Capabilities Offshore Pipelines

Offshore Pipelines Capability and Experience

Overview General INTECSEA, headquartered in Houston, Texas was formed in 2008 by the joining of heritage INTEC with heritage Sea Engineering to provide consolidated floating systems, risers, pipelines and subsea engineering and construction management services within the global WorleyParsons Group. INTECSEA has established operating offices in Houston, Texas; Kuala Lumpur, Malaysia; Singapore; Delft, The Netherlands; Rio de Janeiro, Brazil; Perth and Melbourne in Australia; and London, UK. INTECSEA’s major areas of expertise include subsea and floating production systems, marine pipeline and riser systems, Arctic pipelines, marine terminal systems, and Arctic Structures. Additional areas of expertise include flow assurance and operability, marine surveys, marine operations and offshore equipment design. This document describes INTECSEA’s capabilities and experience specific to Pipelines and Structures. Engineering design and construction management of marine pipeline and riser systems has been one of the INTECSEA core business areas since the company was formed in 1984. Although many other engineering disciplines and other business areas such as offshore terminals, subsea and floating production systems, onshore pipelines and facilities have been added to the INTECSEA range of project services, marine pipeline and riser systems remain a major INTECSEA business area. INTECSEA’s primary emphasis has been on pipeline applications in frontier areas, notably deepwater and arctic environments; and for unusual service conditions such as high pressure and high temperature, aggressive fluids and complex fluid rheology. These specialized technologies are firmly established within INTECSEA’s extensive project experience including practical design and installation technology required for cost effective completion and operation of marine pipeline facilities in all environments. In addition to deepwater pipeline applications, INTECSEA has also been responsible for many long distance, large diameter transmission pipeline projects and conventional offshore platform-toplatform pipeline projects.

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INTECSEA’s capability in marine riser systems has kept pace with the industry, as functional requirements for deepwater and hybrid riser concepts have evolved. Initially INTECSEA’s experience in marine pipeline riser systems was primarily focused on conventional and flexible pipe riser concepts. Conventional riser concepts consisted of steel piping systems attached to platform jackets. For floating production systems, a more compliant flexible pipe riser system was required. INTECSEA has been responsible for engineering design through installation and commissioning of a significant number of projects that have involved both types of riser systems. To meet industry goals of cost reductions and the technical challenges of increasing water depths, alternative riser concepts such as Steel Catenary Risers (SCRs) or Hybrid Riser Towers have become viable riser options. In 1987, INTECSEA performed a Joint Industry Study to evaluate Subsea and Production Riser Enhancements for Gulf of Mexico Deepwater Field Developments. This study included several compliant riser concepts one of which was a hybrid riser consisting of a submerged rigid riser with flexible pipe connections to the floating host facility. INTECSEA continues to develop these concepts, and has been responsible for the design of insulated and non-insulated SCRs for both fixed platforms and floating host facilities. In addition to riser systems associated with pipelines and flowlines, INTECSEA has extensive core capability for top tensioned riser (TTR) systems associated with drilling and production operations. To facilitate well access for drilling and workover operations, such risers are arranged in a vertical or near vertical configuration and are top tensioned either via a hydro-pneumatic tensioner system or passive buoyancy units. Such risers form an integral part of the well system and often carry internal casing and production strings and dry trees at deck level. Other specialized components include stress joints; flexible joints, tensioner spool joints, keel joints, buoyancy collars, wellhead tieback connectors, and mechanical connectors, BOPs, etc. INTECSEA engineers have extensive experience with system engineering, analysis, material specification, procurement, component design, testing and installation for such TTR systems. INTECSEA has also been involved in the design analysis of steel offloading lines, connecting an FPSO to an offloading buoy. The fatigue performance of the offloading lines at the buoy end is usually a critical design issue, and accurate predictions of the buoy motions are the key aspect of the design. Coupled motion analysis is required to account for the effect of inertia and damping from the mooring lines and the offloading lines. To support detailed riser system engineering and analysis, INTECSEA has acquired extensive experience with a wide range of specialized software tools. Analysis packages routinely utilized include the AQWA suite of programs for fully coupled vessel motion analysis and for accurate prediction of offloading buoy motions; FREECOM, MODES and FLEXCOM for frequency and time domain riser response; ORCAFLEX for general time domain studies, installation analysis and coupled riser/mooring/vessel dynamics; RIFLEX for specialized riser simulation studies including advanced modeling of seabed trench and suction effect based on CARISIMA JIP findings; SHEAR7 and VIVA for VIV fatigue assessments; ANSYS for complex non-linear system behavior or local component analysis and design; and INCLEAR, a proprietary software for riser interference analysis which has been validated against test data. These key programs run on a

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network of high specification PCs and are supported by INTECSEA’s extensively verified in-house calculation and design procedures. INTECSEA past and present projects include conventional pipelines, long distance and deepwater pipelines, high pressure/high temperature production flowlines, insulated production flowlines and offshore arctic pipelines.

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Marine Pipeline Systems Project List Capabilities and Resources Conventional Pipeline Systems The following table contains a summary of INTECSEA experience in conventional pipeline projects. Project Name/Location Mobile Bay 77-5

Client

Detailed design of an 8-inch gas flowline and a 4-inch diesel flowline between the well template in Mobile Bay Block 77 (MB 77-BC), approximately 1.9 miles to an existing production structure in Mobile Bay Block 77 (MB 77-B). The depth ranges from 12 feet to 16 feet.

Ongoing

Tractebel

Primary responsibilities included: • Layout of the infield flowlines and gas export pipeline route selection. • Flow assurance of the gas export pipeline and water injection flowlines. • Material selection for water injection and gas export systems. • Detailed mechanical design of the gas export pipeline and water injection flowlines including Flowline Termination Assemblies (FTAs) and Inline Tee Assemblies (ITAs). • Detailed mechanical and fatigue design of the gas export, water injection and production steel catenary risers. • Definition of fatigue test program for steel catenary risers. • Engineering Critical Assessment (ECA) for the steel catenary risers, including the effects of local internal cladding. • Preparation of procurement, fabrication and construction specifications. • Support of installation contractor’s procurement activities including preparation of a detailed Material Take Off, requisitions and technical bid reviews. INTECSEA scope includes FEED and detailed engineering of 8 flowlines connecting two TLPs in water depths of 920 feet and 1640 feet, respectively, and an 12 inch oil export flexible riser connecting to an FPSO in 320 feet of water depth. All flowlines and pipelines connect to a central processing platform in 203 feet of water. Activities include package engineering and procurement support. Work scope also includes construction and installation support.

Ongoing

Offshore East Coast USA

Northern Block G (Okume Complex) Offshore Equatorial Guinea, West Africa

Finish Date

ExxonMobil

Gulf of Mexico

Neptune

Project Description

Amerada Hess

Ongoing

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Project Name/Location Main Pass Oil Gathering (MPOG) System

Client

A 65 mile 18-inch/20-inch pipeline system that transports export quality oil from MP 225 to MP 69. Following Hurricane Ivan and Katrina, this line was inspected with side scan sonar. The 18-inch pipeline segment had moved laterally at various locations. INTECSEA was engaged to assess the pipelines integrity. Through reviewing the survey data and performing finite element analysis, INTECSEA provided engineering consultancy to BP to verify condition including external diving inspections, and performing caliper and intelligent pig inspections. In addition INTECSEA performed subsequent analysis to define remediation requirements and associated system inspection and response criteria.

2008

Petrobras

Multiple 20-inch pipelines and three PLEMs to export the production from deepwater fields through a marine terminal located in 100m water depth. Project included the detail design of the pipelines, PLEMs and construction specifications.

2007

W&T Offshore

Detailed design of one 6-inch subsea flowline in Mobile Bay, Alabama from platform in Block 824 to compressor platform in Block MB 823. Water depth approximately 50 feet.

2006

Oiltanking

Concept study for 36-inch pipeline for a deep water port approximately 25 miles offshore Freeport, Texas. Connected via an offshore and onshore pipeline to Bryan Mound. Included detailed cost estimate encompassing two SPM’s, the offshore pipeline and a shore approach. Overall responsibility for estimates relating to the offshore receiving platform, the onshore pipeline from Quintana Island to Bryan Mound, and the terminal (including tankage and pumping) at Bryan Mound.

2006

Atlantic Sea Island Group

Pipeline engineering to support an application for a license pursuant to the Deepwater Port Act of 1974, as amended (the DWPA), and the United States Coast Guard’s (USCG’s) January 6, 2004, Temporary Interim Rules. The proposed deepwater port, Safe Harbor, is to be located in the federal waters of the Outer Continental Shelf (OCS), approximately 13.5 miles due south of Long Beach, Long Island, and 23 miles east of the New York harbor entrance. The water depth at project site ranges from 61 ft to 73 ft.

2006

Abocol

Conceptual design, evaluation, and cost estimation for a proposed cryogenic ammonia export terminal in approximately 20 meters of water offshore Colombia. The terminal concepts considered were a sea island, a jetty, and a CALM buoy. Flow assurance evaluations made for both pipe-in-pipe and wet insulated pipeline

2006

Campos Basin - Brazil

Mobile Bay 824-1 Detailed Design

Gulf Harbor Deepwater Port Study

Safe Harbor Deepwater Port Pipeline Application Engineering

Ammonia Terminal Phase I Conceptual Design Study

Finish Date

BP

Gulf of Mexico

PRA-1 Marine Terminal

Project Description

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Project Name/Location

Client

Project Description

Finish Date

systems. Scope included capital costs, and operating costs of the evaluated systems, as well as recommendations for proceeding with front end engineering design for the project. Ambatovy Ammonia Pipeline

SNG / Lavilin

Concept Study

Concept Study for Ammonia Offloading Facilities in Madagascar. Study scope commenced with a shipside flange on the ammonia offloading hose, through an unloading buoy and marine pipeline, to the shore crossing and an onshore valve and flange. Concept work consisted of:

2006

• Screening level flow assurance analysis of the marine terminal system to determine line diameter and insulation requirements from ship to shore point battery limit • Analysis of feasibility of methods for construction of the subsea pipeline to transport cryogenic liquid ammonia from an offshore moored tanker to a shore based storage facility • Assessment of available concepts for a marine loading facility for import of cryogenic ammonia • Provision of a -30%/+50% cost estimate and overall project schedules for ammonia pipeline Algeria To Spain Gas Pipeline

MEDGAZ

MEDGAZ involves the construction of 200 km (124 miles) of dual 24-in. high-pressure Ultra-deepwater gas pipelines, in 2160 m of water designed to deliver as much as 16 billion m3/year of Algerian natural gas under the Mediterranean Sea to Spain and other European markets -from Beni Saf, Algeria, to a landfall at Playa del Charco, near Almeria, Spain.

2005

BP

The 8-inch Amberjack export pipeline a portion of the pipeline that exports gas from the Amberjack facility, was found during a survey in 4Q 2004 to have been displaced laterally in Mississippi Canyon Block 109. It was estimated that 800 feet of the 8-inch pipeline was displaced to the south by a maximum distance of approximately 120 feet. INTECSEA was engaged to assess the pipelines integrity through reviewing the survey data and performing finite element analysis.

2005

ExxonMobil

Two pipelines (one 10-inch and one 20-inch) were found to be suspended above the seabed due to erosion of a sand island under which the pipelines were installed using HDD (Horizontal Directional Drilling) method. INTECSEA reviewed the survey data on these pipelines, assessed the pipelines configuration and recommended a method of reburial. INTECSEA modeled the pipelines using finite element

2005

Offshore Algeria/Spain

Amberjack Gulf of Mexico

Mobile Bay 83-2 Pipelines Reburial Project Gulf of Mexico

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Client

Project Description

Finish Date

computer program. Remediation of the pipeline was successfully completed. Mafumeria

Chevron

Performed FEED engineering for the Cabinda Gulf Oil Company Limited (CABGOC) Mafumeira Norte Development. FEED design activities involved final routing of 12-inch production and water injection pipelines, wall thickness and on-bottom stability analysis, bottom roughness analysis, cathodic protection design, expansion analysis and pipeline crossing design. In addition INTECSEA prepared procurement packages for CABGOC and completed a Class 3 cost estimate for the Mafumeira Norte project, which was used for project sanction.

