Shell Exploration & Production

Bonga Steel Catenary Riser Installation

Joe Hoffman May 11, 2005

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Bonga Field Location

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Bonga FPSO Facilities Requirements

FPSO Oil production rate of 225,000 bopd Produced water up to 100,000 bpd Water injection rate up to 300,000 bpd Total produced gas rate up to 170 MM scf/d

Total fluid production capacity up to 280,000 bpd

Subsea System 27 Seabed Well Locations 36 Subsurface Targets

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Bonga Facilities Overview - Subsea

5 Production Manifolds 10 Production PIP flowlines 37 km 3 Water Injection flowlines 25 km 11 Steel Catenary Risers (SCRs)
Two 12 Production Six 10 Production Two 12 water injection One 16 Gas Export

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Bonga FPSO Riser Layout

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Bonga Riser Configuration

SCR Riser Departure angle from FPSO 15 degrees from vertical Nominal touchdown point of riser is approximately 700 meters from the FPSO Overall length of riser is approximately 1690 meters At FPSO interface the riser is designed with a flexjoint to prevent over stressing of the riser due to dynamic motions from the vessel. To suppress Vortex Induced Vibration, VIV strakes are installed from about a depth of 8 meters to 128 meters At the uppermost attachment and touch down area for the production and water injection risers a clad section was included in the design to help increase the overall fatigue performance of the risers

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Bonga Riser Transfer Tensions

Installation Installation Transfer Transfer Tension - Dry Tension - Wet (tonnes) (tonnes) 107 72 137 76 182 125 207 214

Description 12" Production Risers 10" Production Risers 12.75" OD x 1.125" WT API 5L X52 Carbon Steel 10.75" OD x 1.00" WT API 5L X52 Carbon Steel

12" Water Injection Risers 12.75" OD x 1.063" WT API 5L X52 Carbon Steel 16" Gas Export Riser 16.0" OD x 0.812" WT API 5L X52 Carbon Steel

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Bonga FPSO PreInstalled Appurtenances Required for Riser Installation

Riser Porch Receptacles

Riser Chain Jack Supports Riser Pull-in Sheaves

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Bonga Pull-in System

Riser pull-in performed with the same proven technology that Shell has utilized for installation of risers in the Gulf of Mexico. The Pull-in system consists of: Chain jack system 350 tonnes Two Lateral Pull-in Winches 80 tonnes

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Bonga Riser Installation

Flowlines were pre-laid on the Seafloor with the Stolts Seaway Polaris. Flowlines were subsequently retrieved and risers were fabricated with the Polaris. Polaris Specifics: J-lay System that handles double joints Top tension capacity of J-Lay tower 350 tonnes Average riser fabrication time from retrieval of the flowline to hand over of the riser approximately 7 days.

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Bonga Riser Installation Riser Fabrication Complete

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Bonga Riser Installation Installation of Outrigger and Transfer Chain

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Bonga Riser Installation Lowering of Flexjoint

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Bonga Riser Installation Polaris 180 Degree Spin

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Bonga Riser Installation Handover of FPSO Transfer Chain

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Bonga Riser Installation Transfer Chain Makeup and Lowering

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Bonga Riser Installation Load Transfer

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Bonga Riser Installation Complete Load Transfer

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Bonga Riser Pull-In Pull-in Winch Hookup to Transfer Head

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Bonga Riser Pull-In

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Bonga Riser Installation

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Bonga Riser Installation

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Bonga Riser Pull-in

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Bonga Riser Installation Lessons Learned

Relocation and setup of the chain jack and pull-in winches took approximately 1 day offshore. If the pull-in of the risers is on critical path, the design of the pull-in system could be modified so that it travels on trolley system to avoid setup time.

Relocation and setup of the chain jack

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Bonga Riser Installation Lessons Learned

The placement of the lateral pull-in sheaves needs to be well defined for all riser locations.