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TRANSCRIPT
People and Partnerships Delivering a World‐Scale Field Development
Richard H. StraussChevron Energy Technology Company
June 25, 2009
Agbami Field Overview
Nigeria
Benin
Lagos
Warri
Port Harcourt
Escravos
Bonny IslandBrass
OML127
OML128
Gulf of Guinea
100 km
AgbamiAgbami
~ 200
km
N
• 965+ MM bbl reserves• 47° API (sweet crude)• +/- 4,800-ft water
depth
10 Years fromDiscovery to Production
1993OPL 216 license award
1998Agbami #1 discovery well
1999 – 2004Appraisal drillingFront‐end engineering
2004 – DecemberFirst Nigeria Deepwater Unit agreementFPSO contract award
2007 – OctoberFPSO sailaway
2008 – JulyFirst oil production
2008 – OctoberGas injection
2009 +
Development drilling continues
Concessionaires
Nigerian NationalPetroleum Corporation
Famfa Oil Limited
Agbami Unit Operator
Star Deep Water Petroleum Limited (an affiliate of Chevron Corporation)
Other Funding Participants
Statoil Nigeria Limited
Petróleo BrasileiroNigeria Limited
Texaco Nigeria Outer Shelf Inc. (an affiliate of Chevron Corporation)
AGBAMI FIELD
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 Size (If in Houston)
5
South Loop Fwy
North Loop Fwy
AGB-08WM L3
AGB-04
WOL2
W M B
AGB-11(PJL3)
PNL2
PLL3PM C
PQL2
PM DGM D
GAM 1AGB-13(GGL2)
PM EAGB-10(PIL4)
PPL4 AGB-14(PHL4)
PM F AGB-06
PBM 2PAM 3
AGB-15(GDL4)
GM G
GHL6
AGB-12(PGL4)
PDL6 PFL5
W M C
AGB-09
WJL3
WNL3
W M D
AGB-05(WAL4)
WEL5
WDL6
W M AWFL7
WUL1
PVM 1 AGB-07(PDL1)
AGB-03
PAL7
WGL7
PCM 1GEL1
WM B
WM B1
GBM 6AGB-
02
Agbami Contractor Locations
6
KONGSBERG
KOS SS ControlsEng'g & Manuf.
MOSS
PARIS
LE TRAIT
MONACO
OKPO
UAE
NIGERIAAGBAMI FIELD
BRAZIL
HOUSTON
NEWCASTLE
Kvaerner Dynamic UmbilicalDesign & Manuf.
KvaernerPM & EngineeringRisers, Flowlinesand Umbilicals
Acergy Offloading LinesEngineering
Flexi-France
Risers & FlowlinesDesign & Manuf.
SBM Suction Pile Design
Hull EngineeringHull Construction
Topside FabricationHull/Topside Integration
DSME
Lamprell Buoy Turntable
Grinaker SS Manifolds and Piles Manufacture
FMC Operations Support Base
NETCO FPSO TopsidesDetailed Eng'g
DNL FPSO Modulesand Flare Fab'n
Nigerdock FPSO Modulesand Piles Fab'n
Nigerdock Offloading Buoyand Piles Fab'nShore FacilitiesInstallation Site
DSME FPSO
SBM / Acergy Offloading System
TEF Fowlines/UmbilicalsManifold Installation
FMC Installation andHUC Support
MODU Drilling/Completion& Tree Installation
FMC Flowline Swivels
KBR FPSO TopsideEngineering
SBM FPSO MooringEngineering
FMC SS Engineering &Tree Fabrication
SBM OSC Project Mgmt& Buoy Eng'g.
DUCO UmbilicalsDesign & Manuf.
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
• 100+ Nigerian engineers trained worldwide
1,700-ton Flare ModuleDaewoo Nigeria Ltd., Warri
Nigerian Content Successfully Delivered
Offloading Buoy, Suction Piles, Two FPSO Modules, Nigerdock, Lagos
First Fabrication of Subsea Manifolds in Nigeria GrLTA, Port Harcourt
Drilling Program:Decades of Commitment
17DOC ID© Chevron 2005
Typical Agbami IWC…
Field level: 2 separation trains, complex network of 8 sub-sea manifolds & risers (prod/inj)
At the reservoir level, multiple lobes within the same reservoir
At the well level, 2 valves forzonal control plus a number ofmeasurement devices- (6) P,T,Q
Well level
Reservoir level
17D
17E
17F
ZONAL / WELL SURVEILLANCE & MONITORING
WPO-Well Perf. Optm.
Drilling = ~ 50% of total project investment
•Stage 1
– 22 wells to reach plateau production
•Stages 2 & 3
– 16 wells to extend plateau and increase water and gas injection
Intelligent well completions to maximize oil recovery
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 FPSOAGBAMI Production CapacityTotal Liquids (B/D) 450,000Oil Rate (BOPD) 250,000Produced Gas (MMscf/D) 450Injection Gas (MMscf/D) 415Gas Lift (MMscf/D) 50Produced Water (BWPD) 250,000Water Injection (BWPD) 450,000
FPSO ParticularsNew build construction 20-year life in field2.15 MM bbl storage capacityOffloading 45,000 bbl/hr1.0 MM bbl approximately every four daysDimensions 317 m 58 m 32 mDisplacement 404,811 tAccommodations 153 POB
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 ReliabilityHigher Than Forecast
• Excellent teamwork between commissioning and operations
• Phased startup of nearly 100 systems:January 2008 – FPSO Arrival
July 2008 – First Oil
October 2008 – Gas Injection
February 2009 – Water Injection
• Production rampup continues through 2009
Forecast vs. Actual Production Efficiency
Month
0%
20%
40%
60%
80%
100%
1 2 3 4 5 6 7 8 9 10 12
ForecastForecast
ActualActualProduction Efficiency
Base Case Concept
17
M
TT
T
T
M
T T
TT
T
M
T
T T
M
TT
T T
Infield UmbilicalsWater InjectionSystem (Blue)
ProductionSystem (Red)
Piggy-Back Production
System (Red)
Gas InjectionSystem (Green)
Main Umbilical
DrillCenter
Piggy-Back Drill Center
18
Subsea Equipment – SEV Scope5x2 – 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
22
5 Subsea Lessons Learned spanning a wide range of topics
1. Retrievable Flowmeter Issues
2. Flexible Flowline & Jumper Kits
3. Flow Assurance & Insulation
4. Cathodic Protection of Trees
5. Tree Installation
23
Lesson #1:Retrievable Flowmeter issues
– Issue: Unexpectedly complex, expensive, long‐lead ROV tooling.
Flowmeter with ROV retrievable instrumentation
24
Lesson #1:Retrievable Flowmeter issues
Ensure all parties understand scope of Company-required items prior to award.
– Issue: Unexpectedly complex, expensive, long‐lead ROV tooling.
Flowmeter with ROV retrievable instrumentation
25
Lesson #2:Interface Definition in FEEDDirect 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 padeyesresulting in one‐piece elbow/padeye forging
• Swivels required for all Jumpers and Flowlines 2nd end connections.
26
Early, continuing communication between contractors to identify and avoid costly and time consuming interface clashes.
Lesson #2:Interface Definition in FEEDDirect 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 padeyesresulting in one‐piece elbow/padeye forging
• Additional swivels required for all Jumpers and Flowlines
27
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.
28
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.
29
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.
30
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.
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.
32
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!