2005

ExxonMobil

Preliminary design of a typical 10-inch sour gas pipeline in 26 ft to 44 ft water depth in Mobile Bay. Pipeline length was 4 miles with an operating pressure of 3200 psig and operating temperature of 200 deg F. To prevent upheaval buckling of the pipeline, spiral expansion loops enclosed in a box was utilized. Performed the following: • Design of a bypass line that will connect 8-in and 10-in cold flowlines (hydrotested, filled with seawater) to one 12-in flowlines (in production). • Provide procurement assistance and installation planning assistance. Dual 16-inch HT pipeline for heavy oil, which is heated to export the oil from terminal to shuttle tanks. Project included HDD specification, pipeline and subsea tie-in system design and installation procedures.

2005

Design and installation support for an 18-inch diameter Heavy Fuel Oil (HFO) pipeline including the following:

2004

Offshore Cabinda, Angola

Mobile Bay 114 to 115 Gulf of Mexico

Yoho EPS Project

ExxonMobil

Offshore Angola

TNC Export Pipeline

Petrobras

Brazil

PE3

Petrobras

Offshore Brazil

Olowi Field Development Offshore Gabon, West Africa

Pioneer Resources Gabon-Olowi LTD

• Route Selection • System Thermo Hydraulics and Surge Analyses • Wall Thickness Optimization • Hydrodynamic Stability • Upheaval Buckling and Fatigue • Cathodic Protection • Mechanical Stress • Leak Detection • Route Selection • Facility Design and Tie-in Performed FEED engineering for three 4-inch insulated flowlines, two oil and one fuel gas, connecting PLEMs to an FSO in water depths from 95 feet to 120 feet. Installation, scope included a 6-inch HP gas, 6-inch water injection, 8-inch LP gas, 4-inch insulated oil and a power cable connecting two wellhead platforms in 95 feet to 120 feet water depth. Configuration studies

2005

2005

2004

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Client

Project Description

Finish Date

were performed to develop an optimum solution. An ITB document (including specifications and scope of work) was also prepared. Mobile Bay AB-BSB

ExxonMobil

Offshore Alabama, USA

Detailed Design Pipeline Engineering Services for Rasau New Pipeline from RSMN09 to RSMN04 Project

Brunei Shell Petroleum Co

Performed the detailed design that included routing, flow assurance, pipeline and riser design, cost estimates and schedule and constructability. INTECSEA also supported procurement of line pipe, coatings and prepared Bid packages for installation. The length of the pipeline is approximately 16,000 feet. • Preparing Design Basis Memorandum • Preliminary Engineering Report • Pipelines Routing • Flow Assurance and Hydraulics • Pipelines System Design • Fixed Riser design • Preliminary Cost Estimate and Schedule • Procurement Support • Bid Packages for installation Conceptual and Detailed Design for: • One new 8-inch LP pipeline from manifold RM09 to RM04 and across the Sungai Belait River. • One new 4-inch gas lift pipeline across the Sungai Belait River

2004

2004

Brunei F13W Shallow Clastic Drilling Riser (F13DWRA)

Sarawak Shell Berhad

Detailed Design of Shallow Clastic drilling riser, pig trap design, J tube design, submarine cable routing and crossing design.

2004

ExxonMobil Exploration and Production Malaysia Inc.

Detailed Design for the system consist of: • 6” GL to Guntong F pipeline and 12” FWS from Guntong F pipeline, • 6” GL to Irong Barat C (IBC) Pipeline and 12” FWS from IBC pipeline • 18” FWS from East Belumut A (EBA) to Pulai A Pipeline and 6” GL from Seligi E to EBA pipeline • 6” GL to Guntong G pipeline and 12” FWS from Guntong G pipeline The project includes the development of the following facilities:

2004

Offshore Sarawak Guntong F (GuF), Guntong G (GuG), Irong Barat C (IBC) and East Belumut A (EBA) Pipeline Systems Offshore Terengganu

Bergading Drilling Platform ‘A’ (BGDP-A), Flare Tripod (BGVP-A), Two Bridges And Pipelines Offshore Trengganu

Petronas Carigali Sdn Bhd

2003

• A central processing platform, BGCP-A; • A drilling platform, BGDP-A; • A condensate pipeline from BGDP-A • A gas pipeline from BGDP -A

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Project Name/Location Block 12 Development Project

Client Brunei Shell Petroleum Co

Offshore Brunei

PID 029 CHPS Pipeline Replacement Project

Brunei Shell Petroleum Co

Offshore Brunei

E11-Hub Project Offshore Sarawak, Malaysia

Melor, Laho, Tangga and Tangga Barat Field Development

Sarawak Shell Berhad


Offshore Terengganu

Angsi C and Angsi E Development Offshore Terengganu


Project Description Pipeline Detail design for: • 1 DN400 pipeline from AMDP-06 platform to AMRP04 platform • 1 DN500 pipeline from AMRP-04 platform to MPP12 platform • The associated riser (1no. of DN400) on the AMDP06 platform CHPS Pipeline Replacement Project pipeline and riser systems includes: • DN250 pipeline from AMRJ-02 platform to SAINTS, with the external anti-corrosion and concrete weight coats • The associated riser (1 no. of DN250) on the AMRJ02 platform • 1 shore approach at the SAINTS area including onshore pipeline Engineering Studies to develop the E8, F13 and Shallow Clastics gas fields to deliver gas to MLNGSatu. Under this E11-Hub project, the three new Satellite field developments will be tied into the E11 complex. The complex is connected by two 36-inch pipelines. Conceptual Design for the MLTTB and the field has 4 pipelines consisting of: • 1 gas pipeline connecting LHDP-A and MLDP-A of overall length approximately 16 km • 1 gas pipeline connecting MLDP-A and TBDR-A of overall length approximately 28 km • 1 gas pipeline connecting TGDP-A and TBDR-A of overall length approximately 9 km • 1 gas export pipeline connecting TBDR-A and Resak Drilling Platform A (RDP-A) of approximately 52 km long. Detailed design services for six separate pipeline systems consist of: • Two 10-inch FWS pipelines and associated risers from ANDP-C to ANDR-A and from ANDP-E to ANDR-A. • Two 10-inch Water Injection pipelines and associated risers from ANPG-A to ANDP-C and from ANPG-A to ANDP-E. • Two 6-inch Gaslift pipelines and associated risers from ANDR-A to ANDP-C and from ANDP-B to ANDP-E.

Finish Date 2003

2003

2003

2003

2002

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Project Name/Location Baram and Bokor Gas Handling Facilities Offshore Sarawak

Kinarut Development Offshore Sabah Sumandak (SMDK-A) Development Project Offshore Sabah BSP AMRJ-I and Tutlong Pipeline Offshore Brunei Esso Marine Terminal Pipeline System

Client

Offshore Malaysia

Finish Date

Conceptual Engineering and Design Services. The development involved review of five existing pipelines and re-evaluated when the new compression facility being implemented. The five pipelines are: • 10.75-inch gas pipeline from BOK-A to BNG-B • 18-inch gas pipeline from BNG-B to E11RA • 6.625-inch gas pipeline from BEP-A to BOP-A • 12.75-inch gas gathering pipeline from BADP-B to MCOT • 18-inch gas gathering pipeline from BADP-B to BNDP-B Detailed engineering design of the Kinarut gas pipeline and risers system includes one 16-inch gas pipeline system approximately 39km from KINDP-A to EWDP-A platform. Detailed design services for two pipeline systems: • 13km long 8-inch Gaslift pipeline from SMG-A to SUDP-A, including risers at each platform. • 10km long 16-inch FWS pipeline from SUDP-A to SMP-B, risers at each platform. 16-inch x 25 km long offshore pipeline from AMRJ-I Platform to shore, and a 14-inch x 14 km long pipeline with a subsea tap into a 16-inch pipeline.

2002

Esso Thailand

Four 12-inch and one 2-inch diameter pipelines and risers from an offshore tanker terminal to an onshore refinery.

1999

Esso Production Malaysia Inc.

12-inch diameter 10 km long production pipeline 10inch diameter x 6 km long water injection and 6-inch diameter x 6 km long gas life pipeline and risers between Tapis-E and Tapis-A and B Platforms.

1998


Petronas Carigali


Brunei Shell Petroleum Company

Sriracha, Thailand Tapis-E Field Pipeline Detailed Engineering Design

Project Description

2002

2002

1999

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Pipe-in-Pipe Systems The following table contains a summary of INTECSEA experience in PIP systems. Project Name/Location

Client

Project Description

Finish Date

Ammonia Terminal Phase I

Abocol

Conceptual design, evaluation, and cost estimation for a proposed cryogenic ammonia export terminal in approximately 20 meters of water offshore Colombia. The terminal concepts considered were a sea island, a jetty, and a CALM buoy. Flow assurance evaluations made for both pipe-in-pipe and wet insulated pipeline systems. Scope included capital costs, and operating costs of the evaluated systems, as well as recommendations for proceeding with front end engineering design for the project.

2006

Petrobras

Detailed design of a 13 mile long gas flowline to produce gas from a single well ESS-138, in the Canapu Field to the Golfinho platform. The Canapu Field is located north of the State of Espirito Santo, approximately 40 miles off the coast in a water depth of 1608 m. The produced fluids will be processed at the FPSO anchored in a depth of 1386 m and later transferred to land through an existing gas line. A pipe-in-pipe (PIP) flowline system was selected due to gas hydrate concerns.

2006

Conceptual Design Study

Canapu PIP Flowline Detailed Design

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Long Distance Transmission Pipeline Systems The following table contains a summary of INTECSEA experience in long distance pipeline projects. Project Name/Location Mexilhão Gas Production Pipelines Detailed Design

Client

Project Description

Finish Date

Petrobras

Dual 12-inch pipelines, 20km long each from the MSPG-MXL-01 Subsea Manifold in 500 m water depth to the PMXL-01 fixed platform in 170 m water depth. Project comprised detail design of the pipelines, including detail FEA Free Span Assessment.

Ongoing

Petrobras

34-inch pipeline, 130-km long. Project included pipeline and subsea tie-in design and bid package; 500 m water depth

2007

ExxonMobil

28” 440 km gas export pipeline from PNG to northern Australia – FEED

2006

12-inch gas export pipeline 67km long from Golfinho FPSO in 1200 water depth to Cacimbas Beach. Project included pipeline design and installation analysis for BGL-1 S-lay installation in shallow water depths.

2006

24-inch x 32 miles long offshore pipeline crossing the Long Island Sands to the Bronx area

2005

24-inch gas pipeline x 90 miles long from Bahamas LNG storage to Florida gas grid. Preliminary engineering, detail route survey and FERC application

2004

Santos Basin - Brazil

Mexilhão Gas Export Pipeline Santos Basin - Brazil PNG Pipeline Australia Golfinho Gas Export Pipeline

Petrobras

Espírito Santos Basin - Brazil

Eastchester Pipeline Extension Project New York, USA Ocean Express Pipeline Bahamas to Florida

Iroquois Gas Transmission Company AES Aurora

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Project Name/Location Marco Polo

Client

Project Description

Finish Date

GulfTerra

Performed the following for 72 mile long 18/20-inch diameter gas export pipeline in maximum 4400 ft of water:

2004

Gulf of Mexico

Conoco West Natuna Gas Project

Conoco, Inc.

