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PROCEEDINGS, INDONESIAN PETROLEUM ASSOCIATION

Thirty-Third Annual Convention & Exhibition, May 2009

FLOATING LNG TECHNOLOGY FOR ABADI FIELD DEVELOPMENT

Ryo MANABE*
Akinori OGAWA*
Yoshiro NIIHO*

ABSTRACT southern boundary of the block follows the

international border between Indonesia and
The Abadi field development is an authentic frontier Australia.
gas discovery in the Arafura Sea, in Eastern
Indonesia. Exploration and appraisal activities have Exploration and appraisal activities, including
confirmed significant gas and condensate reserves – 2D/3D seismic and 7 well drilling, confirmed
enough to justify a stand-alone development of significant gas and condensate reserves, which were
LNG. However, no easy development solutions to sufficient to justify stand-alone development of
monetize such significant gas resources are LNG. However, no easy solutions to monetize such
available, due to its remotely-located deepwater significant gas resources exist, due to its remotely
setting. Floating LNG (FLNG) technology was located deepwater setting in the Arafura Sea.
identified as a potential solution to overcome this
field development challenge. INPEX has studied FLNG technology since 2000.
This cutting-edge technology was identified as a
The objective of this paper is to demonstrate the potential solution to overcome the Abadi field
technical feasibility of the FLNG application for development challenges. Throughout extensive
Abadi field development, focusing on major concept evaluation studies, including various
technical aspects such as safety, marinization of onshore LNG solutions, INPEX Masela decided to
processes and equipment, reliability, availability develop the Abadi gas field utilizing FLNG
and maintainability (RAM) along with LNG technology. The recommended development
offloading operation. The results reveal that the concept is summarized as follows (Figure 2):
conceptual design here satisfies our safety and
functional requirements enough to be applicable for • The Phased development strategy is
Abadi field development and is thus evaluated as accommodated with 1st Phase development
technically feasible. producing 4.5 million tones per year (MTPA) of
LNG and app. 13,000 bbl/d of condensate, over
INPEX Masela has been selected to develop the 30 years.
Abadi gas field, utilizing FLNG technology, and has
proposed a Plan of Development (POD). Although • The 1st Phase development facility consists of:
technical and commercial risks still remain, INPEX
· 11 to 18 subsea production wells,
Masela intends to overcome such challenges to
· subsea production system with 3 to 5
secure the Abadi gas resources.
subsea clusters and associated flowlines,
INTRODUCTION umbilicals and risers, and
· a single weather-vaning FLNG facility.
Abadi Field Development
• The future expansion plan will be developed
The Abadi gas field is located in the Masela PSC after evaluating the upside potential of the
block in the Arafura Sea (Figure 1). Approximately entire Abadi field.
150 km north of the block, the Tanimbar Islands
follow an east-west direction along the outer ridge The application of FLNG to 1st Phase development
of the Banda Arc. The deep Timor trough lies of the Abadi field has significant advantages over
between the islands’ arc and the Masela block. The the conventional onshore solutions. The major
[
drivers for this decision are:
* INPEX Masela
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• Suitable MetOcean Conditions – The general • Living Quarters

MetOcean conditions around Abadi field are
relatively benign, even with a tropical cyclone 1.1 Process Design
season from October to March. These
conditions are considered within the acceptable The process flow diagram and utility flow diagram
range to design and operate the FLNG. for the FLNG are shown in Figure 4 and Figure 5,
respectively.
• Lower CAPEX / OPEX – The CAPEX and
OPEX associated with FLNG are estimated The feed gas pre-treatment process must be
lower than the onshore options due to avoidance designed based on project-spec data, such as
of duplication of parts of the field development reservoir and fluid data, MetOcean conditions and
facility and the long export pipeline to shore. the applied wells & subsea system operation
philosophies. The design basis of the feed gas
• Minimum Environmental Impact – The field pre-treatment process has a significant impact on
development utilizing FLNG can minimize the the plot area and hull sizes, as well as technology
environmental impact due to avoiding selection, utility consumption and system
significant land acquisition, infrastructure and availability.
harbor facilities relating to the onshore LNG
plant. This can also lead to a shorter permitting The major characteristics of the selected process
schedule than the one for onshore solutions. technologies for the FLNG are described as follows:

