FDesign & Modification of EWT/EPS Jack-Upinal Presentation

Introduction
26th April,
2013
Title:
Design of Jack-up For Extended Well Testing (EWT)/Early
Production System (EPS) and Selection of Floating Storage &
Offloading (FSO) Vessel for Middle East & India Waters
Group F Presentation
Presenter
2 26th April, 2013 Group F Presentation
Gold Agharese

Group Members:
Gold Agharese (Production Engr.)
Babajide Ogunsanya (Mech. Engr.)
Daniel Boadu (Chemical Engr.)
Patrick Omavuezi (Elect. Engr.)
Eli Klu (Actuary)
Daniel Dore (Elect. Engr.)
Wisdom Wakama (Mech. Engr.)
Richard Ivanhoe (Chemical Engr.)
Supervisor: Dr. John Preedy
Introduction
26th April,
2013
Group F Presentation

Introduction
Definitions
EWT
To measure the productivity of wells
To Provide data that aids design of full
field development
EPS
To generate early cash flow
To gather more reservoir data of field

Environmental factors for design considerations.
Modification and upgrading of an existing Jack-up to a mobile offshore production unit.
Appropriate Topside configuration and equipment selection.
Design and selection of suitable Mooring System for both regions.
Selection of a sizable Floating Storage and Offloading (FSO) Vessel for product storage.
Procedures for Transportation, Installation and Decommissioning.
Adopted HSE and SAFETY CASE measures.
Measures for corrosion protection; and
Cost analysis.
Outline
26th April, 2013 4 Group F Presentation
Environment
&
Metocean
Mumbai High & Persian Gulf
Regions of shallow water depth
(90m max.).
Bounded by common water (the
Arabian sea).
Ease of deployment to locations.
Common environmental factors
(Wind, wave, temp., soil
stratigraphy and bathymetry.
Suitability of the Regions for Jack-up Deployment
Design Data
Mumbai High
Climatic
Parameter
Minimum

Maximum

Surface Air
Temp. (C )
23 In January
(extreme can be 19)
30 in May
(extreme can be 33)
Relative
Humidity (%)
67 (Feb & Dec.)
75 (July & August)
(extreme can be 85)
Average monthly
rainfall (mm)
175 mm monthly. July is the wettest period with
710mm of rain and driest 0mm in March.
Visibility (km) 1 20
Salinity (/OO) 30 35
Wind
South-west monsoon
in May Sept.
North-east monsoon
in Oct. April
Occurs during South-
west monsoon at
30kmph
Wave North-east monsoon :Maximum wave height is 3m
South-west monsoon: Maximum can be above 8m.
Wave direction is same as wind directions.
Tidal Currents
&
Tropical Revolving
Storm
Currents: Strong and causes upwelling (Max of
0.5m/s).
TRS: Occurs between Monsoons (Oct . Nov.).
Interrupts offshore operations.
Monsoons Tropical Revolving Storm
Design Data
Persian Gulf
Climatic
Parameter
Minimum

Maximum

Surface Air
Temp. (C )
17

in Jan. Feb.
(extreme can be 0)
38 in August
(extreme can be 50)
Relative
Humidity (%)
59 in June
(extreme can be 40)
77 in Dec.
(extreme can be 90)
Average monthly
rainfall (mm)
25mm monthly. Dec. is the wettest period with
710mm of rain and driest 0mm in June Oct.
Visibility (km) 5 in June Sept. 8 in June July
Salinity (/OO) 37 50
Wind
Winter Shamal in mid
Oct. mid April
Summer Shamal in
June Sept.
Occurs 5 days in April at
22kmph
Wave Winter Shamal: Maximum wave height is 3.5m
Winter Shamal: Maximum can be above 5m.
Tidal Currents
Currents: Strong and causes upwelling (Max of
1.2m/s).
Tidal Zones Current circulation
Soil Stratigraphy
&
Bathymetry
Persian Gulf
Soil stratigraphy indicates the carbonates occurs in stacked
trapping.
Multiple phases of compressed tectonic layers.
The basin is asymmetric through its Northeast-Southwest sections.
Bathymetry: Densely packed sand inter-layered with Gypsum and
carbonate.
Indian
Soil Stratigraphy shows large area of shallow multilayered
reservoirs with gas cap and thin sweet zones.
Bathymetry: Dense sand layers with embedded shell fragments.
Clay layers shows trends of increasing strength as the depth
increases.
Area of interest:
The Persian Gulf
Presenter
Babajide Ogunsanya