Offshore Indonesia

MLNG-Tiga Pipeline Project Offshore Malaysia


•

Route selection

•

Geophysical/geotechnical survey support

•

Detailed design of SCRs

•

Detailed design of pipelines

•

Permitting:

•

Block and pipeline crossing agreements

•

MMS applications

•

In-line tees and PLEMs design interface and support

•

Design of the diverless tie-in jumper

• Installation support 28-inch x 600 km gas trunkline with smaller lateral pipelines connecting several production platforms to the trunkline via subsea manifolds. Pipelines design was based on limit state design approach. 22-inch x 109 km long gas pipeline from Helang Field to E11R-C Riser platform.

1998

1998

36-inch x 150 km long gas pipeline from Jintan Field to E11R-C Riser platform. 32-inch x 132 km long pipeline from E11RC Riser platform to onshore LNG plant at Bintulu, Sarawak.

Trans Caspian Pipeline Project Caspian Sea

Enron USA

Dual 28-inch x 300 km long gas pipelines crossing the Caspian Sea through 200m water depths from Turkmenistan to Azerbaijan.

1998

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Deepwater Pipeline Systems The following table contains a summary of INTECSEA experience in Deepwater Pipeline Projects. Project Name/Location Calypso

Client

Project Description

Finish Date

Suez

Conceptual design of a deepwater port which provides for the distribution of LNG stored onboard Transport Regasification Vessels (TRV). The Deepwater port’s dual unloading buoy system consists of two individual buoys each connected to riser manifold via a Steep-Wave configuration 16-inch ID flexible riser. The Riser Manifolds provide the interface, via 16-inch jumpers, to two in-line tees connected to the proposed FERC-Permitted 26-inch Calypso Pipeline. The Calypso Pipeline travels onshore at Port Everglades, Florida to the Fort Lauderdale Lateral connected to the Florida Gas Transmission Pipeline (FGT). Water depth 600-700 ft (200 m)

Ongoing

Murphy

Detailed design of two 12-inch export pipelines in the Gulf of Mexico’s Mississippi Canyon Block MC 734, in a depth of about 5710 ft. The two flowlines, each about 6 miles in length, will transport the separated oil and gas from Thunderhawk host facility to the BP Mardi Gras Transportation System, tying in at two subsea wye tie-in sleds.

Ongoing

Enbridge

Detailed design for the gas export SCR and pipeline lateral for the Shenzi development in the Gulf of Mexico. The Shenzi development is located in the Gulf of Mexico in approximately 4,300 ft water depth in Green Canyon blocks 609, 610, 653, 654 located approximately 120 miles offshore.

Ongoing

Offshore Florida

Thunderhawk Export Pipeline Engineering

Shenzi Gas Export Pipeline and Riser Detailed Design

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Project Name/Location Mardi Gras Deepwater Pipeline System

Client

Project Description

Finish Date

BP

Large diameter Oil and Gas export pipelines in water depth to 7,200 ft in the Gulf of Mexico. The areas developed include the Holstein, Mad Dog and Atlantis fields in Southern Green Canyon, which will transport oil through the Caesar Pipeline System and gas through the Cleopatra Gas Gathering System; and Thunder Horse in Mississippi Canyon, with the Proteus Oil System and Okeanos Gas Gathering System lateral.

2008

Gulf of Mexico

The export system consists of gas and oil steel catenary risers that are connected to host spars or semi-submersibles through flexjoints and which are connected together on the seabed through piggable wye sleds with associated jumpers. Congo River Pipeline Crossing PreFEED

Chevron

CABGOC, a subsidiary of Chevron, is planning an LNG plant on the coastline south of the Congo River estuary, West Africa. The Congo River Canyon Crossing Pipeline Project will transport gas production from Blocks 0 and 14 offshore Angola to the north of the canyon, to the new LNG facility. The project includes 20 and 22-inch pipelines on the continental shelf and a drilled well crossing beneath the canyon to link the pipeline on the northern shelf with that on the southern shelf. Water depths range from the shoreline to 1300 m. INTECSEA’s scope of work included conceptual and pre-FEED pipeline engineering, marine survey management and geohazard assessment. Average pipeline diameter 16 to 24-inch and average crossing width 5 km. Slide slopes 27º.

2008

Petrobras

Design of 2 x 12-inch oil export pipelines (one to P54 and the other to PRA-1) and 1 x 12-inch gas export pipeline. The lengths of the two longer pipelines were each about 40 km. The water depths ranged from 1800 m to 100 m.

2008

Chevron International Exploration and Production Company

Pre-FEED engineering to evaluate concept options for development of the Nsiko Field, located in block OPL 249, 142 km off the coast of Nigeria in approximately 1800 m of water. Preliminary pipeline route and engineering work was undertaken. The

2007

Offshore Angola

P55 Subsea System Campos Basin - Brazil

Nsiko Pipeline Pre-FEED Engineering

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Client

Project Description

Finish Date

base configuration for Nsiko consists of subsea wells feeding a floating facility with shipment of gas to Bonga SW/Aparo, an FPSO to be operated by Shell located 35 km from Nsiko, then on to the Offshore Gas Gathering System (OGGS) and oil exported to the Escravos Tank Farm infrastructure. Other configurations include oil shipment to Escravos (and other locations) via a pipeline and gas export to Escravos was also evaluated. This work also supported design basis of subsea, risers, host facility, export pipelines and other work groups. Process simulations of numerous potential options were evaluated to determine the best overall solution for the pipeline and facility configuration. Marlim Sul (P51) and Marlim Leste (P53) Export and Gathering Pipelines

Petrobras

Multiple 6 to 12-inch pipelines, ranging from 1100 to 1400 m water depth. Project considered a fast-track design of the pipeline systems. For P51: a 10.75-inch export gas line 10.4 km long, a 10.75-inch oil export line 13.5 km long, 3 x 8-inch oil production pipelines 7-km overall length and 3 x 6.625-inch gas lift line, 7-km long (overall length). For P53: 3 x 10.75-inch and 2 x 8.625-inch production lines with 19-km overall length and 5 x 6.625-inch gas lift line 19-km long.

2007

Petrobras

Detailed design of a 13 mile long gas flowline to produce gas from a single well ESS-138, in the Canapu Field to the Golfinho platform. The Canapu Field is located north of the State of Espirito Santo, approximately 40 miles off the coast in a water depth of 1608 m. The produced fluids will be processed at the FPSO anchored in a depth of 1386 m and later transferred to land through an existing gas line. A pipe-in-pipe (PIP) flowline system was selected due to gas hydrate concerns.

2006

Enbridge

Detailed design of a 20-inch oil and 12-inch gas export lateral pipeline for the transportation of production from the Atwater Valley Blocks 573, 574, 575, 617, and 618 located 120 miles offshore Louisiana, Gulf of Mexico (the “Neptune Field”). These export pipeline systems originated as steel catenary risers (SCR) from a host facility (mini-TLP) operated by BHP Billiton Petroleum at Green Canyon

2006

Campos Basin - Brazil

Canapu PIP Flowline Detailed Design

Neptune Oil and Gas Export Pipelines Detailed Design

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Client

Project Description

Finish Date

Block 613. The pipelines terminate approximately 23 miles away at pipeline end terminations (PLETs) in Green Canyon Block 650. The sled piping will be jumper-connected to the adjacent oil and gas wye sleds assemblies (WSA), W7 and W3 incorporated in the Mad Dog laterals of the Caesar Oil Pipeline and Cleopatra Gas Gathering Pipeline systems of the BP Mardi Gras Transportation System. Water depths range from 4200 ft to 6500 ft. (1500 m) Golfinho Gas Export Pipeline

Petrobras

12-inch gas export pipeline 67km long from Golfinho FPSO in 1200 water depth to Cacimbas Beach. Project included pipeline design and installation analysis for BGL-1 Slay installation in shallow water depths.

2006

MEDGAZ

MEDGAZ involves the construction of 200 km (124 miles) of dual 24-in. highpressure Ultra-deepwater gas pipelines in 2160 m of water designed to deliver as much as 16 billion m3/year of Algerian natural gas under the Mediterranean Sea to Spain and other European markets from Beni Saf, Algeria, to a landfall at Playa del Charco, near Almeria, Spain.

2005

GulfTerra

Performed the following for 72 mile long 18/20-inch diameter gas export pipeline in maximum 4400 ft of water:

2004

Espírito Santos Basin - Brazil

Algeria To Spain Gas Pipeline Offshore Algeria/Spain

Marco Polo Gulf of Mexico

Gorgon Subsea Field Development Offshore Western Australia

Texaco, Inc. and Mobil Oil Company

•

Route selection

•

Geophysical/geotechnical survey support

•

Detailed design of SCRs

•

Detailed design of pipelines

•

Permitting:

•

Block and pipeline crossing agreements

•

MMS applications

•

In-line tees and PLEMs design interface and support

•

Design of the diverless tie-in jumper

• Installation support Multi-well subsea manifolds, in field flowlines and large diameter trunkline to Barrow Island. Water depths from 100 m to 1100 m.

2004

17

Project Name/Location West Delta Deep Scarab/Saffron Field Development

Client

Deepwater Managing Contractor (DMC) for an 8-well subsea field development in 700 m water depth with dual 52-mile long pipelines to an onshore gas processing plant.

2004

TotalFinaElf

12-inch x 96 miles Gas production pipeline in maximum water depth of 7,250 ft, transversing through challenge terrain.

2003

BP (Vastar)

12-inch Oil and 10-inch Gas pipelines each approximately 42 miles long in maximum water depth of 5,600 ft.

2002

Gulf of Mexico Horn Mountain Export Pipelines Gulf of Mexico Front End Engineering

Finish Date

Burullus Gas Company

Offshore Egypt

Canyon Express

Project Description

IOGPT / ONGC

Design for Deepwater Field

• Perform a review and optimisation of the selected options.

2001

• Design exercise as a future “template” for similar deep-water fields. • State-of-the-science sub-sea technology shall be employed to alleviate the flow assurance problems associated with deep-water production

Diana Development Project Gulf of Mexico Blue Stream Pipeline Project Black Sea

Shell Bonga Gas Export Pipeline Offshore Nigeria

East Mississippi Canyon Project Gulf of Mexico Malampaya Pipeline Project Offshore Philippines

Exxon Mobil Development Company

Two 20-inch x 130-mile pipelines at 5000 ft water depth in the Gulf of Mexico.

2000

GazProm / PeterGas B.V.

2 x 24-inch x 300 km gas pipelines crossing the Eastern Black Sea between Djubga, Russia and Samsun, Turkey in water depth of 2,100 m. Seabed has high levels of H2S.

1999

Shell Deepwater Development Systems Inc.

16-inch x 91 km gas export pipeline from the Bonga FPSO with SCR in 1,000 m water depth to a shallow water riser platform.

1999

Shell Oil Company

Three 18-inch to 24-inch OD x 150-mile pipelines in a water depth of 7,500 ft in the Gulf of Mexico.

1998

Shell International Exploration and Production

2x16-inch CRA clad flowlines and a 24-inch 500 km long export pipeline across a 1,000m water depth region susceptible to mass gravity flows and seismic action.

