Norwegian Sea 175
AH001 Ivan Hoe Rob Roy Oil Field
1989 UK North Sea 140
P-20 Marlim 1992 Brazil 625P-08 Marimba Oil Field 1993 Brazil 423
P-13 Bijupira / Salema Oil Field 1993 Brazil 625
P-14 Coral / Esrela / Caravela Oil Fields
1993 Brazil 195
Nan Hai Tiao Zhan Luihua 1995 South China Sea 300P-25 Albacora II Oil Field 1996 Brazil 252P-27 Voador 1996 Brazil 533Tahara PY-3 1997 Indian Ocean 339P-19 Marlim 1997 Brazil 770Janice A Janice Oil Field 1999 UK North Sea 80P-36 Roncador 2000 Brazil 1360SS-11 Coral 2003 Brazil 145P-40 Marlim Sul 2004 Brazil 1080ATP Innovator Gomez Oil Field 2006 Gulf of Mexico 914
Northern Producer FPF
Originally Galley Oil Field now at Don Oil Field
2009 UK North Sea 350
Option A – Historical Precedent
15 conversions were carried out in last major oil downturn between 1986-1999
Mostly semi-submersibles
Water depths < 1000m
Subsea developments using flexible risers
Ref: Deegan, Loffman, Odufuwa, “The conversion of Mobile Offshore Drilling Units to Floating Production System – Issues, Opportunities and Challenges”, DOT 2014
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
A larger % of future developments will be in very deep and ultra deepwater (5,000ft +)
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Riser Selection for DW and UDW Applications
Flexibles > 5000ft WD have several challenges Needs heavy construction vessel for installation Large payload FPU Temperature limit of ~130oC Limit on diameter Expensive
Use of freestanding risers instead of flexibles
Field proven compliant hybrid steel/flexible riser
system suitable for high motion vessel
Low riser payload to allow more for processing and/or drilling equipment
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Option B - Permanent Moored Drilling Semi with FPSO
Drilling semi would have the same functionality as a TLP:
Permanent installation over field life (requiring permanent mooring system and offshore inspection)
Drill grass root wells
Workover / intervene on existing wells to maximum reservoir recoverability of the field life
Install production risers to avoid use of a costly heavy lift installation vessel
Subsea tree and riser configuration are designed to accommodate the following constraints:
The motions of the drilling semi do not allow for dry trees risers so a system of subsea trees and a compliant production riser system is needed
The use of a freestanding production riser and the transfer of production fluid to the FPSO minimizes additional payload and allows the drilling rig to be maintained
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Deepwater W Africa and Asia solution
Alternate to new build TLWP with drilling rig
Produce through subsea trees located under drilling vessel to enable through life drilling/workover access to maximise recovery
Offloads to leased FPSO providing overall low CAPEX solution
Freestanding riser in deepwater for fluid transfer to FPSO
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Liuhua Field Development
300m water depth
South China Sea
Ref: Hall, Sheng, Krenek, Douglas, Macfarlane, “Liuhua 11-1 Development – Subsea Production System Overview”, OTC 1996, Paper 8175
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Preliminary Schedule Comparison 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q
X
X
X
FSHR Installation (1 off)
Install flexibles and umbilicals (w flex
lay vessel)First oil (with 3 wells)
1st Batch 3 off Subsea Trees Delivery
(w manifold, well jumpers and 1st Batch 1 off Riser Delivery (w
surface and seabed jumpers)Mooring Pre Installation
Semi Installation
Drilling and completion from Semi (3
wells)
Integrated Rig With TLP
FEED
Sanction & Detailed Design
Puchase semi and conversion (w
permanent moorings)
Semi-submersible with FSHR
Tendon Installation
TLP Installation & Commissioning
(Ready to drill or complete)First completion and first oil (1 well)
Producing (3 wells)
MODU Drilling (Batch set conductors
and drill 4 wells)
FEED - 20 Slot TLP
Sanction & Detailed Design
TLP Construction & Integration
TLP Tendon Fabircation
1st Batch Riser Delivery (3 production
and 1 drilling)
Year 1 Year 2 Year 3 Year 4 Year 5
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Preliminary CAPEX Comparison
Costing Assumptions West Africa
Day rate Mob/Demob
J-lay vessel $500,000 $3,500,000
Flex-lay MSV $250,000 $5,000,000
5th Gen MODU $250,000 $2,000,000
Crane Barge $175,000 $3,000,000
