Challenges of the Agbami Project (Nigeria)

People and Partnerships Delivering a World‐Scale Field Development
Richard H. Strauss
Chevron Energy Technology Company
June 25, 2009
Agbami Field Overview
Benin
Lagos
Nigeria
N
Escravos
100 km
Warri
Gulf of Guinea
Port Harcourt
OML
127
OML
128
Bonny Island
20
0
km
Brass
~
• 965+ MM bbl reserves
• 47° API (sweet crude) Agbami
• +/- 4,800-ft water
depth
10 Years from
Discovery to Production
f 1993
OPL 216 license award
f 1998
Agbami #1 discovery well
f 1999 – 2004
Appraisal drilling
Front‐end engineering
f 2004 – December
First Nigeria Deepwater Unit agreement
FPSO contract award
f 2007 – October
FPSO sailaway
f 2008 – July
First oil production
f 2008 – October
Gas injection
f 2009 +
Development drilling continues
Concessionaires
Nigerian National
Petroleum Corporation
Famfa Oil Limited
Agbami Unit Operator
Star Deep Water Petroleum Limited (an affiliate of Chevron Corporation)
Other Funding Participants
Statoil Nigeria Limited
Petróleo Brasileiro
Nigeria Limited
Texaco Nigeria Outer Shelf Inc. (an affiliate of Chevron Corporation)
Field Development Plan
• Floating production
storage and
offloading vessel
(FPSO)
• Flexible risers
• 38 subsea wells
• Crestal gas injection
and peripheral water
injection
• Offloading buoy with
U-shaped pipeline
AGBAMI FIELD
Agbami Field Size (If in Houston)
No r t h L o o p F wy
WUL1
A GB03
PVM 1
AGB -07
(PDL1)
PA L7
WM A
WFL7
AGB04
WGL7
WM B1
WM B
WM B
WOL2
PQL2
GEL1
PM D
PCM 1
GM D
AGB -13
GA M 1
(GGL2)
GHL6 AGB-15
(GDL4)
GBM 6
GM G
AGBAGB-12
02
(PGL4)
PDL6 PFL5
PM C
PM F
PBM 2
PNL2
AGB 06
PLL3
A GB-08
WM L3
AGB-11
(PJL3)
PAM 3
WDL6
WM C
WEL5
WM D
PM E
PPL4
AGB -10
(PIL4)
WNL3
AGB -14
(PHL4)
AGB-05
(WAL4)
AGB09
WJL3
So u t h L o o p F wy
5
Agbami Contractor Locations
KOS
SS Controls
Eng'g & Manuf.
KONGSBERG
Kvaerner
Dynamic Umbilical
Design & Manuf.
MOSS
Umbilicals
Design & Manuf.
DUCO
Acergy
Offloading Lines
Engineering
FlexiFrance
Risers & Flowlines
Design & Manuf.
PM & Engineering
Kvaerner Risers, Flowlines
and Umbilicals
LE TRAIT
PARIS
NEWCASTLE
SBM
Suction Pile Design
MONACO
KBR
FPSO Topside
Engineering
SBM
FPSO Mooring
Engineering
FMC
SS Engineering &
Tree Fabrication
SBM
OSC Project Mgmt
& Buoy Eng'g.
