Abo Oml125

Close-out ABO Extension Project
Nigeria -OML 125
Major project milestones
– Ennio Nitti – Engineering Manager Nigerian projects- San
Donato Milanese –
End of March 2008

OML 125 -ABO Extension project

Field production avg data per year during ABO Ext Phase
Green line: produced gas consumed for motive
power of FPSO
50 Additional flow rate of ABO 10 .11 (March 2009 trend) approx 18.000 BOPD
40
31,002 33,96
28,8
30 25,147 28,06
26,48
23,83
18,014
20 16,816

10

0
Prod 2005 Prod 2006 Prod 2007 Prod 2008 Expected 2009
March
(assuming 50%
production yr 2
from start)

Crude Avg Production
Gas injection trend (1 GI)

• Note – Approx Indication in Barrel Per Day for crude and MillionSCFD per injected or produced gas

2

Location of Nae Block

3


CHARACTERISTICS DATA
Past Name / Present GREY WARRIOR / ABO
Name FPSO
ABO FPSO
Built in / Converted in 1976 / 2002

Length overall 280,4 m

Breadth 53,6 m
VESSEL MAIN DATA

Depth 20 m
160.000 Metric Tons
Dead weight
(approx)

Cargo oil tanks 951.658 bbls
capacity

FPSO conversion an field positioning : 2002/2003 March ( Abo Central)

4


Current Porch Configuration
Riser hang-off systems were
designed to be located at
same FPSO side (even for
future expansion)

Hang-off of risers in a free
hanging configuration from a
deck balcony configuration

Control Umbilical through
I-Tube located on the vessel
side (see red line)

Total hang-off available
systems: 5 + 4 (spares)
for risers and 1 + 1 spare for
umbilical

5

ABO Extension = Schematic Block Diagram of the FPSO Facilities
(Receiving manifolds, separation, gas compression, oil handling, water handling)
Data regarding actual design envelope for liquid expressed in BPD (Barrel per Day); for gas expressed in Million
SCFD
Design envelope: Only from
Design envelope HP 44 Million SCFD + Second Design envelope:
Flare:49 Million 10% = 48,4 Compressor 48,4 Million SCFD
SCFD Million SCFD Stage
Heating Utility and Relief System Fuel Gas Fuel Gas
System for Instrument to Flare Reciprocating Dehydration for
Oil Treating Air ( HP, LP) Compressor Glycol Internal Sea Water
(3*50% Contactor Process Lift
Fire Unit and
Fighting capacity ABO Use
Central) over Regen within
Deluge Package
System Three Stages FPSO
Design envelope First Stage From 1st
Separator: 40000 BPD + Stage
10% (= 44000 BPD) of Separato Gas Handling
Via Booster Re-
Liquid (Oil+Water) with a r and 2*100 % Cooling for
Compressor Injection Overboard
Maximum Peak of Water of only Booster Sea Water
Water Compressor
9000 BWPD + 44 Million Compressors Filtering
Pumps and Oil
SCFD of Gas Handling
to Wells
Well ABO 9 LP
Stages
Well ABO 10 Design envelope
Well ABO 11 Flow lines Inlet Crude Booster: 5,5
and separation Million SCFD + 5,5
Existing ABO manifolds (1st and 2nd Oil Treating Million SCFD
Central; Wells 2,3,4 (1st, 2nd Sea Water
Stage (i.e Design envelope:
Existing ABO Central; Design envelope Degassing
stage) Separators, Stabilizing
Wells 6,7 Crude Stabilization 9000 BPD
interfacing Electrostatic and
Abo Central Gas : 40000 BLPD +
Subsea Risers Dehydrator) Desalting)
Injector Well 5 and 10% (= 44000
BLPD) + 5 Million
Umbilicals
SCFD Gas
Design envelope Test Design envelope
Separator :17000 Chemical Hydrocyclons 12000
BOPD+4000 Injection BPD Sea Water
BWPD+19000 MSCFD Produced +12000 BPD as
Skidded Crude Oil Boosting
Water spare Design envelope:
Units for Storaging and
Treatment 30000 BPD + 10
SEE SLIDE 4 FOR Subsea and within FPSO Pumping
Design envelope: %
INTERCONNECTION Topsides System
9000 BPD + 2000
SEQUENCE BPD from
Chemicals loading
Water Overboard Desalting
30PPM Quality (=11000 BPD) +
Oil to Export
10%
FPSO

6

Actual design parameters of ABO Topside
Facilities FPSO
Design Parameter Value / Policy

Life design of existing facilities 10 years (starting from 2002)
Oil design flow rate 40000 BOPD + 10 % overdesign

