akpo project aftp spe rev1 ff - evolen.org · technology pushed to new frontiers 7” sas,...
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AFTP/SPE - Akpo Project - 23-06-10 – A. Lainé / F. Fournié
AKPO
A large Nigerian deep offshore development
Akpo Project
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AFTP/SPE - Akpo Project - 23-06-10
A LARGE PROJECT OFFSHORE NIGERIA BY TOTAL
1400m water depth, 100 miles off Port Harcourt
44 wells, 10 manifolds, 14 SCR risers, 440 000 ton FPSO
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AFTP/SPE - Akpo Project - 23-06-10 3
A Complex Venture Arrangement
Managed through a PSA and a PSC, Partnerships differ in the 2 contracts, Total Operator for the OML
PSCPSA (Farm-in Agreement)
OML 130
50% NNPC ie-45% CNOOC- 5% SAPETRO
1998
OPL 246OPL 246
2005
OPL 246
OML 130
OPL 246
OML 130
10%
24%16%
50%
SAPETRO TOTAL BRASOIL NNPC
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AFTP/SPE - Akpo Project - 23-06-10
A Complex Venture but still a robust one
3 National Oil Companies !
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AFTP/SPE - Akpo Project - 23-06-10
AN HYBRID HIGH TECH SCHEME
Complex sand lobes and channels, critical fluid
Near high pressure / high temperature, gas export to LNG
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AFTP/SPE - Akpo Project - 23-06-10
TECHNOLOGY PUSHED TO NEW FRONTIERS
7” SAS, Perforation/ frac. pack in single run in 10 ¾”, intelligent completions
118°C SPS, 588 bar SCR, FICSS, all electric 180 MW FPSO
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AFTP/SPE - Akpo Project - 23-06-10 7
QUALIFICATIONS FOR TECHNOLOGY RISKS
150 qualification programs
30% initial Test failure, zero Field failure
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AFTP/SPE - Akpo Project - 23-06-10
EXECUTION ON A GLOBAL SCALE
32 million man-hours, 14 million in Nigeria
Global IS/IT for central management in Nigeria
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AFTP/SPE - Akpo Project - 23-06-10 9
INNOVATIVE BIDDING SOLUTIONS
EPC reservation agreements signed 8 month ahead of uncertain FID
Currency & commodity hedging, asset reservation, schedule
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AFTP/SPE - Akpo Project - 23-06-10
Contractual Strategy
DRILLING &COMPLETION
SPSUFR &
Offloadingterminal
FPSO
HullManagement &conceptual studies
Basic Engineering
Detail Engineering
Procurement
Onshore fabrication
Onshore test & com.
Transportation
Offshore installation
Offshore H.U.
Offshore commissioning
Start up & operation
EPS
DORIS Engineering
TUPNI
TUPNI
EPSCCDRILLING EPSCC
DRILLING &COMPLETION
SPSUFR &
Offloadingterminal
FPSOHull
Management &conceptual studiesFEED Engineering
Detail Engineering
ProcurementOnshore fabrication
Onshore test & com.
Transportation
Offshore installation
Offshore H.U.
Offshore commissioning
Start up & operation
EPSCAMERON
DORIS EngineeringTUPNI
DRILLINGTUPNI
EPSCCSAIPEM
Topsides
EPSCCTechnip/HHI
LLI
Drilling: TransoceanCompletion: GlobalSanta Fe
TUPNI
Defined during Basic phase,Large & synchronized EPSCC
Selection approved at Project Sanction
Flotel
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AFTP/SPE - Akpo Project - 23-06-10 11
Time Allowance for Record Nigerian Content
Up to 18 month for capacity building, 50% for learning curve
Delivered quality meets international standards
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AFTP/SPE - Akpo Project - 23-06-10
An Integrated Project Management
Fully integrated project management team till 1st oil
Unified IT tools & EDMS
Lessons learnt from TOTAL deep offshore projects
Akpo Project
DIRECTOR
FIELD OPERATIONSSERVICES
SURFACES FACILITIES
FIELD GSR DRILLING & COMPLETION
FLOATING, PRODUCTION,
STORAGE & OFFLOADING
SUBSEA PRODUCTION
SYSTEM
UMBILICALS, FLOWLINES &
RISERSINTERFACES
HSEQ
NIGERIA INTERFACES
COMMISSIONING
VENTURE
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AFTP/SPE - Akpo Project - 23-06-10
Significant Significant amount of amount of
precipitated precipitated asphalteneasphaltenesticking to sticking to the wall of the wall of
the the transparent transparent
cellcell
RESERVOIR G FLUID RESERVOIR G FLUID –– SWELL TEST SWELL TEST
PHASE DIAGRAM
0
Pres
sure
0Temperature
Critical Points
Condensate
TR
Volatile oil
PRES
SUR
E
TEMPERATURE
Condensate Volatile Oil
Critical Point
PHASE DIAGRAM
0
Pres
sure
0Temperature
Critical Points
Condensate
TR
Volatile oil
PRES
SUR
E
TEMPERATURE
Condensate Volatile Oil
Critical Point
Complex under-saturated near-critical fluids
Light Oil (Up to 50°API) with High GOR,
Widespread impact on the AKPO development project
TEMPERATURE
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AFTP/SPE - Akpo Project - 23-06-10
A Mandatory Meticulous Well Planning
Definition and freezing of the 22 start-up wells at Project Sanction, delivered as planned at Start-Up
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AFTP/SPE - Akpo Project - 23-06-10
Pre-production Interference Testing
Akpo-10 and Akpo-06 Normalised Pressure ResponseDuring Interference with Akpo-15 (PULSER).