• Flexibility for future development – The future Liquefaction Process: The dual mixed refrigerant
development plans for installing additional train (DMR) system, consisting of a warm mixed
and/or tie-in to the 1st Phase FLNG can be refrigerant (WMR) cycle and a cold mixed
flexibly accommodated after evaluating the refrigerant (CMR) cycle, is used for liquefaction.
upside potential of the entire Abadi field. The process was selected with the following criteria,
among existing liquefaction processes:
Based on the above development concept, INPEX
Masela plans to commence the Front End • Safety and Reliability
Engineering Design (FEED) within 2009, and is • Floating LNG Application
projecting the start-up of production around 2016. • Baseload LNG Application

1 INPEX Masela Floating LNG Electric Motor-driven Refrigerant Compressors:

The electric motor and variable speed drive (VSD)
The FLNG is a Floating, Production, Storage and system are employed for the refrigerant compressor
Offloading (FPSO) facility, capable of producing drivers. The schematic diagram of the system is
4.5 MTPA of LNG and app. 13,000 bbl/d of shown in Figure 6. It confirms the benefits,
condensate (Figure 3). The facility also includes compared to the conventional gas turbine drive
ancillary facilities being self-contained on board, system, as follows:
consisting of:
• Safer design to remove the ignition source from
• Feed Gas Pre-treatment Process (Inlet Gas a hazardous environment adjacent to the
Separation, Future Boosting Compressor, Acid congested topside process area
Gas Removal, Dehydration & Mercury • Higher availability and better maintainability
Removal, etc.) • Low CO2 emissions
• Liquefaction Process
• Condensate Process (Condensate Stabilization, Electrical Power Generation: Approximately 280
etc.) MW of electrical load is required to operate the
• Water Process (MEG Reclamation, Produced entire plant, including the refrigerant compressors.
Water Treatment) All the required electricity is generated onboard by
• Utility System the gas turbine generators (GTGs) and the
• Products (LNG & Condensate) Storage & associated combined cycle (Figure 6), consisting of
Offloading the steam turbine generators (STGs), the heat
• Flare System recovery steam generators (HRSGs) and the
• Turret & Mooring auxiliary boilers. The steam provides the heat
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required for the process as well as the motive force of gaseous hydrocarbon releases and to reduce
for the STGs. The waste heat out of the GTG the effects of explosive overpressures.
exhaust stacks and the auxiliary boilers generate the
required steam. The system improves thermal • Primary and secondary escape routes within
efficiency of the total system. each equipment module and area are linked to
the main escape routes, leading to the safe area
The numbers of generators is designed based on and the Temporary Refuge (TR).
N+1 sparing philosophy. A GTG and a STG are
spared to be capable of full LNG production even • The safety and operability of the marine and
during maintaining a GTG or a STG. logistic operations, such as the LNG offloading,
the condensate offloading, the supply boat and
Indirect Water Cooling: The closed loop cooling the helicopter operations, are considered.
water system is used to remove process heat. It is • Vessel motion, material handling (crane
selected: location and laydown area), location of LNG
tank domes and spaces for maintenance are all
• to enhance availability and reliability taken into account in the design.
• to reduce CAPEX by allowing carbon steel
piping and tubing in heat exchangers, • Main operating deck levels above the hull,
minimizing the use of Titanium creating an air gap which accommodates the
• to prevent the pollutants out of the process hull storage tank piping manifolds, topside
flowing to the sea directly, through leakage facilities drainage system, etc.

