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Kikeh – Malaysia’s First

Deepwater Development

SUBSEA ASIA 2008

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LOCATIONLOCATION

S A B A H

BRUNEI

SARAWAK INDONESIA

Block G

SB-304

SB-305

SB-306

0 10 20 30 40 50

KILOMETRES

114º E

Sulu Sea

SB-301

SB-302

Kota Kinabalu

Bandar SeriBegawan

LabuanIsland

Sandakan

Semporna

115º E 116º E 117º E 118º E 119º E

114º E 115º E 116º E 117º E 118º E 119º E

5º N

6º N

7º N

5º N

6º N

7º N

BLOCK HBLOCK H

BAGANG-1

BLIAIS-1

KIKEH FIELD

BLOCK LBLOCK L

BLOCK MBLOCK M

Block E

SK-308

SK-310

SK-307

Block J

BLOCK MBLOCK K

BLOCK NBLOCK N

BLOCK NBLOCK P

BLOCK NBLOCK Q

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• Discovered July 2002: First Oil August 2007

• 120 km NW of Labuan in South China Sea

• Water depths of 1,280 – 1,370m

• Multiple reservoirs @ depths around 3,000m

• 34 Development wells – 16 are subsea

• Design rates:

– 120,000 BPD Oil

– 150 MMSCF/D Gas

– 260,000 BWPD Water Injection

• 80:20 partnership between Murphy & Petronas

Carigali Sdn Bhd

KIKEH FACTS & FIGURESKIKEH FACTS & FIGURES

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Risers

Subsea Drill

CentresFTLs

Flowlines

FPSO

DTU

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LAYOUTLAYOUT

KIKEH

EAST

KIKEH

SOUTH

KIKEH

GAS

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EQUIPMENT SUPPLYEQUIPMENT SUPPLY

• Equipment from 3 EPCIC Contracts:

• Technip (Technip/Subsea 7 JV)– 5 x flexible risers; 8 x flexible flowlines

– 7 x riser/umbilical holdback suction anchors

• Aker Kvaerner Subsea– 16 x trees (+ tree running tools)– 1 x IWOCS– 5 x manifolds c/w suction piles– 4 x steel tube electro/hydraulic umbilicals; 1 x power/fibre optic umbilical– 15 x rigid jumpers– 5 x SDUs– 48 x EFLs; 27 x HFLs– HPU, EPU, MCS, 2 x TUTA (topsides controls equipment)

• SBM– Gravity Actuated Pipe (GAP™)

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Risers

Subsea Drill

CentresFTL

Flowlines

FPSO

DTU

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RISERS / FLOWLINESRISERS / FLOWLINES

• Weather-vaning FPSO with turret

drove selection of flexible risers

• Seabed topography drove selection

of flexible flowlines

• Eliminated subsea connection

between risers and flowlines –

continuous from manifold to FPSO

• Single pipelay vessel

5 x flexible risers from Flexi-France, France

• 2 x 7” production (insulated)

• 2 x water injection (8½”, 10”)

• 1 x 8” gas injection

8 x flexible flowlines from Wellstream International, UK

• 2 x 7” production (insulated)

• 5 x water injection (6”, 8½”, 10”)

• 1 x 8” gas injection

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RISERS / FLOWLINESRISERS / FLOWLINES

7 x riser/umbilical holdback anchors by HL Engineering, Lumut, Malaysia

• 1 x 8.5m dia. x 8.5m long, 90 tonnes

• 4 x 7m dia. x 8.5m long, 81 tonnes

• 2 x 5m dia. x 4.8m long, 34 tonnes

FPSO/DTU Anchors

SS Drill Centres

Pipelay - avoiding seabed obstacles but minimizing length of high cost flexible flowline product

FPSO

DTU

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SUBSEA DRILL CENTRESUBSEA DRILL CENTRE

TreeJumper

Manifold

Flowline

Umbilical

SDU

EFLHFL

Suction Pile

UTH

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TREETREE

TreeJumper

Manifold

Flowline

Umbilical

SDU

EFLHFL

Suction Pile

UTH

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TREESTREES

• Horizontal trees selected to:

– Eliminate requirement for

costly and space consuming

special dual bore completion

riser and emerg. disconnect

package

– Reduce any future completion

workover time & cost as tree

can be left in situ

Note: additional cost of extra BOP riser run (associated

with horizontal tree) was all but eliminated by rig

moonpool - large enough to skid entire riser to one

side during tree running

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TREESTREES

16 x 10,000 psi side valve (horizontal) trees – Tubing hanger c/w dual wireline plugs

– ROV retrievable choke insert

– ROV retrievable SCM

– 8H/1E penetrations through tubing hanger

– manufactured by AKS, Norway and assembled initially by AKS, Norway (trees 1-8) then latterly AKM, West Port, Malaysia (trees 9–16)