-0.50
-0.25
0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
2.25
2.50
11/1
2/08
12/1
2/08
13/1
2/08
14/1
2/08
15/1
2/08
16/1
2/08
17/1
2/08
18/1
2/08
19/1
2/08
20/1
2/08
21/1
2/08
22/1
2/08
23/1
2/08
24/1
2/08
25/1
2/08
26/1
2/08
Date
Diff
eren
tial P
ress
ure
(psi
)
press - Akpo-10press - Akpo-06
Start Injection on Akpo-15
End Injection on Akpo-15
2psi response consistent with test design
A-2 and A-3 normalised pressure responseduring Interference test with A-1 (Pulser)
A-3A-2
A-1
A-1
Akpo-10 and Akpo-06 Normalised Pressure ResponseDuring Interference with Akpo-15 (PULSER).
-0.50
-0.25
0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
2.25
2.50
11/1
2/08
12/1
2/08
13/1
2/08
14/1
2/08
15/1
2/08
16/1
2/08
17/1
2/08
18/1
2/08
19/1
2/08
20/1
2/08
21/1
2/08
22/1
2/08
23/1
2/08
24/1
2/08
25/1
2/08
26/1
2/08
Date
Diff
eren
tial P
ress
ure
(psi
)
press - Akpo-10press - Akpo-06
Start Injection on Akpo-15
End Injection on Akpo-15
2psi response consistent with test design
A-2 and A-3 normalised pressure responseduring Interference test with A-1 (Pulser)
A-3A-2
A-1
A-1
Akpo-16
Akpo-10
Akpo-6Akpo-5G
Akpo-5st
Akpo-15Akpo-10
Akpo-6-
Akpo-15
Akpo-16
Akpo-10
Akpo-6Akpo-5G
Akpo-5st
Akpo-15Akpo-10
Akpo-6-
Akpo-15
A-1
A-3A-2
Akpo-16
Akpo-10
Akpo-6Akpo-5G
Akpo-5st
Akpo-15Akpo-10
Akpo-6-
Akpo-15
Akpo-16
Akpo-10
Akpo-6Akpo-5G
Akpo-5st
Akpo-15Akpo-10
Akpo-6-
Akpo-15
A-1
A-3A-2
Subsea Well Intervention Monitoring System (SWIMS) used for pressure data recovery, storage and transmittal
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AFTP/SPE - Akpo Project - 23-06-10
A Very Large Drilling OperationDiscovery Jack Ryan
2006 2007 2008 2009DWDJ RyanS- TayDWP
305 days
709 days
305 days
751 days
Stena Tay Pathfinder
4 drilling units, 2000 rig days, 3.6 Millions man hoursTwo ‘’flagship rigs’’ : Transocean Deepwater Discovery and Jack Ryan
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AFTP/SPE - Akpo Project - 23-06-10
Rig specialization to push the performance limit
Well testing equipment on Jack Ryan
Transocean Jack Ryan
Management decision to dedicate one rig for drilling, one rig for completionSavings in rig upgrades and service costs, efficient specialized rig crew
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AFTP/SPE - Akpo Project - 23-06-10
Batch drilling helps for continuous improvement
Mud Mat/TGB in moon pool
Top-Hole DurationDeep Water Discovery
Batch operations improved learning processSustained continuous progress for two years
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AFTP/SPE - Akpo Project - 23-06-10
Batch completions for quality & performance
X-Tree installation time
Performance achieved, keeping high quality standards by batching operations of frac. pack, completions and X-trees
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AFTP/SPE - Akpo Project - 23-06-10
22 wells delivered ON TIME
AKPO strong management achieved a GREAT step
in the efficiency of deep water well delivery
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AFTP/SPE - Akpo Project - 23-06-10
12km
10 k
m
21
Subsea Layout, a Key Feature of the Development
An Optimized Sub-Sea Layout with multi Drilling Centers, taking onboard
SCR constraints and Flow Assurance requirements, frozen at FEED
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AFTP/SPE - Akpo Project - 23-06-10
Flow Assurance: a major factor in project definition
Flow assurance influences field architecture, requires early definition
WELL READY
TO RESTARTSUBSEA SYSTEM
PROTECTED
NO TOUCHTIME 4-hour
DEPRESSURISATIONOF WELL, JUMPER,
MANIFOLDAND RISER
STABILISED CRUDECIRCULATION
TimeFLOW LINE / RISER INSULATION
PERFORMANCES
INJECTIONOF METHANOL
Shut-down
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AFTP/SPE - Akpo Project - 23-06-10 OTC - 20993 23
STANDARDIZED DRILL CENTRE LAYOUTSTANDARDIZED DRILL CENTRE LAYOUT
HYDRAULIC FLYING LEADS
HORIZONTAL CONNECTORS &
DOGHOUSES
SUBSEA UMBILICAL TERMINATION
.