Maximum design temperature process side 50 °C

Maximum design pressure at manifold inlet 21 barg
Design capacity of gas treatment 44 MMscfd + 10% = 48.4 MMscfd

Gas injection line design 42MMscfd + 10% (total 44 MMscfd at exit of 3rd stage
injection compressor when two trains operating in
parallel; one in stand by)

Maximum gas injection pressure at gas lift line to 250 barg (@ porch)
existing ABO_5
Gas Strategy Gas reinjection into the Reservoir

Maximum water production handling flowrate 9000 BWPD; overboard water quality (Oil in Water)
discharged to sea: < 30 ppm

7

Abo – Extension Project -OML 125
Actual FPSO mooring system and existing flow lines arrangement
with indication of the new wells

ABO 11c -producer

ABO 9b –
Gas injector
ABO 10- producer
proposed oordinates wells at
sanctioning
ABO 9B 661919.0 E 631920.0 N
ABO 10 660343.7 E 631713.1 N
ABO11C 660653.0 E 632729.0 N
Mooring chain number 3
required to be lowered for
installation

8


n
TOPSIDE EVENTS MAJOR MILESTONES OF ABO
EXTENSION

9


Project follow up by subcontractors from project start up
till completion

The engineering “volume” of manhours associated with the extension works is
as follow:

Subsea EPC: manhours (Pm+Eng). Approx: 75000
Topsides-FPSO Vessel: manhours (Pm + Eng):12000

Engineering Follow -up: manhours (13000)
Installation contractor: manhours (100000)

Note : Documents issued by Install contractor: approx 220
Documents issued by Subsea EPC supplier: approx 500
Documents issued by FPSO owner: app. 150 (new); 330
(revision of exixting one)

10


Release 1_A of Nae
3229.41.000.L.DL.FC88001
Field lay-out without bathymetry
ABO 9b –Gas
injector
Abo Ext

11


12


Subsea lines scope of installation.

Description Service From To Length (m)
RG2 GI riser FPSO ABO-9 950
GI flowline FPSO ABO-9 1976
R10 6” production riser FPSO ABO -10 850
6” production riser FPSO ABO -10 3630
R11 6” production riser FPSO ABO -11 850
6” production riser FPSO ABO -11 3573
F10-11 Pigging loop ABO-10 ABO -11 1286
UM2 Dynamic Umbilical FPSO UTA-UM2 2825
(including riser 745.5
m to TDP
UP-10 Infield umbilical UTA-UP10 UTA-UP10 B 1630
A
UP-11 Infield umbilical UTA-UP11 UTA-UP11 B 1580
A

13

Porch area:well connections

AFT
SIDE
FORE SIDE
New sequence approved during detailed
DECK SIDE
engineering
Abo Spare New Abo Abo AFT SIDE

11 slot Umbi 9 10
lical

Umbilical ABO
Central

ABO FPSO vessel

Existing Water injct
(ABO 6 ,7)
Existing ABO GI (ABO 5)

Existing ABO 2 (Prod)
Existing ABO 4 Producer
Existing ABO 3 (prod) FORE SIDE

14

Daisy chain : proposed arrangement of the new production wells.

Final configuration as per
attached P&I

ABO
10
ABO 11

Dinamic Flowline

Pig receiving line
ABO 11 – Production Header Riser to Pig Receiver
Pig launcher line
ABO 10 – Production Header Riser to Pig Launcher

15


16


TOPSIDE FACILITIES
B. Areas of FPSO deck interested in ABO Central Upgrade
1. MANIFOLD/PORCH AREA:
• i.e. interconnections between new risers and existing manifolds; winch refurbishment
2. RACK AREA BETWEEN PROCESS AND INJECTION/BOOSTER COMPRESSOR MODULES:
• i.e. new line to new gas injector well and associated control ( nearby process equipment
module) ;
3. RISERS AND UMBILICAL (AND SUBSEA FOR FACILITIES):
• i.e. new risers and umbilical at porch, complete of greylock, venting and necessary wiring
and tubing;
4. HPU area/TUTU1 area:
• installation of new skid packages (i.e. new HPU, new TUTU) for control of subsea equipment
on deck as well as new Topside chemical injection unit;
5. DCS control room area/Instrument technical room upgrade for the new wells:
• expansion of the existing subsea control dedicated to the new subsea users; interface with
existing UPS;
• modification of existing DCS for new topside users;
6. MCC and Engine room area:
• new power supply lines to ABO Ext equipment/ instrument;
7. FWD Crane Area:
• tie-ins for methanol and wax inhibitors for new producer well using existing installations or
new wax inhibitors and methanol pump motor skid for new producer well.and installation of
proper heat radiation shields where required due to higher flare gas flow rates originated
from subsea fields ( namely ABO2 field)
8. Aft Crane Area:
• Minor servicing of existing winches for chain slackening.