1.2 Topside Layout 2 Feasibility Assessments

The topside general arrangement is considered the The challenges regarding the FLNG are
key design consideration for the FLNG. The facility characterized as the integration of proven
is designed on the principle of maximizing the technologies, such as FPSOs, baseload onshore
segregation of hydrocarbon processing equipment, LNG plants, LNG carriers (LNGCs).
turret area and the flare system from the
accommodation area. Power generation and The following critical aspects must be assessed to
non-hazardous utilities are located between the confirm the feasibility of the FLNG under the
hydrocarbon processing plant and the site-specific conditions, design and operational &
accommodation area, to afford segregation and maintenance philosophies.
provide a buffer zone.
• Safety
The general arrangement of the topside process • Marinization of Process and Equipment
plant is designed, as shown in Figure 7, based on • Reliability, Availability and Maintainability
the following philosophies: (RAM)
• LNG Offloading Operation
• Process and utility equipment will be installed
within module structures or pre-assembled 2.1 Safety
units.
The inherent safety factor is the foremost
• Local equipment rooms are placed in the major consideration and requirement for the FLNG. The
process modules to reduce hookup work following activities were performed:
onboard.
• Issuing safety design philosophies
• Living quarters are placed at the stern of the • HAZID
FLNG to achieve maximum separation from the • Consequence Analysis (Fires & Explosions)
flare stack and the high pressure turret located
at the bow. Hazardous Identification (HAZID)
• The naturally ventilated open deck concept is HAZID is the first part of assessing safety aspects.
adopted to encourage and maximize disperion Comprehensive identification of all hazards is
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required to ensure that the potential consequences filling the volume of three modules in a line.
of those hazards are reviewed and an appropriate • Mixed Refrigerant explosion in the process area
level of risk reduction considered. The Major –same as the above
Accidental Events (MAEs) are identified and
qualitatively assessed as to whether the risk • LNG explosion under process deck –same as
reduction measures reduced the level of risk to “As the above
Low as Reasonably Practicable” (ALARP). As the
results of the qualitative assessment, there are no • LNG explosion between FLNG and LNGC
showstopping hazards identified. during LNG offloading – the worst case release
scenario was taken as filling the volume
between FLNG and LNGC
Consequence Analysis (Fires and Explosions)
The key findings are as follows:
The following MAEs are identified as inherent
safety risks for the FLNG concept, to conduct the
• The maximum overpressures in Feed Gas /
consequence analysis.
LNG and MR explosions in the process area are
estimated significantly lower compared to
• Gas Dispersion, Flash Fires, Jet Fires, Pool
conventional congested platforms. This is due
Fires and Boiling Liquid Expanding Vapor
to the relatively open nature of the topside
Explosions (BLEVEs)
layout of the FLNG.
• Vapor Cloud Explosions (VCEs)
• Explosion overpressures are unlikely to impinge
The explosion following the release and delayed
upon accommodation and the TR. This is
ignition of hydrocarbon flammable gases and
because a relatively long buffer zone, over
vapors is a significant part of the overall safety
100m wide at the utility area, exists between the
assessment. At this stage, explosion risks could not
accommodation and process area.
be fully quantified, due to the absence of levels of
• Any explosion overpressures are unlikely cause
detail design information, such as P&ID, isolatable
damage to the essential system, such as the
hydrocarbon inventories, detailed pipework
GTGs and High-pressure knockout drum.
isometrics, etc. The goals of the explosion risk
analysis here included gaining confidence on the
current design basis with regard to management of • Whilst a representative level of pipework was
potential explosion overpressure without included in the 3D model, a sensitivity study
overturning the basic layout. There was also a was undertaken on adding additional pipework
requirement to provide further considerations in to the model. The results indicate that the
design with regard to the topside module layout, the overpressures may increase by a factor of 2 to 3.
optimum gap spaces between the modules, the need Even in such a case, expected overpressures
for a blast wall, the lifeboat location, etc. still remain relatively lower compared to the
conventional congested platforms.
Although only 2D drawings showing the layout of
the major equipment were available, the 3D model • The overpressures in LNG explosions under the
was constructed (Figure 8). All relevant geometry process deck are unlikely to cause damage to
was incorporated into the model, from equipment the LNG tank dome, hull and deck structure
and support structures to the decks and module (Figure 10).
supports. In order to increase the amount of
congestion in each module, major piping was • The overpressures in a LNG explosion between
assumed, based on the representative piping FLNG and LNGC during offloading are
schematics. unlikely to cause damage to the hull plates, due
to the relatively open nature between the FLNG
The consequence scenarios, such as vapor cloud and LNGC.
sizes, ignition point, etc., were chosen in order to be
conservative (Figure 9). The chosen scenarios are as In summary, the current FLNG conceptual design
follows: has no inherent safety risks compared to
conventional congested platforms. It represents a
• Feed gas / LNG explosion in the process area – robust, safe and environmentally-friendly sound
the worst case release scenario was taken as design for proceeding to the FEED Phase.
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2.2 Marinization of Process and Equipment such as MIGAS, etc.