Hull Engineering
Hull Construction
Topside Fabrication
Hull/Topside Integration
DSME
OKPO
HOUSTON
UAE
Lamprell
Buoy Turntable
BRAZIL
FMC
Flowline Swivels
Grinaker
SS Manifolds and
Piles Manufacture
DSME
FPSO
FMC
Operations
Support Base
SBM /
Acergy
Offloading System
NETCO
FPSO Topsides
Detailed Eng'g
TEF
Fowlines/Umbilicals
Manifold Installation
DNL
FPSO Modules
and Flare Fab'n
FMC
Installation and
HUC Support
MODU
Drilling/Completion
& Tree Installation
AGBAMI FIELD
NIGERIA
Nigerdock
FPSO Modules
and Piles Fab'n
Installation Site
Shore Facilities
Nigerdock
Offloading Buoy
and Piles Fab'n
6
Critical Success Factors • Establishing a worldwide Incident‐ and Injury‐Free®
culture
• Achieving schedule benchmarks
• Setting new standards in Nigerian content
• Maintaining high production reliability
• Managing a challenging cost environment
Creating an Incident‐ and Injury‐Free Culture
• Agbami was delivered safely; however, every injury was clearly preventable: Five days away from work (DAFW) injuries in 18 million work‐hours • Commitment and belief in working injury‐ and incident‐free across the global Agbami team
• Creative approaches to safety procedures and practices
Delivering a New Standard in Nigerian Content
• Strategic objective embraced by all project participants
• 10,000 tons fabricated in Nigeria
• 3 million work‐hours with zero DAFW injuries
• 300,000 FPSO Nigerian engineering work‐hours
1,700-ton Flare Module
Daewoo Nigeria Ltd., Warri
• 100+ Nigerian engineers trained worldwide
Nigerian Content Successfully Delivered
First Fabrication of Subsea Manifolds
in Nigeria GrLTA, Port Harcourt
Offloading Buoy, Suction Piles, Two FPSO Modules, Nigerdock, Lagos
Drilling Program:
Decades of Commitment
WPO-Well
Perf. Optm.
Well level
Drilling = ~ 50% of total project investment
Typical Agbami IWC…
¾Field level: 2 separation trains,
complex network of 8 sub-sea
manifolds & risers (prod/inj)
¾At the reservoir level, multiple
lobes within the same reservoir
¾At the well level, 2 valves for
zonal control plus a number of
measurement devices- (6) P,T,Q
•Stage 1 – 22 wells to reach plateau production
Reservoir level
•Stages 2 & 3
17D
ZONAL / WELL
SURVEILLANCE
& MONITORING
– 16 wells to extend plateau and increase water and gas injection
17E
17F
© Chevron 2005
DOC ID
Intelligent well completions to
maximize oil recovery
17
Agbami Subsea System
Subsea Highlights
•One of the largest flexible subsea systems •Design conditions pushing technology limits
•Interface design challenges led to construction success
•Marine vessel breakdowns required creative contingency planning
Agbami FPSO
AGBAMI Production Capacity
Total Liquids (B/D)
Oil Rate (BOPD)
Produced Gas (MMscf/D)
Injection Gas (MMscf/D)
Gas Lift (MMscf/D)
Produced Water (BWPD)
Water Injection (BWPD)
FPSO Particulars
New build construction
20-year life in field
2.15 MM bbl storage capacity
Offloading 45,000 bbl/hr
1.0 MM bbl approximately every four days
Dimensions 317 m ¯ 58 m ¯ 32 m
Displacement 404,811 t
Accommodations 153 POB
450,000
250,000
450
415
50
250,000
450,000
Offshore Hookup and Commissioning Offshore Highlights
•Offshore work‐hours greater than planned
•Interface management success
•No major technical problems
Simultaneous Operations (SIMOPs)
Left to Right: Accommodation Vessels, FPSO, Diving
Support Vessel, Riser Installation Vessel
Startup Reliability
Higher Than Forecast
Forecast vs. Actual Production Efficiency
Production Efficiency
• Excellent teamwork between commissioning and operations
Actual
100%
Forecast
80%
• Phased startup of nearly 100 systems:
January 2008 – FPSO Arrival
July 2008 – First Oil
60%
October 2008 – Gas Injection
40%
February 2009 – Water Injection
20%
0%
1
2
3
4
5
6
Month
7
8
9
10
12
• Production rampup continues through 2009
Subsea Design,
Installation and Lessons
Learned
16
Base Case Concept
Infield Umbilicals
Water Injection
System (Blue)
T
T
T
T
M
Main Umbilical
T
M
T
T
T
Piggy-Back Drill
Center
T
T
T
T
M
Drill
Center
M
Gas Injection
System (Green)
Production
System (Red)
T
T
T
T
Piggy-Back
Production
System (Red)
17
Subsea Equipment – SEV Scope
5x2 – 10 ksi Horizontal Trees
(17 Production, 9 Water Injection
& 6 Gas Injection)
4 Slot Manifolds
(Suction Pile Mounted)
• MUX Controls (Top Sides &
Subsea)
• Flowline & Jumper Connectors
• Electrical & Hydraulic Flying Leads
• IWOCS & Tooling
18
Loading Trees onto Installation Vessel – Onne Port
Tree Being Lowered into Water, Drilling Rig in Background
Tree On Wellhead
5 Subsea Lessons Learned spanning a wide range of topics
1.