Load Response:-
Shear Stress
Overturning Moment
Loads:-

External Loads
Hydrodynamic
Loads
Current induced drag
force
Wave Force = Drag Force
+ Inertia Force
Wave Spectrum Analysis
Wind
Wind induced
drag force
External Loads &
Load Responses
Wave Spectrum
Analysis
Wave spectrum with the Significant Wave Height and
Mean Wave Period to define the sea state
Douglas Sea Scale;
Persian Gulf :- Very Rough
Mumbai High :- High
JONSWAP wave spectrum approximation best fit
observations from both regions
(using approach of Mazaheri and Ghaderi for Persian
Gulf and Kumah for Indian Ocean)

Wave Profile
Mumbai High
The natural frequency of
the structures should be
greater than 0.075 Hz
Persian Gulf
The natural frequency of
the structures should be
greater than 0.1 Hz

Jack-up Design
Approach
This design seeks to upgrade and modify an existing unit of,
the baker marine 375 series", jack-up.
Documents adopting the SNAME and ISO design approach
were used.
Other structural analysis was based on the API
requirements.
The design unit was in line with relevant government safety
regulations/standards.

13 Group F Presentation 26th April, 2013
Jack-up Leg Design
In Jack-up design, two
types of legs are used.
They are;
Truss legs
Columnar legs

More stable legs
Adapts to loads and stresses
better
Columnar legs

Truss legs

Foundation design
The jack-up leg penetrations,
soil bearing capacity of the
Indian waters and Persian
Gulf with spudcans footing
designs was analyzed for use
in the foundation design.

The spudcans can be used on a variety of seabed.
It is currently the offshore industry standard for jack-
up legs footings.

spudcan
Hull Design
The design entailed the reinforcement of hull
using cross-stiffened panel plates.

The DnV criteria for plate thickness/stiffener sizing was
adopted because, it considers fabrication tolerance in
plate thickness analysis.
An AutoCAD schematic of
a cross-stiffened plate

Hull Design
cont.
The hull was refurbished from drilling to production
configuration.

An AutoCAD schematic of
the Hull

Helideck
The deck is made of
aluminum with steel
supporting structure for
strength purpose.
The design was verified in
line with all relevant
regulations.
Lighting was installed to aid
night flights, while design
accommodates a variety of
helicopter.

Presenter
Daniel Boadu

Topside Processing
and Utilities
DESIGN OBJECTIVES
Processing plant configuration

Process requirements

Equipment Specification

Well measurement system

21
Basic Reservoir Data
Reservoir Pres. 2000psi
Reservoir Temp. 100
o
C
GOR (scf/bbl) 300
API gravity 28
H
2
S < 3ppm
Total Sulphur Cont. 2.82%wt
CO
2
0.02%mole
RVP, psi 7.8
BS&W, %v/v 0.05
Plant Design Basis
Oil handling capacity = 25000bopd
Associated gas = 7.5Mmscfd
Effluent Handling capacity= 6250bwpd
Middle-East
Middle-East
Topside Processing
and Utilities cont.
Group F Presentation 26th April, 2013
22
Basic Reservoir Data
Reservoir Pres. 157 kg/cm
2

Reservoir Temp. 115
o
C
GOR (m
3
/m
3
) 37
API gravity 39.52
H
2
S 12ppm
Total Sulphur Cont. 0.25%wt
CO
2
10.33 %mole
RVP, psia 10
BS&W, %v/v 0.2

Plant Design Basis
Oil handling capacity = 25000bopd
Associated gas = 5.19Mmscfd
Effluent Handling capacity = 15000bwpd

India
India
Topside Processing
and Utilities cont.
A single train facility (1x100%) plant configuration
was selected
Fluid Packages: PR, Glycol and Amine

Topside Processing
Overview
Fluid Phase and
Hydrate Analysis with
HYSYS
India Fluid Phase envelope
Middle-East Fluid Phase envelope

INDIA
Reservoir condition(154bar,115C)
Single Phase
Arrival Cond.(10bar, 60
o
C) Multi
phase
Hydrate range - 6
o
C-9
o
C

MIDDLE-EAST
Reservoir Condition
(137bar,100C) Single Phase
Arrival Cond.(28.6bar, 60
o
C)
Multi phase
Hydrate range 6
o
C-20
o
C

Throughput, GOR and Component Analysis
Middle-East - 3-stage flash stabilisation unit
India - 2-stage flash stabilisation unit
Oil Processing
with HYSYS

Sweetening, Dehydration, and
Final Compression Processes
with HYSYS
Glycol Dehydration By absorption,
99.8wt% pure TEG is used to remove water still
entrained.