• 3 x production (insulated), 41 tonnes

• 12 x water injection, 38 tonnes

• 1 x gas injection, 38 tonnes

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MANIFOLDMANIFOLD

TreeJumper

Manifold

Flowline

Umbilical

SDU

EFLHFL

Suction Pile

UTH

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MANIFOLDSMANIFOLDS

• Manifolds (and drill clusters)

were selected

– to allow the development drilling

programme to commence ahead of

manifold delivery

– to increase subsea architecture

flexibility

– to simplify transportation and

installation, i.e. smaller and lighter

with moonpool deployment possible

– to simplify manufacture in Malaysia

– to allow workovers without shutting

in adjacent wells

Jumper guide rail

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MANIFOLDSMANIFOLDS

5 x manifolds by AKPSAP, West Port, Malaysia)

• 1 x 4-slot production (double header, flowloop, actuated valves), 76 tonnes

• 3 x 4-slot water injection (single header, ROV valves), 48 tonnes

• 1 x 2-slot gas injection (single header, ROV valves), 35 tonnes

5 x suction piles by Oilfab, West Port, Malaysia

• 1 x 6.5m dia x 13m long, 63 tonnes

• 4 x 6.5m dia x 10m long, 45 tonnes

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RIGID JUMPERRIGID JUMPER

TreeJumper

Manifold

Flowline

Umbilical

SDU

EFLHFL

Suction Pile

UTH

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JUMPERSJUMPERS

Rigid jumpers with vertical

connections were selected

as these were favoured

design in GoM (FEED

engineering contractor)

Designed to be installed by

single ROV

Landed out Cone engagement

14 x 16m jumpers (3 insulated)

by AKM in Labuan, Malaysia

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JUMPERSJUMPERS

MANIFOLDMANIFOLD

XMAS TREEXMAS TREE

CABLECABLE

MEASURING PINMEASURING PIN

AZIMUTH PLATEAZIMUTH PLATE

MEASURING TOOLMEASURING TOOL

Jumper measurement between

tree and manifold by ROV

deployable “taut wire” tool

Insulated – 12.2 tonnes

Uninsulated – 9.7 tonnes

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UMBILICALUMBILICAL

TreeJumper

Manifold

Flowline

Umbilical

UTHSDU

EFLHFL

Suction Pile

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UMBILICALSUMBILICALS

• Steel tube (Duplex SS) E/H/C umbilicals – no armouring

• Dynamic section in low “lazy wave” configuration with 31

buoyancy modules per umbilical

Production

Cross-section

Injection

Cross-section

Outer sheath

Conduit

Tube

Cable

Wire

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UMBILICALSUMBILICALS

Before pull-in

Bend Stiffener

I-tube (FPSO)

After pull-in

Bend Stiffener

Connector

Manufactured by

AKS

Bullnose

Pigtails

…Norway

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CONTROLS SCHEMATICCONTROLS SCHEMATIC

HYDRAULICS BLOCK DIAGRAM

ICSS

HPU

MCS

EPU

TUTAEJB

UTH SDU PXT PM

WXT

CHEMICALSKID

HPU

TUTA UTH SDU PXT PM

WXT

ELECTRICAL BLOCK DIAGRAM

SW

IVE

L

HMI

RS485

4-20mA + D/I

LPHP

AMON

TOPSIDES SUBSEA

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SDU / EFL / HFL / SCMSDU / EFL / HFL / SCM

TreeJumper

Manifold

Flowline

Umbilical

SDU

EFLHFL

Suction Pile SCM

UTH

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CONTROLS CONTROLS -- SDUSDU

Fold up mud mats

Hydraulic out

Electrical out –

separate A & B

channels

Hydraulic in

Electrical in –

separate A & B

channels

5 x SDUs, standard design with varying nos. electrical

connectors & J-plates - AKS, Australia

SDU structures kept separate from manifold to reduce

maximum structure size

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CONTROLS CONTROLS -- FLYING LEADS…..FLYING LEADS…..

….OR NOT….OR NOT• EFL

– 40 to 120m long

– Min bend radius = 0.3 m

– Flexible cable

– Tronic connectors, weight in water = 2.4 kg

– Overall weight in water for 120m EFL = 54 kg • HFL

– 40 to 120m long

– Min bend radius = 1 m

– Stiff steel tubes

– Cobrahead connectors, weight

in water = 200 kg

– Overall weight in water for

120m HFL = 1105 kg

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CONTROLS CONTROLS -- SCMSCM

• Principle components:– SEM (electronics

module)

– Solenoid operated hydraulic DCVs (directional control valves)

– Accumulator

– Hydraulic fluid filters

– Wet mate connectors (electric)

– Self sealing couplers (hydraulic)

• 16 x SCM, compatible with all 3 tree types – single design and

common spares – manufactured by AKS, UK and assembled

initially in UK and latterly by AKM, West Port, Malaysia

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CONTROLS CONTROLS -- TOPSIDESTOPSIDES

Hydraulic Power Unit (HPU)

Master Control

Station (MCS)

AKS, UK and Australia

What, no

yellow paint?