2.
3.
4.
5.
22
Retrievable Flowmeter Issues
Flexible Flowline & Jumper Kits
Flow Assurance & Insulation
Cathodic Protection of Trees
Tree Installation
Lesson #1:
Retrievable Flowmeter issues
Flowmeter with ROV retrievable
instrumentation
– Issue: Unexpectedly complex, expensive, long‐
lead ROV tooling.
23
Lesson #1:
Retrievable Flowmeter issues
Flowmeter with ROV retrievable
instrumentation
– Issue: Unexpectedly complex, expensive, long‐
lead ROV tooling.
Ensure all parties
understand scope of
Company-required items
prior to award.
24
Lesson #2:
Interface Definition in FEED
Direct Connect Flowlines
– Cross‐Contract Situation:
• FMC to provide Flowline & Jumper end Kits
• Installation contractor to provide Flexible flowlines / Jumpers and installation responsibility
– Issue: Installation engineering details arriving late in fabrication program
– Analysis:
• 2nd End Flexible Flowline Connectors have integral padeyes
resulting in one‐piece elbow/padeye forging
• Swivels required for all Jumpers and Flowlines 2nd end connections.
25
Lesson #2:
Interface Definition in FEED
Direct Connect Flowlines
– Cross‐Contract Situation:
• FMC to provide Flowline & Jumper end Kits
• SIC to provide Flexible flowlines / Jumpers and installation responsibility
– Issue: Installation engineering details arriving late in fabrication program
– Analysis:
• 2nd End Flexible Flowline & Jumpers have integral padeyes
resulting in one‐piece elbow/padeye forging
• Additional swivels required for all Jumpers and Flowlines
Early, continuing communication between
contractors to identify and avoid costly and
time consuming interface clashes.
26
Lesson #3:
Flow assurance and Insulation
•
Ten Hour target cool‐down period specified, 2” thick insulation calculated for trees.
– Issue: More conservative assumptions were introduced late.
– Result: Insulation thickness increased to 3” and less aggressive cool‐down period of 7 hrs agreed.
27
Lesson #3:
Flow assurance and Insulation
•
Ten Hour target cool‐down period specified, normally require 2” thick insulation for trees.
– Issue: More conservative assumptions were introduced late.
– Result: Insulation thickness increased to 3” and less aggressive cool‐down period of 7 hrs agreed.
Assumptions for thermal
analysis should be agreed in
early phase to avoid potential
delays and costs.
28
Lesson #4:
Cathodic Protection – Trees
•
Insufficient Cathodic protection on trees
– Issue: Calculations for cathodic protection of trees initially did not include for subsea well. – Solution:
• Additional anodes added in‐country to several trees already shipped, as well as all trees still in Houston.
• FMC determined tree funnel could be removed in‐country, anodes welded to funnel & re‐attached.
29
Lesson #4:
Cathodic Protection – Trees
•
Cathodic risk to sensitive tree sensors
– Issue: Initial calculations for cathodic protection of trees initially did not include for subsea well. – Solution:
• Additional anodes added in‐country to several trees already shipped, as well as all trees still in Houston.
• FMC determined tree funnel could be removed in‐country, anodes welded to funnel & re‐attached.
Assumptions for cathodic protection analysis
agreed in early project phase to avoid potential
delays and costs.
30
Lesson #5:
Tree Installation
• Planned Tree deployment from A‐frame from edge of drilling rig. – Issue: Concerns raised as to safety on rig and offshore transfer of trees to rig. – Better solution: Trees loaded out onto surface support vessel and installed from same vessel offshore from wire rope.
31
Lesson #5:
Tree Installation
• Planned Tree deployment from A‐frame from edge of drilling rig. – Issue: Concerns raised as to safety on rig and offshore transfer of trees to rig. – Better solution: Trees loaded out onto surface support vessel and installed from same vessel offshore from wire rope.
Careful consideration of safety
issues in conjunction with
alternatives can save costs as
well as lowering risks!
32
Thank You!