· Class Survey
One of the major technical challenges on FLNG is · Major Equipment Turnaround, such as
“marinization”. All the process technologies and GTGs, Compressors, etc.
equipment installed on FLNG must be tolerant
against the motion of the FLNG. • The unplanned shutdowns are estimated based
on failure data obtained from OREDA,
The MetOcean design basis is developed through published information, vendor information and
simulation models based on the public data and internal information. The mean time to repair is
site-specific measured data. The sea swell (long adjusted taking its remoteness and our sparing
period waves) was separately modeled apart from philosophy into account.
wind-sea waves. The design basis includes extreme
conditions, fatigue condition and operational • The loss of production due to excessive motion
condition of the hull and topside facility. of the FLNG is probabilistically considered.
The FLNG motion, such as inclination angle, The design of the FLNG is adequate to meet the
acceleration, frequency and their probabilistic production efficiency target and compares favorably
distribution, etc., is then calculated, based on the with the standard onshore LNG ones even taking
developed MetOcean design basis. The key findings remote offshore environments into account. It is
are: largely contributed by utilizing the electric driven
LNG concept. It provides relatively higher system
• The maximum inclination against extreme reliability and availability compared to the
conditions is estimated to be less than 5 degrees conventional mechanical drive system, due to:

• The inclination angle is unlikely exceed 1 • high reliability of the electric drives
degree. • short downtime for the GTGs maintenance
under applying N+1 sparing philosophy
The study even used relatively conservative • Short startup duration through using VSDs
assumptions as usual in the absence of detail design
information at this stage. The motion characteristics 2.4 LNG Offloading Operation
of the FLNG are relatively small compared to
conventional FPSOs operating under harsh The side by side offloading using the loading arm is
environments, such as North Sea, GOM, etc., due to applied to LNG transfer from the FLNG to LNGC.
the benign MetOcean conditions and its large vessel The safety and availability of the offshore
size. offloading operation is governed by many factors,
including the performance of the assisting tug boats,
In such conditions, the process technologies and MetOcean conditions, the mooring line and fender
equipment installed on the FLNG can be designed arrangement, the loading arm operational envelope,
and be tolerant in terms of the process performance LNGC maneuverability, etc.
as well as mechanical strength and fatigue.
The LNGC maneuverability was evaluated in
2.3 Reliability, Availability and Maintainability various MetOcean conditions covering nearly a
(RAM) 1-year return period (Figure 11). The objectives of
this study are the high-level screening and
The RAM analysis was conducted to evaluate the evaluation of maneuvering methods. All the
production efficiency for the current design of the maneuvering operations are successful through the
FLNG. The following assumptions are made: use of a FLNG thruster, 2 tug boats and a LNGC
thruster. Although detail maneuvering operation
• The RAM of the FLNG is evaluated over a procedures will be developed in the later phase of
30-year life cycle. the project, we have become confident of its
operational feasibility.
• The planned maintenance and plant turnaround
are considered based on: The LNG transfer takes place while the manifold of
the LNGC stays within the operational envelope of
· Indonesian Regulation Requirements, the loading arm, with the given mooring line and
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fender arrangement. The relative motion of the two • All the process technologies and equipment can
floating bodies, such as FLNG and LNGC, were be marinized under the Abadi field conditions.
simulated under various MetOcean conditions,
covering nearly a 1-year return period. The results • The FLNG conceptual design is adequate to
show that the relative motion of the FLNG and meet the production efficiency target and
LNGC is unlikely to go outside the operational compares favorably with standard onshore LNG
envelope with proper heading control of FLNG by ones.
thruster.
• Although the LNG offloading procedure with
Although the LNG offloading procedure with optimized mooring, fender and assisting tugs
optimized mooring, fender and assisting tugs arrangement will be developed in the future
arrangement will be established at a later stage, the stage of the project, the availability of the LNG
availability of the LNG offloading operation is offloading operation is estimated to be unlikely
unlikely to lead to loss of production. to lead loss of production.