1998

18

HPHT Experience INTECSEA’s primary emphasis has been on pipeline applications in frontier areas, notably deepwater and Arctic environments; and for unusual service conditions such as high pressure and high temperature, aggressive fluids and complex fluid rheology. These specialized technologies are firmly established within INTECSEA’s extensive project experience including practical design and installation technology required for cost effective completion and operation of marine pipeline facilities in all environments. In addition to deepwater pipeline applications, INTECSEA has also been responsible for many long distance, large diameter transmission pipeline projects and conventional offshore platform-to-platform pipeline projects. INTECSEA past and present projects include conventional pipelines, long distance and deepwater pipelines, high pressure/high temperature production flowlines, insulated production flowlines and offshore arctic pipelines. PROJECT NAME/LOCATION Blind Faith

CLIENT

PROJECT DESCRIPTION

FINISH DATE

Chevron

Concept screening and cost estimate, PreFEED and FEED of subsea tie-backs to various host options via PIP SCRs. Local host is in 7000 feet of water depth. FEED study evaluates SCR and hybrid riser options. The SCRs are very challenging with features such as high temperature, high pressure, Pipe-In-Pipe and sour service. SCRs with Lazy-wave tails were assessed to establish SCR feasibility. Based on the results of feasibility study, the appropriate riser concept will be selected and preliminary riser design performed.

Ongoing

Gulf of Mexico

T=300°F, P=1000bar Tubular Bells Conceptual Engineering Study

South Pars Phases 17 and 18

BP

IOEC (via the National Iranian Oil company)

Conceptual design study for flowlines associated with the Tubular Bells subsea system. The Tubular Bells field is located in Mississippi Canyon, Blocks 725 and 726 in approximately 4,500 ft water depth in the Gulf of Mexico. Some of the reservoirs in this conceptual study have pressures and temperatures above 21,000 psi and up to 340°F. These are termed Extra High Pressure High Temperature (XHPHT). Two 32inch wet sour gas pipelines, each with a 4inch piggy back service pipeline, are running from the platforms South Pars Deck (SPD) 23 and SPD 24 to the shore at Assaluyeh. The platforms are located approximately 100km away from the Iranian Southern Coast. Onshore, the pipelines

Ongoing

2008

19

PROJECT NAME/LOCATION

CLIENT

PROJECT DESCRIPTION

FINISH DATE

are routed to the facilities located approximately 4.5km inside Iran. The average length of the onshore and offshore pipelines equals 111km. Each 32inch pipeline is designed for a flow rate of 1000 MMSCFD and a maximum temperature of 90 degrees Celsius. The basic and detail design is partly performed by INTECSEA and partly by IOEC. Cavendish Area Development

R.W.E.

Southern North Sea

Cili Padi Lateral Buckling Design

Shell

FEED design for a high temperature (100°C), high pressure (385 bar) 6” Corrosion Resistant Alloy clad 45km flowline and 45km 10” gas export pipeline with associated 3” piggyback to BS:EN 14161. The pipeline was in 30m water depth and was located in the southern north sea in an environmentally sensitive area. In addition to the design of the pipelines, flow assurance was also performed. Technip Malaysia which was contracted by Shell SSB to perform the conceptual and detailed engineering for the required facilities for the Cili Padi Gas Field Development. Technip engaged INTECSEA to assist them to perform the conceptual and detailed engineering for the lateral buckling mitigation for the high pressure and high temperature 30km, 16” Cili Padi pipeline to F23R-A platform.

2007

2007

INTECSEA scope was divided into two phases, i.e., Conceptual and Detailed Engineering Phase. The conceptual phase scope covered the assessment of the potential risk associated with lateral buckling and preliminary assessment of the mitigation method to mitigate the risk. The detailed engineering phase the scope covered a detailed 3D Finite Element Analysis to verify the acceptability of the proposed mitigation method. To mitigate the risk associated with “unplanned” lateral buckles, measures involving the introduction of controlled buckle formation along the pipeline route using the “Bend on Trigger” concept developed by Shell. To meet the stringent acceptance criteria, performance of numerous finite element analyses to

20


CLIENT

PROJECT DESCRIPTION

FINISH DATE

assess the formation of intended and unintended buckles were carried out. The FEA work involves the detailed modeling of the soil–pipe interaction, planned and unplanned buckle behavior, trawl gear interaction and full route simulations including possible pipeline walking. Fatigue analysis was performed for the trigger sections. The results of the sensitivity analyses will then be used for the probabilistic assessment to demonstrate that the robustness of the developed buckling strategy for the Cili Padi pipeline system. The temperatures and pressures are as follows: Cili Padi: T=120 DegC P= 212 barg Pluto Deepwater Flowline Study

Woodside

Conceptual design and flowline routing study for dual insulated gas flowlines connecting a series of subsea manifolds to a shallow water platform located approximately 18 km east of the development in approximately 140 m minimum water depth and 1050 m maximum water depth. The flowline diameters being considered during this phase ranged from 12-inch to 20-inch. The objective of the study was to identify all the technical challenges that the project would need to manage for the flowline design that traversed a steep slope (local gradients as high as 45 deg) and transported high temperature, high pressure production to the shallow water platform.

2006

P= 6650 psi (458 barg) Rhum Field Development Offshore Aberdeen

Iranian Oil Company

The Rhum field is a high temperature, high pressure reservoir (705 bar and 130°C), corrosive (6.5% CO2 and 10ppm H2S) gas field development requiring exotic materials, long distance PIP systems and subsea High Integrity Pressure Protection System (HIPPS).

2005

21

PROJECT NAME/LOCATION Gyrfalcon Gulf of Mexico

Mobile Bay Flowlines

CLIENT

Total Offshore Production Systems (TOPS)

Exxon USA

Gulf of Mexico

PROJECT DESCRIPTION

The Gyrfalcon Project consists of a 2.7 mile, single well tie-back from an existing high pressure, deep gas well located in Green Canyon 20 in 885 ft of water. The Gyrfalcon Project includes the following industry firsts: •

First 15K subsea tree

•

First 15K chemical injection system

•

First 15K Super Duplex umbilical and first flexible flying leads rated 12,500 psi

• First 12.2K flexible riser (5-inch ID) Flowline systems for high pressure, high temperature sour gas using special corrosion resistant alloy materials and pipe-in-pipe insulated flowlines and risers.

FINISH DATE 2000

1999

T=300°F, P=750bar Mensa

Shell Offshore

This technically challenging Subsea project includes continuous choking at the wellheads and transporting gas at high pressure through a 12-inch flowline. The project is located in the GoM Mississippi Canyon area in 5400 ft of water depth. P=690bar

1999

22

Work performed by personnel now employed by INTECSEA:


CLIENT

Jade Field Development North Sea

Phillips

Erskine Replacement Pipeline North Sea

Texaco

PROJECT DESCRIPTION

FINISH DATE

Dr A. Walker and Mr P. Cooper were engineers responsible for Phillips UK supervising and assessing the 16/20” x 18km pipe-in-pipe design work by JPK and EMC, and the spool design work by APA. In addition, they undertook the review and verification of complete Jade pipeline design, the detailed verification of lateral buckling analysis performed by JPK and EMC. Pressure was 160 barg and temperature 160 C. Dr A. Walker and Mr P. Cooper performed the verification of the 16/24” x 30km PIP and provided specialist engineering including strain based analysis and design. Pressure was 118 barg and temperature 150 C.

2005

2000

23

Marine Pipeline System Engineering Services Conventional Pipeline Design Submarine pipeline design, preliminary and/or detailed, generally includes the following elements, the degree of detail depending on the project stage and level of information available at the time: f

Design Basis Document

f

Safety Schematic

f

Pipeline flow assurance and line sizing

f

Pipeline route selection

f

Geohazard Analysis

f

Pipeline Route Alignment Drawings

f

Stability analysis and determination of weight coating and/or trenching requirements

f

Determination of wall thickness and steel grade using traditional or limit state design criteria and associated mechanical design

f

Pipe spanning analysis and determination of pipe support requirements and design

f

Risk study considering other external influences and definition of remedial measures

f

Pipeline installation studies to verify alternative installation options, which can be maintained for cost competitiveness

f

Material Specifications

f

Construction Specifications

f

Design Report

f

Invitation to Bid (ITB) Documents

Long Distance and Deepwater Pipeline Design The design of long distance and deepwater pipelines encompasses most of the fundamentals of conventional pipeline design. However, several additional aspects warrant a thorough and rigorous level of engineering. These key aspects include flow assurance and operability, pipeline routing, material selections, installation methods and construction logistics. The design of long distance and deepwater pipelines require particular attention to flow assurance to ensure deliverability and to prevent or mitigate hydrates, paraffin and/or asphaltene 24

accumulation. Furthermore, the system design effort must consider the capabilities and requirements for all parts of the system throughout the entire service life. Pipeline routing is a major factor that can directly influence cost and feasibility of a pipeline project. For example, this may impact technical considerations such as excessive water depth or the presence of geohazards, or geopolitical reasons such as national boundaries. Furthermore, these factors generally become more pronounced when pipeline routes traverse continental slopes to the abyssal or deep ocean depths. INTECSEA’s diverse project experience has resulted in an unparalleled capability in the provision of survey and routing services for marine pipelines. In recent years this has included noticeable long distance pipeline projects such as Horn Mountain export pipelines, Mardi Gras export pipelines, Marco Polo export pipeline, Canyon Express export pipeline in the Gulf of Mexico, Malampaya export pipeline offshore Philippines, Blue Stream export pipelines across the Black Sea and the Oman to India export pipeline. Typically long distance pipelines utilize conventional installation methods. However, in recent years installation has become a critical factor as water depths have increased significantly (from 200 m to 2,000 m for the Blue Stream Project). Regardless of technical challenges, long distance and deepwater pipelines require careful advance planning to ensure that schedules can be achieved. As pipeline lengths and water depth increase, the demands on pipe mills and installation contractors to be able to manufacture and install pipelines to meet the technical challenges and project schedules also increase. INTECSEA has extensive experience in limit state design. INTECSEA performed a code review and compliance study for the DeepStar 3308 sub-committee for limit state design. Through a limit state design approach and by considering various uncertainties in an appropriate manner, a rational design of pipelines/flowlines can be established which is safe and effective in deepwater and for long distance pipelines. Cost savings due to reduced wall thickness and thereby reduced material cost can be very significant for large diameter, long distance and high-pressure pipelines/flowlines. INTECSEA personnel have an excellent understanding of the capabilities of existing pipe mills and installation vessels. This allows, at feasibility and conceptual stages, reliable schedules for project developments, to be produced, to identify overall project durations and critical activities. If necessary, market research is also performed to further identify and confirm critical schedule activities.

Production Flowline Design In 1987 INTECSEA completed a joint industry study for Insulated Marine Pipelines that led to a better understanding of the technology and economics of transporting viscous, waxy or high pour point fluids through marine pipelines. As a result INTECSEA was awarded the design engineering for the Petronas Carigali Dulang Insulated Pipeline System offshore Malaysia, which transports waxy crude to a floating storage and offloading (FSO) system. INTECSEA has also

25

designed and supervised the construction of numerous insulated flowlines including applications for hydrate prevention in special alloyed sour gas pipelines, and others for arctic applications to prevent permafrost degradation. INTECSEA staff is very familiar with numerous types of insulation materials such as syntactic PE, PE foam, rock wool and EPDM. INTECSEA has been involved with numerous high temperature and high pressure (HT/HP) field developments. Most notable, INTECSEA has performed conceptual through detailed design and provided construction management support for the Exxon Mobile Bay Sour Gas Pipeline Project from 1988 to 1999. The Mobile Bay Field contains high temperature, high pressure sour gas. The field has up to 10% H2S, a product temperature of 3000°F cooled to 2000°F for inlet to the flowlines and 6,500 to 11,000 psig operating pressures. There are several important issues related specifically to (HT/HP) field developments. These include thermal expansion control, pipeline/flowline buckling (lateral or upheaval), stress/strain localization, corrosion protection system, flowline and component material selection, and flow assurance. Many of these issues conversely interact; therefore, a clear understanding of the limitations, interaction and dependency is required to develop a system design process. While no system is alike, INTECSEA experience and understanding of the issues and solutions can provide a cost effective fast track design. INTECSEA has extensive expertise in the design of flowline systems for HP/HT applications including: f

Pipe-in-Pipe and Bundled Flowlines

f

Externally Insulated Flowlines

f

Flexible Pipe Flowlines

Pipe-in-Pipe and Bundled Flowlines Pipe-in-pipe (PIP) and bundled flowline construction methods have been the primary HT/HP pipeline design method. The PIP system mechanically connects one or more product inner or carrier pipes to an outer jacket pipe with structural bulkheads. The bulkheads transfer loads from the inner pipe(s) to the jacket pipe. While the inner pipe expands, the jacket pipe resists the expansion loads. Spacing and configuration of bulkheads (internal spacers and structural connections) are dependent upon the buckling potential of the inner pipe and ease of fabrication and installation. Benefits of a PIP or bundle system include: f

Significantly reduced expansion and the potential of lateral or upheaval buckling.

f

Reduced risk of wax and hydrate formation during shut down or low flow conditions.

f

More efficient cathodic protection system as anodes are designed for much reduced temperatures (often ambient temperature).