Final Compression Compresses gas finally
to 175bar.
Amine Sweetening H
2
S, Mercaptan and CO
2

removal using aqueous Diethanolamine (DEA) of
34.45wt% Soln Strength.
Well Measurement
System
Each of the wells will be connected to a multiphase flow
measurement system (MPFMS) for metering of all fluid
phases (oil, liquid and gas) during production.
Effluents (flared gas and produced water) from production
system will also be metered.
Other internally used fluids (fuel gas, make up water for
amine sweetening and continuous purging) during
production will also be metered.
Design, testing and operation of all forms of metering
must comply with applicable guidelines and regulations

Topside Utilities
Power Generation System

Process Pipework

Gas Flaring System

Seawater and Sewage Treatment

Others: Cooling, Heating, Chemical Injection, fuel,
VOC Recovery System.
Gas powered turbine generator, configured with a
single redundancy diesel/gas generator to
produce 12MW of electricity.
The unit comprises of 2 generators, UPS battery
backup for critical emergency, a change-over station,
transformer unit, control and distribution units.
Generators uses produced gas as fuel.
Generated electricity is used to power the rig system,
topside processing units, pumps (ESPs), control
module, accommodation, etc.
Power
Generation
System
Presenter
Patrick Omavuezi

In-Field Floating
Storage Offloading
Vessel
The purpose of deploying an FSO vessel for Jack-Up
Extended Well Testing (EWT)/Early Production
Systems is to store and export oil from Persian Gulf
and Mumbai high oil fields at a flow rate of 25,000
barrels per day for a 3 year period. FSO Endeavour
was selected
FSO Machinery and
Utilities

Cargo Handling System
Accommodation and Central Control Room
Pumping and Metering Systems
Inert Gas and Venting Systems
Ballast Systems and Cargo Heating Systems
Tandem Offloading and Shuttle Tankers
FSO Selection
Justifications
FSO has provision for storing off specification crude while
in seabed system it is absent.

FSOs segregated tanks prevent oil spill and scouring.

An FSO is not affected by the seabed uncertainty which
may not permit deployment .

In an FSO concept there are less production equipment
and component on the Jack-Up Platform while a seabed
storage system may have congested topside platform.

FSO Selection
Justifications
cont.
The complexity in equipment and components required for
fabricating, installing and operating a seabed storage
system is more than that of an FSO deployment.

An FSO can be easily disconnected to operate in a
separate location while a seabed storage system is fixed
thereby less mobile.

The FSO vessel will provide performance data during the
period for making investment decision and future design

FSO Size and
Offloading
Operations
DIMENSIONS DATA

Length overall
Length between
perpendiculars
Beam moulded
Scantling Draft
Depth on Deck
Deadweight
Operating Draft
Oil Storage Capacity
Slop Tanks
Diesel oil
Maximum Accommodation

157.5m
110.7m
28.0m
13.0
13.0m
15.5m
65,000DWT
3,800 cu m
540,000
2,350 cum
53,000 cu m
60 persons

Presenter
Eli Klu

Cost Effective
FSO vessel withstand Loads with NO interruption in
operations
Hydrodynamic Loads
Wind Loads
And Loads from the mooring system itself
Design Standards: API 2SK, 2005, IACS Req. 1993/Rev.5,
2009, GL Noble Denton Mooring Guidelines 0032/ND, 2010

Aims of Mooring
Design for The Persian
Gulf & Indian
Waters

Major Mooring
Challenges

Wave loads over entire mooring system and risers in
shallow water
High wave height especially Mumbai High (Hs = 8m)
Water depth influences catenary risers design thus
mooring design
Water depth influences choice FSO vessel capacity thus
mooring design


Mooring Designs Considered: turret mooring, Soft Yoke
Mooring, Fixed Arm Catenary Anchor Leg Mooring
(CALM), and Single Anchor Leg Mooring
Selected Design: Fixed Arm CALM Mooring (turret buoy);
Withstands wave height as high as 8m
Deployable in water depth of 30m to 150m
Easily installed - pre installation
Requires minimum FSO vessel modification
Ballast to maintain restoring force
Relatively Cost effective