CONCLUSIONS
ACKNOWLEDGEMENTS
The following major conclusions have been
formulated:
INPEX Corporation kindly permitted the authors to
• The Floating LNG has been conceptually present this paper. MIGAS and BPMIGAS are also
designed successfully to satisfy the safety and gratefully acknowledged for providing their
functional requirements for developing the authorization for publication.
Abadi field.
The authors wish to express our appreciation to
• The inherent safety has been assessed based on everybody involved in the Pre-FEED activities of
the FLNG conceptual design. It represents the Abadi project, particularly to Masayoshi
robust safe and environmental friendly sound Watanabe, Shozo Tanaka, Shinichi Akaishi,
design, compared to industrial standard Masashige Kato, Yoshikazu Ichimaru, Tetsuya
conventional FPSOs, for proceeding to the Ikeda and Takeshi Terashima who all contributed to
FEED Phase. complete the study.
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Kai
Banda
Banda Sea Sea Islands
Aru
0 200km Islands
Tanimbar
Islands
Saumlaki Indonesia
Masela Is
Arafura Sea
Dili
Abadi
East Timor g h
ro u
Timor or T
Tim Masela PSC Block

Kupang
Australia

Darwin

Figure 1- Location Map (Abadi Field, Masela PSC block)

Figure 2 - Schematics of Development Concept for Abadi field (The field development of the Abadi gas
field consisting of subsea production system and a single Floating LNG plant)
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Flare Stack

Accommodation Utility

Process
Stern Swivel
Bow
LNG Loading Tank Turret
Arm

Figure 3 - Graphic Image of INPEX Masela Floating LNG

Fuel Gas Fuel Gas

(EFG) (BOG)
Feed Gas
from LNG
DEHYDRATION LIQUEFACTION, offloading
SURF INLET GAS BOOSTING & REFRIGERATION
LNG STORAGE
ACID GAS
SEPARATION COMPRESSOR &
(FUTURE) REMOVAL MERCURY &
REMOVAL LOADING
FRACTIONATION

Rich MEG
Acid
Lean MEG Gas
to SURF
CO2
CONDENSATE MEG ACID GAS to
STABILIZATION RECLAMATION INCINERATION ATM

Produced
Water
Water to
Treatment Sea Condensate
CONDENSATE offloading
CONDENSATE
STORAGE
PROCESSING
&
LOADING

FLARE UTILITY
SYSTEM SYSTEM

Figure 4- Process Flow Diagram

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HP FG
FG
Fuel Gas Power Instrument Nitrogen &
System LP FG Generation & Plant Air Inert Gas
System System System

SW SW
HPS Flue Gas

Steam & Waste

SW Sea Water Deminerali Steam Water
System -zation Unit Condensate Treatment
SW DMW System System

SW
SW
Closed Utility &
SW Cooling Potable Fire Water Fuel Oil
Water Water System System
System System

Figure 5 - Utility Flow Diagram

GTG x5 HRSG x 5

GT G C
VSD M WMR

STG x4 S/S
GT G
VSD M C C CMR

ST G
Other Users

GT G
ST G

GT G ST G

ST G
GT G

Steam Boiler x 3 AGRU Regen

Reboiler

Water Treat

Figure 6 - Electrical Driven LNG plant with Combined Cycle

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Flare Stack

Stern Topside Bow

Hull (Tank)

Living
Quarter Utility Area Process Area Turret

LNG Loading arm

Figure 7 - Topside Layout

Figure 8 - Isometric View of 3D model

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Figure 9 - Gas Dispersion Simulation (Left-side: Vapor Cloud of Leaked Mixed refrigerant at 1.3 sec after
leak start, Right-side: The one at 3.0 sec after leak start)

Figure 10 - Explosion Overpressure Contours (The explosion simulation overpressure counters in a case
of LNG explosion under the process deck)
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Bridge view of LNGC, 500m to go

About 250m to go

Figure 11 - Maneuvering Simulation (a case of the simulation maneuvering the LNGC along side of the
FLNG)