17


– FPSO arrangement- Areas interested by
modifications

affected areas:

Crane area
DCS Rack area
MCC (compressor )
area Flare area
Manifold area
Exist HPU -TUTU
and main winch
Porch area

ABO FPSO

18

OML 125 - ABO Extension project

Offshore Installation –Topsides works in support of Vetco Control topside installations (1)
Major works recap

Description Scope Notes

ABS certification of subsea HPU, TUTU and Control
Topside items container

Upgrade of Container design to Fireproofing with
meet safety ABS requirements Chartek 7 to ABS
due to deck “C” installation requirements
Transformer installation to suit
available on-board power supply
Engineering and
(440 V /3 phase) to the power
Material supply
supply rating of the container (220
V monophase

Note (1) = Whole installation process completed safely with “0” LTI

19

Engineering
developed by FPSO vessel owner in support of their EPC (1/1)

-P&I’ s of new elaboration/ rework:
- Chemical injection system methanol and wax inhibitor units servicing
the new TUTU, supplied by VETCO and Instrument air, Nitrogen, closed
drain , sea water cooling
- new manifold area P&I scheme in order to show new the pig
launcher( x-234) and receiver (x-235)
- Reissue new P&Is pig launcher-receiver equipment/ instrumentation
as well as show piping connections with inhibitors lines
- Manage tie-ins on existing schemes
- Provide support for SIMPOP-HAZID-HAZOP
- Activation of MTO of piping valves and in line material

-General arrangement drawings (Layouts and Piping):
-elevation and plan drawings at porch area and manifold area
-New plot plan drawing(s) of the new pumps and relevant
installation
-Installation drawing(s) of the new TUTU
Installation drawing of the New HPU
-plot plan of FPSO areas where new technical room of the new ECS
Cabinets has to be installed. Wire connections to ITR existing in
order to ensure DCS-ESD and subsea datalogging continuity.

20


TOPSIDE FACILITIES
Engineering developed by FPSO vessel owner “2/2”

Specification /BoQ-MTO
New duty specifications of new equipment,piping, instrumentation and electric HW
supply, including Chocke valves, SDV and miscellanea.
Provide BoQ and isometric drawings for piping and valves
Instrumentation and control ( “Cause –effect” ) documents:
Provide instrumentation list with settings and main design data
Revision of the EDS/PSD diagram
Review of the UPS connectiona
Revision of the Juncion box connection diagrams
Interfaces with I/0 of new subsea
Implementation of new video pages for existing DCS
Electrical distribution drawing:
New wiring from diatribution 440 V/3ph engine switchgear room associated ones to
feed new HPU ,TUTU,ECS panels by VETCO
Revise diagrams and terminals for miscellanea ( instrumentation feed)
Provide BoQ of cabling of new supply for different cable design specification
Update / procure cable ways when required

21


Offshore Installation –Topsides works in support of Flow line installation (1)
Major works recap

Description Scope Notes
Load re-testing and ABS
Additional certification for deck winch (22t) and
Main FPSO winch (75t design capacity) recertification, (including
tugger winch (5t)
pulling wire)

Leak testing and tubing
Greylock fittings of flow lines routing for venting of
connection

Abo 9 injection; 10, and 11 production
pipelines statisfactorily tested at 270 bar ABS certified
and 240 bar respectively

Mooring analysis and procurement of
new parts (chain links) for slackening of
chain number 3 and additional works/ ABS supervised
personnel to achieve the installation
Technip schedule

Support for precommissioning flow Support to safely dewater
lines and diesel fill new flowlines

Cleaning bellmouth and
Diving squad in support of installation fixing / installing new
umbilicals

Note (1) = Whole installation process completed safely with “0” LTI

22


TOPSIDE FACILITIES
B. Areas interested in ABO Central Upgrade
RACK AREA BETWEEN PROCESS
AND INJECTION/BOOSTER
COMPRESSOR MODULES (i.e. new
line to new gas injector well ABO 9 )

Abo 10
Rack Xssing Foreside-Aft side

Abo 9

23


TOPSIDE FACILITIES

MANIFOLD/PORCH AREA (i.e.
interconnections between new risers and
existing manifolds)

24


TOPSIDE FACILITIES

• RISERS AND UMBILICAL (AND
SUBSEA FOR FACILITIES - i.e.
new risers and umbilical at porch)