MANIFOLD MODULE
MANIFOLD PILE
WELLHEAD
XMAS TREE
SYSTEM DESIGNED FOR MAXIMUM AVAILABILITYSYSTEM DESIGNED FOR MAXIMUM AVAILABILITY
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AFTP/SPE - Akpo Project - 23-06-10
Akpo Subsea Production Facilities
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AFTP/SPE - Akpo Project - 23-06-10
Running Xmas Trees
50 tons at the end of the riser to be accurately positioned and connected to the wellhead
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AFTP/SPE - Akpo Project - 23-06-10
Jumper installation & Connection
150 line pipe subsea connections completed at First OIL
Connector Running Tool
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AFTP/SPE - Akpo Project - 23-06-10 27
One Riser Concept Selected at Pre-Basic Stage
Main FactorsWater depthFlow AssuranceNo Gas liftGeneric conceptLocal contentBidding process
900 m
15°
WD
: 13
00m
SCR + wet insulation: best solution for AKPO
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AFTP/SPE - Akpo Project - 23-06-10 28
• Early maturity assessment during FEED
• Extensive qualification during detail engineering
• Fluid compatibility testing• Hyper-Elastic law development for FEA• Resistance to explosive decompression• Ageing – stiffening and impact on design • Fatigue resistance under pressure cycles
Flexible Joint Qualification
Early Maturity Assessment defined qualification scope for FJ design
Full scale test confirmed manufacturing process & design fitness for severe conditions
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AFTP/SPE - Akpo Project - 23-06-10 29
Pulling rig
SCR Pre-installed, Recovered & Transfered to FPSO
Transfer wirepassed to FDS
from FPSO pulling rig
SCR transferred
to FPSO
SCR includingFlex-joint ready
to transfer
FPSO
FLET
Step 1 : FDS picks up FL
Head
Step 2 : FL head on FDS
SCR loadtransfer fromFDS to FPSO
pulling rigSCR laying
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AFTP/SPE - Akpo Project - 23-06-10
AKPO FPSO
Hull: 310m x 61m x 31m
Living Quarter: 240 POB
2 million barrels storage
Oil processing: 185,000 bbl/d
Water injection: 420,000 bbl/d
Produced water treatment: 150,000 bbl/d
Gas treatment: 530 mmscfd
Gas export: 290 mmscfd
Gas injection: 210 mmscfd
110,000 tons fabricated & moored in 1400 m water depth,
14 Steel Catenary Risers
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AFTP/SPE - Akpo Project - 23-06-10
An Hybrid Gas Injection - Gas export FPSO
Flexibility to maintain liquid production
Gas export to LNG production
Akpo Central Akpo Central Akpo East
+D B, EF, G A
WI
Condensate Condensate
Gas ExportG
asR
e-In
ject
ion
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AFTP/SPE - Akpo Project - 23-06-10 32
An all-electric FPSO
Single 160 Mw power generation plant, shorter commissioning & start-up
Higher availability & lower maintenance cost
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AFTP/SPE - Akpo Project - 23-06-10 33
E&I decentralized Technical Buildings
Easier and earlier commissioning before sail-away
Easier start-up of FPSO facilities
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AFTP/SPE - Akpo Project - 23-06-10 34
Field Integrated Control and Safety System
Global ICSS approach selected during FEEDNo barrier to communication
Topsides
Subsea
Hull
Downhole
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AFTP/SPE - Akpo Project - 23-06-10 35
Tow Opportunity between Korea and Nigeria
High state of readiness once on location
Team continuity between onshore and offshore
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Simultaneous Operations Strategy
3 drilling rigs, 4 construction vessels, 1 flotel and FPSO
SCR installation, hook up, commissioning while producing
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AFTP/SPE - Akpo Project - 23-06-10
2 Years of Active People Development
Mobilise and train early - start production early
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AFTP/SPE - Akpo Project - 23-06-10
High Production Delivery Performance
Cumulative Production
PLANACTUAL
Align project activities completion with production goals
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AFTP/SPE - Akpo Project - 23-06-10
AKPO Operations: the Keys to Success
• Integrated Project organisation
• Technological expertise
• Deep offshore operational experience
• Early operators mobilisation
• Focused Nigerians development
• Robust site organisation
• Personal Commitment
Operations success is the AKPO Project teams overall success