26

f

Enhanced flexural rigidity and increased unit weight leading to reduced trenching and burial requirements.

f

Where the retention of product temperature is important, PIP can allow the use of vacuum insulation and active heating by circulation of hot water.

Externally Insulated Flowlines Wet insulated flowline systems can be used instead of pipe-in-pipe or bundled flowline systems in some applications, depending on the flow assurance requirements. A wet insulated deepwater flowline consists of a single pipe coated externally with a multi-layer build-up of anti-corrosion and insulation materials. The insulation materials most commonly used in deepwater applications are syntactic polyurethane and polypropylene. The thermal performance of a wet insulated flowline is generally not as good as that of a pipe-in-pipe system, but it has a significantly lower cost. Wet insulated flowlines can be used to: f

Reduce the risk of wax and hydrate formation during shut down or low flow conditions.

f

Increase the cool-down time during a shut-down.

f

Meet the operational and process equipment requirements.

Flexible Pipe Flowlines Flexible pipe flowlines can be utilized to absorb expansion at the ends of a pipeline, or can be utilized for the entire flowline to absorb expansion and relieve axial stress. Flexible pipelines have an order of magnitude higher material cost particularly in short lengths. However, flexible flowlines can be installed by smaller vessels at a higher lay rate and lower day rate. The use of vessels such as diving support vessels (DSV) fitted with a hydraulic reel or dedicated reel lay vessels avoid the high cost of mobilizing conventional pipelay equipment. For short distance tie backs with relatively short field life, flexible pipe flowlines may be recovered and reused elsewhere providing economical and adaptable field development options. For such applications, flexible pipe flowlines may be the most economical solution.

Marine Risers Conventional Steel Pipe Risers INTECSEA has performed detailed designs for numerous conventional pipeline riser systems for Gulf of Mexico and Southeast Asia offshore platform applications. The key consideration for high temperature risers is pipeline expansion at the base of the riser and the resulting bending stresses in the riser. This can be accommodated by various methods including pipeline expansion loops and offsets, and also by cold springing risers during installation such that the pipeline expansion relieves the cold springing effects. 27

The general approach for riser design involves optimization of riser routing from the platform topsides tie in point to the pipeline tie in point on the seabed. Analyses include vortex-shedding analysis to determine maximum allowable riser span lengths at given elevations above the seabed; fatigue analysis to investigate the possibility of failure for the proposed span length and detailed stress analysis of the riser and pipeline offset. Stress analyses consider functional and environmental load conditions for operational and hydrotest conditions, and also for platform jacket deflections. Flexible Pipe Risers INTECSEA has been responsible for the design and installation of flexible pipe risers for various projects worldwide. Flexible risers are used with both fixed and floating production systems in shallow water developments, and with floating production facilities (TLPs and SPARs) in deepwater developments. For shallow water applications, flexible risers may be used in steep or lazy wave or steep or lazy S configurations. For deepwater applications, flexible risers are used primarily in a free hanging catenary configuration. The required physical characteristics of risers and buoyancy modules have to be established, and suitable locations for the riser bases relative to the surface vessel determined. Preliminary design includes optimization and confirmation of the proposed riser configuration through static analysis. More detailed static and dynamic analysis are then performed to optimize riser configurations under design environmental conditions considering motions and offsets of the surface vessel. The forces exerted on the riser base and the surface vessel by each riser are calculated and the tie in connection systems designed together with the bend stiffeners and restrictors at the upper and lower ends of each riser. Other design factors include maximum allowable tensile loads and bending stresses in the flexible pipe, maximum angular deviations at the top of the risers and avoidance of impact between the flexible pipe and the seabed or vessel mooring lines. Steel Catenary Risers INTECSEA has performed both preliminary and detailed designs for steel catenary riser (SCR) systems within the Gulf of Mexico and offshore West Africa. The use of SCRs is becoming more common for deep-water riser applications. For Mobil, INTECSEA has performed a general study for the use of 6-inch to 24-inch SCRs in water depths ranging from 1,500 ft to 6,000 ft. The design experience includes uninsulated, insulated and pipe-in-pipe SCRs. The major issues to be considered in the design of SCRs are pipeline stresses, fatigue analyses and end-fitting designs as noted below: f

Maximum Pipe Stresses: Maximum stresses in the riser normally occur either immediately below the top support point or in the sagbend of the catenary. The stresses are calculated considering catenary tension and pipe properties, hydrodynamic loads acting on the riser, extreme offsets and motions of the top support point and seabed soil conditions.

28

f

Fatigue Analysis: SCRs are exposed to potential sources of fatigue damage including vortex-induced vibration (VIV) due to steady currents, vessel offsets, wave-induced vessel motions, direct wave action on the suspended riser and low-cycle, high strain fatigue if the SCR is installed from a reel barge. The concern that has attracted most attention in recent years is fatigue due to VIV. Overall fatigue damage is normally most severe near the top of the SCR and just above the touchdown point on the seabed. Due to many uncertainties in the various fatigue analyses, a minimum safety factor of 10 is normally required.

f

Design of End Fittings: For SCRs suspended from floating vessels, the top support fitting is normally a flexjoint, which allows relatively high angular rotations between the top of the riser and the support structural connection. For SCRs suspended from fixed platforms, a carbon steel tapered stress joint will normally suffice.

Hybrid Risers There are many hybrid riser configurations such as compliant vertical access risers, hybrid riser towers, SCRs with submerged buoyant air can support and flexible jumpers to the surface, and tension leg riser systems. The tension leg riser configuration consists of a support buoy tethered to a piled foundation on the seabed with SCRs extending down from the buoy to riser bases on the seabed with flexible pipe jumpers from the near surface support buoy to the floating vessel. The hybrid riser tower concept design has been selected for the Girassol and Exxon Angola Block 15 (AB15) Projects to connect subsea wells to an FPSO. This design incorporates a vertical bundle of flowlines supported by a buoyant air can and connected to the FPSO by flexible pipe jumpers. Potential benefits of hybrid riser towers in deep water projects include: f

Hybrid riser arrangements are designed to permit onshore fabrication and installation of the riser tower by tow out and upending as a single unit.

f

High thermal performance to overcome wax and hydrate problems.

f

Highly compliant riser system, which decouples vessel, motions from riser motions.

f

Provides compact riser designs with minimal congestion on the seabed and in the water column.

f

Minimizes the loads transferred through riser porches when compared with other deepwater riser systems.

29

Pipeline Shore Crossing Design The shore crossing design for a pipeline system is a combination of site selection and design activities required to ensure pipeline stability and integrity while minimizing impact to environmentally sensitive areas and adjacent property or facilities. Several key activities include site selection, design basis definition, pipeline stability analyses, operational requirements and construction methods. A thorough and rigorous degree of engineering is often warranted in view of the potential for significant construction cost reduction and operational reliability of the pipeline system. INTECSEA technical expertise and involvement in a wide range of shore crossing designs provide the basis for implementing a cost effective design. Site Selection Site selection for a pipeline shore crossing includes the following considerations: f

Facility locations are considered to minimize overall pipeline length. Prevention of facilities damage to existing equipment and facilities, and use of in a common corridor, where possible.

f

Shore crossing sites are evaluated to minimize impact to the environment and shore crossing areas.

f

Various survey methods, which may be used independently or in conjunction with one another, include aerial, marine geophysical and diver or Remote Operated Vehicle (ROV) surveys.

Design Basis A complete and accurate design basis is critical to ensuring a cost-effective shore crossing design. Key parameters to be defined are listed below: f

Meteorological data is required to determine wind speed persistency and direction for use in subsequent design tasks.

f

Wave height, period and direction data are required. Wave refraction and shoaling analyses are performed to translate deepwater wave conditions into the shore crossing area. Aerial limits of the surf zone will be defined for installation, operation and survival conditions. Current speeds and directions are defined from current data and supplemented with wind-induced current analyses.

f

Geotechnical data are defined and the requirements for any additional soils data must be determined.

Pipeline Stability Pipeline stability analyses require the calculation of hydrodynamic loads acting on the pipeline for various shore crossing configurations. Hydrodynamic stability analyses are performed with 30

emphasis on shallow water pipelines and may include a limit state design approach in which the pipeline-soil interaction during pipeline movement and subsequent pipeline embedment is included. Optimization of concrete weight coating and discrete anchoring stabilization techniques versus trenching requirements must be performed. Pipeline stability analyses are required to ensure pipeline design; construction and installation processes are suitable for the anticipated environmental and operational conditions. Evaluation of near shore soil conditions, seasonal coastal processes and shoreline erosion/accretion processes are also often considered in the stability analyses.

Operational Requirements Operational aspects of the pipeline system, such as thermal and pressure expansion must be evaluated in the shore crossing design to ensure pipeline integrity. These aspects define the requirements for pipeline end anchoring or expansion loops, upheaval buckling prevention and pipeline settlement.

Construction Methods Candidate construction methods are evaluated to define the resultant trench cross sections. Dredging (hydraulic and conventional), directional drilling, drilling and blasting, mechanical trenching, jetting and plowing techniques are considered in conjunction with seabed soils data to determine method suitability. Shore crossing installation methods and equipment, including pipe pull, pipelay, directional drilling and/or a combination of the above methods, may be evaluated. Pipe weight, stiffness, pulling requirements, bathymetry and shore crossing length are considered for each installation method. In addition selection of the optimum construction method, the availability of the required construction equipment must also be considered. In some cases the preferred method may not be cost effective due to lack of availability and/or high mobilization costs. Vessel draft limitations in the shore approach may also limit the type of trenching/dredging and pipeline construction equipment, which can feasibly be used.