25


TOPSIDE FACILITIES
HPU area/TUTU1 area -
installation of new skid packages (i.e. new HPU, new TUTU)
for control of subsea equipment on deck ( Abo central
pkgs shown)

26


TOPSIDE FACILITIES

DCS control room area/Instrument technical room ‘B’ (expansion of the
existing subsea control dedicated to the new subsea users; interface
with existing UPS
modification of existing DCS for new topside users)-Cabinet of abo
extension located elsewhere ( Deck ‘C’)

27


TOPSIDE FACILITIES

FWD Crane Area -
tie-ins for methanol and wax inhibitors for new producer
well using existing installations or new wax inhibitors
and methanol pump motor skid for new producer
well

28


TOPSIDE FACILITIES

Engineering/Procurement Activities by FPSO vessel owner (1/2)

Project Management throughout the project;
Site visit by designer to verify the design /installation if required, including surveys for subsea-
installation contractor and precommissioning of flow lines ;
Design, engineering, procure, install and hydraulic testing of new piping pertaining to production
header tie-ins and gas injection header tie-ins, using local content labor;
Prepare piping isometrics for piping pre-fabrication with the aim of minimizing hotwork and shutdown
requirements; Shut down minimized in march 2008 for manifold line tie-ins ( HP,LP,Header,testing
line)
Procurement of piping, valves, control valves, shutdown valves, instrumentation systems, cables,
tubing, cable trays and etc. as required to tie-in the new wells from the riser porch dummy spool;
Support and assist Company in refurbishing mooring line ( required for chain slackening #3) as
well as maintain and service existing hydraulic winches for umbilical and flowlines installation

29


TOPSIDE FACILITIES

Engineering/Procurement Activities (2/2)

Revise all relevant existing drawings, safety plans, P&ID's, cause and effect, vessel general
arrangement, instrument drawings etc to incorporate the new modifications;
Develop modifications to the process control system to reflect the new equipment;
Obtain Class approvals as required to implement the changes; obtain permits, license and
authority approvals (Support Documentation for approval of Nigerian authorities, Support
Documentation for approval of ABS);
Perform HAZOPS, HAZIDS for the construction and operations phases;
Develop Job Cards and Procedures for the offshore installation as well as implement installation
details in Office Project for all the installation activities ( Prosafe scope and interface scope) ;
Logistics, Coordination of shipments and Offshore Construction works in cooperation with Nae;
Revise Operating Manuals to suit the modifications;
Monitor punch lists after First oil.
As-built all drawings preparation and final documentation affected by the change.

30


TOPSIDE FACILITIES

Offshore Installation (1/3)

Mobilise construction crews to offshore for installation of mechanical, electrical, controls and
instrument scope of work;
Transport all equipment, tools, and materials to offshore;
Install all valves, instruments, tubing, piping and cabling to connect the new equipment;
Modify the process control system (DCS) to include the new wells (field instrumentation);
Preserve the system ready for riser pull-in (final dummy spool -if required- and one section of
pipe to be left intact for later removal during riser pull-in should these activities not be
combined;
Obtain ABS Class Supervision during key installation phases

31


TOPSIDE FACILITIES

Offshore Installation (2/3)
Subsea Control System Interface activities:

- Coordinate with Subsea Contractor regarding supply and
installation of hydraulic tubing from the HPU/TUTU to the riser
porch JB according NAS 6 quality standard;
- Supply, install and test hydraulic tubing as required to suit the
new well control requirements;
- Cabling and hook up tubing for subsea controls, terminating in new
junction box at riser porch;
- Mobilise specialists for process system software changes and
perform site modifications for the subsea control system
interface.
- Keep under control POB during crucial installation phase ( off-shore)

32


Offshore Installation –Topsides (3/3)

Key Parameters (internal
evaluation based on FPSO vessel owner final
numbers for 2+1 wells)

Installation
Description Installation Manhours
Parameters

Piping and Ancillaries (1) 30.000 kg
Indicative data from
OIM:
Packaged Equipment (2) 10000 – 13000
20.000 kg

Cable/Cableways
3000 m 4500
(Power and Control)

NOTES (1) It includes approx 8000 Kg of valves and light steelwork for support;
(2) it includes 2 off pigs, 1TUTU,1HPU, 1 control cabinet 1 Chemical injection skid

