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Abstract
Discovered in 1998, the Rosa field is located offshore Angola
in the prolific Block 17, at a distance of 16 kilometers from
the spread-moored Girassol FPSO. Water depth in the area is
about 1,350 meters.
Sanctioned in July 2004, the Rosa Development Project
proposes to tieback the Rosa wells to the Girassol FPSO. This
project handles challenges never faced before in deepwater
West Africa: long-length subsea production flowlines in cold
environment and extensive tie-in works in simultaneous
operations (SIMOPS) conditions on a live FPSO.
For processing the Rosa production on the Girassol FPSO,
5,600 tonnes of new modules, equipment and temporary steels
are added to the existing installation. This paper will
contribute to benchmarking such development alternative,
focusing on the revamping of the FPSO topsides.
The difficulties in preparing and achieving the objectives
are presented for such scale of modifications works in West
Africa. The decisions that were made on the Project execution
plan and on the contractual strategy for the topsides works are
described with their materialization on the essential aspects of
HSE, Engineering and Procurement for onshore fabrication
and offshore integration in SIMOPS conditions. In particular,
this paper covers the rationale and the feedback for planned
shutdowns - piping tie-ins (with mandatory maintenance and
inspection of existing FPSO equipment) and heavy lifts of
modules - as well as the solutions implemented for the Flotel
and logistical means in Angola.
Finally, the conclusions address the main lessons learnt
and keys to success for the hook-up, commissioning and startup of the Rosa Project.
The significance of this paper is to share the knowledge of
a major Project worked out in SIMOPS conditions, knowing
that the modifications of the Girassol FPSO are the greatest
ever made so far on a recent-built FPSO and lead to a worldfirst 2-year offshore works campaign on a live FPSO.
Introduction
At concept selection stage of the Rosa Project in June 2001,
new-built FPSO and new-built FPU options have been
envisaged. At the time of concept selection, the economic
conditions were such that the cost of a stand-alone production
pole which was under consideration was too high to yield
acceptable economic results. Thus these options were not
carried out further.
In addition, an assumed leasing system for a FPSO or a
FPU would have improved the economics without
representing a major breakthrough for the Angolan economic
value.
The direct subsea tieback to Girassol was the best-suited
concept to reach the different economic threshold limits. This
FPSO was also the ideal candidate to welcome a tieback:
available areas on the topsides, recent-built plant in good
condition for structural reinforcements and piping tie-ins,
compatible process with Oligocene oil, extension of the
production plateau and full use of an existing asset.
Although it required significant challenges - innovative
design criteria, coping with the overall liquid treatment
capabilities in the critical years, development of existing
technology for the flowlines and risers, flow assurance issues
for the subsea systems, SIMOPS constraints for the hook-up
phase - such project was considered feasible.
It was also emphasized that the industrial market would be
sufficiently open for a fair bidding competition, based on a
preliminary design competition for SURF and an extensive
Basic Engineering for Topsides.
Overview of the Rosa Project
The adopted development scheme includes:
i. Drilling of 25 wells including 14 production wells
and 11 water injection wells,
ii. Connection of the production wells to four subsea
manifolds,
iii. Laying of 65km of pipe-in-pipe subsea production
flowlines (two loops) and of 40km of water injection
pipelines (two single lines) connecting Rosa to
Girassol,
iv. Installation of a "Riser Tower" West of the FPSO,
ensuring the connection between the subsea lines and
the surface,
v. Installation of seven modules dedicated to Rosa, and
their tie-in to the existing Girassol installations,
making a total permanent additional weight of 5,300
tonnes.
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ii.
iii.
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Main Achievements
Detailed Design.
Weight optimization was one of the main assigned targets.
The Weight Reduction Initiative undertaken at the beginning
of the detailed design and thoroughly pursued afterwards was
not infringed by cost consideration. As a result, the first
weight report produced by the Engineering Contractor had
predicted an overall Gross Dry Weight (in-place) of 5,800
tonnes, whereas it became 5,300 tonnes at contract end in July
2006 (i.e. 4,000 tonnes for the modules and 1,300 tonnes for
interconnecting, excluding 300 tonnes of temporary steels for
installations guides).
Another important challenge was the early identification of
engineering solutions allowing the minimization of the
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offshore man-hours and hot works. Close and early input from
the various contractors through a comprehensive Interface
Management System led by the TOTAL Rosa Project Group
was of paramount importance. This was in particular
implemented with the Installation Contractor for the definition
of the installation aids and installation volumes restrictions,
and with the Hook-up Contractor for the critical
constructability aspects. Agreed solutions were always taken
to the sole benefit of the offshore scope, even with cost and
planning impact on the onshore construction works.
Onshore Construction.
Fos yard, France.
Four out of the seven Rosa modules were built in this yard,
plus the supporting frame of an additional 60-seat freefall
lifeboat (part of the Early Small Lifts):
i.
M1 is a 6-leg supported module designed for
flowlines preservation with dead oil circulation and
dedicated electrical generation (two diesel generators
of 3.2 MillionVA each), with a lift weight of 1,200
tonnes.
ii.
M2 is devoted to methanol injection and is the
lightest module with a lift weight of 135 tonnes.
iii.
M4, dedicated to water treatment and injection (two
water injection centrifugal turbo-pumps), is to be
located on the FPSO on top of a new-built
substructure installed during the Early Small Lifts
campaign and is the heaviest module with a lift
weight of 1,750 tonnes.
iv.
M6 is dedicated to separation with one first stage
separator and hydrocyclone, with a dry lift weight of
600 tonnes.
Flotel.
A hydrodynamic engineering study was performed on the
relative motions between the FPSO and the MSV Regalia to
determine the Flotel behavior and to assess the best
configuration for her hydraulically operated telescopic
gangway. The availability target of the gangway in operation
was set by the Project over 98% of the time, taking into
account the one-year weather condition and the FPSO extreme
drafts in operations of +11m to +22m. In this case the
maximum angle for the gangway is ranging between -11 to
+12 to the horizontal. This had led to an optimization of the
gangway pedestal height to 8.1 meters. The 38m nominal
length of the aluminium telescopic gangway was kept with its
+7m to -7m possible extension.
Over more than one year of utilization, the Regalia did not
had any breakdown, and out of the 6 hours spent for planned
maintenance, the gangway has always been operational.
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