Mooring Design
Selection
Mooring Line
Selection
Options: Chain Line, Wire Line and
Studless Link Chain Mooring line
(R4s);
Chain weight provide damping force
Not damaged by abrasion with
seafloor
Studless link dont suffer crevices
corrosion, weld decay due to poor
stud welds

OrcaFlex Analysis

Compared chain weight
and minimum breaking
load with result of valid
simulation

Comparing Drag Force and Submerged chain weight (= 0.1875 d
2
in N/m)
Submerge Weight (N)
for a 110m chain line
FSO Hydrodynamic Drag
Force approx. (N)
FSO Wind Drag Force
approx. (N)
Mumbai High Persian Gulf Mumbai High Persian Gulf
186,140.9 7,021.90 11,364.60 876,365.40 238,150.40
OrcaFlex Analysis
MUMBAI HIGH
Comparing line tension, minimum breaking load (= 0.0304 d
2
(44-0.08d)
In kN) and proof load (= 0.0213 d
2
(44-0.08d) In kN)
Line Line Tension (kN)
(Orcaflex Result)
Design
Safety
Factor
(Intact)
Net Line Tension
(kN)
(Orcaflex Result)

Minimum
Breaking
Load (kN) (95
cm Diameter
Studless link)
Proof Load
(kN) (95
cm Dia.
Studless
link)

End A End B End A End B
ML1 32.6 280.9 2 65.1 561.7 9,986.7 6,997.3
ML2 29.2 33.7 2 58.4 67.4 9,986.7 6,997.3
ML3 2,775.9 2,992.1 2 5,551.8 5,984.3 9,986.7 6,997.3
ML4 29.8 34.8 2 59.6 69.9 9,986.7 6,997.3
ML5 1,747.9 1685.1 2 3,495.8 3,370.1 9,986.7 6,997.3
ML6 33.0 34.23 2 65.9 68.5 9,986.7 6,997.3
OrcaFlex Analysis
PERSIAN GULF
Comparing line tension, minimum breaking load (= 0.0304 d
2
(44-0.08d)
In kN) and proof load (= 0.0213 d
2
(44-0.08d) In kN)
Line Line Tension
(kN)
(Orcaflex Result)
Design
Safety
Factor
(Intact)
Net Line Tension
(kN)
(Orcaflex Result)

Minimum
Breaking
Load (kN) (95
cm Diameter
Studless link)
Proof Load
(kN) (95
cm Dia.
Studless
link)

End A End B End A End B
ML1 32.6 280.9 2 65.1 561.7 9,986.7 6,997.3
ML2 29.2 33.7 2 58.4 67.4 9,986.7 6,997.3
ML3 2,775.9 2,992.1 2 5,551.8 5,984.3 9,986.7 6,997.3
ML4 29.8 34.8 2 59.6 69.9 9,986.7 6,997.3
ML5 1,747.9 1685.1 2 3,495.8 3,370.1 9,986.7 6,997.3
ML6 33.0 34.23 2 65.9 68.5 9,986.7 6,997.3
Presenter
Daniel Dore

Jack-up Installation and
Decommissioning
45
WET TOW
Cheaper.
High vessel availability.
Weather limitations.
Suitable for short distances; below
1000km.
Within the Persian Gulf/Mumbai
High.
DRY TOW
Expensive.
Limited vessel availability.
Safest means of transportation.
Suitable for long distances.
Persian Gulf - Mumbai High.
Transportation Modes
Transportation & Distance
Route Approximate
distance (Km)
Transportation
method
Within West Indian
field
500 Wet tow
Within East Indian
field
500 Wet tow
Within the Persian
Gulf
500 Wet tow
East India West
India
5000 Dry tow
East India
Persian Gulf
7500 Dry tow
West India
Persian Gulf
2500 Dry tow
46 Group F Presentation
The distance is an
important factor that can
determine the choice of
transportation in most
cases.

26th April, 2013
Transportation
Considerations

Size
Tow distance
Weather conditions
Vessel availability
Vessel-sharing opportunity
Preloading and Punch-
through risk
consideration

Causes
Existing footprints.
Hard clay crust over softer soils, decreasing with depth.
Sand over soft clay strata.
Firm clay with sand or silt pockets.
Preloading and
Punch-through risk
consideration
cont.
Methods of preloading
Preloading sequentially.
Preloading above water (with air gap).
Preloading in water (without air gap).

Decommissioning
Plan
Jack Up
Jacking system is reactivated.
Equipment in the legs are disconnected from the deck.
Buoyancy chambers filled with air.
Lower the deck into the water to generate sufficient pull.
Jack Legs.
Towed to the yard for continued decommissioning or
refurbishing.