33


installation contractor sub-orders ( major)
Description Scope Company
Flexible pipe and ancillary equipment (Hang off Material, shop production, FlexiFrance (France)
collar, Bend stiffner and Bend stiffner spacer) shop testing
Anodes for flowlines Material, production, shop Impalloy (UK)
testing
Insulation Covers Material, production, shop Bardot (France)
testing
Precommisioning Service (FPSO and Installation Detail Engineering and BJ (UK)
Vessel) Offshore rental equipment
- labour for commissioning
activities
Steel Bend Restrictor Material, shop production, Asturfeito (Spain)
shop testing
Survey Service Detail Engineering, DOF (UK)
offshore personnel, labour
and ancillary tools /
equipment
Turning points Material, shop fabrication, COMETRA (France)
testing AMS (Nigeria)*
Umbilical Tether Base & Tether Material, fabrication, COMETRA (France)
testing
NOTE : (*) Spare items
Note (1) = Whole installation process completed safely with “0” LTI. - main subcontractors list for
ABO Extension. (Installation of all items managed by Installation contractor)

34
Technip


Major subcontractor packages for Topsides FPSO works
Description Scope Company
Mooring equipment for chain Material (air shipped) and
Noble Denton Singapore
number 3 slackening labour
Overhaul and refurbish 75,25,5 Laad cell monitoring, Mc-Gregor Plinsol
tonn winches service parts and labour Singapore
Personnel assistance during Labour in support of Noble Denton- Mc
hook-up phase operations by Technip Gregor
Labour, tools and tool –
HP Tubing and Chemical tubing
service container to
on board of vessel up to Hulliburton Nigeria
perform NAS 6 quality
Umbilical plate
flushing
Labor and logistic to clean
Diving and divers equipment bellmouth and install / fix Ken-dive Nigeria
new umbilical
Small bore spare valves for
Material supply Alton
piping works
Material (air shipped) and
Flare radiation shields Thermolimitec
engineering
Material supply for
continuty of installation
Dummy fittings Dormen long
between piping and
flowlines

Prefabricated piping (above 2”) Material supply, support
for all pipework from porch area during installation, field Amber resources Nigeria
back to manifold an Pigs welding Xray testing

ABS Singapore and
ABS supervision/ approval Process review
connected offices

35


Estimated subsea contractor delivery schedule (only Items
interfacing topsides )

Final delivery for
installation : trees
between February
2008 and April 2008

Topside control End
of June 2008

36

OML 125 -ABO Extension project-Installation of FPSO
modification

37


38


39

The scope of supply for Integrated Control and Safety System modifications included but was
not limited to following:
• Design, Engineering, Procurement, Programming, Configuration, Software, Graphics, Logics, Fabrication,
Assembly, Testing and Commissioning, Preparation for Shipment, packing and supply of System hardware with
cabinets, I/O Modules, and Controllers for the “ modification of existing control system at offshore (on the FPSO).
Integrated Control and Safety System (ICSS) consisted of :
• Process Control System (PCS)
• Process Shutdown System (PSD)
• Emergency Shutdown & Fire and Gas System (ESD/F&G)

• Specifically :
• Updating the existing configuration and configuring additional I/O Modules, Spare Channels and Marshalling
Termination
• Configuration and integration with new ECS system HPU system supplied by Vetco with existing PCS.
• Modification to existing graphics and build new graphics.
• Upgrading of the redundant controllers for 6MB Capacity.
• Supply of IS barrier for intrinsically safe signals.
• Review existing M-NET capabilities for additional nodes and its adequacy.
• Configuration of existing Tag server database for new I/O’s and its adequacy.
• Configuration of existing Historian Server database for new I/O’s.
• 4-mation Configuration
• Software Configuration and testing (on-shore-offshore)
• Configuration of alarm functions for existing inputs-3 Nos
• FAT,SAT & Commissioning assistance.
• Update Client’s comments at site.
• RS485/RS 232 serial link connectors and required network adaptors.
• Engineer site deputation for installation, testing and commissioning at ABO FPSO.
• Packing and Shipment.
• Tagging and labelling.
• Supply of special tools.
• Documentation.

40


ITEM 5.1 -TOPSIDE FACILITIES-modification of overall subsea control system to be integrated with ABO
central ( Using Multi drop communication system protocol)

41


Location Deck “C” where Container will be placed

Internal view Container hosting sub sea

43


44

Offshore Installation field precommissioning (sample of
signed hand over document)
TOPSIDE FACILITIES- List of commissioned sub-system

45


FIELD START-UP EFFECTIVE DATES OF ABO EXTENSION
Wells start-up dates of ABO COMBINED PROFILE (CENTRAL + ABO EXTENSION) :

Wells Date

ABO 11 (P1) 14° February 2009

ABO 10 (P2) 15° February 2009

ABO 9 (GI) 20° February 2009

Test of production : mid 2009

46

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