ROV survey vessel $150,000 $2,000,000
Anchor Handler $75,000 $500,000
Field Support Vessel $50,000 $500,000
Note: costs do not include day rate for drilling crew and consumables
$417,250,000Total
Mooring Pre Installation
Semi Installation
Drilling and completion from Semi (3 wells)
FSHR Installation (1 off)
Install flexibles and umbilicals (w flex lay vessel)
First oil (with 3 wells)
FEED
$35,000,000
$290,000,000
$35,500,000
Semi-submersible with FSHR
Sanction & Detailed Design
Puchase semi and conversion (w permanent
moorings)1st Batch 3 off Subsea Trees Delivery (w manifold,
well jumpers and umbilical)1st Batch 1 off Riser Delivery (w surface and seabed
jumpers)$25,000,000
$5,250,000
$6,500,000
$12,500,000
$7,500,000
$1,377,250,000
Integrated Rig With TLP
TLP Installation & Commissioning (Ready to drill or
complete)
First completion and first oil (1 well)
Producing (3 wells)
MODU Drilling (Batch set conductors and drill 4 wells)
FEED - 20 Slot TLP
Sanction & Detailed Design
TLP Construction & Integration
TLP Tendon Fabrication
1st Batch Riser Delivery (3 production and 1 drilling)
Tendon Installation
$90,000,000
$1,000,000,000
$90,000,000
$40,000,000
$25,000,000
$39,000,000
$93,250,000
Total
Learn more at www.2hoffshore.com
OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Option B - Key Advantages over TLP/Spar
Significant CAPEX saving - up to 50% vs. TLWP/Spar
Faster schedule to first oil by one year or more
Lower installation RISKEX compared with TLP and Spar installations
Maintain life of field workover capability for maximum reservoir recoverability
Conventional subsea recoverability lower than dry tree fields based on long term North Sea and Norway offshore experience
Similar advantage provided by TLP, Spar or FDPSO vessels
Manage reservoir uncertainty
Maximum end of life well count is not a driver for drilling vessel selection
Can initially be an early production system
Subsea architecture is organically expandable using the drilling vessel and a MSV to install more trees, risers, flowlines and jumpers
Vessel and riser system can be readily retrieved and relocated
Learn more at www.2hoffshore.com
OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
FSHR Rig Installation…..1
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
FSHR Rig Installation…..2
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
FSHR Rig Installation…..3
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OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
FSHR Rig Installation…..4
Learn more at www.2hoffshore.com
OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
MODU Conversion Considerations
Study of candidate vessel semi vs. drill ships W Africa swells, heave response, vessel heading older vs. newer generation vessels
Establish production characteristics, riser payload range and export options Mooring design configuration and loads - global performance analysis Retrofit mooring structural design Structural and fatigue analysis for long term permanently moored service Weight control and damage stability Corrosion and fatigue survey and assessment Any remedial structural work at dry dock Long term offshore inspection and maintenance requirements Level and stage of processing required (if any) Chemical injection storage Deck space allocation for drilling and production equipment Riser hang-off structures Change in vessel designation under class rules
Learn more at www.2hoffshore.com
OPT 2016 – February 23 & 25, 2016
Advances in Riser & Flexibles Design and Technology Seminar
Summary
Surplus rigs in the drilling market is an opportunity to reduce CAPEX by up to 50% and time to first oil by one year compared to an equivalent TLWP
There have been many drilling rig conversions over the last 35 years, mostly to production platforms, except for Luihua which is a drilling and WO semi in 300m water depth moored over a cluster of subsea trees
Subsea trees and freestanding risers enable a MODU to be repurposed as a permanent moored drilling and workover vessel for deepwater
Arrangement provides expansion flexibility to minimize upfront CAPEX and protect against reservoir uncertainty
Risers and vessels can be retrieved and relocated
The drilling vessel and a light construction vessel can be used to install the freestanding risers to avoid the use of an expensive heavy lift installation vessel
Learn more at www.2hoffshore.com