31

Project Resumes f

ExxonMobil Mica Flowline Project

f

Canyon Express Project

f

BP Mardi Gras Deepwater Transportation System

f

ChevronTexaco Blind Faith Field

f

Maoming Subsea Pipeline Integrity Check

f

Gazprom Blue Stream Pipeline Project

f

MEDGAZ Algeria to Spain Gas Pipeline

f

BGEPIL-NRPOD Tapti Expansion Project

f

Duke Energy Tasmania Natural Gas

f

ExxonMobil Blackback and Kingfish

f

ExxonMobil PNG Gas Pipeline

f

Kipper Development

f

Petronas MLNG Tiga Transmission Pipelines

f

Sarawak Shell BHD F23 Facilities & Pipeline

f

SPT-ExxonMobil Pesek Submarine Bundle

f

Woodside Blacktip Gas Project

32

Some of the alternative means of insulation that have been evaluated in the past include conventional external pipe insulation, and the use of burial (soil overburden) to extend cool down periods. In addition, INTECSEA has experience with vacuum insulated pipe systems. Additionally, INTECSEA is licensed to design heated pipeline and flowline systems covered by Shell patents. These have been successfully deployed in three separate fields in the Gulf of Mexico to date. Other studies completed by INTECSEA relevant to pipeline insulation include: f

Chevron Vacuum Insulated Pipe Study

f

Chevron Flowline Wax/Hydrate Mitigation Study

f

Chevron Insulated Offshore Pipeline Study

Pipeline Shore Approaches INTECSEA has extensive experience in the design and construction of pipeline shore approaches. Our design approach extends well beyond the basic mechanical design of the shore approach and includes geotechnical engineering and marine geology aspects as well. As a world leader in pipeline design and construction management, INTECSEA again has had the opportunity to showcase this experience on a number of challenging projects including the following partial list of INTECSEA projects for which shore approach studies, design and/or construction was a part: f

Medgaz Algeria to Spain Pipeline

f

Gazprom Bluestream Pipeline

f

Iroquois Eastchester Pipeline

f

Burrullus Scarab/Saffron Subsea Development

f

BP Northstar Pipeline

f

BP Amoco Liberty

f

AES Ocean Express Pipeline

f

Chevron Angola LNG

f

West Coast Energy Vancouver Island Pipeline

f

Exxon Angola Block 15

f

Shell Nigeria Gas Gathering Project

f

Shell Caspian Sea Pipeline

f

Oman to India Pipeline

33

f

Pectin Merluza Pipeline

f

Wapet Chrysaor Field Pipeline

f

Texaco/Mobil Gorgon

f

Petronas MLNG-TIGA Pipeline

f

Total Yadana Gas Pipeline

f

Enagas Bay of Cadiz Pipeline

f

Thirteen Various SPM/CBM Terminal Pipeline Shore Approaches Worldwide

f

Public Utilities Board’s Newater Submarine Pipeline/Cable Bundle

f

Total Sisi Nubi Field Development Project Phase 1

Advanced Analysis f

Finite Element Heat Condition Study

f

Top of Line Corrosion (TOLC) Study using OLGA

f

ABAQUS – Anchor Drop and Drag Analysis

34

Project Profile Project: Client: Location: Scope: Timeframe: Project Value: Phases:

SPT - ExxonMobil Pesek Submarine Bundle ExxonMobil/Foster-Wheeler Singapore FEED June 2006 - Ongoing US$ 6 million

1

2

3

4

5

Identify

Select

Define

Execute Operate

Project Description: Perform a FEED study of the proposed bundle, prepare a subcontract requisition package including bid evaluation and construction management. Proposed bundle: • 1 length of 8-inch 150# carbon steel pipeline for Heavy Aromatic

• • • •

1 length of 8-inch 300# carbon steel pipeline for Transplus Product 1 length of 8-inch 300# carbon steel pipeline for Lubes Feedstock/Resid 1 length of 4-inch 300# carbon steel pipeline for LPG vapor return 4 lengths of fibre optic cables

Key Achievement: Various design analysis and methodology were developed in the pipeline bundle design with the intention of ensuring a safe, feasible and installable bundle configuration.


F23 Facilities and Pipeline Rejuvenation Sarawak Shell Bhd Sarawak, Malaysia FEED, Detailed Design, Procurement, Construction Management April 2004 - April 2006 Contract Value - RM 14.7 million

1

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3

4

5

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Select

Define

Execute Operate

Project Description: The F23 gas production and processing complex is located 170 km offshore of the Malaysia LNG plant, Bintulu in 88 meter water depth and 45 km NNW of the E11 Complex. The gas and condensate from F23 is evacuated in a commingled flow to E11 via a 32” pipeline. F23 commenced production in 1983 and will now have to be operated beyond their original design service or operating lives until 2023. This facility together with E11 and F6 will have to be rejuvenated to ensure technical integrity and therefore, security of gas supply to MLNG plant until 2023. Scope of Services:

• • • • •

Detailed design services - project management, planning/scheduling, quality assurance, cost estimating, documentation and data control and material procurement and expediting services Preparation of as-built drawings and PDMS models Preparation of Technical Requisition Packages for procurement of long lead company supplied equipment packages Design follow up to include: VDI, final as-built documentation, design support during fabrication, offshore construction, installation, hook-up, commissioning and start-up Design of new living quarters

Key Achievements:

• •

Zero lost time injury performance Performed as-building of entire facility

Project Profile Project: Client: Location: Scope: Timeframe: Phases:

MLNG - Tiga Transmission Pipelines, Riser Platform and Onshore Slugcatcher Project Petronas Carigali Sdn Bhd Sarawak, Malaysia Conceptual Engineering/Pre-FEED/FEED/Detailed Design and Engineering 2002

1

2

3

4

5

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Select

Define

Execute Operate

Project Description: Conceptual, basic and detailed design and procurement services for the new MLNG Tiga offshore gas transmission scheme which included: Four pipelines (total length of 520 km) Riser platform and offshore tie-ins Onshore slugcatcher Condensate storage and metering facilities Fiscal metering 3 trains The hydrocarbon transportation scheme was devised to transport 1,400 MMSCFD (expandable to 1,900 MMSCFD) gas and 70,000 BPD condensates from the Jintan and Helang offshore fields to the third liquefaction plant (MLNG-TIGA) to be located in Bintulu, Sarawak.

Project Profile Project: Client: Location: Scope: Timeframe:

Phases:

BGEPIL - NRPOD Tapti Expansion Project BG Exploration and Production India Limited Hazira in the Gulf of Khambhat, West Coast of India Detailed Engineering, Riser Design, Tie-In and PLEM Design, ITT Packages

-

February 2006 - July 2007

1

2

3

4

5

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Select

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Project Description: The Panna, Mukta and Tapti (PMT) Joint Venture, plan to develop the Mid Tapti Field Gas reserves situated approximately 150 km southwest of Hazira in the Gulf of Khambhat, West Coast of India. The Mid Tapti Field reserves will be transported from a new minimum facilities wellhead platform (MTA) via a new 20” intrafield pipeline to a new production and compression platform (TCPP). At TCPP, the Mid Tapti production is commingled with South Tapti production, compressed and dehydrated before transportation, via a new 20” export pipeline and the existing 18” export pipeline, to the dual ONGC export trunklines. From there, the combined gas fluids are sent to the ONGC gas receiving facilities at Hazira for processing. Key Achievement: 20” infield pipeline piggybacked with 4.5” instrument air pipeline/tight schedule

Project Profile Project: Client: Location: Scope: Timeframe:

Maoming Subsea Pipeline Integrity Check Maoming King Ming Petroleum Co Ltd (MKMPCL) South China Sea A fitness-for-purpose assessment November 1994

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The Rhum field is a high temperature, hig pressure reservoir (705 bar and 130°C), corrosive (6.5% CO2 and 10ppm H2S) gas field development requiring exotic materials, long distance PIP systems and subsea High Integrity Pressure Protection System (HIPPS). The Rhum field is located 380 km northeast of Aberdeen in Block 3/29 in 109m water depth. The development includes a subsea tie-back to the Bruce field. First gas expected 2005. Rhum represents the first development in the North Sea for IOC (50%). It is being developed with co-venture and operator, BP (50%). SCOPE OF SERVICES: INTECSEA was given the task of FEED verification of the subsea system and topsides. Scope for FEED verification activities included:

• • • • • • • •

Subsea HIPPs system Materials selection/welding PIP system mechanical design Topsides modifications Subsea hardware Controls/umbilicals Construction schedule Costs associated with CAPEX/OPEX


Kipper Development Various Bass Strait, Australia Conceptual Engineering/Pre-FEED 1998 - 2005

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Project Description: Australia Worldwide Exploration (AWE), BHP, Esso, Shell, Gulf Resources Canada, News Corporation and Petroz are partners together in the undeveloped Kipper Field located in the Bass Strait. Kipper is a gas and oil field located about 45 km from the coast and 15 km from the Esso operated Tuna platform. Scope of Services:

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Installation of subsea wellheads High pressure subsea gas pipeline and umbilical line to shore HDD shore crossing Onshore gas processing complex Compression equipment for processing and export of gas Amine processing Standalone facilities Preliminary design of the preferred standalone option


PNG Gas Pipeline ExxonMobil Papua New Guinea FEED January 2005 - January 2007 TIC - US$ 3 billion / Contract Value - US$ 49 million

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Project Description: New field development in a remote area of PNG. Wellhead facilities feeding to a 23 km gathering system which supplies a local production facility. The production facility separates the gas and liquid for further piping 117 km to the new gas processing facility which produces sales gas, LPG and stabilized condensate streams. Sales gas is then exported via a new pipeline 191 km onshore to join an offshore pipeline for export to Australia. Scope of Services:

• •

FEED for total development, including processing plants, onshore pipelines, offshore pipeline, roads and infrastructure Management of PNG field survey programs

Key Achievements:

• •

Application of LIDAR in triple canopy rainforest to provide 1 meter contours along pipeline route. This required development of experience within the survey contractor and proved the capability of this methodology in a previously untried environment. Conducted PNG field survey program without recordable incident.


Blackback and Kingfish Fuel Gas Line - Offshore Installation ExxonMobil Bass Strait, Australia Owners Engineer 1998 - 1999 Contract Value - AU$ 0.1 million

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Project Description: The Blackback facilities comprised three subsea completions in a water depth of 402 meters, connected in a daisy chain formation and controlled from Mackerel platform 18 km away. A 200 mm pipeline inside a 300 mm diameter carrier pipe wsa laid between Mackerel platform and the Blackback facilities using the “Apache” reel-lay vessel in December 1998 to January 1999. The pipeline was wound onshore onto a reel in eight km lengths and then unreeled into position at sea. Scope of Services:

• • • • • •

Project management Preparation of pipeline licenses for government submission Preparation of Risk Assessment resolution sheets for close-out of offshore installation hazards Preparation of specifications and SOW for KFFG SSIVs Review of installation contractor’s installation manuals Esso representative and offshore supervision of the installation contractor

Key Achievements:

• • •

Diverless installation in over 400 meters of water Deepest installation to date in Bass Strait First time SSIVs have been installed in Bass Strait

Project Profile Project: Client: Location: Scope: Timeframe: Project Value:

Tasmania Natural Gas Pipeline - Offshore Section Duke Energy Bass Strait, Australia FEED, Procurement, Construction Management, Detailed Engineering

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1998 - 2002

TIC US$ 200 million / Contract Value - AU$ 5 million

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Project Description: Duke Energy constructed a 14-inch pipeline to transport gas from the Longford Gas Plant in Victoria across Bass Strait to Tasmania. In addition, a Tasmanian gas pipeline network was developed to supply industrial, commercial and residential customers. The offshore section of the Tasmania Natural Gas Pipeline (TNGP) runs for an approximate length of 300 km from Seaspray in Victoria to File Mile Bluff in Tasmania. Maximum water depth is 70 meters. Scope of Services:

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Preliminary engineering Pipeline sizing and routing Cost estimates Pipeline route selection and survey contract tendering Management of offshore route survey, geotechnical investigations and benthic surveys Offshore pipeline design (optimization of concrete coating thickness) Identification of shore crossing locations Engineering analysis of crossings Selection of tenderers for offshore installation Preparation of tender package and construction specifications Evaluation of tenders and assistance in contract award Ongoing engineering and construction management

Key Achievement: Longest subsea pipeline in Australia at the time.


