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Project Experience: Floating Production, Storage, and Offloading Systems
INTEC has provided Floating Production Systems and project management services for numerous clients and many worldwide field developments. In the area of Floating Production Systems, INTEC provides services ranging from field development planning to total project implementation. These services include concept evaluations, concept designs, cost analysis, system selection, preliminary design, front end engineering design (FEED), preparation of bid documents, bid evaluation, project and construction management. Project responsibilities also include FPS installation and commissioning. INTEC has experience with all types of floating production system projects including:
- New Build FPSO/FSO Systems
- Tanker-Based FPSO/FSO Conversions
- Tension Leg Platforms (TLP)
- SPAR Type Surface Support Structures
- Semi-Submersible FPS Conversions
INTEC's knowledge in all aspects of Floating Production Systems and the various interfaces between the vessel hull, production process equipment, mooring and riser systems, and offloading systems allow INTEC to design a floating production system from an overall systems level. INTEC defines the overall system during concept development and (FEED) followed by functional specifications for major system components within the framework of the total field development. For most projects, FPS contractors and shipyards perform the detailed design of the major components, and INTEC reviews the detailed design as part of project and construction management services.
One of INTEC's most recent projects is the Agbami Field Development Project for Star Deep Water Petroleum Ltd. (Texaco). INTEC is providing (FEED) services for this development offshore Nigeria. The development concept is based on a new build Floating Production Storage and Offloading (FPSO) system producing from nine subsea production wells. The Agbami Field is located 70 miles offshore Nigeria approximately 220 miles southeast of Lagos. The discovery is located in water depths ranging from 4,200 ft to 5,400 ft. Like many other West African discoveries, it is an oil field with a high percentage of gas.
The FEED scope of work includes development of a base case concept, study and evaluation of technical options, preparation of a detailed cost estimate, development of an Engineering, Procurement, Construction and Installation (EPCI) schedule, preparation of an EPCI bid package, and bid evaluation support.
The FPSO scope of work includes:
- Design and development of a 400,000 dwt FPSO vessel to support a 200,000 BOPD production unit.
- Evaluate a new-build vessel versus a tanker conversion for 20-year life service life.
- Evaluate vessel mooring systems and select a concept for the Agbami Development.
- Perform preliminary design of the FPSO hull, accommodations, vessel mooring system, and all vessel marine systems.
- Prepare FPSO functional specifications, compile a vessel EPCI bid package, provide technical support during bid clarification, and evaluate technical proposals.
The FPSO riser scope of work includes:
- Evaluate potential deepwater riser concepts.
- Select the optimum riser design concept based on technology, schedule and cost factors.
- Develop and confirm selected riser designs through static, dynamic, VIV and various fatigue analyses.
- Perform preliminary design calculations and installation analyses.
- Prepare construction specifications, alignment sheets and MTOs.
- Compile a EPCI bid package for installation contractors, provide technical support during bid clarifications, and evaluate technical proposals.
The most significant tanker-based FPSO conversion project included design and project management for the Thaipo Tantawan Field offshore Thailand. As Thaipo's designated Project Management Contractor (PMC) for the Tantawan Field, INTEC had technical, procurement, contracting, QA, and project management responsibility for most aspects of this $200 million field development project with exception of the drilling and completion activities.
The development concept for the Tantawan Field located in 70 m water depth was based on peak gas and oil production rates of 300 million SCFD and 50,000 BOPD, respectively, and included the following major components:
- Two wellhead platforms with first stage separation equipment and associated compression facilities.
- Tanker-based FPSO system with full process and compression facilities.
- Integrated flowlines, PLEM and riser system connecting the platforms to the FPSO, and connecting the FPSO to the Gas Sales Export pipeline.
- External Turret Mooring System
- Five 10.75-inch ID flexible pipe production and export risers and two hydraulic control umbilicals.
Project management services included:
- Cost and schedule control and reporting.
- Recommended contracting strategies.
- Preparation of information for governmental agencies and approval authorities.
- Coordination of safety and HAZOP studies.
- Estimating and tracking the use of contingencies for major components.
- Obtaining and assessing geophysical, bathymetric and environmental survey data.
- Selection of the shipyard to perform the conversion of the tanker to an FPSO.
- Purchase of 30 plus major items of owner-furnished equipment for the tanker conversion including all process equipment and compression trains.
- Selection of the mooring system product swivel and mooring system manufacturer.
- Selection of a flexible pipe riser manufacturer.
- Selection of design, fabrication and installation contractors for the platform jacket and deck structures.
- Selection of design and fabrication contractors for process and compression modules.
- Selection of fabrication and installation contractors for flowlines and associates PLEMs.
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