Decommissioning
Plan cont.
FSO
Disconnect in-field pipeline system.
Disconnect Moorings.
Sail to shipyard.

Presenter
Wisdom Wakama

Safety
Considerations

Safety consideration in jack-up installation &
decommissioning.

Safety consideration for jack-up design

Safety consideration in
jack-up installation &
decommissioning
Facility : Jack up
General Hazard
Category
Specific
Hazard
Causes Consequences
Safe
Guards
Action Actionee Remarks
Installation and
Decommissioning
Hazard
Jack up
Leg Punch
Through
Risk
Excessive
penetration
of one foot/
unbalance
leg
penetration
over turning/
collapse of Jack
up
Sequential
Preloading
or
Preloading
at limited air
gap
Jetting out
legs
Installation &
Decommisionin
g team

Environmental
Hazard
Scouring
Wave and
current effect
around spud
can
over turning/
collapse of Jack
up
Efficient
Penetration
or Concrete
Mattress
Refilling
with soil
Installation &
Decommissioni
ng team

Hazard Management
Penetration
Monitoring
Devices
Cone penetration test and
data acquisition device.
Anti-silt/punch connector
floater.
Bow Tie Diagram

Jack up Design Safety
Considerations

Efficient topside layout to
move hazard away from
the temporary refuge

Process Area is High risk

Accommodation (TR) is
low risk

Utility area reduces
possible impact from
process area to TR

Other Jack-up Topside
Design Safety Measures

Temporal Refuge (TR) with ballast wall

Helideck made of steel support structure extended
as cantilever to reduce of impact with TR

Water deluge at vital areas especially the topside
processing units

Safety Regulations

Safety Regulation are in line with:
SOLA- International convention for the safety of life.
SOLA-Requirements for A60 fire protection
standard(SOLAS 2002).
Act 1974-Health and safety at work place etc.

Presenter
Richard Ivanhoe

Corrosion
Environment Conditions
Micro-organisms
Salinity
Temperature
Pressure
Reservoir Characteristics
H
2
S
CO
2

Types of Corrosion
Crevices corrosion
Stress corrosion
cracking
Galvanic
Water line corrosion
Pitting corrosion

26th April, 2013 Group F Presentation 61
Corrosion Protection
Types of Protection
Coating
Fusion bond epoxies (FBE)
Two and three layers FBE and extruded polyurethane
(to reduce corrosion and impart of fire)
Coal tar enamels have been used to protect offshore
facilities

Cathodic protection
Sacrificial Anode (Aluminium Zinc - Indium)

Corrosion Inspection &
Monitoring
Inspection
Routine general visual Inspection by a remotely
operated vehicle (ROV) after the first year
Use of Non-destructive testing such as ultra sonic
survey to inspect wall thickness
Monitoring
Use of corrosion coupon

Costing
Cost of Calm
Buoy
Mooring
Chains &
Clamps
Design Cost of Jack-Up and EWT/EPS
Calm Buoy &
Mooring
Cost of
Jack up
Cost of
acquisition
Cost of
modification
Cost of
Topside
Cost of Utility
equipments
Cost of
processing
equipments
FSO
Cost of
Lease
Miscellan
eous
DESIGN COST
(PERSIAN GULF & INDIAN)
FACILITY Persian Gulf
COST $M
India
COST $M
Jack up acquisition 135 135
Jack up modification 30 30
Topside
154.42 145.28
FSO 26 26
Calm Buoy & Mooring 20 20
Total 365.42 356.28
COST COMPARISION
BETWEEN REGIONS
38%
8%
41%
7%
6%
OVERALL PROJECT COST
BREAKDOWN
Jack up acquisition Jack up conversion
Topside FSO
Calm Bouy & Mooring
0
20
40
60
80
100
120
140
160
180
INDIA
MIDDLE EAST
Conclusion
PAY BACK PERIOD
CAPEX YEAR 0 YEAR 1
Cost of oil per year
($M) 0 812.1
Design cost ($M) (365.42) 0
Installation cost ($M) (18.271) 0
Miscellaneous
(10% -$M) (38.37)
OPEX ($M) 0 (324.84)
(422.06) 70.20
This study addressed the
design and deployment of a
jack-up and Floating Storage
and Offloading vessel for
extended well test/early
production system in the
Middle East and Indian
waters in a cost effective
and excellent safety system.

Thank You

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