MEDGAZ Algeria to Spain Gas Pipeline MEDGAZ Consortium Mediterranean Sea INTECSEA performed Front-end engineering design, pipeline design and preparing the EPIC (engineering, procurement, installation and commissioning) bid packages. July 2003 - February 2004 USD 615 thousand

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MEDGAZ involves the construction of 200 km (124 miles) of dual 24-in. high-pressure Ultradeepwater gas pipelines, designed to deliver as much as 16 billion m3/year of Algerian natural gas under the Mediterranean Sea to Spain and other European markets -from Beni Saf, Algeria, to a landfall at Playa del Charco, near Almeria, Spain. Almeria Landfall (Spain) Beni Saf Landfall (Algeria) The lines will include shore approaches and short onshore pipeline sections connecting onshore terminals at each end of the mainlines. The proposed pipeline will traverse a maximum water depth of 2,160 meters (7,087 feet). Initial deliveries expected 3Q 2006. SCOPE OF SERVICES:

• • •

INTECSEA performed Front-end engineering design, pipeline design and preparing the EPIC (engineering, procurement, installation and commissioning) bid packages for the project’s completion over a period of six months Relevant issues include geo-hazards associated with steep continental shelf margins and the bio-diverse coastal areas of Spain and Algeria, both of which cater to fishing and tourism industries Novel approaches to mechanical design are being considered, based on historical INTECSEA collapse testing data

The FEED was completed February 2004.


Gazprom Blue Stream Pipeline Project Gazprom and PeterGaz B.V., a wholly owned subsidiary of Gazprom Black Sea Feasibility Study and FEED January 1999 - November 2002

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The Blue Stream Pipeline Project is a gas transportation system for delivery of processed gas from the gas grid in Southern Russia, across the Black Sea to Ankara, Turkey. The Blue Stream Project includes two 24-inch offshore pipelines, which traverse a route from Djubga, Russia to a landfall east of Samsun, Turkey. The pipelines are approximately 390 kilometers long and were installed in water depths to 2,150 meters. SCOPE OF SERVICES: INTECSEA was responsible for the feasibility study and the detailed engineering of the pipeline system. This included:

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Route selection, bathymetric, geophysical, geotechnical and seismic surveys Geo-hazard, on-slope stability and pipeline integrity assessments Bottom roughness and span assessments Materials testing including lab and field crack susceptibility, anode and coating tests, for the sour environment of the Black Sea Cathodic protection and coating design Line pipe specification Full-scale collapse testing including buckle propagation and the effects of thermal aging Probabilistic and deterministic wall thickness and buckle arrestor designs Hydraulic analysis and hydrate mitigation Risk analysis for design, construction and operational phases of the project Operations and maintenance studies

Gas delivery via the Blue Stream started late 2002.

Project Profile Project: Client: Location: Scope:

Timeframe: Project Value: Phases:

Chevron Blind Faith Field Development Chevron Blind Faith Field, Gulf of Mexico INTECSEA assisted Chevron in evaluating field development options and supported their steps through the concept selection process, FEED and detailed design. March 2004 - Ongoing USD 1.9 million

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Chevron’s Blind Faith field is located in Mississippi Canyon Block 696 at a water depth of approximately 7,000 ft. Blind Faith is an oil system with a high pressure reservoir (approximately 12,500 psi WHSITP) and the potential of high temperatures at the wellhead in excess of 250° F. The high pressure and high temperature production in 7,000 ft water depth make Blind Faith a technically challenging project. In fact, these parameters put design requirements at the leading edge of industry supplier capability. SCOPE OF SERVICES: INTECSEA assisted Chevron in evaluating field development options and supported their steps through the concept selection process. Following concept selection, INTECSEA worked as part of Chevron’s FEED Team to develop the technical requirements for the Blind Faith subsea system. INTECSEA provided support as part of the Client Team managing detailed design and construction. INTECSEA provided: • In pre-concept, a detailed cost estimate

• • •

In concept selection, identification of viable field development options, development of these options for evaluation, detailed cost estimates for each option, evaluation of the options and selection support to be carried into FEED During FEED, INTECSEA developed functional and technical requirements for the subsea systems and provided bid support during bid evaluations In the execution phase, INTECSEA is providing technical support, procurement management, and construction oversight

INTECSEA’s scope of work includes all subsea systems: trees, manifolds, controls, umbilicals, jumpers, PLETs, flowlines and risers. INTECSEA provided support for evaluation of hull structure studies and flow assurance and evaluated some key technologies being considered for the Blind Faith Field Development. Studies were performed for: • Artificial lift

• • • • •

Subsea multiphase pumps Subsea multiphase flowmeters High Integrety Pipeline Protection Systems (HIPPS) Electrical flowline heating Subsea distribution for chemical injection


Canyon Express Project TotalFina Elf in partnership with BP and Marathon Oil Aconcagua, King’s Peak, and Camden Hills Fields, Gulf of Mexico FEED and Project Execution for the complete subsea development. Preparation and evaluation of ITB packages for all subsea equipment and installation, etc. December 1999 - December 2001 USD 9 million

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The Canyon Express Project is a first-of-a-kind industry initiative to jointly develop three area gas fields in the Gulf of Mexico, operated by different companies through a common production gathering system. The three separate fields include Aconcagua in Mississippi Canyon 305 operated by TotalFina Elf, King’s Peak in Desoto Canyon 177 and 133, and Mississippi Canyon 173 and 217 operated by BP, and Camden Hills in Mississippi Canyon 348 operated by Marathon Oil. Peak gas production from the three fields will be approximately 500 MMSCFD. A gathering system consisting of dual 12-inch pipelines will transport the gas from the three fields approximately 55 miles to Williams Canyon Station Platform located in Main Pass 261. The deepest portion of the Canyon Express pipeline system is in the Camden Hills area where the water depth is approximately 7,250 ft. Water depth at the Canyon Station Platform is 299 ft. The Canyon Express Pipeline System must be able to produce the three fields under different operating regimes and varying production rates from multiple zone completions without any field taking on the performance risk of another field. Accurate flow allocation is therefore essential, which resulted in the use of subsea multiphase flow meters on each of the subsea wells. Multiple well manifolds and infield flowlines have been eliminated through the use of inline well tie-in sleds installed as part of the flowlines. These inline tie-in sleds have been designed to accommodate individual subsea wells. As a result, flowline routing is dictated in large part by the location of the subsea wells. Wells are connected to the flowline tie-in sleds using conventional inverted ‘U’ shaped jumpers. SCOPE OF SERVICES: • FEED for the complete subsea development including: - Flow Assurance and Systems Engineering and Subsea Equipment Specifications - Flowline Design and Routing - Steel Catenary Risers at the Virgo Platform - Subsea Well Tie-in Jumpers - Subsea Control System, Umbilicals, and Multiphase Flow Meters - Intervention/Workover Control System • Project execution support through installation of start-up • Preparation and evaluation of ITB packages for all subsea equipment and installation • Review of design and installation engineering • QC services and management of offshore surveys • Equipment qualification • Procurement, expediting, SIT/EFAT, construction management, operator training and rig modification support • O&M, IMR and intervention manuals • Post installation start-up and operations support • O&M, IMR and Intervention Manuals


BP Mardi Gras Deepwater Transportation System BP Exploration Holstein, Mad Dog, and Atlantis Fields, Gulf of Mexico INTECSEA is responsible for the Design Engineering, Procurement and Project Management Services, Preliminary Engineering, etc. August 2001 - July 2008 USD 64.4 million

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In May of 2000, BP awarded INTECSEA a contract for the provision of Design Engineering, Procurement and Project Management support services for deepwater pipelines, steel catenary risers (SCRs), piggable wye sleds and associated jumper systems, for BP’s Gulf of Mexico deepwater developments. BP was developing the Mardi Gras Transportation System (MGTS), which is a system of large diameter pipelines that will transport gas and oil from its deepwater fields to shore. The areas being developed included the Holstein, Mad Dog and Atlantis fields in Southern Green Canyon, which will transport oil through the Caesar Pipeline System and gas through the Cleopatra Gas Gathering System; and Thunder Horse in Mississippi Canyon, with the Proteus Oil System and Okeanos Gas Gathering System lateral. The export system consists of gas and oil steel catenary risers that are connected to host spars or semi-submersibles through flexjoints, which are connected together on the seabed through piggable wye sleds with associated jumpers. Water depths range from 4,300 to over 7,000 ft in deepwater sections and as shallow as 400 ft at the conventional platforms. Pipeline diameters and associated jumpers, connectors, valves and piggable wyes range from 16 to 28 inches. Total pipeline length is approximately 330 miles. Scheduled completion is 2005. Scope of Services: INTECSEA is responsible for the Design Engineering, Procurement and Project Management Services through Conceptual Engineering (EVALUATE), Preliminary Engineering (DEFINE), and Detailed Engineering and Construction Support (EXECUTE).


ExxonMobil Mica Flowline Project ExxonMobil Development Company Mississippi Canyon Block 211, Gulf of Mexico INTECSEA scope of work included preliminary and detailed engineering design of the production flowlines and associated risers. -

August 1999 - October 2002

USD 610 thousand

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The Mica Field is located in Mississippi Canyon Block 211 in the Gulf of Mexico, approximately 100 miles south of Mobile Bay, Alabama in a water depth of 4,350 ft. Two 28 mile long production flowlines (an 8-inch x 12-inch pipe-in-pipe insulated flowline and an 8inch uninsulated flowline) will transport hydrocarbons from a subsea manifold to the BP Amoco Pompano Platform in Viosca Knoll Block 989. The Pompano Platform is located in a water depth of 1,300 ft. The two flowlines terminate at the top of a single existing Jtube on the Pompano Platform, and are linked via a pigging loop at the subsea manifold to enable round trip pigging operations. SCOPE OF SERVICES: INTECSEA scope of work included preliminary and detailed engineering design of the production flowlines and associated risers. INTECSEA’s scope begins at the Mica Field with the bulkheads on the laydown PLEMs, and ends at the Pompano Platform at the top of the Jtube. Design tasks included: Project specifications and drawings

• • • • • • • • • • • • • • •

Material grade selection and wall thickness design Cathodic protection design On-bottom stability analysis Allowable span lengths due to vortex-induced vibration Bottom roughness analysis Flowline expansion analysis Pipeline End Manifold (PLEM) embedment assessment J-Tube pull load analysis Buckle arrestor sizing and design Pipe-in-pipe intermediate bulkhead design Pipe-in-pipe flowline to riser termination Bulkhead design Flowline to PLEM termination bulkhead design Follow-on procurement and construction support

Construction was complete 4th Quarter 2000.


Blacktip Gas Project Woodside Energy Limited Joseph Bonaparte Gulf, Northern Territory, Australia FEED May 2004 - July 2005 TIC - US$ 150 million / Contract Value - US$ 8 million

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Project Description: FEED for the development of a remotely operated wellhead platform (fixed steel jacket structure), a 110 km subsea pipeline and an onshore processing plant (1 x 100% process train, located near Wadeye) The facilities were designed to deliver sales quality gas to the Trans Territory Pipeline (TTP) at a Daily Contractual Quality (DCQ) of 192 MMSCFD (70 PJ/annum). Key Achievements:

• • • • • •

Successfully completed FEED and preliminary detailed design for initial construction activities within budget and in accordance with all project requirements Critical review of concept selection and subsequent process reconfiguration yielded projected savings against the CAPEX of $6.2 million Achieved design reliability of >97.5% necessary for the potentially unmanned onshore facilities Awareness of cultural differences with traditional owners in providing a design solution Client formally acknowledged the “enthusiasm and professionalism of the project team contributing to a successful outcome” Zero lost time performance

Project Management WorleyParsons maintains a comprehensive suite of tools to manage projects at the highest level around the world. WorleyParsons employs a consistent, proven suite of group-wide processes, systems and tools supported by functional managers (Business Process Owners, or BPOs) and Business Systems Groups (developers, trainers, start-up support, help desk, commercial agreements, etc) scalable for any size project. Enterprise Management System (EMS) web enabled repository of policies, directives, standard workflows, procedures, guidelines, forms, and checklists content controlled by BPOs EMS is easily accessible in any of our offices and is company standard enabling the more than 30,000 staff in 110 offices to share work on a common platform. The supporting systems are tailored to apply in each of the following stages of a project: Identify, Select, Define, Execute, and Operate.