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FLOW ASSURANCEFLOW ASSURANCE

• Passive insulation on– Trees

– Jumpers

– Manifold

– Flowlines

– Risers

• Chemical injection – via umbilical– Hydrate inhibitor (tree & downhole)

– Wax inhibitor (tree & downhole)

– Scale/Corrosion inhibitor (downhole)

• Operating procedures– Hot oil flushing, flow loop circulation

– Line conditioning pre/post shutdown

– Pigging

ThermoFlo ® –

polyurethane

insulation system

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SYSTEM INTEGRATION TESTSYSTEM INTEGRATION TEST

(SIT)(SIT)• Critical onshore fit up test

prior to offshore installation

• Actual components

– Tree

– Manifold

– Suction pile (pile top)

– SDU

– Rigid jumper

– HFL

– EFL

• Mock components

– ROV

– Flowline connector

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INSTALLATIONINSTALLATION

• 4 distinct phases for installation of subsea equipment

PHASE 1 • (July 2006 – Present) :- trees run on drill pipe from MODU (Diamond

Offshore)Ocean Rover

Tree

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INSTALLATIONINSTALLATION

PHASE 2A

– (Nov 2006 – Dec 2006) :- suction

piles, manifolds & SDUs by medium

size construction vessel with heave

compensated crane (TS7)

Suction pile

Manifold

Rockwater 2

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INSTALLATIONINSTALLATION

PHASE 2B– (Dec 2006 – Feb 2007) :- flowlines,

risers and umbilicals (wet parked) by deepwater flexible pipelay vessel (TS7)

Deep Pioneer

Flowline

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INSTALLATIONINSTALLATION

Riser

Normand Ivan

PHASE 3 – (July 2007) :- recovery from seabed

and pull-in of wet parked risers and umbilicals to FPSO turret by anchor handling tug with A-frame (TS7)

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INSTALLATIONINSTALLATION

PHASE 4 – (Apr 2007 – Present) :- rigid jumpers,

HFLs and EFLs by vessels including AHT, rig and Field Support Vessel (Murphy/Oceaneering)

Armada Tuah 100

Rigid Jumper

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AND NOW FOR SOMETHING AND NOW FOR SOMETHING

COMPLETELY DIFFERENT…COMPLETELY DIFFERENT…

….A SUBSEA IMPOSTER?….A SUBSEA IMPOSTER?

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Risers

Subsea Drill

CentresFTL

Flowlines

FPSO

DTU

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FTL or GAPFTL or GAP™™

Bundle:

• 1 x Carrier pipe

• 4 x rigid pipelines

• 1 x umbilical

DTUFPSO

Slack tether

chains

Flexible pipes

& umbilical

1300m

Towhead Towhead

Taut tether

chains

1600m

Carrier pipe – EEW, KoreaTowheads – SBM, Bintulu, MalaysiaRigid pipelines – Sumitomo, JapanFlexibles - NKT, GermanyUmbilical – AKS, NorwayTethers – Vicinay, Spain

• Once decision made to have 80% oil production from “wellhead only” DTU, requirement for fluid transfer lines (FTL) to/from FPSO born

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GAPGAP™™

• SBM GAP™ offered several advantages– Ambient water temperature increased from 3°C (at seabed) to 16°C at

180m

– Reduced slugging in 1.3km near-horizontal pipelines

– Pressure and temperature drops reduced by reducing overall flowpath from 4km (seabed) to 1.8km

– No impact on seabed congestion

– Able to be assembled by SBM in Bintulu, East Malaysia

….FIRST EVER PIPE BUNDLE USED IN A DYNAMIC MID-WATER CONFIGURATION

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GAPGAP™ ™ -- TOWHEADTOWHEAD

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GAP™ GAP™ -- LAUNCHLAUNCH

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GAP™ GAP™ -- GOING UNDERGOING UNDER

After submerging to

depth:

• Tether to DTU

• Tether to FPSO

• Connect flexibles

• Lay umbilical

• Install spools

Deepest saturation

dive in Malaysian

waters (200m)

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IN SUMMARYIN SUMMARY

• Kikeh was not highly demanding for current subsea

technology – not HP, not HT and not ultra deep

• The effort required to transport and import from

around the world and fabricate and install deepwater

equipment in a new deepwater region should not be

(but, of course, always is) underestimated

•• Subsea in Malaysia?........OK Subsea in Malaysia?........OK lahlah!!

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