WorleyParsons Project Management Process (WPMP) is our scalable, risk based framework for project execution – some content mandatory, most is advisory. The main principles of WorleyParsons Management Processes are: f

It is s a matrix of mandatory or potential tasks applicable for each project phase. Mandatory tasks kept to a minimum

f

Project Value Objectives are clearly documented, and Maximum Value identified and realized

f

Decision support package requirements are fundamental to what is planned for and delivered in each phase

f

Value Improving Practices (VIPs) are used as appropriate

f

Each of the tasks is summarized in an overview task sheet, supported as required by: –

Procedures

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Corporate Guidelines

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Template Project Plans

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Go-Bys

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The system includes prompts and go-bys easily available for each phase of the work, illustrated by the following examples for Select Phase projects:

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InControl InControl is our CTR based project cost and resources control tool - for small or large projects. It is WorleyParsons proprietary, but interfaces with third party applications plus selected third party applications under global agreements – Intergraph (PDS, Marian and SmartPlant Foundation), Primavera, Oracle, Quest, etc. Other supporting systems include: f

Primavera Project P3 –

f

Cost Management System (CMS) –

f

f

Estimating cost and schedule impact due to project changes

Scorecard –

f

Project planning and control

Engineering progress measurement and productivity

Project Portal (EDMS) –

Secure, web-based, integrates closely with Microsoft Office 2003

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Data, schedules, and documents can be accessed from a central location by project teams, clients and vendors worldwide

Encompass® –

Total project management information tool

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Up-to-date and accurate information not only in the home office, but at the job site and at select partner or customers sites as well

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Information can be shared worldwide by project teams

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Interface Management is one of the most critical management practices that must be performed to an excellence-in-execution result. Interface Management is core-defined as eliminating "the gaps and the overlaps.” In principle, Interface Management is clearly recognized by INTECSEA as a key active component of our Project Execution Plan. The key is to recognize what information is required at what time by whom and where and to handle the constant flow of information, decisions, and requirements between all the stakeholders in the project. To this effect a common interface management process needs to be established among all parties; this requires that the interface management process is clearly identified as a contractual obligation between all parties. There are multiple levels of information exchange: Internal: f

Between individual disciplines within Client team

f

Between Client team and contractors,

External: f

Between the internal groups within the contractor

f

Between vendors, subcontractors, and 3rd parties and the main Contractor

Based on the experiences gained by INTECSEA, a methodology has been developed that suits most projects and applies to both internal and external interface management. The purpose of the IMS will be to maintain lines of communication between different stakeholders and Contractor(s) and, ensuring that technical details are consistent, schedule delivery dates are achieved and costs are kept within an agreed budget, as well as providing early warning to interfacing conflicts and tracking the effects of change.

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The objectives of our Interface Management process are to: f

f

f

Define the Information Exchange Requirements throughout all Phases of a Project –

General Project Information

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Equipment Interfaces

Information Required by Who and When –

Project Schedule and Milestones

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Deliverables

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Contractor Workscopes

Monitor the Exchange of Information –

Take Corrective Action through an Early Warning System

Excellent communication is of course an essential ingredient, but it needs to be accomplished in a systematic way to ensure interfaces are handled most effectively. Typically managing, coordinating and resolving interfaces are the role of an Interface Manager who reports directly to the Project Manager. His role is to systematically track the information exchange and its impact on progress. INTECSEA’s Interface Management Process is a proven system tool to support the tracking, management, and effectiveness of the exchange of important project information. Our IM system provides the following reports: f

General Interface Information Reporting (general interface physical properties)

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Interface Schedule Information Reporting (inter-related activities associated with search)

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Interface Clarification Register (listing issues, date raised, due date, resolution)

f

Change Report (documenting the changes and the responsible parties)

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Document and Drawing Register (listing project and ‘shadow’ document status)

INTECSEA personnel have been responsible for interfaces on a number of recent projects, such as the ChevronTexaco Agbami project. This major undertaking requires the management of over 85,000 interfaces between disciplines and contracts. The system was established during the FEED phase to coordinate the design effort and will continue throughout project execution phase to support management of the vendors and contractors.

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The INTECSEA Interface Management System (IMS) General interface information is organized on three working levels with increasing detail. It reports general interface physical properties for attributes, components and tasks. The system links with the project scheduling tools to identify impacts and monitor status. The Interface Clarification Register lists issues, dates raised and due, resolution, responsible party and resolution team. The change report documents changes to interfaces, tasks and milestones. The Document and Drawing Register lists current document and "shadow" document status. A graphical interface, an example of which is shown in Figure 1 below, enables ease in finding related interfaces and facilitates coordination among the project participants.

INTECSEA IMS Concept Presentation

Figure 1: Graphical Interface on Typical Multi-Faceted Development

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Effective interface management is key to the successful delivery of FEED and Detailed design. An Interface Management System (IMS) will be established during the FEED phase to identify and define design and disciplines interfaces and then continue through project execution to coordinate multiple contracts and suppliers. The purpose of the IMS will be to maintain lines of communication between different disciplines, groups, companies, and contractors to ensure that technical details are consistent, schedule delivery dates are achieved, and costs are kept within an agreed budget, as well as providing early warning to interface issues and a mechanism for resolving. Interfaces are either internal (within a defined component, assembly, or work scope) or external (between components, assemblies, work scopes, or organizations). As the project advances into the FEED, detail design, and execution phases, the management of external interfaces becomes more important and complex. INTECSEA has developed an Interface Management System (IMS) methodology consisting of procedures, work processes and computer tools. The model is applicable to both internal and external project interfaces and can be adapted to suit any size or type of single or multi-faceted project. The Interface Management System (IMS) was developed by INTECSEA and incorporates the necessary procedures, work processes and computer tools to aid in the management of project interfaces. INTECSEA is currently providing complete interface management of ChevronTexaco’s Agbami project, a major project including an FPSO, subsea, flowlines and offloading. Initially, the system was applied to the substantial engineering tasks and will continue into management of the multiple EPC contract elements of the project. The Interface Management Tool (IM Tool) is a robust database application accessible worldwide though the intranet. It stores and manages project interface information as well as interface links and key dates. Parties receive notifications of interface queries and actions by email, and can use the web interface to respond. INTECSEA will offer Client the Interface Management System (IMS) modified to suit the particular needs of the project, including both internal and external interface management, and with suitably experienced engineers. The full IMS package will ensure that interface issues are identified and discussed between all affected parties. The IMS will control the following aspect of the project: f

Contractual responsibilities and requirements

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Engineering tasks and activities

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Design reports issue and revision dates

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Interface physical properties

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Project milestones

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f

Procurement

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Construction

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Installation and commissioning

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Operation and Maintenance

Interface Management Process The Interface Management Process ensures effective management of functional, physical, schedule and cost interfaces within the project. The Interface Management System will be the basis for all parties to communicate on interface issues to ensure that interface issues are identified and discussed between all affected parties and to develop agreed mechanisms, responsibilities, and completion dates for resolution of issues. The Interface Management Process for the project will be periodically updated to account for revisions to the working process accounting for CLIENT requirements. Figure 2 below, shows the key elements in the IMS Work Process.

INTECSEA IMS Work Process

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Figure 2: IMS Work Process Flow Integration management will be a key element in ensuring the successful outcome of the project and will avoid costly delays during fabrication, hook-up, installation and commissioning activities. The Interface Manager will be responsible for the following: f

Chair regularly scheduled project-wide Interface Meetings. Chair and/or attend other meetings as required and appropriate.

f

Ensure that technical interfaces (both functional and physical) and contractual interfaces (cost and schedule) within its own scope of supply and between itself and other relevant parties are identified, recorded, understood, agreed upon by all parties, and reported to the IMS.

f

Review Client and Contractor interface documentation to ensure that appropriate responsible parties have been informed of and have been provided input to interface issues and that issues have been properly identified, resolved, and documented.

f

Review all Change Requests and significant non-conformance reports and dispositions to assure that interface issues are appropriately identified and resolved.

f

Maintain an Interface Register and Interface Database.

f

Identify and report progress, concerns and actions to resolve problems and any impact to other areas of the development.

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Manage the resolution and timely closeout of relevant interface issues.

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Provide relevant information or data to those groups within the Client, own organization and other contracting parties, which may have need of, or be impacted by, the subject information.

f

Coordinate review and approval for all procedures, data, instructions, drawings, etc. at relevant work interfaces.

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Coordinate review and approval of Change Requests to ensure that interface issues are recognized and addressed.

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Coordinate review and approval of all significant non-conformance reports and dispositions to ensure that interface issues are recognized and addressed.

f

Communicate (via appropriate documentation) issues and resolutions to all affected parties.

f

Inform the Client and INTECSEA IMS Team of all inter-organization interface meetings at the time they are organized. Client and INTECSEA may attend these meetings as necessary or appropriate.

Each of the managed (EPC) contractors will be made responsible for implementing an interface management system within its own organization and shall participate in operation of the PMT Interface Management System. Each managed contractor will appoint an Interface Coordinator who will coordinate

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issue resolution activities within their organization and will communicate these resolutions to the PMT Interface Manager. The Interface Coordinator shall be a single-point-of-contact on the managed contractor’s interface issues. Each contractor shall establish within its own organization an interface management system to: f

Ensure that technical interfaces (both functional and physical) and contractual interfaces (cost and schedule) within its own scope of supply and between itself and other relevant parties are identified, recorded, understood, agreed upon by all parties, and reported to the IMS.

f

Manage the resolution and timely closeout of relevant interface issues.

f

Provide relevant information or data to those groups within the contractor’s own organization, which may have need of, or be impacted by, the subject information.

f

Provide relevant information or data to other contracting parties and to the IMS, which may have need of, or be impacted by, the subject information.

f

Coordinate review and approval for all procedures, data, instructions, drawings, etc. at relevant work interfaces.

f

Coordinate review and approval of Change Requests to ensure that interface issues are recognized and addressed.

f

Coordinate review and approval of all significant non-conformance reports and dispositions to ensure that interface issues are recognized and addressed.

Reporting Following resolution of an interface issue, the resolving party will provide appropriate documents, including Change Request and significant non-conformance review and actions, to the affected parties and to the Interface Manager for the record. The Interface Manager will record all agreements and actions in a suitable form and other appropriate documentation, as required. Systems Interface information shown in the form(s) will also be tracked in a database to provide ready access to the data developed. A sample of typical IMS report is shown below.

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IMS Tool The INTECSEA IMS is a Web based application, accessible from all project locations through the Internet. The interface database resides on INTECSEA’s server in Houston, where the program is maintained periodically updated when new features become available. The application will provide: f

WEB based Interface Management System for remote job site access and secure access from anywhere in the world;

f

Unbiased procedures to formally assess, resolve and document interface issues and conflicts;

f

IMS Team defined Fabricator(s), Contractor(s) and Sub-contractor(s) access rights;

f

A high level Graphic User Interface (GUI) for quick location of project interfaces;

f

Early warning of interface clashes, reduced schedule float, and notification of change;

f

Reporting of schedule and cost issues;

f

“Traffic Light” status to clearly present interface, management and contract issues;

f

General data, e.g. interface liaison personnel details, interface matrices etc.;

f

Single item data entry by each user to a “Virtual Database”;

f

Mass data file upload via IMS tools using industry standard application files (e.g. Excel, Primavera, MS Project, etc.); and

f

Adaptable search tools for database Interrogation and Reporting.

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Capabilities Offshore Pipelines

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